RediStart-RBX-RCX Hardware Manual PDF

PUBLICATION #890023-02-02
RediStart Solid State Starter

Hardware Manual for
RBX / RCX PowerStack
The Leader In
Solid State Motor Control
Technology
© 2004 Benshaw Inc. All Rights Reserved

TRADEMARK NOTICE
Benshaw and are registered trademarks of Benshaw Incorporated.

Modbus is a registered trademark of Schneider Electric.
UL is a trademark of Underwriters Laboratories, Incorporated
ii
SAFETY PRECAUTIONS
WARNING
1. This starter contains hazardous voltage that can cause electric shock
resulting in personal injury or loss of life.
2. Before servicing, be sure all AC power is removed from the starter and
the motor has stopped spinning
3. Wait at least 1 minute after turning off the AC power for the bus
capacitor to discharge on the control card.
4. Do not connect or disconnect the wires to or from the starter when

power is applied.
5. Ensure shielded cables are discharged.
WARNING
1. Service only by qualified personnel.
2. Make sure ground connection is in place.
3. Make certain proper shield installation is in place.
iii
TABLE OF CONTENTS
1 INTRODUCTION ......................................................................................................................................................... 1
1.1 USING THIS MANUAL ................................................................................................................................................. 2
1.2 CONTACTING BENSHAW ............................................................................................................................................ 4
1.3 INSPECTION ............................................................................................................................................................... 5
1.4 GENERAL OVERVIEW OF A REDUCED VOLTAGE STARTER ........................................................................................... 6
2 TECHNICAL INFORMATION.................................................................................................................................... 7
2.1 GENERAL INFORMATION ............................................................................................................................................ 8
2.2 ENVIRONMENTAL CONDITIONS .................................................................................................................................. 8
2.3 ALTITUDE DERATING................................................................................................................................................. 8
2.4 APPROVALS ............................................................................................................................................................... 8
2.5 CERTIFICATE OF COMPLIANCE .................................................................................................................................... 8
2.6 MX CONTROL BOARD ............................................................................................................................................... 9
2.6.1 Terminal Points, Functions and Ratings ............................................................................................................. 9
2.6.2 Terminal Block Rating ..................................................................................................................................... 10
2.6.3 Connectors, Functions and Ratings .................................................................................................................. 10
2.6.4 Measurements, Accuracy and Ratings............................................................................................................... 10
2.6.5 CT Ratios......................................................................................................................................................... 11
2.6.6 List of Motor Protection Features.................................................................................................................... 11
2.6.7 Solid State Motor Overload.............................................................................................................................. 12
2.7 POWER SECTION ...................................................................................................................................................... 13
2.7.1 Horse power Starter Rating.............................................................................................................................. 13
2.7.2 Power Stack Input Ratings with Protection Requirements for Integral Bypass ................................................... 17
2.7.3 Power Stack Input Ratings with Protection Requirements for Separate Bypass.................................................. 18
2.7.4 Power Stack Input Ratings with Protection Requirements for RC No Bypass ..................................................... 19
2.8 DIMENSIONS............................................................................................................................................................ 20
2.8.1 RB Chassis with Integral Bypass ...................................................................................................................... 20
2.8.2 RC Chassis with no Bypass............................................................................................................................... 30
2.9 KEYPAD/DISPLAY OPTIONS ..................................................................................................................................... 33
2.9.1 LCD Keypad .................................................................................................................................................... 33
3 INSTALLATION......................................................................................................................................................... 35
3.1 SITE PREPARATION .................................................................................................................................................. 36
3.2 INSTALLATION PRECAUTIONS .................................................................................................................................. 36
3.3 INSTALLATION PROCEDURES .................................................................................................................................... 37
3.3.1 Installation Procedures .................................................................................................................................... 37
3.3.2 Wiring Practices .............................................................................................................................................. 37
3.3.3 Basic Control Wiring Drawing ......................................................................................................................... 39
3.3.4 Control Board Layout ...................................................................................................................................... 40
3.4 POWER AND CONTROL DRAWINGS FOR BYPASSED AND NON BYPASSED POWER STACKS ............................................ 41
3.4.1 CT Ratio Scaling.............................................................................................................................................. 58
3.4.2 Configuring the Analog Input ........................................................................................................................... 60
3.4.3 Configuring the Analog Output......................................................................................................................... 60
3.5 RBX, POWER STACK, INTEGRAL BYPASS OR SEPARATE........................................................................................... 61
3.5.1 Introduction ..................................................................................................................................................... 61
3.5.2 Motor Connections........................................................................................................................................... 61
3.5.3 Application Consideration between Line Connected and Inside Delta Connected Soft Starter............................ 62
3.5.4 Motor Lead Length........................................................................................................................................... 63
3.5.5 Bypass Contactor............................................................................................................................................. 63
3.5.6 Incoming Line .................................................................................................................................................. 63
3.5.7 Use of Electro-Mechanical Brakes.................................................................................................................... 64
3.6 POWER WIRING ....................................................................................................................................................... 64
3.6.1 Compression Lugs............................................................................................................................................ 64
3.6.2 Recommended Wire Gauges ............................................................................................................................. 64
3.6.3 CT Mounting.................................................................................................................................................... 65
3.6.4 Torque Requirements for Power Wiring Terminations ...................................................................................... 66
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TABLE OF CONTENTS
3.6.5 Meggering a Motor .......................................................................................................................................... 66
3.6.6 High Pot Testing .............................................................................................................................................. 66
3.7 MOUNTING CONSIDERATIONS .................................................................................................................................. 67
3.7.1 Bypassed Starters............................................................................................................................................. 67
3.7.2 Non-Bypassed Starters (with out bypass) .......................................................................................................... 67
3.8 ENCLOSED PRODUCT ............................................................................................................................................... 67
3.8.1 Packaged by Benshaw Inc. ............................................................................................................................... 67
3.9 PREVENTIVE MAINTENANCE .................................................................................................................................... 67
3.9.1 General Information......................................................................................................................................... 67
3.9.2 Preventive Maintenance ................................................................................................................................... 67
3.10 OPTIONS ................................................................................................................................................................. 68
3.10.1 Remote LCD Keypad/Display; MX-1M-RKP-00, MX-2M-RKP-00 .................................................................... 68
3.10.2 Single Phase Soft Starter.................................................................................................................................. 70
4 KEYPAD OPERATION.............................................................................................................................................. 73
4.1 INTRODUCTION ........................................................................................................................................................ 74
4.2 STANDARD KEYPAD AND DISPLAY ........................................................................................................................... 74
4.2.1 Special Messages Displayed............................................................................................................................. 74
4.2.2 Viewing and Changing Parameters for the Standard Keypad ............................................................................ 75
4.2.3 Display Output for the Standard Keypad .......................................................................................................... 75
4.2.4 Quick Meters ................................................................................................................................................... 76
4.2.5 Restoring Factory Parameter Settings .............................................................................................................. 77
4.2.6 Resetting a Fault.............................................................................................................................................. 77
4.2.7 Emergency Thermal Reset ................................................................................................................................ 77
5 TROUBLESHOOTING .............................................................................................................................................. 79
5.1 THE TROUBLESHOOTING SECTING IS DIVIDED INTO 3 SECTIONS.................................................................................. 80
5.2 MX CONTROL; GENERAL TROUBLESHOOTING.......................................................................................................... 80
5.2.1 Motor does not start, no output to motor........................................................................................................... 80
5.2.2 During starting, motor rotates but does not reach full speed ............................................................................. 81
5.2.3 Acceleration not operating as desired............................................................................................................... 81
5.2.4 Deceleration not operating as desired .............................................................................................................. 82
5.2.5 Motor stops unexpectedly while running........................................................................................................... 82
5.2.6 Metering incorrect ........................................................................................................................................... 83
5.2.7 Other Situations ............................................................................................................................................... 84
5.3 FAULT CODE TROUBLESHOOTING T ABLE ................................................................................................................. 85
5.4 SCR TESTING.......................................................................................................................................................... 92
5.5 SCR REPLACEMENT ................................................................................................................................................ 93
Typical Stack Assembly.................................................................................................................................................. 93
5.5.2 SCR CLAMP PARTS........................................................................................................................................ 93
5.5.3 SCR Clamp ...................................................................................................................................................... 94
5.5.4 SCR Removal ................................................................................................................................................... 94
5.5.5 SCR INSTALLATION ....................................................................................................................................... 94
5.5.6 Tightening Clamp............................................................................................................................................. 94
5.5.7 Testing SCR ..................................................................................................................................................... 94
6 APPENDICES ............................................................................................................................................................. 95
LIST OF TABLES ................................................................................................................................................................. 96
LIST OF FIGURES ................................................................................................................................................................ 97
APPENDIX A – CE MARK................................................................................................................................................... 98
APPENDIX B – FAULT CODES ............................................................................................................................................. 99
APPENDIX C – ALARM CODES .......................................................................................................................................... 100
APPENDIX D – SPARE PARTS ............................................................................................................................................ 102
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TABLE OF CONTENTS
vi
1 Introduction
1 – INTRODUCTION
Using This Manual
1.1 Using this manual
Layout
This manual is divided into 6 sections. Each section contains topics related to the section.
The sections are as follows:

1. Introduction
2. Technical Information
3. Installation
4. Keypad Operation
5. Troubleshooting
6. Appendices
Symbols
There are 2 symbols used in this manual to highlight important information. The symbols appear as the following:
Warning: 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.
2
1 – INTRODUCTION
Using This Manual
General Information
Benshaw offers its customers the following:

• Start-up services
• On-site training services
• Technical support
• Detailed documentation
• Replacement parts
NOTE: Information about products and services is available by contacting Benshaw refer to Contacting Benshaw on page 4..
Start-Up Services
Benshaw technical field support personnel are available to do startup and conduct on-site training on the starter operations and
troubleshooting.
On-Site Training Services
Benshaw technical field support personnel are available to conduct on-site training on the operations and troubleshooting.
Technical Support
Benshaw technical support personnel are available (at no charge) to answer customer questions and provide technical support over
the telephone. For more information about contacting technical support personnel, refer to Contacting Benshaw on page 4.
Documentation
Benshaw provides all customers with:

• Parameter Configuration Manual, Publication # 890023-01-xx
• Hardware Manual, Publication # 890023-02-xx
• Quick Start Reference Guide for LED Display, Publication # 890023-03-xx
• Quick Start Reference Guide for LCD Display, Publication # 890023-04-xx
On-line Documentation
All documentation is available on-line at http://www.benshaw.com.
Replacement Parts
Spare and replacement parts can be purchased from Benshaw.
Publication History
Refer to the Revision History in the appendices.
3
1 – INTRODUCTION
Contacting Benshaw
1.2 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.

550 Bright Street East
Listowel, Ontario N4W 3W3
Canada
Phone: (519) 291-5112
Fax: (519) 291-2595
Benshaw West
14715 North 78th Way, Suite 600
Scottsdale, AZ 85260
United States of America
Phone: (480) 905-0601
Fax: (480) 905-0757
E-Mail: [email protected]
[email protected]
Technical support for MX Control Series 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 the caller can be contacted
• Fax number of caller
• Benshaw product name
• Benshaw model number
• Benshaw serial number
• Name of product distributor
• Approximate date of purchase
• System Voltage
• FLA of motor attached to Benshaw product
• A brief description of the application
4
1 – INTRODUCTION
Interpreting Model Numbers
1.3 Inspection
Before storing or installing the RediStart starter with MX control, thoroughly inspect the device for possible shipping damage.
Upon receipt:
• Remove the starter from its package and inspect exterior for shipping damage. If damage is apparent, notify the shipping agent
and your sales representative.
• Open the enclosure and inspect the starter for any apparent damage or foreign objects. Ensure that all of the mounting hardware
and terminal connection hardware is properly seated, securely fastened, and undamaged.
• Ensure all connections and wires are secured.
• Read the technical data label affixed to the starter and ensure that the correct horsepower and input voltage for the application
has been purchased.
• The starter numbering system for a chassis is:
R __ __ __ __ __ __ __ A __ __ __
Enclosures
C = Open Chassis
Frame Size
Amp Rating, (0 – 999A )
Fault Level
S = Standard
H = High
Type of Bypass
0 = None (only available with RC)
1 = Integrated
2 = Separate, Definite Purpose (Only with 1000V Starter)
3 = Separate, ATL IEC AC3 Rated
4 = Separate, ATL NEMA Rated (AC4)
Type of Control
M = Micro II Control
X = MX Control
Family of RediStart Starter

B = Bypass
C = Continuos
Example of the model Number: RBX-1S-361A-14C
A RediStart starter with bypass, MX control, Integrated Bypass, Standard Fault, 361 Amp unit, Frame 14, open Chassis
5
1 – INTRODUCTION
General Overview
1.4 General Overview of a Reduced Voltage Starter
The RediStart MX motor starter is a microprocessor-controlled starter for single or three-phase induction motors. The starter can be
custom designed for specific applications. A few of the features are:
• Solid state design.
• Reduced voltage starting and soft stopping.
• Closed-loop motor current control, power control, torque control.
• Programmable motor protection.
• Programmable operating parameters.
• Programmable metering.
Each starter can operate within applied line voltage and frequency values of 100VAC to 600VAC (optional 1000VAC) and 23 to
72Hz.
The starter can be programmed for any motor FLA and all of the common motor service factors. It enables operators to control both
motor acceleration and deceleration. It can also protect the motor and its load from damage that could be caused by incorrect phase
rotation, normally caused by wiring changes after startup.
The starter continually monitors the current being supplied to each phase of motor. This protects the motor from overheating or from
excess current. The starter will automatically stop the motor if the Phase to Phase line current is not within acceptable configurable
ranges or if the current is lost in a line.
Features The enhanced engineering features of the starter include:

• Multiple frame sizes
• Universal voltage operation
• Universal frequency operation
• Programmable motor overload multiplier
• Controlled acceleration and deceleration
• Phase rotation protection
• Regulated current control
• Electronic motor thermal overload protection
• Electronic over/under current protection
• Single phase protection
• Line-to-line current imbalance protection
• Stalled motor protection
• Programmable metering
• Passcode protected
• Programmable Relays
• Analog output with digital offset and span adjustment
• Analog input with digital offset and span adjustment
6
2 Technical Information
7
2 – TECHNICAL INFORMATION
Technical Specifications
2.1 General Information
The physical specifications of the starter vary depending upon its configuration. The selectable motor current determines
the configuration and its specific application requirements.
This document covers the control electronics and several power sections:
• MX control board
• RB Power Stack with Bypass, Integral and Separate
• RC Power Stacks, Continues operation, NO bypass
2.2 Environmental Conditions
Table 1 – Environmental Ratings

Operating Temperatures 0°C to +50°C (32°F to 122°F)
Storage Temperatures -20°C to +70°C (-4°F to 155°F)
Maximum heatsink temperatures 90°C (194°F), during a start
Humidity 0% to 95% non condensing
Altitude 1000m (3300ft) without derating
Maximum Vibration 5.9m/s2 (19.2ft/s2 ) [0.6G]
Cooling Natural convection RB, Forced Air RC
2.3 Altitude Derating
Benshaw’s starters are capable of operating at altitudes up to 3,300 feet (1000 meters) without requiring altitude derating.
Table 2 provides the derating percentage to be considered when using a starter above 3,300 feet (1000 meters).
Table 2 – Altitude Derating

Altitude Percent Derating (Amps)
3300 Feet 1006 meters 0.0%
4300 Feet 1311 meters 3.0%
5300 Feet 1615 meters 6.0%
6300 Feet 1920 meters 9.0%
7300 Feet 2225 meters 12.0%
8300 Feet 2530 meters 15.0%
9300 Feet 2835 meters 18.0%
For derating above 10,000 feet consult Benshaw Inc.
2.4 Approvals
MX control UL, cUL Recognized
RB__ power stacks & Controls UL, cUL Listed
RC__ power stacks & Controls UL, cUL Listed
2.5 Certificate of compliance
CE Mark
8
2.6 MX Control Board
2.6.1 Terminal Points, Functions and Ratings
Refer to section 3.3.4 on page 40 for terminal placement.
Table 3 – Terminals
Function Terminal Number Description
TB1
Control Power Input N, neutral 96 – 144V AC input
L, line 45VA current requirements
G, ground Line Frequency, 23 to 72Hz
Relay Output R1 NC1: Normally Closed Relay Output, SPDT form C
RC1:Common 5 Amp, 125VAC, resistive
NO1:Normally Open 1 Amp, 125VAC, 0.4PF
100VA Inrush
Relay Output R2 & R3 NC2, RC2, NO2 Relay Output, SPDT form C
NC3, RC3, NO3 16 Amp, 250VAC, resistive
8 Amp, 250VAC, 0.4PF
2000VA Inrush
TB2
Digital Inputs Start, DI1, S/DI1 Com 120V AC digital input, 2500V optical isolation, 4mA cur. draw
Start & DI1 Off = 0 to 35 VAC, On = 60 to 120VAC
Digital Inputs DI2, DI3, 120V AC digital input, 2500V optical isolation, 4mA cur. draw
DI2 & DI3 DI2/DI3 Com Off = 0 to 35 VAC, On = 60 to 120V AC
Serial Comm. (Slave) SA-, SB+, SCOM, Modbus slave serial communication port.
SHLD RS485 interface, SHLD is chassis ground
Data Rates; 19.2k baud maximum Modbus RTU
2500V Optical Isolation
Serial Comm MA-, MB+, MCOM, Factory Use Only, not isolated
SHLD
TB12
Analog Output AOUT, COM, SHLD Voltage or Current Output, selectable by JP1
Voltage; 0-10VDC (20mA Maximum),
Current; 0-20mA, Software scalable, 500ohm load max.
Accuracy ±1.5% Full Scale
Update rate: 25msec.
TB13
Analog Input AIN+, ANI-, SHLD Voltage or Current Input, selectable by JP3
Voltage; 0-10VDC, 1 Meg. impedance
Current; 0-20mA, 499 ohm impedance, Software scalable,
Accuracy ± 3% of full scale
Reference Supply AIN PWR 10V DC (4 mA Maximum) Reference Source
Jumpers
JP1 Analog Output Voltage output when installed, Current loop removed
JP3 Analog Input Current input when installed, Voltage input removed
JP0, JP2,JD3 Factory Use Only
9
2.6.2 Terminal Block Rating
2.6.2.1 Wire Gauge
The terminals can support a quantity of one- 14 AWG wire or two-16 AWG wires, with two-22 AWG being the
smallest.
2.6.2.2 Wire Strip Length
The strip length should be 5/16”
2.6.2.3 Torque rating
The terminals on the control board have a torque rating of 3.5-inch lb. or 0.4nm. This MUST be followed or damage
will occur to the terminals.
2.6.3 Connectors, Functions and Ratings

Table 4 - Connectors
Connectors Description
Aux Power TB0 120V AC, 5 amps, Aux. Connector for control voltage
Current Transformers TB3 CT connection for CT1, CT2 and CT3
(CT) Molex Connector: #39-01-2065
Connection Molex Connector Pins: #39-00-0090 crimp,
SCR Connection TB4 Cathode and Gate for SCR # 1
Molex Connector for gates: #39-01-3028
Molex Connector pins: #39-00-0056 crimp,
Remote Display Conn 3 Remote Display or Option Board Interface
TB10, Conn 4 Factory Use Only
2.6.4 Measurements, Accuracy and Ratings
Table 5 – Accuracy
Internal Measurements
CT Inputs Conversion; True RMS, Sampling @ 1.562kHz
Line Voltage Inputs Conversion; True RMS,
Range; 100VAC to 600VAC ± 10%
Metering
Current 0 – 40,000 Amps ± 3%
Voltage 0 – 660 Volts ± 3%
Watts 0 – 9,999 MW ± 5%
Volts-Amps 0 – 9,999 MVA ± 5%
Vars 0 – 9,999 Mvar ± 5%
Watt-Hours 0 – 10,000 MWh ± 5%
PF -0.01 to +0.01 (Lag & Lead) ± 5%
Line Frequency 23 – 72 Hz ± 0.1 Hz
Ground Fault 5 – 100% FLA ± 5% (Machine Protection)
Run Time ± 3 seconds per 24 hour period
Analog Input Accuracy ± 3% of full scale
Analog Output Accuracy ±1.5% of full scale
Note: Percent accuracy’s are percent of full scale of the given ranges, Current = Motor FLA Full
Range, Voltage = 660V, Watts/Volts-Amps/Watt-Hours = Motor & Voltage range
10
2.6.5 CT Ratios
Table 6 – CT Ratios
CT Ratio Minimum FLA (A rms) Maximum FLA (A rms)
72 (4 wraps 288.1) 2 16
96 (3 wraps 288:1) 3 21
144 (2 wraps 288:1) 4 32
288 8 64
864 24 190
1320 (2 wraps 2640) 37 290
2640 73 590
2880 73 640
3900 105 870
5760 160 1280
8000 223 1800
14400 Mult. CT-CT 400 3200
Combinations
28800 Mult. CT-CT 800 6400
Combinations
2.6.6 List of Motor Protection Features

• ANSI 51 – Electronic motor overload (Off, class 1 to 40, separate starting and running curves available)
• ANSI 86 – Overload lockout
• ANSI 51 – Overcurrent detection (Off or 50 to 800% and time 0.1 to 90.0 sec. in 0.1 sec. intervals)
• ANSI 50 - Instantaneous electronic overcurrent trip
• ANSI 37 – Undercurrent detection (Off or 5 to 100% and time 0.1 to 90.0 sec. in 0.1 sec. intervals)
• ANSI 46 – Current imbalance detection (Off or 5 to 40%)
• ANSI 51G – Ground fault detection (Off or 5 to 100%)
• ANSI 48 – Adjustable up-to-speed / stall timer (1 to 900 sec. in 1 sec. intervals)
• ANSI 59 / 27 – Adjustable over/under voltage protection (Off or 1 to 40%, time 0.1 to 90.0 sec. in 0.1 sec. intervals,
independent over and under voltage levels)
• ANSI 47 - Phase rotation (selectable ABC, CBA, Insensitive, or Single Phase)
• ANSI 81 – Over / Under Frequency
• ANSI 74 – Alarm relay output available
• Single Phase Protection
• Shorted SCR detection
11
2.6.7 Solid State Motor Overload
The MX control has an advanced I2t electronic motor overload (OL) protection function. For optimal motor protection
the MX control has forty standard NEMA style overload curves (in steps of one) available for use. Separate overloads
can be programmed, one for acceleration and another for normal running operation. The overloads can be individually,
the same or completely disabled if necessary. The MX motor overload function also implements a NEMA based current
imbalance overload compensation, user adjustable hot and cold motor compensation and user adjustable exponential
motor cooling. For more detailed information, please refer to Section 7 of the software manual, Solid State Motor
Overload Protection.
Figure 1 – Common Motor Overload Curves
CommonlyUsedOverloadCurves
10000
1000
Seconds to Trip
100
Class40
Class30
10 Class20
Class15
Class10
Class5
1
100 150 200 250 300 350 400 450 500 550 600 650 700 750 800
Current %(FLA)
The motor overload will NOT trip when the current is less than motor Full Load Amps (FLA) * Service Factor (SF).
The motor overload “pick up” point current is at motor Full Load Amps (FLA) * Service Factor (SF).
The motor overload trip time will be reduced when there is a current imbalance present.
Note: Refer to Theory of Operation section in the software manual for more motor overload details and a larger
graph.
Refer to http://www.benshaw.com/olcurves.html for an automated overload

calculator.
12
2.7 Power Section
2.7.1 Horse power Starter Rating
Each model number can be rated for different classes of operation. For example, a starter can operate a:
300HP motor for a class 10 start (350% for 30 seconds)
Or
200HP for a class 20 start (500% for 30 sec)
Or
150HP motor for a class 30 start (600% for 30 seconds)
Or
450HP motor when connected to the inside delta of a motor for a class 10 start (350% for 30 seconds
Table 7 – Class 10 (Standard Duty) Horsepower Ratings
CLASS 10 (350% current for 30 seconds, 115% Continuous)
MODEL NUMBER NOMINAL HORSEPOWER RATING
AMPS 200-208V 230-240V 380-400V 440-480V 575-600V
RBX-1-S-027A-11C 27 7.5 10 15 20 25
RBX-1-S-040A-11C 40 10 15 25 30 40
RBX-1-S-052A-12C 52 15 20 30 40 50
RBX-1-S-065A-12C 65 20 25 40 50 60
RBX-1-S-077A-13C 77 25 30 ⎯ 60 75
RBX-1-S-096A-13C 96 30 40 50 75 100
RBX-1-S-125A-14C 125 40 50 75 100 125
RBX-1-S-156A-14C 156 50 60 ⎯ 125 150
RBX-1-S-180A-14C 180 60 75 100 150 200
RBX-1-S-180A-15C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-240A-15C 240 75 100 150 200 250
RBX-1-S-302A-15C 302 100 125 ⎯ 250 300
RBX-1-S-361A-16C 361 125 150 200 300 400
RBX-1-S-414A-17C 414 150 ⎯ 250 350 ⎯
RBX-1-S-477A-17C 477 ⎯ 200 300 400 500
RBX-1-S-515A-17C 515 200 ⎯ ⎯ 450 ⎯
RBX-1-S-590A-18C 590 ⎯ 250 350 500 600
RBX-1-S-720A-19C 720 250 300 400 600 700
RBX-1-S-838A-20C 838 300 350 500 700 800
NOTE: For Inside delta ratings refer to Table 10, Table 11and Table 12
13
Table 8 – Class 20 (Heavy Duty) Horsepower Ratings

CLASS 20 (500% current for 30 seconds, 125% Continuous)
AMPS 200-208V 230-240V 380-400V 440-480V 575-600V
RBX-1-S-027A-11C 24 7.5 10 15 20 25
RBX-1-S-040A-11C 40 10 15 25 30 40
RBX-1-S-052A-12C 52 15 20 30 40 50
RBX-1-S-065A-12C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-077A-13C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-096A-13C 96 30 40 50 75 100
RBX-1-S-125A-14C 125 40 50 75 100 125
RBX-1-S-156A-14C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-180A-14C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-180A-15C 204 60 75 100 150 200
RBX-1-S-240A-15C 215 ⎯ ⎯ 125 ⎯ ⎯
RBX-1-S-302A-15C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-361A-16C 252 75 100 150 200 250
RBX-1-S-414A-17C 372 125 150 200 300 400
RBX-1-S-477A-17C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-515A-17C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-590A-18C 551 200 200 300 450 500
RBX-1-S-720A-19C 623 200 250 350 500 600
RBX-1-S-838A-20C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
14
Table 9 – Class 30 (Severe Duty) Horsepower Ratings

CLASS 30 (600% current for 30 seconds 125% Continuous)
AMPS 200-208V 230-240V 380-400V 440-480V 575-600V
RBX-1-S-027A-11C 24 5 7.5 10 15 20
RBX-1-S-040A-11C 40 10 10 20 30 40
RBX-1-S-052A-12C 45 ⎯ 15 25 ⎯ ⎯
RBX-1-S-065A-12C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-077A-13C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-096A-13C 77 25 30 40 60 75
RBX-1-S-125A-14C 105 30 40 60 75 100
RBX-1-S-156A-14C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-180A-14C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-180A-15C 180 50 60 100 125 150
RBX-1-S-240A-15C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-302A-15C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-361A-16C 210 60 75 125 150 200
RBX-1-S-414A-17C 310 100 125 150 250 300
RBX-1-S-477A-17C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-515A-17C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-590A-18C 515 150 200 300 450 500
RBX-1-S-720A-19C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-838A-20C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
15
Table 10 – Inside Delta Class 10 (Standard Duty) Horsepower Ratings

INSIDE DELTA CLASS 10 (350% start for 30 seconds 115% Continuous)
AMPS 200-208V 220-240V 380-415V 440-480V 575-600V
RBX-1-S-027A-11C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-040A-11C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-052A-12C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-065A-12C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-077A-13C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-096A-13C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-125A-14C 180 60 75 100 150 200
RBX-1-S-156A-14C 240 75 100 150 200 250
RBX-1-S-180A-14C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-180A-15C ⎯ ⎯ ⎯ ⎯ ⎯ ⎯
RBX-1-S-240A-15C 361 125 150 200 300 400
RBX-1-S-302A-15C 414 150 ⎯ 250 350 ⎯
RBX-1-S-361A-16C 515 200 ⎯ ⎯ 450 ⎯
RBX-1-S-414A-17C 590 ⎯ 250 350 500 600
RBX-1-S-477A-17C 720 250 300 400 600 700
RBX-1-S-515A-17C 800 ⎯ ⎯ 500 ⎯ ⎯
RBX-1-S-590A-18C 838 300 350 ⎯ 700 800
RBX-1-S-720A-19C 1116 ⎯ ⎯ 700 900 ⎯
RBX-1-S-838A-20C 1300 400 500 800 1000 1200
Model Number VA Minimum VA Model Number VA Minimum VA

Requirements Transformer Size Requirements Transformer Size
RBX-1-S-027A-11C 140 175 RBX-1-S-240A-15C 750 938
RBX-1-S-040A-11C 140 175 RBX-1-S-302A-15C 750 938
RBX-1-S-052A-12C 140 175 RBX-1-S-361A-16C 1365 1706
RBX-1-S-065A-12C 265 331 RBX-1-S-414A-17C 1365 1706
RBX-1-S-077A-13C 265 331 RBX-1-S-477A-17C 1365 1706
RBX-1-S-096A-13C 265 331 RBX-1-S-515A-17C 1365 1706
RBX-1-S-125A-14C 330 413 RBX-1-S-590A-18C 1365 1706
RBX-1-S-156A-14C 750 938 RBX-1-S-720A-19C 1365 1706
RBX-1-S-180A-14C 750 938 RBX-1-S-838A-20C 750 938
RBX-1-S-180A-15C 750 938
Note: If Micro II controller is used, add 20 VA to the VA requirements.
16
2.7.2 Power Stack Input Ratings with Protection Requirements for Integral Bypass
Table 11 – Power Ratings with Integral Bypass
Model Nominal 115% Current Nominal 115% Current Unit Withstand Unit Withstand Connection Allowable Fuse Maximum Maximum Running Watt
Number Current(A) Rating(A) Current(A) Rating(A) Rating (KA) Rating (KA) Type Class Fuse Size Circuit Breaker Loss, After
6 6
Inside Delta Inside Delta Std. Fault High Fault Line Load Current(A) Trip Rating(A) Bypassed (W) 5
1 3
RB_1_027A11C 27 31 - 48 5 5 Power Block Bus Tab J/T/RK1/RK5 45/70* 60/100* 4.0
1 3
RB_1_052A12C 52 60 - 93 10 10 Power Block2 Bus Tab3 J/T/RK1/RK5 90/125* 125/200* 6.0
2 3
3 3
RB_1_077A13C 77 89 - 137 10 10 Bus Tab Bus Tab J/T/RK1/RK5 125/200* 175/300* 11
RB_1_096A13C 96 110 - 171 10 10 Bus Tab3 Bus Tab3 J/T/RK1/RK5 150/250* 225/350* 14
4 4
RB_1_125A14C 125 144 194 223 18 30 Bus Tab Bus Tab J/T/RK1/RK5 200/300* 300/450* 17
4 4
RB_1_180A14C 180 207 279 321 18 30 Bus Tab4 Bus Tab4 J/T/RK1/RK5 300/450* 450/700* 26
4 4
4 4
RB_1_302A15C 302 347 468 538 30 65 Bus Tab4 Bus Tab4 J/T/RK1/RK5/L 500/800* 700/1100* 37
4 4
RB_1_361A16C 361 415 560 643 30 65 Bus Tab Bus Tab J/T/RK1/RK5/L 600/900* 900/1300* 47
4 4
RB_1_414A17C 414 476 642 738 42 65 Bus Tab Bus Tab L/T 700/1100* 1000/1600* 58
RB_1_477A17C 477 549 739 850 42 65 Bus Tab4 Bus Tab4 L/T 800/1200* 1200/1800* 75
4 4
RB_1_515A17C 515 592 798 918 42 65 Bus Tab Bus Tab L 900/1300* 1300/2000* 95
4 4
RB_1_720A18C 720 828 1116 1283 42 65 Bus Tab4 Bus Tab4 L 1200/1800* 1800/2500* 160
4 4
* Rating for Inside Delta Application
1 Power Block wire size #12-#4awg
3 Bus Tab with 1 hole 1/4" diameter
4 Bus Tab with NEMA 2 hole pattern 1/2" diameter 3/4" apart as defined by NEMA Standard CC1
5 Does not include the control Watt Loss (MX =45 watts, Micro II = 56 watts)
6 For higher kAIC ratings, consult factory
17
2.7.3 Power Stack Input Ratings with Protection Requirements for Separate Bypass
Table 12 – Power Ratings with Separate Bypass
Model Nominal 115% Current Nominal 115% Current AC3 NEMA (AC4) Connection Allowable Fuse Maximum Maximum Running Watt
Number Current(A) Rating(A) Current(A) Rating(A) Unit Withstand Unit Withstand Type Class Fuse Size Circuit Breaker Loss, After
6 6
Inside Delta Inside Delta Fault Rating (KA) Fault Rating (KA) Line Load Current(A) Trip Rating(A) Bypassed (W) 5
1 3
RB_ _ _027A11C 27 31 _ 48 5 5 Power Block Bus Tab J/T/RK1/RK5 45/70* 60/100* 4.0
RB_ _ _040A11C 40 46 _ 71 5 10 Power Block1 Bus Tab3 J/T/RK1/RK5 70/100* 100/150* 4.8
RB_ _ _052A12C 52 60 _ 93 5 10 Power Block2 Bus Tab3 J/T/RK1/RK5 90/125* 125/200* 6.0
2 3
RB_ _ _065A12C 65 75 _ 116 10 10 Power Block Bus Tab J/T/RK1/RK5 110/175* 150/250* 8.7
RB_ _ _077A13C 77 89 _ 137 10 10 Bus Tab3 Bus Tab3 J/T/RK1/RK5 125/200* 175/300* 11
RB_ _ _096A13C 96 110 _ 171 10 10 Bus Tab3 Bus Tab3 J/T/RK1/RK5 150/250* 225/350* 14
4 4
RB_ _ _125A14C 125 144 194 223 10 10 Bus Tab Bus Tab J/T/RK1/RK5 200/300* 300/450* 17
RB_ _ _156A14C 156 179 242 278 10 18 Bus Tab4 Bus Tab4 J/T/RK1/RK5 250/400* 350/600* 21
4 4
RB_ _ _180A15C 180 207 279 321 10 18 Bus Tab Bus Tab J/T/RK1/RK5 300/450* 450/700* 26
RB_ _ _302A15C 302 347 468 538 18 30 Bus Tab4 Bus Tab4 J/T/RK1/RK5/L 500/800* 700/1100* 37
4 4
RB_ _ _361A16C 361 415 560 643 30 30 Bus Tab Bus Tab J/T/RK1/RK5/L 600/900* 900/1300* 47
RB_ _ _414A17C 414 476 642 738 30 30 Bus Tab4 Bus Tab4 L/T 700/1100* 1000/1600* 58
RB_ _ _477A17C 477 549 739 850 30 30 Bus Tab4 Bus Tab4 L/T 800/1200* 1200/1800* 75
4 4
RB_ _ _515A17C 515 592 798 918 30 30 Bus Tab Bus Tab L 900/1300* 1300/2000* 95
RB_ _ _590A18C 590 679 915 1052 30 30 Bus Tab4 Bus Tab4 L 1000/1600* 1400/2000* 120
RB_ _ _720A18C 720 828 1116 1283 30 30 Bus Tab4 Bus Tab4 L 1200/1800* 1800/2500* 160
4 4
RB_ _ _838A19C 838 964 1299 1494 Consult Factory Consult Factory Bus Tab Bus Tab L 1400/2000* 2000/3000* 200
* Rating for Inside Delta Application
3 Bus Tab with 1 hole 1/4" diameter
4 Bus Tab with NEMA 2 hole pattern 1/2" diameter 3/4" apart as defined by NEMA Standard CC1
5 Does not include the control Watt Loss (MX =45 watts, Micro II = 56 watts)
6 For higher kAIC ratings, consult factory
18
2.7.4 Power Stack Input Ratings with Protection Requirements for RC No Bypass
Table 13 – Power Ratings with No Bypass
Model Nominal 125% Unit Connection Fuse Protected Rating Current Limiting Circuit Breaker Protected Rating Running Watt
Number Current(A) Current Withstand Type Allowable Fuse Maximum Short Catalog Trip Short Loss, After
1 1
Fault Rating Power Block Power Block Class Fuse Circuit Number Plug Circuit Bypassed (W) 5
(kA) Current(A) Rating Rating
RC_ _ _014A11C 14 17.5 42 Power Block1 Power Block1 J/600V AC T/RK1 20 100kA CED63B 50A 42kA
30 50kA
45 50kA
60 50kA
1 1
RC_ _ _040A11C 40 50 42 Power Block Power Block J/600V AC T/RK1 60 100kA CED63B 60A 42Ka
100 50kA
RC_ _ _052A12C 52 65 42 Power Block2 Power Block1 J/600V AC T/RK1 60 100kA CED63B 100A 42kA
100 50kA
RC_ _ _096A13C 96 120 42 Power Block1 Power Block1 J/600V AC T/RK1 225 100kA CFD63B 225A 42kA
4 4
RC_ _ _125A14C 125 155 42 Bus Tab Bus Tab J/600V AC T/RK1 350 100kA CFD63B 225A 42kA
RC_ _ _156A14C 156 195 42 Bus Tab4 Bus Tab4 J/600V AC T/RK1 400 100kA CFD63B 225A 65kA
4 4
RC_ _ _240A15C 240 300 42 Bus Tab Bus Tab J/600V AC T/RK1 600 100kA CFD63B 400A 65kA
RC_ _ _361A16C 361 421 42 Bus Tab4 Bus Tab4 J/600V AC T/RK1 800 100kA CJD63B 400A 65kA
CLD63b 600A
RC_ _ _477A17C 477 596 42 Bus Tab4 Bus Tab4 J/600V AC T/RK1 800 100kA CJD63B 400A 65kA
CLD63b 600A
RC_ _ _590A18C 590 737 42 Bus Tab4 Bus Tab4 L 1400 100kA CND63B 800A 85kA
CND63b 1200a
RC_ _ _720A18C 720 900 42 Bus Tab4 Bus Tab4 L 1600 100kA CND63B 800A 85kA
CND63b 1200A
4 4
RC_ _ _840A19C 840 1050 85 Bus Tab Bus Tab L 1600 100kA CND63B 800A 85kA
CND63b 1200A
4 4
RC_ _ _960A19C 960 1200 85 Bus Tab Bus Tab L 1600 100kA HPD63F160 1200 – 1600A 85kA
2000 50kA
RC_ _ _12KA19C 1200 1440 85 Bus Tab4 Bus Tab4 L 1600 100kA HPD63F160 1200 – 1600A 85kA
2000 50kA
19
Mechanical Drawings
2.8 Dimensions
2.8.1 RB Chassis with Integral Bypass
Figure 2 - Dimensions for 2 to 65 Amp RB_1 Starter
MX Card
Amp Frame A B C (w/MX) C (w/MII) D E F G Weight

Size in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) lbs (kg)
2 –40 11 14.00 10.00 6.91 7.85 8.75 12.50 0.79 0.75 14
(355.60) (254.00) (175.51) (199.4) (222.25) (317.45) (20.06) (19.10) (6.4)
52 – 65 12 14.00 10.00 6.91 8.60 8.75 12.50 0.79 0.75 17
(355.60) (254.00) (175.51) (218.44) (222.25) (317.45) (20.06) (19.10) (7.7)
Mounting Holes: Slot: 0.31 x 0.84 (7.87 x 21.33) Bottom : 0.31 (7.87)
20
Mechanical Drawings
MX Card

Size in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) lbs (kg)
77 – 96 13 15.00 10.00 7.66 8.60 8.75 14.50 0.79 0.75 18
(381.00) (254.00) (194.56) (218.44) (222.25) (317.45) (20.06) (19.10) (8.2)
21
Mechanical Drawings
MX Card
Amp Frame A B C (w/MX) C (w/MII) D E F G H J Weight

Size in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) lbs (kg)
in (mm)
125 – 14 19.80
(205.92) 12.27 8.91 9.4 17.00 3.88 4.00 3.88 1.00 .75 43
180 14 21.55 (311.8) (226.3) (238.7) (431.8) (98.5) (101.5) (98.5) (25.4) (19.1) (19.5)
(547.4)
1
180 – 15 22.00 12.27 9.16 9.65 18.50 3.88 4.00 3.88 1.00 .75 51
302 (558.8) (311.8) (232.6) (245.1) (469.9 (98.5) (101.5) (98.5) (25.4) (19.1) (23.1)
361 16 23.87 12.90 9.16 9.65 20.25 4.03 4.31 4.03 1.00 .75 56
(606.2) (327.6) (232.6) (245.1) (514.4) (102.4) (109.5) (102.4) (25.4) (19.1) (25.4)
Mounting Holes: Keyhole: 0.31 x 0.63 (7.87 x 15.88) Bottom : 0.31 (7.87)
22
Mechanical Drawings
MX Card

in (mm)
414 – 515 17 28.29 18.5 11.33 11.83 27.25 25.25 3.25 6.00 151
(718.5) (269.9) (287.8) (300.5) (692.2) (641.4) (82.6) (152.4) (68.5)
590 18 28.29 18.5 11.33 11.83 27.25 25.25 3.25 6.00 159
(718.5) (269.9) (287.8) (300.5) (692.2) (641.4) (82.6) (152.4) (72.1)
720 19 29.34 18.5 11.33 11.83 29.00 27.00 3.25 6.00 159
(745.23) (269.9) (287.8) (300.5) (736.6) (685.8) (82.6) (152.4) (72.1)
23
Mechanical Drawings
Figure 6 - Dimensions for 838 Amp RB_1 Starter
MX Card

in (mm)
838 20 27.75 26.60 12.90 13.39 24.50 22.50 4.60 8.70 160
(704.9) (675.6) (327.5) (340.1) (622.3) (571.5) (116.8) (221.0) (72.6)
24
Mechanical Drawings
Figure 7 - 2 to 65 Amp Dimensions with ATL Bypass (AC3 or AC4/NEMA rating)
MX Card
Amp Frame A B C (w/MX) C (w/MII) D E F G

Size in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm)
2 –27 11 14.00 10.00 6.91 7.85 8.75 12.50 0.79 0.75

(AC3) (355.60) (254.00) (175.51) (199.4) (222.25) (317.45) (20.06) (19.10)
28 –65 12 14.00 10.00 6.91 8.60 8.75 12.50 0.79 0.75
(AC3) (355.60) (254.00) (175.51) (218.44) (222.25) (317.45) (20.06) (19.10)
2 - 40 12 14.00 10.00 6.91 8.60 8.75 12.50 0.79 0.75
(AC4) (355.60) (254.00) (175.51) (218.44) (222.25) (317.45) (20.06) (19.10)
25
Mechanical Drawings
Figure 8 - 66 to 77 Amp Dimensions with ATL Bypass (AC3 rating)
MX Card

66 - 77 13 15.00 10.00 7.66 8.60 8.75 14.50 0.79 0.75
(AC3) (381.00) (254.00) (194.56) (218.44) (222.25) (317.45) (20.06) (19.10)
26
Mechanical Drawings
Figure 9 - 78 to 96 Amp Chassis Dimensions for use with separate ATL Bypass
MX Card

78 - 96 13 15.00 10.00 7.66 8.60 8.75 14.50 0.79 0.75
(381.00) (254.00) (194.56) (218.44) (222.25) (317.45) (20.06) (19.10)
Add 6” to width for ATL bypass (AC3 or AC4/ NEMA) contactor
27
Mechanical Drawings
Figure 10 - 97 to 361 Amp Chassis Dimensions for use with Separate Bypass (ATL)
MX Card
Amp Frame A B C (w/MX) C (w/MII) D E F G H J

Size in (mm) in (mm) in (mm) in (mm) in (mm) in (mm) in (mm)
in (mm)
125 –180 14 14.75 11.91 9.91 10.85 11.00 3.88 4.00 3.88 .75 .75
(374.7) (302.5) (251.7) (275.5) (279.4) (98.5) (101.5) (98.5) (19.1) (19.1)
180– 302 15 18.75 12.16 10.16 11.10 14.31 3.88 4.00 3.88 1.00 .75
(476.3) (308.8) (258.0) (281.8) (363.5) (98.5) (101.5) (98.5) (25.4) (19.1)
361 16 17.8 12.22 10.16 11.10 16.00 4.05 4.31 3.85 1.00 1.00
(452.1) (310.4) (258.0) (281.8) (406.4) (102.9) (109.5) (97.8) (25.4) (25.4)
The contactor and control relays for ATL operation are NOT included in the above dimensions
28
Mechanical Drawings
Figure 11 - 362 to 840 Chassis Dimensions for use with Separate Bypass (ATL)
MX Card
in (mm)
414 – 515 17 20.00 21.50 10.89 11.83 21.38 19.39 3.75 7.00
(508.0) (546.1) (276.7) (300.5) (543.2) (492.4) (95.3) (177.8)
590 18 20.00 21.50 10.89 11.83 21.38 19.39 3.75 7.00
(508.0) (546.1) (276.7) (300.5) (543.2) (492.4) (95.3) (177.8)
720 19 20.00 21.50 10.89 11.83 21.38 19.39 3.75 7.00
(508.0) (546.1) (276.7) (300.5) (543.2) (492.4) (95.3) (177.8)
838 20 22.25 26.60 12.46 13.49 17.00 15.00 4.60 8.70
(565.2) (675.6) (316.4) (340.2) (431.8) (381.0) (116.8) (221.0)
The contactor and control relays for ATL operation are NOT included in the above dimensions
29
Mechanical Drawings
2.8.2 RC Chassis with no Bypass
Figure 12 - 2 to 124 Amp Dimensions for Continuous Operation Chassis
MX Card
MX Card

in (mm)
2-52 31 14.00 9.87 7.63 8.61 .25 3.38 4.69 1.31
(355.6) (250.7) (193.8) (218.7) (6.35) (85.9) (119.1) (33.3)
53-77 32 18.00 9.99 9.58 10.52 .25 4.38 4.75 1.31
(457.2) (254) (243.3) (260.4) (6.35) (111.25) (120.65) (33.3)
78 -124 33 27.00 10.00 9.58 10.52 .25 6.63 4.75 1.31
(685.8) (254) (243.3) (260.4) (6.35) (168.4) (120.65) (33.3)
30
Mechanical Drawings
MX Card

in (mm)
125 –180 34 19.00 17.25 11.77 12.77 16.46 14.00 2.88 5.75
(482.6) (438.2) (298.9) (324.4) (418.0) (355.6) (73.2) (146.0)
181– 477 35 27.67 17.25 10.86 11.80 24.27 21.75 2.88 5.75
(702.8) (438.2) (275.8) (299.7) (616.5) (552.45) (73.2) (146.0)
31
Mechanical Drawings
MX Card

in (mm)
478 - 838 36 35.32 20.25 11.77 12.71 31.52 29.00 3.25 6.88
(897.2) (514.4) (299.0) (322.8) (800.6) (736.6) (82.6) (174.6)
32
Mechanical Drawings
2.9 Keypad/Display Options
The MX control has one of two types of keypads, either LED display or LCD display. As standard, LED display is permanently
mounted on the control board. The LCD keypad is optional and is mounted remotely from the control board.
2.9.1 LCD Keypad
The LCD keypad is remotely mounted from the MX control board. The cable connecting the display can be 1 or 2 meters in length
(39 or 78 inches).
The display comes with a bezel for improved appearance and a higher enclosure rating. When the display is mounted in the bezel the
service rating is NEMA 4.
Figure 15 - Keypad Mounting Dimensions without Bezel
33
Mechanical Drawings
Figure 16 - Keypad Bezel Mounting Dimensions Bezel
34
3 Installation
35
3 – INSTALLATION
Control Board Layout
3.1 Site Preparation
General Information
Before the starter can be installed, the installation site must be prepared. The customer is responsible for:
• Providing the correct power source.
• Providing the correct power protection.
• Selecting the control mechanism.
• Obtaining the connection cables, lugs and all other hardware
• Ensuring the installation site meets all environmental specifications for the enclosure NEMA rating.
• Installing and connecting the motor.
Power Cables
The power cables for the starter must have the correct NEC/CSA current rating for the unit being installed. Depending upon the
model, the power cables can range from a single #14 AWG conductor to four 750 MCM cables. (Consult local and national codes
for selecting wire size)
Site Requirements
The installation site must adhere to the applicable starter NEMA/CEMA rating. For optimal performance, the installation site must
meet the appropriate environmental and altitude requirements
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.
3.2 Installation Precautions
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 and voltage 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 connection cables have been obtained. (LUGS and associated mounting hardware)
• The necessary installation tools and supplies are procured.
• 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 (PFC) are installed on the power source side of the starter and not on the motor side.
Failure to remove power factor correction or surge capacitors from the load side of the starter will result in serious
damage to the starter that will not be covered by the starter warranty. The capacitors must be connected to the line side
of the starter. The up-to-speed (UTS) contact can be used to energize the capacitors after the motor has reached full
speed.
36
3 – INSTALLATION
Control & Power Schematics

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 36).
• 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.
• Consult Table 11, Table 12 and Table 13 Power Ratings for the fault rating.
• Follow all NEC (National Electrical Code) and/or C.S.A. (Canadian Standards Association) standards or Local Codes as
applicable.
• Remove any foreign objects from the interior of the enclosure, especially wire strands that may be left over from installation
wiring.
• Ensure that a qualified electrician installs wiring.
• Ensure that the individuals installing the starter have protective eyewear and clothing.
• Ensure the starter is protected from debris, metal shavings and any other foreign objects.
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.
3.3 Installation Procedures
3.3.1 Installation Procedures
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.
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 or crane).
NOTE: The RB/RC Power Chassis is built with all Metric Hardware.
3.3.2 Wiring Practices
When making power and control signal connections, the following should be observed:
• Never connect input AC power to the motor output terminals T1/U, T2/V, or T3/W.
• Power wiring to the motor must have the maximum possible separation from all other wiring. Do not run control wiring in the
same conduit; this separation reduces the possibility of coupling electrical noise between circuits. Minimum spacing between
metallic conduits containing different wire groups should be three inches (8cm).
• Minimum spacing between different wiring groups in the same tray should be six inches.
• Wire runs outside an enclosure should be run in metallic conduit or have shielding/armor with equivalent attenuation.
• Whenever power and control wiring cross it should be at a 90 degrees angle.
• Different wire groups should be run in separate conduits.
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• Good wiring practice also requires separation of control circuit wiring from all power wiring. Since power delivered from the
starter contains high frequencies while starting and may cause interference with other equipment, do not run control wires in
the same conduit or raceway with power or motor wiring.
NOTE: Local electrical codes must be adhered to for all wiring practices.
3.3.2.1 Considerations for Signal Wiring
Signal wiring refers to the wires connected to the control terminal strip that are low voltage signals, below 15V.
• Shielded wire is recommended to prevent electrical noise interference from causing improper operation or nuisance tripping.
• Signal wire rating should carry as high of a voltage rating as possible, normally at least 300V.
• Routing of signal wire is important to keep as far away from control and power wiring as possible.
3.3.2.2 Considerations for Control and Power Wiring
Control wiring refers to wires connected to the control terminal strip that normally carry 24 to 115V and Power wiring refers to the
line and load connections made to terminals L1/R, L2/S, L3/T, and T1/U, T2/V, T3/W respectively. Select power wiring as follows:
• Use only UL or CSA recognized wire.
• Wire voltage rating must be a minimum of 300V for 230VAC systems and 600V (Class 1 wire) for 460VAC and 600VAC
systems.
• Use a line disconnect in conjunction with fuses on the incoming power lines.
• Grounding must be in accordance with NEC, CEC or local codes. If multiple starters are installed near each other, each must
be connected to ground. Take care to not form a ground loop. The grounds should be connected in a STAR configuration.
• Wire must be made of copper and rated 60/75°C for units 124 Amps and below. Larger amp units may use copper or
aluminum wire. Refer to NEC table 310-16 or local codes for proper wire selection.
3.3.2.3 EMC Installation Guidelines
General In order to help our customers comply with European electromagnetic compatibility standards,
Benshaw Inc. has developed the following guidelines.
Attention This product has been designed for Class A equipment. Use of the product in domestic environments
may cause radio interference, in which case the installer may need to use additional mitigation
methods.
Enclosure Install the product in a grounded metal enclosure.
Grounding Connect a grounding conductor to the screw or terminal provided as standard on each controller.
Refer to layout/power wiring schematic for grounding provision location.
Wiring Refer to Wiring Practices on page 37.
Filtering To comply with Conducted Voltage Limits, a high voltage (1000V or greater) 0.33 uF capacitor
should be connected from each input line to ground at the point where the line enters the cabinet.
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3 – INSTALLATION
Control Board Basic Wiring
3.3.3 Basic Control Wiring Drawing
Digital inputs DI1, DI2, DI3 and relay outputs R1, R2, R3 are pre-programmed. This wiring diagram illustrates a 3-wire start/stop
control by programming DI1 as a stop input. 2-wire start/stop control can be implemented by just using the start input. Refer to
sections 5 & 6 for configuring the Digital and Analog input and output in software.
Figure 17 – Basic Wiring Diagram
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3 – INSTALLATION
3.3.4 Control Board Layout
Figure 18 – Control Board Layout
BIPC 300050-00-01 Serial

SN
Number
120V
Control
SCR 1
Shield Gnd
Ground
120V
Control
SCR 4
NO1
RC1
NC1
SCR 2
NO2
Relay Output
RC2
R1, R2, R3
NC2
NO3
SCR 5
RC3
NC3
START
DI 1
SCR 3
S/DI
Digital Inputs COM
Start, DI1, Terminating Conn 3
DI2
DI2, DI3 Resistor Conn 2
DI3
DI2/D3
CPU Heart Beat LED
COM Serial Com LEDs SCR 6
Modbus
Serial Port
Reset
Button
Analog
Input
& Config
Jumper
CT Input
CT Burden
Selector Switch LED Display & Analog Output
Keypad & Config Jumper
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3 – INSTALLATION
3.4 Power and Control drawings for Bypassed and Non Bypassed Power Stacks
The following figures illustrate the power and control drawings for the different power stacks.
SGH – 700135 – 00 Sheet 1 of 2 Master Power Schematic RBX, 0 – 96 A
SGH – 700135 – 00 Sheet 2 of 2 Master Control Schematic RBX, 0 – 96 A
SGH – 700135 – 01 Sheet 1 of 2 Master Power Schematic RBX, 97 - 361A
SGH – 700135 – 01 Sheet 2 of 2 Master Control Schematic RBX, 97 - 361A
SGH – 700135 – 07 Sheet 1 of 2 Master Power Schematic RBX w/ATL Separate Bypass, 0 – 96 A
SGH – 700135 – 07 Sheet 2 of 2 Master Control Schematic RBX w/ATL Separate Bypass, 0 – 96 A
SGH – 700135 – 08 Sheet 1 of 2 Master Power Schematic RBX w/ATL Separate Bypass, 97A – 838 A
SGH – 700135 – 08 Sheet 2 of 2 Master Control Schematic RBX w/ATL Separate Bypass, 97A – 838 A
SGH – 700135 – 09 Sheet 1 of 2 Master Power Schematic RBC, 3 - 124A
SGH – 700135 – 09 Sheet 2 of 2 Master Control Schematic RBC, 3 - 124A
SGH – 700135 – 10 Sheet 1 of 2 Master Power Schematic RBC, 125 - 838A
SGH – 700135 – 10 Sheet 2 of 2 Master Control Schematic RBC, 125 - 838A
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3 – INSTALLATION
Figure 19 – Power Schematic for RBX Integral Bypass Power Stack, 3 Amps to 96 Amps
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Figure 20 – Control Schematic for RBX Integral Bypass Power Stack, 3 Amps to 96 Amps
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Figure 23 – Power Schematic for RBX Integral Bypass Power Stack, 362 Amps to 720 amps
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Figure 24 – Control Schematic for RBX Integral Bypass Power Stack, 362 Amps to 720 amps
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Figure 27 – Power Schematic for RBX with ATL Separate Bypass 3 – 96 Amp
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Figure 28 – Control Schematic for RBX with ATL Separate Bypass 3 to 96 Amp
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Figure 29 – Power Schematic for RBX with ATL Separate Bypass 97 Amps and up
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Figure 30 – Control Schematic for RBX with ATL Separate Bypass 97 Amp and up
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Figure 31 – Power Schematic for RCX No Bypass 3 to 124 Amp
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Figure 32 – Control Schematic for RCX with No Bypass 3 to 124 Amp
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Figure 33 – Power Schematic for RCX with No Bypass 125 to 840 Amp
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Figure 34 – Power Schematic for RCX with No Bypass 125 to 840 Amp
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3 – INSTALLATION
Installation Procedures
3.4.1 CT Ratio Scaling
The motor current signal scaling is set according to the motor size and the application specified when the starter is ordered. To ensure
accurate operation, the motor current signal must be correctly scaled for the motor (and its application) being controlled by the
starter. Motor current signal scaling may have to be changed if:
• Motor size has been changed from the original specification.
• Motor load has been changed from the original application.
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:
Figure 35 – CT Inputs and CT switches
• ON in the RIGHT position
• OFF in the LEFT position
• Refer to Figure 18 – Control Board Layout for

actual location of switches
CT Input, White wire (+)

CT Input Black wire (-)
NOTE: The applicable ratio is stamped on each CT. Adjust the DIP switches only when there is no current being supplied to the
motor, or the switches could be damaged.
NOTE: See CT Ratio Parameters FUN 03, P68
3.4.1.1 CT Polarity
The CT has a polarity that must be correct for the starter to correctly measure Watts, kW Hours, Power Factor, and for the Power and
TruTorque motor control functions to operate properly.
Each CT has a dot on one side of the flat surfaces. This dot, normally white in color, must be facing in the direction of the line.
The CT can be placed either before or after the starter. In specific applications, like Inside Delta and a starter with a DC brake, the
CT’s must be before the starter.
CT1 must be on Line L1 (R), CT2 must be on Line L2 (S), CT3 must be on Line L3 (T).
3.4.1.2 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 control card to ensure that the DIP switches are in the correct positions for the applicable CT ratio and the motor
full-load Amps (FLA).
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Table 14 – CT Ratios and Burden Switch Settings
CT Ratio Minimum Maximum Switch 6 Switch 6
FLA (A rms) FLA (A rms) Position 1 Position 2
72 2 3 Off Off
(4 wraps 3 4 Off On
288:1) 4 9 On Off
9 16 On On
96 3 4 Off Off
(3 wraps 4 5 Off On
288:1) 5 12 On Off
12 21 On On
144 4 7 Off Off
(2 wraps 7 8 Off On
288:1) 8 18 On Off
18 32 On On
288 8 14 Off Off
14 16 Off On
16 32 On Off
36 64 On On
864 24 42 Off Off
42 50 Off On
50 108 On Off
108 190 On On
1320 37 64 Off Off
(2 wraps 64 76 Off On
2640) 76 165 On Off
165 290 On On
2640 73 128 Off Off
128 151 Off On
151 330 On Off
330 590 On On
2880 73 140 Off Off
140 165 Off On
165 361 On Off
361 640 On On
3900 105 190 Off Off
190 225 Off On
225 490 On Off
490 870 On On
5760 160 280 Off Off
280 330 Off On
330 720 On Off
720 1280 On On
8000 223 390 Off Off
390 465 Off On
465 1000 On Off
1000 1800 On On
14400 400 700 Off Off
Mult. 700 840 Off On
CT-CT 840 1800 On Off
Combinations 1800 3200 On On
28800 800 1400 Off Off
Mult. 1400 1680 Off On
CT-CT 1680 3600 On Off
Combinations 3600 6400 On On
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3.4.2 Configuring the Analog Input
The analog input can be configured for Voltage or Current loop. The input is shipped in the Current Loop configuration unless
specified in a custom configuration. Next to the analog input terminal block is JP3. When the jumper is installed, the input is current
loop. When removed, it is a voltage input. The control is shipped with the jumper JP3 installed.
NOTE: The analog output common also serves as the analog input common.
NOTE: The analog input is a low voltage input, maximum of 15VDC. The input will be damaged if control power (115VAC) or line
power is applied to the analog input.
3.4.3 Configuring the Analog Output
The analog output can be configured for Voltage or Current loop. The output is shipped in the Voltage configuration unless specified
in a custom configuration. Next to the analog output terminal block is JP1. When the jumper is installed, the output is Voltage. When
removed, it is a current loop output. The control is shipped with the jumper installed.
NOTE: The analog output common also serves as the analog input common.
Figure 36 – MX Control Board Analog Jumper Placement
Analog Input Jumper
Analog Output Jumper
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3.5 RBX, Power Stack, Integral Bypass or Separate
3.5.1 Introduction
The RBX power stacks combine the SCR and heatsinks with integrated bypass contactors. Two styles of SCR and heatsinks are used
in the RBX product line. The first is the use of an isolated heatsink with dual flat pack SCR modules mounted on the heatsink. This
style is used up to 96A. The second style uses hockey puck SCR devices, which are sandwiched between two pieces of heatsink. In
this style, the heatsinks are not isolated; in fact they carry the current for the associated phase.
3.5.2 Motor Connections
Illustrated below are two common connections of asynchronous motors that are connected to a solid state motor starter.
3.5.2.1 Line Connected Soft Starter
In Figure 37, the power poles of the soft starter are connected in series with the line. The starter draws line current (L1 ,L2 ,L3 ).
Figure 37 – Typical Motor Connection
6
L1
3 T1
5 T2
L2 Motor
2
T3
4
L3
1
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3.5.2.2 Inside Delta Connection
An inside delta soft starter is shown in Figure 38, where the power poles are connected in series with the stator windings of a delta
connected motor.
Figure 38 – Typical Inside Delta Motor Connection
L3
3 T6 T3
1
6 4
Motor
T1 T5
L1 T4 T2
5 L2
For an Inside Delta connected motor, the inside windings average SCR current is less than that of the outside average line current by
a factor of 1.55 (FLA/1.55). By comparison of Figure 37 and Figure 38, the most obvious advantage of the inside delta starter is the
reduction of current seen by the soft starter. The soft starter current rating can be downsized by a factor of 1.55, providing significant
savings in cost and size of the starter.
An inside delta soft starter can also be considered for motors with more than 6 leads, including 12 lead dual voltage motors.
NEMA and IEC use different nomenclature for motor terminal markings, for 3 and 6 leaded motors.
NEMA labels motors leads, 1,2,3,4,5,6,
IEC labels motor leads, U1, V1, W1, U2, V2, W2
3.5.3 Application Consideration between Line Connected and Inside Delta Connected Soft Starter
There are differences between a line connected soft starter as shown in Figure 37 and the inside delta connected soft starter as shown
in Figure 38.
By observation of Figure 38, access to all six stator-winding terminals is required for an inside delta application. In the line
connected soft starter of Figure 37, access to only three leads of the stator windings of the motor is required. For a 12-lead motor, all
12 stator terminals must be accessible.
One failed SCR on any phase of the inside delta soft starter will result in a single-phase condition. A in line contact or shunt trip
circuit breaker is recommended to protect the motor. A programmable relay can be configured as a shunt trip relay and can be used to
trip the breaker. When certain faults occur, the shunt trip relay energizes. Refer to Appendix B for those faults that cause a shunt trip.
The SCR control for an inside delta application is different than the SCR control for a standard soft starter. The starter type
(parameter FUN 07 or P64) needs to be properly set so that the SCRs are gated correctly.
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If a circuit breaker is the only means to disconnect the soft starter and motor from the line, then one leg of the motor leads in the
inside delta soft starter is always electrically live when the circuit breaker is closed. This requires caution to ensure these leads of the
motor are not exposed to personnel.
3.5.4 Motor Lead Length
The standard starter can operate a motor with a maximum of 2000 feet of properly sized cable between the “T” leads of the starter
and that of the motor. For wire runs greater than 2000 feet contact Benshaw Inc. for application assistance. If shielded cable is used,
consult factory for recommended length.
3.5.5 Bypass Contactor
3.5.5.1 Integral Bypass
The RBX power stack has an integrated contactor that is used to bypass the SCR once the motor is up to speed. The contactor is sized
to handle the current of the motor while running, but is NOT sized to start or stop the motor, this is the function of the solid state
starter. The bypass contactor is used to reduce the heat that would be generated if the SCR’s were not bypassed. While bypassed, the
SCR’s continue to file even though the contactor is bypassing SCR.
3.5.5.2 Separate Bypass
In some starters, the contactor is sized to accommodate a full line start. This variation is typically used as a backup, if for some
reason the solid state starter cannot start the motor.
Benshaw Inc. offers bypass contactor ratings from AC1/definite purpose for bypassing the SCR’s to NEMA rating used for full
voltage starting and plugging.
3.5.6 Incoming Line
3.5.6.1 Recommended Incoming Line Protection
Circuit Breaker, Refer to Table 11 & Table 12
Fuses Refer to Table 11 & Table 12
Input Line Requirements
The input line source needs to be an adequate source to start the motor, generally 2 times the rating of the motors FLA. (This may not
apply in some cases such as being connected to a generator).
The starter may not work correctly when connected to corner grounded delta or split –T (wild leg) connections. Consult factory when
this type of source is to be used.
3.5.6.2 Use of Power Factor Capacitors
Power factor correction capacitors and surge capacitors CAN NOT be connected between the starter and the motor. These devices
can damage the SCRs 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
starter and sequenced into the power circuit after the start is completed. A programmable relay can be configured as an up-to-speed
(UTS) relay and then used to pull-in a contactor to connect the capacitors after the motor has reached full speed.
NOTE: If the motor manufacturer supplies surge capacitors they should be removed before starting
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3 – INSTALLATION
3.5.7 Use of Electro-Mechanical Brakes
If an electro-mechanical brake is used with the starter, it must be powered from the line side of the starter to ensure full voltage is
applied to the brake during a start so it will properly release. A programmable relay can be set to a run and then used to pull-in a
contactor to power the brake whenever the starter is providing power to the motor.
3.6 Power Wiring
Thread the power and motor cables through the correct connector plate opening. Strip away the motor cable insulation and apply anti-
oxidation paste to the conductors, if applicable.
Attach the motor cables:
• Use the T1, T2 and T3 terminals. Use lugs/crimps or terminals. (Lugs and Crimps are to be provided by the user)
Attach the power source cables:
• Use the L1, L2 and L3 terminals. Use lugs/crimps or terminals (Lugs and Crimps are to be provided by the user)
3.6.1 Compression Lugs
The following is a list of the recommended crimp-on wire connectors manufactured by Penn-Union Corp. for copper wire
Table 15 – Single Hole Compression Lugs

Wire Size Part # Wire Size Part #
1/0 BLU-1/0S20 500 MCM BLU-050S2
2/0 BLU-2/0S4 600 MCM BLU-060S1
3/0 BLU-3/0S1 650 MCM BLU-065S5
4/0 BLU-4/0S1 750 MCM BLU-075S
250 MCM BLU-025S 800 MCM BLU-080S
400 MCM BLU-040S4 2000 MCM BLU-200s
450 MCM BLU-045S1
Table 16 – Two Hole Compression Lugs
Wire Size Part # Wire Size Part #
1/0 BLU-1/0D20 500 MCM BLU-050D2
2/0 BLU-2/0D4 600 MCM BLU-060D1
3/0 BLU-3/0D1 650 MCM BLU-065D5
4/0 BLU-4/0D1 750 MCM BLU-075D
250 MCM BLU-025D 800 MCM BLU-080D
400 MCM BLU-040D4 2000 MCM BLU-200D
450 MCM BLU-045D1
3.6.2 Recommended Wire Gauges
The wire gauge selection is based on the FLA of the motor. Refer to NEC table 310-16 or CEC Part 1, Table 2 or local
code requirements for selecting the correct wire sizing. Ensure appropriate wire derating for temperature is applied. If
more than three current carrying conductors are in one conduit, ensure NEC table 310.15(B)(2) is adhered to. In some
areas local codes may take precedence over the NEC. Refer to your local requirements.
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3 – INSTALLATION
3.6.3 CT Mounting
For starters larger than 124 amps, the CTs are shipped loose from the power stack and need to be mounted on the power wiring.
Thread the motor or incoming lead through the CT with the polarity mark towards the line side. (The polarity marks may be a white
dot, an “X” on the side of the CT, or the white wire.) Each phase has its own CT. The CT must then be attached to the power wiring,
at least three inches from the power wire lugs, using two tie-wraps.
3.6.3.1 Line Connected Soft Start
For line connected starters, the CT is on the output of the starter. Refer to Figure 39 – Typical CT Mounting, Output of Starter
Figure 39 – Typical CT Mounting, Output of Starter
MUST BE A 3" (MIN.)

SPACE BETWEEN CT
AND BOTTOM OF
LUG
CUSTOMER MUST FASTEN CT

TO POWER WIRE WITH TWO 1/4"
NYLON WRAPS TO PREVENT
MOVEMENT DURING RUNNING
SIDE VIEW DETAIL FRONT VIEW DETAIL
3.6.3.2 Inside Delta Connection
For inside delta connected starters, the CTs are on the incoming line. Refer to Figure 40 – Typical CT Mounting, Input of Starter.
Figure 40 – Typical CT Mounting, Input of Starter
CUSTOMER MUST FASTEN CT

TO POWER WIRE WITH TWO 1/4"
NYLON WRAPS TO PREVENT
MOVEMENT DURING RUNNING Dot, or X,
White Wire
MUST BE A 3" (MIN.)

SPACE BETWEEN CT
AND TOP OF LUG
FRONT VIEW SIDE VIEW DETAIL
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3 – INSTALLATION
3.6.4 Torque Requirements for Power Wiring Terminations
Table 17 – Slotted Screws and Hex Bolts

Tightening torque, pound-inches (N-m)
Wire size installed in Hexagonal head-external drive socket
conductor Slotted head NO. 10 and larger wrench
AWG or Slot width-0.047 inch Slot width-over 0.047
kcmil (mm2) (1.2mm) or less and slot inch (1.2mm) or slot Split- bolt Other connectors
length ¼ inch (6.4mm) or length – over ¼ inch connectors
less (6.4mm) or less
18 – 10 (0.82 – 5.3) 20 (2.3) 35 (4.0) 80 (9.0) 75 (8.5)
8 (8.4) 25 (2.8) 40 (4.5) 80 (9.0) 75 (8.5)
6–4 (13.3 – 21.2) 35 (4.0) 45 (5.1) 165 (18.6) 110 (12.4)
3 (26.7) 35 (4.0) 50 (5.6) 275 (31.1) 150 (16.9)
2 (33.6) 40 (4.5) 50 (5.6) 275 (31.1) 150 (16.9)
1 (42.4) -- -- 50 (5.6) 275 (31.1) 150 (16.9)
1/0 – 2/0 (53.5 – 64.4) -- -- 50 (5.6) 385 (43.5) 180 (20.3)
3/0 – 4/0 (85.0 – 107.2) -- -- 50 (5.6) 500 (56.5) 250 (28.2)
250 – 350 (127 – 177) -- -- 50 (5.6) 650 (73.4) 325 (36.7)
400 (203) -- -- 50 (5.6) 825 (93.2) 375 (36.7)
500 (253) -- -- 50 (5.6) 825 (93.2) 375 (42.4)
600 – 750 (304 – 380) -- -- 50 (5.6) 1000 (113.0) 375 (42.4)
800 – 1000 (406 – 508) -- -- 50 (5.6) 1100 (124.3) 500 (56.5)
1250 – (635 – 1010) -- -- -- -- 1100 (124.3) 600 (67.8)
2000
NOTE – For a value of slot width or length not corresponding to those specified above, the largest torque value associated with the
conductor size shall be marked. Slot width is the nominal design value. Slot length is measured at the bottom of the slot.
Table 18 – Tightening Torque for Inside Hex Screws
Socket size across flats Tightening torque
inches (mm) Pound-inches (N-m)
1/8 (3.2) 45 (5.1)
5/32 (4.0) 100 (11.3)
3/16 (4.8) 120 (13.6)
7/32 (5.6) 150 (16.9)
1/4 (6.4) 200 (22.6)
5/16 (7.9) 275 (31.1)
3/8 (9.5) 375 (42.4)
1/2 (12.7) 500 (56.5)
9/16 (14.3) 600 (67.8)
NOTE – For screws with multiple tightening means, the largest torque
value associated with the conductor size shall be marked. Slot length
shall be measured at the bottom of the slot.
3.6.5 Meggering a Motor
If the motor needs to be meggered, remove the motor leads from the starter before conducting the
test. Failure to comply may damage the SCRs and WILL damage the control board, which will not be
replaced under warranty.
3.6.6 High Pot Testing
If the starter needs to be high pot tested, remove the SCR gate leads from the control board before
conducting the test. Failure to comply WILL damage the control board WHICH will not be replaced
under warranty.
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3.7 Mounting Considerations
3.7.1 Bypassed Starters
Provisions should be made to ensure that the temperature inside the enclosure never rises above 50°C. If the temperature inside the
enclosure is too high, the starter can be damaged or the operational life can be reduced.
3.7.2 Non-Bypassed Starters (with out bypass)
Provisions should be made to ensure that the temperature inside the enclosure never rises above 50°C. If the temperature inside the
enclosure is too high, the starter can be damaged or the operational life can be reduced. As a general rule of thumb, the following
ventilation guidelines can be followed.
Table 19 – Ventilation Requirements

Current Range Bottom of Enclosure Top of Enclosure
< 200 amps Fans or grills depending on enclosure size
200 to 300 amps 2 x 4” grills (12 sq. in.) 2 x 4” grills (12 sq.in.)
301 to 400 amps 1 x 4” fan (115 cfm) 2 x 4” grills (12 sq.in.)
> 700 amps Consult factory Consult Factory
3.8 Enclosed Product
3.8.1 Packaged by Benshaw Inc.
Benshaw supplies starters under 124 amps non-bypassed, with the heat sink protruding from the back of the enclosure. This allows a
small enclosure size while still maintaining the cooling capability of the starter. The starter produces 4 watts of heat per amp of
current and 14 square inches of enclosure surface is required per watt of heat generation. Contact Benshaw and ask for the enclosure
sizing technical note for more information concerning starters in sealed enclosures.
3.9 Preventive Maintenance
3.9.1 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: a trained technician should always perform preventive maintenance.
3.9.2 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.
• If fans are installed, ensure proper operation
One month after the starter has been put in operation:
• Re-torque all power connections during the month. This includes pre-wired equipment.
• Inspect the cooling fans after two weeks to ensure proper operation.
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3 – INSTALLATION
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 electrical connections more frequently.
3.10 Options
3.10.1 Remote LCD Keypad/Display; MX-1M-RKP-00, MX-2M-RKP-00
The LCD display is remotely mounted from the MX control. The cable connecting the display can be 1 or 2 meters in length (39 or
78 inches).
The display comes with a bezel for improved appearance and a high enclosure rating. The display and bezel have a NEMA 4 service
rating.
3.10.1.1 Installing Driver Board, BIPC-3000049-01
When a remote keypad is used, a driver board is added to the MX control. The driver board connects to connector conn 3 on the MX
control board via a header connector. The driver circuit board is held in place by double-sided tape between the backside of the driver
board and the control card terminal strip. When installing the driver board, first remove the cover over the tape, install the header
connector to the bottom side of the board into the driver board conn J2, and then install the header into Conn 3 on the MX board.
The double-sided tape will adhere to the terminal strip, securing the driver board to the MX control board.
Figure 41 – Driver Board for Remote Keypads
Red Wire
Remote Cable
Ground Wire
3.10.1.2 Installing Remote Cable
The remote interconnect cable is connected between J1 of the driver board and J1 of the remote display. The cable has a 12 pin
connector on each end with one end having a ground wire. The ground wire end is to be connected to J1 of the driver board. Connect
the cable to J1 of the MX control and connect the ground wire to the terminal marked G in the upper left hand corner of the control
terminal strip. The red wire of the connector is on the pin 1 side of the connector for both the driver board and the display.
68
3 – INSTALLATION
3.10.1.3 Mounting The Keypad
Figure 42 –Mounting Remote Keypads
GKT-100008-00
MD-100001-00
Part of GKT-100008-00
KPMXLCDSKP
Note: See Figure 16 for mounting dimensions and hole locations
69
3 – INSTALLATION
3.10.2 Single Phase Soft Starter
There are times a single phase motor may need to be started using a soft starter. This can be accomplished with any 3 phase starter
with the following modifications to the starter.
• Ground L2 Input
• Line power to L1 and L3
• Remove gate leads from TB6 and TB7 and tie off so the leads will not touch anything.
• Remove gate leads from TB8 (SCR 3) and reinstall to TB6, from TB9 (SCR 6) and reinstall to TB7,
• Change Input Phase Sensitivity, P66/FUN04 to “SPH” Single Phase
• Connect motor to terminal T1 and T3
70
3 – INSTALLATION

Figure 43 – Power Schematic for RBX integral Bypass Power Stack for Single Phase Operation
71
3 – INSTALLATION
72
4 Keypad Operation
73
4 – KEYPAD OPERATION
Standard LED Keypad and Display
4.1 Introduction
The MX Control provides a comprehensive set of parameters to allow the use of the reduced voltage solid state starter in nearly any
industrial application. While the starter can meet the requirements of many applications right out of the box, customization of
parameter values to better suit your particular application is easily accomplished with the standard, on-board, 4-digit, 7-segment LED
display/keypad, a remote display/keypad, or via remote serial communication.
The MX control has two remote keypads and displays that are optional equipment; a remote 4-digit, 7-segment LED display and a
2x16-backlit LCD display. Both keypads have the same keys as the standard display with several additional keys including start and
stop keys for operation of the starter from the keypad. When the remote keypad is connected, the local keypad and display are
disabled.
4.2 Standard Keypad and Display
The LED display provides information on starter operation and programming. The 4-digit, 7-segment display shows starter meter
outputs and programming data. Special symbols provide further information about the starter operation (see the following section).
Figure 44 – Standard Keypad and Display
RESET
PARAM DOWN UP ENTER
4.2.1 Special Messages Displayed
The keypad's display may show special information under certain conditions.
Table 20 – LED Special Characters Displayed

No Line Phase order meter showing ABC
Ready Phase order meter showing CBA
Accelerating or Kicking Phase order meter showing Single Phase
Accelerating or Kicking with ramp 2 xxx xxx = overload content.
Up to Speed xx xx = Parameter code.
Run – Done with Accel ramp but not yet Up to xx xx = Alarm code. If the condition persists,
Speed. a fault will occur.
Decelerating Motor xx xx = Fault code.
Overload Alarm – The motor overload level is Instantaneous Overcurrent
between 90% and 100%. Default – Flashes when parameter defaults
Overload Fault – The motor overload level has are loaded.
reached 100%. Heater/Anti-windmill Mode
Overload Lockout – A start is not allowed until the Energy Saver
motor overload level cools below 60%. In reflash mode
Control Power Lockout – A start is not allowed In reflash mode, programming
because the control power is too low. In reflash mode, verifying
Lock out State In reflash mode, complete
74

4.2.2 Viewing and Changing Parameters for the Standard Keypad
4.2.2.1 Viewing Parameter Values
Parameter view mode can be entered by:

1. At the default meter display, press the PARAM key to enter parameter mode. “P 1” will be displayed to indicate Parameter 1.
2. Use the UP and DOWN keys to scroll through the available parameters.
3. Pressing the UP key from “P 1” will advance to parameter “P 2”.
4. Pressing the DOWN key from “P 1” will wrap around to the highest parameter.
5. The value of the parameter can be viewed by pressing the ENTER key.
6. To view another parameter without changing/saving the parameter, press the PARAM key to return to the parameter number
display.
To return to the default meter display either:
1. Press the PARAM key while in the parameter number display mode.
2. Wait 60 seconds and the display will return to the default meter display.
4.2.2.2 Changing Parameter Values
Parameter change mode can be entered by:

1. At the default meter display, press the PARAM key to enter parameter mode.
2. Use the UP and DOWN keys to scroll through the available parameters.
3. The value of the parameter can be viewed by pressing the ENTER key.
4. When viewing the parameter value, the parameter can be changed by using the UP and DOWN keys.
5. To store the new value, press the ENTER key. When the ENTER key is pressed the value will be saved and the display will go
back to parameter # “P_”.
To exit parameter change mode without saving the new parameter value either:
1. Press the PARAM key to return to the parameter number display.
2. Wait 60 seconds and the display will return to the default meter display.
4.2.3 Display Output for the Standard Keypad
The display will output different information depending on the operation of the starter Table 20 – LED Special Characters Displayed.
4.2.3.1 Power Up
The software version will be displayed as a series of blinking digits once power has been applied to the MX control. If the parameters
were being reset on power up, “dFLt” will be flashed on the display for three seconds, then the software version will be displayed.
4.2.3.2 Stopped
When the starter is not in the run mode, the display will show the status condition of the starter, such as “rdY” (ready), “L OL”
(Overload Lockout), “noL” (No Line).
75

4.2.3.3 Running
When running, the display will show the user selected meter function. The following meters can be selected using the “Meter”
display parameter P68.
Avg. RMS current GF Current (% FLA) Overload % MWh Running Time Days
Phase 1 RMS current Avg. Voltage (RMS) Power Factor Phase Rotation Running Time Hours
Phase 2 RMS current L1-L2 Voltage (RMS) KW Line Frequency Starts
Phase 3 RMS current L2-L3 Voltage (RMS) KVA Analog Input % TruTorque %
Current Imbalance % L3-L1 Voltage (RMS) KWh Analog Output % Power %
4.2.3.4 Alarm Condition
When an alarm condition exists, the display alternates between displaying the selected meter and the alarm code. The alarm code is
displayed as “A XX”, where XX is the alarm code.
• When a thermal overload alarm condition exists, “A OL” will be displayed.
• When a no line alarm condition exists, “noL” will be displayed.
When the starter is stopped, the selected meter is not displayed.
4.2.3.5 Lockout Condition
When a lockout condition exists, the display shows the lockout code. The lockout code is displayed as “L XX: where XX is the
lockout code. Following are the defined lockout conditions and their codes:
• When a motor thermal overload lockout condition exists, “L OL” will be displayed.
• When a power stack thermal overload lockout condition exists, “L Ot” will be displayed.
• When a low control power lockout condition exists, “L CP” will be displayed.
When there are multiple lockout codes, each will be displayed at 2 second intervals.
4.2.3.6 Faulted Condition
When a fault condition exists, the display shows the fault code. The exceptions to this are as follows:
• When the fault is thermal overload trip, “F OL” will be displayed.
• When the fault is Instantaneous over current, ioc will be displayed.
4.2.4 Quick Meters
Although any meter may be viewed by changing the meter parameter, there are 3 “Quick Meters” that are always available with a
single key press. When the starter is in the normal display mode, the display may be toggled between the information currently
displayed and the following quick meters.
Status Meter Toggle between the programmed meter display and the starter operational status display (rdY, run,
utS, dcL, etc) by pressing the ENTER key.
Overload Meter Toggle between the programmed meter display and the overload content by pressing the DOWN key.
The overload will be displayed as “oXXX” where XXX is the overload content. For example if the
overload content is 76 percent, it will be displayed as “o 76”.
Phase Order Meter Toggle between the programmed meter display and the phase order by pressing the UP key. The
phase order will be displayed as “AbC” or “CbA”.
76

4.2.5 Restoring Factory Parameter Settings
To restore ALL parameters to the factory default settings, press and hold the PARAM and ENTER pushbutton switch on power up. The
display will blink “dFLt”. Parameters unique to the motor starter applications will need to be set again to appropriate values before
motor operation
4.2.6 Resetting a Fault
To reset from a fault condition, press RESET.
4.2.7 Emergency Thermal Reset
To perform an emergency thermal reset, press RESET and DOWN. This will set the motor thermal overload content to 0.
77
78
5 Troubleshooting
79
5–TROUBLESHOOTING
5.1 The troubleshooting section is divided into 3 sections.
• 5.2 MX Control; General Troubleshooting when MX controlled is installed
• 5.4 SCR Testing
• 5.5 SCR Replacement
5.2 MX Control; General Troubleshooting
The following troubleshooting charts can be used to help solve many of the more common problems that may occur when the MX
control is installed.
5.2.1 Motor does not start, no output to motor
Condition Cause Solution

Display Blank, CPU Heartbeat LED Control voltage absent. Check for proper control voltage
on MX board not blinking. input. Verify fuses and wiring.
MX control board problem. Consult factory.
Fault Displayed. Fault Occurred. See fault code troubleshooting table
for more details.
Start command given but nothing Start/Stop control input problems. Verify that the start/stop wiring and
happens. start input voltage levels are correct.
Control Source parameters (QST 04- Verify that the parameters are set
05, P4-5) not set correctly. correctly.
NOL or No Line is displayed and a No line voltage has been detected by Check input supply for inline
start command is given, it will fault the MX when a start command is contactor, open disconnects, open
in F28. given.. fuses, open circuit breakers, or
disconnected wiring.
Verify that the SCR gate wires are
properly connected to the MX control
board.
On medium voltage systems, verify
wiring of the voltage feedback
measurement circuit.
See fault code troubleshooting table
for more details.
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5 –TROUBLESHOOTING
5.2.2 During starting, motor rotates but does not reach full speed
for more details.
Display shows Accel or Run. Maximum Motor Current setting Review acceleration ramp settings.
(QST 07, P7) set too low.
Motor loading too high and/or current Reduce load on motor during
not dropping below 175% FLA starting.
indicating that the motor has not
come up to speed.
Motor FLA (QST 01, P1) or CT ratio Verify that Motor FLA and CT ratio
(FUN 03, P68) parameter set parameters are set correctly.
incorrectly.
Abnormally low line voltage. Fix cause of low line voltage.
A mechanical or supplemental brake Verify that any external brakes are
is still engaged. disengaged.
Motor Hums before turning Initial current to low Increase initial current
FLA or CT incorrect Verify FLA or CT’s
5.2.3 Acceleration not operating as desired

Motor accelerates too quickly. Ramp time (QST 08, P8) too short. Increase ramp time.
Initial current (QST 06, P6) set too Decrease Initial current.
high.
Maximum current (QST07, P7) set Decrease Maximum current.
too high.
Kick start current (CFN10, P13) too Decrease or turn off Kick current.
high.
Kick start time (CFN11, P14) too Decrease Kick time.
long.
incorrectly.
Starter Type parameter (FUN 07, Verify that Starter Type parameter is
P64) set incorrectly. set correctly.
Motor accelerates too slowly Maximum Motor Current setting Review acceleration ramp settings.
(QST 07, P7) set too low. Increase max current
Motor loading too high. Reduce load on motor during
starting.
incorrectly.
Abnormally low line voltage. Fix cause of low line voltage.
Ramp time to long Decrease ramp time
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5–TROUBLESHOOTING
5.2.4 Deceleration not operating as desired
Motor stops too quickly. Decel Time (CFN17, P18) set to Increase Decel Time.
short.
Decel Begin and End Levels CFN Increase Decel Begin and/or Decel
15-16, P16-17) set improperly. End levels.
Decel time seems correct but motor Decel Begin Level (CFN15, P16) set Decrease Decel Begin Level until
surges (oscillates) at beginning of too high. surging is eliminated.
deceleration cycle.
Decel time seems correct but motor Decel End Level (CFN16, P17) set Increase Decel End Level until motor
stops before end of deceleration too low. just stops at the end of the
cycle. deceleration cycle.
Water hammer still occurs at end of Decel End Level (CFN16, P17) set Decrease Decel End Level until water
cycle. too high. hammer is eliminated.
Decel Time (CFN17, P18) too short. If possible, increase Decel Time to
decelerate system more gently.
Motor speed drops sharply before Decel begin level to low. Increase the Decel Begin Level until
decel drop in speed is eleminated.
5.2.5 Motor stops unexpectedly while running

for more details.
Ready Displayed. Start command lost. Verify start command input signal is
present or serial communications
start command is present.
Check any permissives that may be
wired into the run command
(Start/Stop)
Display Blank, Heartbeat LED on Control voltage absent. Check for proper control voltage
MX board not blinking. input. Verify wiring and fuses.
MX control board problem. Consult factory.
82
5.2.6 Metering incorrect

Power Metering not reading CTs installed or wired incorrectly. Verify correct CT wiring and verify
correctly. that the CTs are installed with all the
White dots towards the input line
side.
CT ratio parameter (FUN 03, P68) set Verify that the CT ratio parameter is
incorrectly. set correctly.
Burden switches set incorrectly. Verify that the burden switches are
set correctly.
PF Meter not reading correctly. CTs installed or wired incorrectly. Verify correct CT wiring and verify
that the CTs are installed with all the
side.
Motor Current or Voltage meters Energy Saver active. Turn off Energy Saver if not desired.
fluctuating with steady load.
Loose connections. Shut off all power and check all
connections.
SCR fault. Verify that the SCRs gate leads are
connected properly and the SCRs are
ok.
Load actually not steady. Verify that the load is actually steady
and that there are not mechanical
issues.
Other equipment on same power feed Fix cause of power fluctuations
causing power fluctuations and/or and/or distortion.
distortion.
Voltage Metering not reading Rated Voltage parameter (FUN 05, Verify that Rated Voltage parameter
correctly. P66) set incorrectly. is set correctly.
Current Metering not reading CT ratio parameter (FUN 03, P68) set Verify that the CT ratio parameter is
correctly. incorrectly. set correctly.
set correctly.
CTs installed or wired incorrectly. Verify correct CT wiring and verify
side.
Ground Fault Current Metering not CT ratio parameter (FUN 03, P68) set Verify that the CT ratio parameter is
reading correctly. incorrectly. set correctly.
set correctly.
CTs installed or wired incorrectly. Verify correct CT wiring and verify
side.
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5–TROUBLESHOOTING
5.2.7 Other Situations
Motor Rotates in Wrong Direction Phasing incorrect If input phasing correct, exchange
any two output wires.
If input phasing incorrect, exchange
any two input wires.
Erratic Operation Loose connections Shut off all power and check all
connections.
Motor Overheats Motor overloaded Reduce motor load.
Too many starts per hour Allow for adequate motor cooling
between starts. Set Hot/Cold ratio
higher or lengthen cooling time.
High ambient temperature Reduce ambient temperature or
provide for better cooling. Set OL
class lower to compensate for
ambient temperature.
Acceleration time too long Reduce starting load and/or review
acceleration ramp settings.
Incorrect motor OL settings Review and correct if necessary
motor OL settings.
Motor cooling obstructed/damaged Remove cooling air obstructions.
Check motor cooling fan.
Starter cooling fans do not operate Fan power supply lost Verify fan power supply, check fuses.
(When Present)
Fan wiring problem Check fan wiring.
Fan failure Replace fan
Analog Output not functioning Voltage/Current output jumper (JP1) Set jumper to give correct output.
properly not set correctly.
Wiring problem Verify output wiring.
Analog Output Function parameter Verify that the Analog Output
(I/O 12, P50) set incorrectly. Function parameter is set correctly.
Analog Output Offset and/or Span Verify that the Analog Output Span
parameters (I/O 13-14, P51-52) set and Offset parameters are set
incorrectly. correctly.
Load on analog output too high. Verify that load on analog output
meets MX control analog output
specifications.
Ground loop or noise problems. Verify correct grounding of analog
output connection to prevent noise
and/or ground loops from affecting
output.
Remote Keypad does not operate Keypad cable not plugged in properly Verify that the remote keypad cable
correctly. or cable damaged. has not been damaged and that it is
properly seated at both the keypad
and the MX Control board.
Display interface board (when Verify that the display interface
present) not firmly plugged in. board (if present) is firmly attached
to MX control card.
Remote display damaged. Replace remote display.
84
5.3 Fault Code Troubleshooting Table
The following is a list of possible faults that can be generated by the MX starter control.
Fault Code Description Detailed Description of Fault / Possible Solutions

F01 UTS Time Limit Expired Motor did not achieve full speed before the UTS timer (QST 09, P9)
expired.
Check motor for jammed or overloaded condition.
Verify that the combined kick time (CFN11, P14) and acceleration ramp
time (QST 08, P8) is shorter than the UTS timer setting.
Evaluate acceleration ramp settings. The acceleration ramp settings may
be too low to permit the motor to start and achieve full speed. If so, revise
acceleration ramp settings to provide more motor torque during starting.
Evaluate UTS timer setting and, if acceptable, increase UTS timer setting
(QST 09, P9).
F02 (F OL) Motor Thermal Overload The MX motor thermal overload protection has tripped.
Trip
Check motor for mechanical failure, jammed, or overloaded condition.
Verify the motor thermal overload parameter settings (QST 03, P3 and
PFN 12-16, P35-38) and motor service factor setting (QST 02, P2).
Verify that the motor FLA (QST 01, P1), CT ratio (FUN 03, P68), and
burden switch settings are correct.
If motor OL trip occurs during starting, review acceleration ramp profile
settings.
Verify that there is not an input line power quality problem or excessive
line distortion present.
Verify that PF caps, if installed, are ahead of CT’s and starter.
Reset overload when content falls below 15%.
F10 Phase Rotation Error, not Input phase rotation is not ABC and Input Phase Sensitivity parameter
ABC (FUN 04, P67) is set to ABC only.
Verify correct phase rotation of input power. Correct wiring if necessary.
Verify correct setting of Input Phase Sensitivity parameter (FUN 04, P67).
F11 Phase Rotation Error, not Input phase rotation is not CBA and Input Phase Sensitivity parameter
CBA (FUN 04, P67) is set to CBA only.
Verify correct phase rotation of input power. Correct wiring if necessary.
Verify correct setting of Input Phase Sensitivity parameter (FUN 04, P67).
F12 Low Line Frequency Line frequency below 23 Hz was detected.
Verify input line frequency.
If operating on a generator, check generator speed governor for
malfunctions.
Check input supply for open fuses or open connections
Line power quality problem / excessive line distortion.
F13 High Line Frequency Line frequency above 72 Hz was detected.
Verify input line frequency.
If operating on a generator, check generator speed governor for
malfunctions.
Line power quality problem / excessive line distortion.
85
5–TROUBLESHOOTING
F14 Input power not single Three-phase power has been detected when the starter is expecting single-
phase phase power.
Verify that input power is single phase.
Verify that single-phase power is connected to the L1 and L3 inputs.
Correct wiring if necessary.
Verify that the SCR gate wires are properly connected to the MX control
board.
F15 Input power not three Single-phase power has been detected when the starter is expecting three-
phase phase power.
Verify that input power is three phase. Correct wiring if necessary.
board.
On medium voltage systems, verify wiring of the voltage feedback
F21 Low Line L1-L2 Low voltage below the Undervoltage Trip Level parameter setting (PFN
08, P31) was detected for longer than the Over/Under Voltage Trip delay
time (PFN 09, P32).
Verify that the actual input voltage level is correct.
Verify that the Rated Voltage parameter (FUN 05, P66) is set correctly.
Check input supply for open fuses or open connections.
On medium voltage systems, verify wiring of the voltage measurement
circuit.
time (PFN 09, P32).
time (PFN 09, P32).
F24 High Line L1-L2 High voltage above the Over voltage Trip Level parameter setting (PFN
time (PFN 09, P32).
Line power quality problems/ excessive line distortions.
86
time (PFN 09, P32).
time (PFN 09, P32).
F27 Phase Loss The MX control has detected the loss of one or more input or output
phases when the starter was running. Can also be caused by line power
dropouts.
Check input supply for open fuses.
Check power supply wiring for open or intermittent connections.
Check motor wiring for open or intermittent connections.
Check Gate and Cathode connections to MX board
F28 No Line No input voltage was detected for longer than the Inline Configuration
time delay parameter setting (I/O 15, P53) when a start command was
given to the starter.
If an inline contactor is being used, verify that the setting of the Inline
Configuration time delay parameter (I/O 15, P53) allows enough time for
the inline contactor to completely close before the No Line fault occurs.
Check input supply for open disconnects, open fuses, open circuit
breakers, or disconnected wiring.
board.
F30 I.O.C. During operation, the MX controller detected a very high level of current
in one or more phases.
(Instantaneous
Overcurrent Current) Check motor wiring for short circuits or ground faults.
Check motor for short circuits or ground faults.
Check if power factor or surge capacitors are installed on the motor side
of the starter.
F31 Overcurrent Motor current exceeded the Over Current Trip Level setting (PFN 01,
P24) for longer than the Over Current Trip Delay Time setting (PFN 02,
P25).
Check motor for a jammed or an overload condition.
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5–TROUBLESHOOTING
F34 Undercurrent Motor current dropped under the Under Current Trip Level setting (PFN
03, P26) for longer than the Under Current Trip Delay time setting (PFN
04, P27).
Check system for cause of under current condition.
F37 Current Imbalance A current imbalance larger than the Current Imbalance Trip Level
parameter setting (PFN 05, P28) was present for longer than ten (10)
seconds.
Check motor wiring for cause of imbalance. (Verify dual voltage and 6
lead motors for correct wiring configuration).
Check for large input voltage imbalances that can result in large current
imbalances.
Check motor for internal problems.
F38 Ground Fault Ground current above the Ground Fault Trip level setting (PFN 06, P29)
has been detected for longer than 3 seconds.
Check motor wiring for ground faults.
Check motor for ground faults.
Megger motor and cabling (disconnect from starter before testing).
Verify that the CTs are installed with all the White dots towards the input
line.
In Single phase applications, verify that only two CTs are being used; that
they are installed with all the White dots or Xs in the correct direction;
and that the CTs are connected to the L1 and L3 CT inputs on the MX
control card.
F39 No Current at Run Motor current went below 10% of FLA while the starter was running.
Verify Motor Connections.
Verify the CT wiring to the MX control board.
Check if load is still connected to starter
Check if motor may have been driven by the load (a regeneration
condition)
Check Gate and Cathode connections to MX for loose connections.
Check for inline contactor or disconnect.
F40 Shorted / Open SCR A shorted or open SCR condition has been detected.
Verify that all SCR gate leads wires are properly connected at the SCR
devices and the MX control board.
Check all SCRs with ohmmeter for shorts.
Verify that the Input Phase Sensitivity parameter setting (FUN 04, P67) is
correct.
Verify that the Starter Type parameter setting (FUN 07, P64) is correct.
Verify the motor wiring. (Verify dual voltage motors for correct wiring
configuration).
88
F41 Current at Stop Motor current was detected while the starter was not running.
Examine starter for shorted SCRs.
Examine bypass contactor (if present) to verify that it is open when starter
is stopped.
F47 Stack Protection Fault The MX electronic power stack OL protection has detected an overload
(stack thermal overload) condition.
Check motor for jammed or overloaded condition.
Verify Starter Model Number parameter setting (FUN 13, P70) is correct
(if available).
Verify that the CT ratio (FUN 03, P68) and burden switch settings are
correct.
Motor load exceeds power stack rating. Consult factory
F48 Bypass /2M Contactor A digital input has been programmed as a Bypass/2M Contactor Feedback
Fault input and an incorrect bypass feedback has been detected for longer than
the Bypass Confirm time parameter setting (I/O 16, P54).
Verify that the bypass/2M contactor coil and feedback wiring is correct.
Verify that the relay output that is connected to the bypass/2M contactor(s)
is programmed to the UTS function.
Verify that the bypass/2M contactor power supply is present.
Verify that the appropriate Digital Input Configuration parameter has been
programmed correctly.
Verify that the bypass contactor(s) are actually not damaged or faulty.
F50 Control Power Low Low control power (below 90V) has been detected while running, by the
MX controller.
Verify that the control power input level is correct especially during
starting when there may be significant line voltage drop.
Check control power transformer tap setting (if available).
Check control power transformer fuses (if present).
Check wiring between control power source and starter.
F51 Current Sensor Offset Indicates that the MX control board self-diagnostics have detected a
Error problem with one or more of the current sensor inputs.
Verify that no actual current is flowing through any of the starter’s CTs
when the starter is not running.
Consult factory if fault persists.
F52 Burden Switch Error The burden switch settings were changed when starter was running. Only
change burden switches when starter is not running.
F60 External Fault on DI#1 DI#1 has been programmed as a fault type digital input and the input
Input indicates a fault condition is present.
Verify wiring and level of input.
89
5–TROUBLESHOOTING
F61 External Fault on DI#2 DI#2 has been programmed as a fault type digital input and input indicates
Input a fault condition is present.
F62 External Fault on DI#3 DI#3 input has been programmed as a fault type digital input and input
input indicates a fault condition is present.
F71 Analog Input Level Fault Based on the Analog Input parameter settings, the analog input level has
Trip. either exceeded or dropped below the Analog Input Trip Level setting (I/O
08, P46) for longer than the Analog Input Trip Delay time (I/O 09, P47).
Measure value of analog input to verify correct reading.
Verify settings of all Analog Input parameters (I/O 07-11, P45-49).
Verify correct positioning of input jumper JP3 (Voltage or Current) on the
MX control card.
Verify correct grounding of analog input connection to prevent noise or
ground loops from affecting input.
F81 SPI Communication Fault Indicates that communication has been lost with a remote device such as a
remote keypad.
(This fault will normally occur if the remote keypad is disconnected while
the MX control board is powered up. Only connect and disconnect a
remote keypad when the control power is off.)
Verify that the remote keypad cable has not been damaged and that its
connectors are firmly seated at both the keypad and the MX Control
board.
Verify that the display interface board (when present) is firmly attached to
MX control card.
Route keypad cables away from high power and/or high noise areas to
reduce possible electrical noise pickup.
F82 Modbus Timeout Fault Indicates that the starter has lost serial communications. Fault occurs
when the starter has not received a valid serial communications within the
Communication Timeout parameter (FUN 12, P59) defined time.
Verify communication parameter settings (FUN 10-12, P59-P61).
Check wiring between the remote network and the MX control card.
Examine remote system for cause of communication loss.
F94 CPU Error – SW fault Typically occurs when attempting to run a version of control software that
is incompatible with the MX control board hardware being used. Verify
that the software is a correct version for the MX control board being used.
Consult factory for more details.
Fault can also occur if the MX control has detected an internal software
problem. Consult factory.
90
F95 CPU Error – Parameter The non-volatile user parameter values have been found to be corrupted.
EEPROM Checksum Typically occurs when the MX control is re-flashed with new software.
Fault
Perform a Factory Parameter reset and then properly set all user
parameters before resuming normal operation.
If fault persists after performing a Factory Parameter reset, consult
factory.
F96 CPU Error The MX control has detected an internal CPU problem. Consult factory.
F97 CPU Error – SW The MX control has detected an internal software problem. Consult
Watchdog Fault factory.
F98 CPU Error The MX control has detected an internal CPU problem. Consult factory.
F99 CPU Error – Program The non-volatile program memory has been corrupted.
EPROM Checksum Fault
Consult factory. Control software will need to be reloaded in to the MX
control card before normal operation can resume.
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5–TROUBLESHOOTING
5.4 SCR Testing
Resistance The SCR in the starter can be checked with a standard ohmmeter to determine their condition.
Remove power from the starter before performing these checks
Check from L to T on each phase. The resistance should be over 50k ohms.
Check between the gate leads for each SCR (red and white twisted pair). The resistance should be
from 8 to 50 ohms.
NOTE: The resistance measurements may not be within these values and the SCR may still be good.
The checks are to determine if an SCR is shorted “L” to “T” of if the gate in an SCR is shorted or
open. An SCR could also still be damaged even though the measurements are within the above
specifications.
Voltage When the starter is running, the operation of SCR can be confirmed with a voltmeter.
Extreme caution must be observed while performing these checks since the starter has lethal
voltages applied while operating
While the starter is running and up to speed, use an AC voltmeter, check the voltage from “L” to “T”
of each phase. The voltage should be less that 1.5 Volts. If the starter has a bypass contactor, the
voltage drop should be less that 0.3 volts.
Using a DC voltmeter, check between the gate leads for each SCR (red and white twisted pair). The
voltage should between 0.5 and 2.0 volts.
Integral Bypass A voltage check from “L” to “T” of each phase of the RediStart starter should be preformed every 6
months to confirm the bypass contactors are operating correctly.
Extreme caution must be observed while performing these checks since the starter has lethal
voltages applied while operating
While the starter is running and Up to Speed, use an AC voltmeter; check the voltage from “L” to
“T” of each phase. The voltage drop across the contactor contacts should be less than 300mV. If
greater that 300mV the integral bypass should be disassembled. It may be necessary to clean the
contact tips or replace the contactor.
92
5.5 SCR Replacement
This section is to help with SCR replacements on stack assemblies. Please read prior to installation.
5.5.1 Typical Stack Assembly
5.5.2 SCR CLAMP PARTS
Item # Quantity Description

1 1 Loader Bar
2 2 Insulator cup
3 2 Bolt
4 2 Washer
5 2 Serrated nut (larger style clamp has 1 support bar)
6 1 or 2 Indicator Washer – Quantity dependant on style of
clamp
93
5–TROUBLESHOOTING
5.5.3 SCR Clamp
Below is an exploded view of a typical SCR clamp. Refer to the Clamp Parts List for names of the parts being
used.
5.5.4 SCR Removal

To remove the SCR from the heatsink, loosen the two bolts (3) on the loader bar side of the clamp. Do not turn on the
nuts (5). The nuts have a locking ridge that sink into the aluminum heatsink. Do ¼ turns until the SCR comes loose.
Remove the SCRs from the heatsink.
Note: Do not loosen nut on indicator washer (6). This will change the clamping pressure of the clamp and the clamp
will be defective.
5.5.5 SCR INSTALLATION

• Coat the faces of the SCRs to be installed with a thin layer of EJC.
• Place the SCRs onto the dowel pins. The top SCR will have the cathode to the left and the bottom SCR will have
the cathode to the right. The SCR symbol has a triangle that points to the cathode.
• Finger tighten nuts on the bolts.
5.5.6 Tightening Clamp

Finger tighten the clamp. Ensure both bolts are tightened an equal amount so that the loader bar (item 1) is square in the
heatsink. Tighten the bolts equally in 1/8 turn increments until the indicator washer(s) (item 6), which are under the
nut(s) in the center of the loader bar, becomes loose indicating the clamp is tight. On the loader bars with two indicator
washers, it may be necessary to tighten or loosen one side of the clamp to get both indicator washers free.
5.5.7 Testing SCR
After the SCRs have been replaced, conduct the resistance test as defined in section 5.4
94
6 Appendices
95
List of Tables
Table 1 – Environmental Ratings................................................................................................................................................................ 8
Table 2 – Altitude Derating ........................................................................................................................................................................ 8
Table 3 – Terminals ................................................................................................................................................................................... 9
Table 4 - Connectors .................................................................................................................................................................................10
Table 5 – Accuracy ...................................................................................................................................................................................10
Table 6 – CT Ratios ..................................................................................................................................................................................11
Table 7 – Class 10 (Standard Duty) Horsepower Ratings............................................................................................................................13
Table 8 – Class 20 (Heavy Duty) Horsepower Ratings ...............................................................................................................................14
Table 9 – Class 30 (Severe Duty) Horsepower Ratings...............................................................................................................................15
Table 10 – Inside Delta Class 10 (Standard Duty) Horsepower Ratings.......................................................................................................16
Table 11 – Power Ratings with Integral Bypass..........................................................................................................................................17
Table 12 – Power Ratings with Separate Bypass ........................................................................................................................................18
Table 13 – Power Ratings with No Bypass.................................................................................................................................................19
Table 14 – CT Ratios and Burden Switch Settings......................................................................................................................................59
Table 15 – Single Hole Compression Lugs.................................................................................................................................................64
Table 16 – Two Hole Compression Lugs ...................................................................................................................................................64
Table 17 – Slotted Screws and Hex Bolts...................................................................................................................................................66
Table 18 – Tightening Torque for Inside Hex Screws .................................................................................................................................66
Table 19 – Ventilation Requirements.........................................................................................................................................................67
Table 20 – LED Special Characters Displayed ...........................................................................................................................................74
96
List of Figures
Figure 1 – Common Motor Overload Curves .............................................................................................................................................12
Figure 2 - Dimensions for 2 to 65 Amp RB_1 Starter .................................................................................................................................20
Figure 3 - Dimensions for 66 to 96 Amp RB_1 Starter ...............................................................................................................................21
Figure 4 - Dimensions for 97 to 361 Amp RB_1 Starter............................................................................................................................22
Figure 5 - Dimensions for 362 to 720 Amp RB_1 Starter............................................................................................................................23
Figure 6 - Dimensions for 838 Amp RB_1 Starter......................................................................................................................................24
Figure 7 - 2 to 65 Amp Dimensions with ATL Bypass (AC3 or AC4/NEMA rating) ..................................................................................25
Figure 8 - 66 to 77 Amp Dimensions with ATL Bypass (AC3 rating).........................................................................................................26
Figure 9 - 78 to 96 Amp Chassis Dimensions for use with separate ATL Bypass........................................................................................27
Figure 10 - 97 to 361 Amp Chassis Dimensions for use with Separate Bypass (ATL) ..................................................................................28
Figure 11 - 362 to 840 Chassis Dimensions for use with Separate Bypass (ATL) ........................................................................................29
Figure 12 - 2 to 124 Amp Dimensions for Continuous Operation Chassis...................................................................................................30
Figure 13 - 125 to 477 Amp Dimensions for Continuous Operation Chassis..............................................................................................31
Figure 14 - 478 to 840 Amp Dimensions for Continuous Operation Chassis..............................................................................................32
Figure 15 - Keypad Mounting Dimensions without Bezel...........................................................................................................................33
Figure 16 - Keypad Bezel Mounting Dimensions Bezel..............................................................................................................................34
Figure 17 – Basic Wiring Diagram ............................................................................................................................................................39
Figure 18 – Control Board Layout .............................................................................................................................................................40
Figure 19 – Power Schematic for RBX Integral Bypass Power Stack, 3 Amps to 96 Amps ..........................................................................42
Figure 20 – Control Schematic for RBX Integral Bypass Power Stack, 3 Amps to 96 Amps ........................................................................43
Figure 21 – Power Schematic for RBX Integral Bypass Power Stack, 97 Amps to 361 Amps ......................................................................44
Figure 22 – Control Schematic for RBX Integral Bypass Power Stack, 97 Amps to 361 Amps ....................................................................45
Figure 23 – Power Schematic for RBX Integral Bypass Power Stack, 362 Amps to 720 amps .....................................................................46
Figure 24 – Control Schematic for RBX Integral Bypass Power Stack, 362 Amps to 720 amps....................................................................47
Figure 25 – Power Schematic for RBX Integral Bypass Power Stack, 721 Amps to 840 Amp......................................................................48
Figure 26 – Control Schematic for RBX Integral Bypass Power Stack, 721 Amps to 840 Amp ....................................................................49
Figure 27 – Power Schematic for RBX with ATL Separate Bypass 3 – 96 Amp ........................................................................................50
Figure 28 – Control Schematic for RBX with ATL Separate Bypass 3 to 96 Amp .....................................................................................51
Figure 29 – Power Schematic for RBX with ATL Separate Bypass 97 Amps and up .................................................................................52
Figure 30 – Control Schematic for RBX with ATL Separate Bypass 97 Amp and up.................................................................................53
Figure 31 – Power Schematic for RCX No Bypass 3 to 124 Amp ..............................................................................................................54
Figure 32 – Control Schematic for RCX with No Bypass 3 to 124 Amp ....................................................................................................55
Figure 33 – Power Schematic for RCX with No Bypass 125 to 840 Amp ..................................................................................................56
Figure 34 – Power Schematic for RCX with No Bypass 125 to 840 Amp ..................................................................................................57
Figure 35 – CT Inputs and CT switches .....................................................................................................................................................58
Figure 36 – MX Control Board Analog Jumper Placement .........................................................................................................................60
Figure 37 – Typical Motor Connection ......................................................................................................................................................61
Figure 38 – Typical Inside Delta Motor Connection ...................................................................................................................................62
Figure 39 – Typical CT Mounting, Output of Starter ..................................................................................................................................65
Figure 40 – Typical CT Mounting, Input of Starter.....................................................................................................................................65
Figure 41 – Driver Board for Remote Keypads ..........................................................................................................................................68
Figure 42 –Mounting Remote Keypads......................................................................................................................................................69
Figure 43 – Power Schematic for RBX integral Bypass Power Stack for Single Phase Operation.................................................................71
Figure 44 – Standard Keypad and Display .................................................................................................................................................74
97
Appendix A – CE Mark
According to the EMC – Directive 89/336/EEC as Amended by 92/31/EEC and 93/68/EEC
Product Category: Motor Controller
Product Type: Reduced Voltage Solid State Motor Controller
Model Numbers:
RBX-1-S-027A-11C RBX-1-S-096A-13C RBX-1-S-240A-15C RBX-1-S-515A-17C
RBX-1-S-077A-13C RBX-1-S-180A-15C RBX-1-S-477A-17C
RCX-1-S-096A-13C RCX-1-S-240A-15C RCX-1-S-515A-17C

RCX-1-S-180A-15C RCX-1-S-477A-17C
Manufacturer’s Name: Benshaw, Inc.
Manufacturer’s Address: 1659 East Sutter Road

Glenshaw, PA USA
15116
The before mentioned products comply with the following EU directives and Standards:
Safety: UL 508 Standard for Industrial Control Equipment covering devices for starting, stopping, regulating,
controlling, or protecting electric motors with ratings of 1500 volts or less.
EMC: 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 products referenced above are for the use of control of AC motors.
For application information, consult the following document from Benshaw:
The use in residential and commercial premises (Class B) requires an optional EMC series filter.
Via internal mechanisms and Quality Control, it is verified that these products conform to the
requirements of the Directive and applicable standards.
Glenshaw, PA USA - 1 October 2003
Neil Abrams Durand Miller

Quality Control VP General
Manager Manager
98
Appendix B – Fault Codes
See Section 7 for Troubleshooting Solutions

Fault Description Controlled Shunt Trip Auto-Reset
Code Fault Stop Fault Allowed
F00 No fault - - -
F01 UTS Time Limit Expired Y N Y
F02 Motor Thermal Overload Trip Y N Y
F03 Jog Time Limit Expired N N N
F04 Reserved
F10 Phase Rotation Error, not ABC N N Y
F11 Phase Rotation Error, not CBA N N Y
F12 Low Line Frequency N N Y
F13 High Line Frequency N N Y
F14 Input power not single phase N N Y
F15 Input power not three phase N N Y
F21 Low Line L1-L2 Y N Y
F24 High Line L1-L2 Y N Y
F27 Phase Loss N N Y
F28 No Line N N Y
F29 Reserved
F30 I.O.C. N Y N
F31 Overcurrent Y N Y
F34 Undercurrent Y N Y
F35 Reserved
F36 Reserved
F37 Current Imbalance Y N Y
F38 Ground Fault N Y Y
F39 No Current at Run N N Y
F40 Shorted / Open SCR N Y N
F41 Current at Stop N Y N
F47 Stack Protection Fault (stack thermal overload) N N Y
F48 Bypass Contactor Fault Y N N
F50 Control Power Low N N Y
F51 Current Sensor Offset Error - Y N
F52 Burden Switch Error N N N
F53 Reserved
F60 External Fault on DI 1 Input N N Y
F63 Reserved
F64 Reserved
F71 Analog Input #1 Level Fault Trip (local) Y N Y
F72 Reserved
F73 Reserved
F81 SPI Communication Fault Y N N
F82 Modbus Timeout Fault Y N Y
F94 CPU Error – SW fault N N N
F95 CPU Error – Parameter EEPROM Checksum Fault N N
F96 CPU Error N Y N
F97 CPU Error - SW Watchdog N Y N
F98 CPU Error N N N
F99 CPU Error – Program EPROM Checksum Fault N N N
99
Appendix C – Alarm Codes
The following is a list of all MX alarm codes. The alarm codes correspond to associated fault codes. In general, an alarm indicates a
condition that if continued, will result in the associated fault.
Alarm Description Notes
Code
A02 Motor Overload Alarm This occurs when the motor thermal content reaches the
90%. The MX will trip when it reaches 100%. The alarm
will continue until the overload trip lockout is reset.
A10 Phase Rotation not ABC This alarm exists while the MX is stopped and line voltage
is detected and phase sensitivity parameter is set to ABC.
If a start is commanded, a Fault 10 will occur.
A11 Phase Rotation not CBA This alarm exists while the MX is stopped and line voltage
is detected and phase sensitivity parameter is set to CBA.
If a start is commanded, a Fault 11 will occur.
A12 Low Line Frequency This alarm exists when the MX has detected a line
frequency below the user defined low line frequency level.
The alarm will continue until either the line frequency
changes to be in range or the fault delay timer has expired.
A13 High Line Frequency This alarm exists when the MX has detected a line
frequency above the user defined high line frequency level.
The alarm will continue until either the line frequency
changes to a valid frequency or the fault delay timer has
expired.
A14 Input power not single phase This alarm exists while the MX is stopped, set to single
phase mode, and line voltage is detected. If a start is
commanded, a Fault 14 will occur.
A15 Input power not three phase This alarm exists while the MX is stopped, set to a three-
phase mode, and single-phase line voltage is detected. If a
start is commanded, a Fault 15 will occur.
A21 Low Line L1-L2 This alarm exists while the MX is stopped and low line
voltage is detected. If a start is commanded, a Fault 21
may occur.
may occur.
may occur.
A24 High Line L1-L2 This alarm exists while the MX is stopped and high line
may occur.
may occur.
may occur.
A27 Phase Loss This alarm exists while the MX is running and a phase loss
condition is detected, but the delay for the fault has not yet
expired. When the delay expires, a Fault 27 will occur.
A28 No Line This alarm exists while the MX needs to be synced or is
trying to sync to the line and no line is detected.
A31 Overcurrent This alarm exists while the MX is running and the average
current is above the defined threshold, but the delay for the
fault has not yet expired. When the delay expires, a Fault
31 will occur.
A34 Undercurrent This alarm exists while the MX is running and the average
current is below the defined threshold, but the delay for the
fault has not yet expired. When the delay expires, a Fault
34 will occur.
A35 Reserved
100
Alarm Description Notes
Code
A36 Reserved
A37 Current Imbalance This alarm exists while the MX is running and a current
imbalance above the defined threshold is detected, but the
delay for the fault has not yet expired. When the delay
expires, a Fault 37 will occur.
A38 Ground Fault This alarm exists while the MX is running and a ground
current above the defined threshold is detected, but the
delay for the fault has not yet expired. When the delay
expires, a Fault 38 will occur.
A47 Stack Overload Alarm This occurs when the stack thermal rises above 105%.
A53 Reserved
A71 Analog Input #1 Trip This alarm will exist if analog input #1 exceeds the defined
threshold, but the delay for the fault has not yet expired.
When the delay expires, a Fault 71 will occur.
101
Appendix D – Spare Parts
Consult Factory
102
Revision History
Revision Date Changes ECO#

00 26 June 2004 Initial Release
01 30 June 2004 Corrected figures 27, 28, 29, 30, 31, 32 E0833
02 29 July 2005 Corrected keypad grounding E1041
103
Sales and Service
United States
Pittsburgh, Pennsylvania
Indianapolis, Indiana
Syracuse, New York
Boston, Massachusetts
BENSHAW PRODUCTS Charlotte, North Carolina
Birmingham, Alabama
Los Angeles, California
Detroit, Michigan
Milwaukee, Wisconsin
Phoenix, Arizona
Seattle, Washington
Low Voltage Solid State Reduced Voltage Starters Denver, Colorado
Houston, Texas
® RSD/RSM6 - SSRV Non or Separate Bypass Minneapolis, Minnesota
® RDB/RMB6 - SSRV Integral Bypass Newark, New Jersey
® RSM7 - SSRV + DC Injection Braking Canada

Listowel, Ontario
® RSM10 - SSRV + Reversing Toronto, Ontario
Montreal, Quebec
® RSM11 - SSRV + DC Injection Braking + Reversing Calgary, Alberta
® RSM10/12TS - SSRV Two Speed South America

Sao Paulo, Brazil
® WRSM6 - SSRV Wound Rotor Santiago, Chile
Lima, Peru
® SMRSM6 - SSRV Synchronous Bogota, Columbia
Beunos Aires, Argentina
® DCB3 - Solid State DC Injection Braking Santa Cruz, Bolivia
Guayaquil, Ecuador
Mexico
Shanghai
Medium Voltage Solid State Reduced Voltage Starters Australia
® 5kV - Induction or Synchronous to 10,000HP Singapore
® 7.2kV - Induction or Synchronous to 10,000HP BENSHAW Inc.
1659 East Sutter Road
® 15kV - Induction or Synchronous to 60,000HP Glenshaw, PA 15116
Phone: (412) 487-8235
Fax: (412) 487-4201
BENSHAW West
Low Voltage - AC Drives 14715 North 78th Way
Suite 600
® Standard Drives to 1000HP Scottsdale, AZ 85260
® Custom Industrial Packaged Drives Phone: (480) 905-0601
Fax: (480) 905-0757
® HVAC Packaged Drives
BENSHAW High Point
® 18 Pulse/IEEE 519 Compliant Drives EPC Division
645 McWay Drive
High Point, NC 27263
Phone: (336) 434-4445
Fax: (336) 434-9682
RSC Series Contactors
BENSHAW Mobile
® SPO/SPE/SPD Motor Protection Relays CSD Division
5821 Rangeline Road Suite 202
® Enclosed Full Voltage, Wye Delta, Two Speed Theodore, AL 36582
Part Winding and Reversing Starters Phone: (251) 443-5911
Fax: (251) 443-5966
BENSHAW Pueblo
Trane Division
Custom OEM Controls 1 Jetway Court
Pueblo, CO 81001
Phone: (719) 948-1405
Fax: (719) 948-1445
BEN-Tech Industrial Automation

2904 Bond Street
Rochester Hills, MI 48309
Phone: (248) 299-7700
Fax: (248) 299-7702
BENSHAW Canada Controls

550 Bright St. E.
Listowel, Ontario N4W 3W3
Phone: (519) 291-5112
Fax: (519) 291-2595

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What safety precautions are outlined in the manual?

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What components does the RediStart Solid State Starter consist of?

What components does the RediStart Solid State Starter consist of?

PUBLICATION #890023-02-02

RediStart Solid State Starter

© 2004 Benshaw Inc. All Rights Reserved

Benshaw and are registered trademarks of Benshaw Incorporated.

4. Do not connect or disconnect the wires to or from the starter when

5. Ensure shielded cables are discharged.

1. Service only by qualified personnel.

2. Make sure ground connection is in place.

3. Make certain proper shield installation is in place.

Using This Manual

1.1 Using this manual

The sections are as follows:

Warning: Electrical Hazard that could result in injury or death.

Caution that could result in damage to the starter.

Using This Manual

Benshaw offers its customers the following:

On-Site Training Services

Benshaw provides all customers with:

All documentation is available on-line at http://www.benshaw.com.

Spare and replacement parts can be purchased from Benshaw.

Refer to the Revision History in the appendices.

1.2 Contacting Benshaw

Benshaw Inc. Corporate Headquarters

Benshaw Canada Controls Inc.

Interpreting Model Numbers

• Ensure all connections and wires are secured.

• The starter numbering system for a chassis is:

Family of RediStart Starter

Example of the model Number: RBX-1S-361A-14C

1.4 General Overview of a Reduced Voltage Starter

Features The enhanced engineering features of the starter include:

2.1 General Information

2.2 Environmental Conditions

Table 1 – Environmental Ratings

2.3 Altitude Derating

Table 2 – Altitude Derating

MX control UL, cUL Recognized

RB__ power stacks & Controls UL, cUL Listed

RC__ power stacks & Controls UL, cUL Listed

2.5 Certificate of compliance

2.6.1 Terminal Points, Functions and Ratings

Refer to section 3.3.4 on page 40 for terminal placement.

2.6.2 Terminal Block Rating

2.6.2.1 Wire Gauge

2.6.2.2 Wire Strip Length

The strip length should be 5/16”

2.6.2.3 Torque rating

2.6.3 Connectors, Functions and Ratings

2.6.4 Measurements, Accuracy and Ratings

2.6.6 List of Motor Protection Features

2.6.7 Solid State Motor Overload

Figure 1 – Common Motor Overload Curves

Refer to http://www.benshaw.com/olcurves.html for an automated overload

2.7.1 Horse power Starter Rating

Table 8 – Class 20 (Heavy Duty) Horsepower Ratings