MX Hardware Manual

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
ii

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
SAFETY PRECAUTIONS
iii

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.
TABLE OF CONTENTS
iv
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
TABLE OF CONTENTS
v
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 TABLE ................................................................................................................. 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

TABLE OF CONTENTS
vi

1 Introduction
1 INTRODUCTION
Using This Manual
2
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.
1 INTRODUCTION
Using This Manual
3
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.

1 INTRODUCTION
Contacting Benshaw
4
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 78
th
Way, Suite 600
Scottsdale, AZ 85260
United States of America
Phone: (480) 905-0601
Fax: (480) 905-0757
E-Mail: usatechsupport@benshaw.com
cantechsupport@benshaw.com
Technical support for MX Control Series is available at no charge by contacting Benshaws 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

1 INTRODUCTION
Interpreting Model Numbers
5
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
Amp Rating, (0 999A )
Family of RediStart Starter
B = Bypass
C = Continuos
Type of Control
M = Micro II Control
X = MX Control
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)
Fault Level
S = Standard
H = High
Frame Size

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
1 INTRODUCTION
General Overview
6
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

7
2 Technical Information
2 TECHNICAL INFORMATION
Technical Specifications
8
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 0C to +50C (32F to 122F)
Storage Temperatures -20C to +70C (-4F to 155F)
Maximum heatsink temperatures 90C (194F), during a start
Humidity 0% to 95% non condensing
Altitude 1000m (3300ft) without derating
Maximum Vibration 5.9m/s
2
(19.2ft/s
2
) [0.6G]
Cooling Natural convection RB, Forced Air RC
2.3 Altitude Derating
Benshaws 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
9
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
L, line
G, ground
96 144V AC input
45VA current requirements
Line Frequency, 23 to 72Hz
Relay Output R1 NC1: Normally Closed
RC1:Common
NO1:Normally Open

Relay Output, SPDT form C
5 Amp, 125VAC, resistive
1 Amp, 125VAC, 0.4PF
100VA Inrush
Relay Output R2 & R3 NC2, RC2, NO2
NC3, RC3, NO3
Relay Output, SPDT form C
16 Amp, 250VAC, resistive
8 Amp, 250VAC, 0.4PF
2000VA Inrush

TB2

Digital Inputs
Start & DI1
Start, DI1, S/DI1 Com 120V AC digital input, 2500V optical isolation, 4mA cur. draw
Off = 0 to 35 VAC, On = 60 to 120VAC
Digital Inputs
DI2 & DI3
DI2, DI3,
DI2/DI3 Com
120V AC digital input, 2500V optical isolation, 4mA cur. draw
Off = 0 to 35 VAC, On = 60 to 120V AC
Serial Comm. (Slave) SA-, SB+, SCOM,
SHLD
Modbus slave serial communication port.
RS485 interface, SHLD is chassis ground
Data Rates; 19.2k baud maximum Modbus RTU
2500V Optical Isolation
Serial Comm MA-, MB+, MCOM,
SHLD
Factory Use Only, not isolated

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
10
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
(CT)
Connection
TB3 CT connection for CT1, CT2 and CT3
Molex Connector: #39-01-2065
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
Voltage
Watts
Volts-Amps
Vars
Watt-Hours
PF
Line Frequency
Ground Fault
Run Time
Analog Input
Analog Output

0 40,000 Amps 3%
0 660 Volts 3%
0 9,999 MW 5%
0 9,999 MVA 5%
0 9,999 Mvar 5%
0 10,000 MWh 5%
-0.01 to +0.01 (Lag & Lead) 5%
23 72 Hz 0.1 Hz
5 100% FLA 5% (Machine Protection)
3 seconds per 24 hour period
Accuracy 3% of full scale
Accuracy 1.5% of full scale
Note: Percent accuracys are percent of full scale of the given ranges, Current = Motor FLA Full
Range, Voltage = 660V, Watts/Volts-Amps/Watt-Hours = Motor & Voltage range
11
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
Combinations
400 3200
28800 Mult. CT-CT
Combinations
800 6400
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

12
2.6.7 Solid State Motor Overload
The MX control has an advanced I
2
t 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
1
10
100
1000
10000
100 150 200 250 300 350 400 450 500 550 600 650 700 750 800
Current %(FLA)
S
e
c
o
n
d
s

t
o

T
r
i
p
Class40
Class5
Class10
Class20
Class15
Class30

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.
13
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)
HORSEPOWER RATING MODEL NUMBER NOMINAL
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
14
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

15
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

16
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
Requirements
Minimum VA
Transformer Size
Model Number VA
Requirements
Minimum VA
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.

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_

_

_
1
2
5
A
1
4
C

1
2
5

1
5
5

4
2

B
u
s

T
a
b
4

B
u
s

T
a
b
4

J
/
6
0
0
V

A
C

T
/
R
K
1

3
5
0

1
0
0
k
A

C
F
D
6
3
B

2
2
5
A

4
2
k
A

R
C
_

_

_
1
5
6
A
1
4
C

1
5
6

1
9
5

4
2

B
u
s

T
a
b
4

B
u
s

T
a
b
4

J
/
6
0
0
V

A
C

T
/
R
K
1

4
0
0

1
0
0
k
A

C
F
D
6
3
B

2
2
5
A

6
5
k
A

R
C
_

_

_
1
8
0
A
1
5
C

1
8
0

2
2
2
5

4
2

B
u
s

T
a
b
4

B
u
s

T
a
b
4

J
/
6
0
0
V

A
C

T
/
R
K
1

4
0
0

1
0
0
k
A

C
F
D
6
3
B

2
5
0
A

6
5
k
A

R
C
_

_

_
2
4
0
A
1
5
C

2
4
0

3
0
0

4
2

B
u
s

T
a
b
4

B
u
s

T
a
b
4

J
/
6
0
0
V

A
C

T
/
R
K
1

6
0
0

1
0
0
k
A

C
F
D
6
3
B

4
0
0
A

6
5
k
A

R
C
_

_

_
3
0
2
A
1
5
C

3
0
2

3
7
7

4
2

B
u
s

T
a
b
4

B
u
s

T
a
b
4

J
/
6
0
0
V

A
C

T
/
R
K
1

8
0
0

1
0
0
k
A

C
F
D
6
3
B

4
0
0
A

6
5
k
A

R
C
_

_

_
3
6
1
A
1
6
C

3
6
1

4
2
1

4
2

B
u
s

T
a
b
4

B
u
s

T
a
b
4

J
/
6
0
0
V

A
C

T
/
R
K
1

8
0
0

1
0
0
k
A

C
J
D
6
3
B

C
L
D
6
3
b

4
0
0
A

6
0
0
A

6
5
k
A

R
C
_

_

_
4
7
7
A
1
7
C

4
7
7

5
9
6

4
2

B
u
s

T
a
b
4

B
u
s

T
a
b
4

J
/
6
0
0
V

A
C

T
/
R
K
1

8
0
0

1
0
0
k
A

C
J
D
6
3
B

C
L
D
6
3
b

4
0
0
A

6
0
0
A

6
5
k
A

R
C
_

_

_
5
9
0
A
1
8
C

5
9
0

7
3
7

4
2

B
u
s

T
a
b
4

B
u
s

T
a
b
4

L

1
4
0
0

1
0
0
k
A

C
N
D
6
3
B

C
N
D
6
3
b

8
0
0
A

1
2
0
0
a

8
5
k
A

R
C
_

_

_
7
2
0
A
1
8
C

7
2
0

9
0
0

4
2

B
u
s

T
a
b
4

B
u
s

T
a
b
4

L

1
6
0
0

1
0
0
k
A

C
N
D
6
3
B

C
N
D
6
3
b

8
0
0
A

1
2
0
0
A

8
5
k
A

R
C
_

_

_
8
4
0
A
1
9
C

8
4
0

1
0
5
0

8
5

B
u
s

T
a
b
4

B
u
s

T
a
b
4

L

1
6
0
0

1
0
0
k
A

C
N
D
6
3
B

C
N
D
6
3
b

8
0
0
A

1
2
0
0
A

8
5
k
A

R
C
_

_

_
9
6
0
A
1
9
C

9
6
0

1
2
0
0

8
5

B
u
s

T
a
b
4

B
u
s

T
a
b
4

L

1
6
0
0

2
0
0
0

1
0
0
k
A

5
0
k
A

H
P
D
6
3
F
1
6
0

1
2
0
0

1
6
0
0
A

8
5
k
A

R
C
_

_

_
1
2
K
A
1
9
C

1
2
0
0

1
4
4
0

8
5

B
u
s

T
a
b
4

B
u
s

T
a
b
4

L

1
6
0
0

2
0
0
0

1
0
0
k
A

5
0
k
A

H
P
D
6
3
F
1
6
0

1
2
0
0

1
6
0
0
A

8
5
k
A

Mechanical Drawings
20
2.8 Dimensions
2.8.1 RB Chassis with Integral Bypass
Figure 2 - Dimensions for 2 to 65 Amp RB_1 Starter

Amp Frame
Size
A
in (mm)
B
in (mm)
C (w/MX)
in (mm)
C (w/MII)
in (mm)
D
in (mm)
E
in (mm)
F
in (mm)
G
in (mm)
Weight
lbs (kg)
2 40 11 14.00
(355.60)
10.00
(254.00)
6.91
(175.51)
7.85
(199.4)
8.75
(222.25)
12.50
(317.45)
0.79
(20.06)
0.75
(19.10)
14
(6.4)
52 65 12 14.00
(355.60)
10.00
(254.00)
6.91
(175.51)
8.60
(218.44)
8.75
(222.25)
12.50
(317.45)
0.79
(20.06)
0.75
(19.10)
17
(7.7)
Mounting Holes: Slot: 0.31 x 0.84 (7.87 x 21.33) Bottom : 0.31 (7.87)
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Amp Frame
Size
A
in (mm)
B
in (mm)
C (w/MX)
in (mm)
C (w/MII)
in (mm)
D
in (mm)
E
in (mm)
F
in (mm)
G
in (mm)
Weight
lbs (kg)
77 96 13 15.00
(381.00)
10.00
(254.00)
7.66
(194.56)
8.60
(218.44)
8.75
(222.25)
14.50
(317.45)
0.79
(20.06)
0.75
(19.10)
18
(8.2)

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22

Amp Frame
Size
A
in (mm)
B
in (mm)
C (w/MX)
in (mm)
C (w/MII)
in (mm)
D
in (mm)
E
in (mm)
F
in (mm)
G
in (mm)
H J Weight
lbs (kg)
125

180
14

14
19.80
(205.92)
21.55
(547.4)

12.27
(311.8)

8.91
(226.3)

9.4
(238.7)

17.00
(431.8)

3.88
(98.5)

4.00
(101.5)

3.88
(98.5)

1.00
(25.4)

.75
(19.1)

43
(19.5)
180
1

302
15 22.00
(558.8)
12.27
(311.8)
9.16
(232.6)
9.65
(245.1)
18.50
(469.9
3.88
(98.5)
4.00
(101.5)
3.88
(98.5)
1.00
(25.4)
.75
(19.1)
51
(23.1)
361 16 23.87
(606.2)
12.90
(327.6)
9.16
(232.6)
9.65
(245.1)
20.25
(514.4)
4.03
(102.4)
4.31
(109.5)
4.03
(102.4)
1.00
(25.4)
.75
(19.1)
56
(25.4)
Mounting Holes: Keyhole: 0.31 x 0.63 (7.87 x 15.88) Bottom : 0.31 (7.87)
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Amp Frame
Size
A
in (mm)
B
in (mm)
C (w/MX)
in (mm)
C (w/MII)
in (mm)
D
in (mm)
E
in (mm)
F
in (mm)
G
in (mm)
Weight
lbs (kg)
414 515 17 28.29
(718.5)
18.5
(269.9)
11.33
(287.8)
11.83
(300.5)
27.25
(692.2)
25.25
(641.4)
3.25
(82.6)
6.00
(152.4)
151
(68.5)
590 18 28.29
(718.5)
18.5
(269.9)
11.33
(287.8)
11.83
(300.5)
27.25
(692.2)
25.25
(641.4)
3.25
(82.6)
6.00
(152.4)
159
(72.1)
720 19 29.34
(745.23)
18.5
(269.9)
11.33
(287.8)
11.83
(300.5)
29.00
(736.6)
27.00
(685.8)
3.25
(82.6)
6.00
(152.4)
159
(72.1)

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24
Figure 6 - Dimensions for 838 Amp RB_1 Starter

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

Amp Frame
Size
A
in (mm)
B
in (mm)
C (w/MX)
in (mm)
C (w/MII)
in (mm)
D
in (mm)
E
in (mm)
F
in (mm)
G
in (mm)
2 27
(AC3)
11 14.00
(355.60)
10.00
(254.00)
6.91
(175.51)
7.85
(199.4)
8.75
(222.25)
12.50
(317.45)
0.79
(20.06)
0.75
(19.10)
28 65
(AC3)
12 14.00
(355.60)
10.00
(254.00)
6.91
(175.51)
8.60
(218.44)
8.75
(222.25)
12.50
(317.45)
0.79
(20.06)
0.75
(19.10)
2 - 40
(AC4)
12 14.00
(355.60)
10.00
(254.00)
6.91
(175.51)
8.60
(218.44)
8.75
(222.25)
12.50
(317.45)
0.79
(20.06)
0.75
(19.10)
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Figure 8 - 66 to 77 Amp Dimensions with ATL Bypass (AC3 rating)

Amp Frame
Size
A
in (mm)
B
in (mm)
C (w/MX)
in (mm)
C (w/MII)
in (mm)
D
in (mm)
E
in (mm)
F
in (mm)
G
in (mm)
66 - 77
(AC3)
13 15.00
(381.00)
10.00
(254.00)
7.66
(194.56)
8.60
(218.44)
8.75
(222.25)
14.50
(317.45)
0.79
(20.06)
0.75
(19.10)
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Figure 9 - 78 to 96 Amp Chassis Dimensions for use with separate ATL Bypass

Amp Frame
Size
A
in (mm)
B
in (mm)
C (w/MX)
in (mm)
C (w/MII)
in (mm)
D
in (mm)
E
in (mm)
F
in (mm)
G
in (mm)
78 - 96

13 15.00
(381.00)
10.00
(254.00)
7.66
(194.56)
8.60
(218.44)
8.75
(222.25)
14.50
(317.45)
0.79
(20.06)
0.75
(19.10)
Add 6 to width for ATL bypass (AC3 or AC4/ NEMA) contactor
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Figure 10 - 97 to 361 Amp Chassis Dimensions for use with Separate Bypass (ATL)

Amp Frame
Size
A
in (mm)
B
in (mm)
C (w/MX)
in (mm)
C (w/MII)
in (mm)
D
in (mm)
E
in (mm)
F
in (mm)
G
in (mm)
H J
125 180 14 14.75
(374.7)
11.91
(302.5)
9.91
(251.7)
10.85
(275.5)
11.00
(279.4)
3.88
(98.5)
4.00
(101.5)
3.88
(98.5)
.75
(19.1)
.75
(19.1)
180 302 15 18.75
(476.3)
12.16
(308.8)
10.16
(258.0)
11.10
(281.8)
14.31
(363.5)
3.88
(98.5)
4.00
(101.5)
3.88
(98.5)
1.00
(25.4)
.75
(19.1)
361 16 17.8
(452.1)
12.22
(310.4)
10.16
(258.0)
11.10
(281.8)
16.00
(406.4)
4.05
(102.9)
4.31
(109.5)
3.85
(97.8)
1.00
(25.4)
1.00
(25.4)
The contactor and control relays for ATL operation are NOT included in the above dimensions
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Figure 11 - 362 to 840 Chassis Dimensions for use with Separate Bypass (ATL)

Amp Frame
Size
A
in (mm)
B
in (mm)
C (w/MX)
in (mm)
C (w/MII)
in (mm)
D
in (mm)
E
in (mm)
F
in (mm)
G
in (mm)
414 515 17 20.00
(508.0)
21.50
(546.1)
10.89
(276.7)
11.83
(300.5)
21.38
(543.2)
19.39
(492.4)
3.75
(95.3)
7.00
(177.8)
590 18 20.00
(508.0)
21.50
(546.1)
10.89
(276.7)
11.83
(300.5)
21.38
(543.2)
19.39
(492.4)
3.75
(95.3)
7.00
(177.8)
720 19 20.00
(508.0)
21.50
(546.1)
10.89
(276.7)
11.83
(300.5)
21.38
(543.2)
19.39
(492.4)
3.75
(95.3)
7.00
(177.8)
838 20 22.25
(565.2)
26.60
(675.6)
12.46
(316.4)
13.49
(340.2)
17.00
(431.8)
15.00
(381.0)
4.60
(116.8)
8.70
(221.0)
The contactor and control relays for ATL operation are NOT included in the above dimensions

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2.8.2 RC Chassis with no Bypass
Figure 12 - 2 to 124 Amp Dimensions for Continuous Operation Chassis

Amp Frame
Size
A
in (mm)
B
in (mm)
C (w/MX)
in (mm)
C (w/MII)
in (mm)
D
in (mm)
E
in (mm)
F
in (mm)
G
in (mm)
2-52 31 14.00
(355.6)
9.87
(250.7)
7.63
(193.8)
8.61
(218.7)
.25
(6.35)
3.38
(85.9)
4.69
(119.1)
1.31
(33.3)
53-77 32 18.00
(457.2)
9.99
(254)
9.58
(243.3)
10.52
(260.4)
.25
(6.35)
4.38
(111.25)
4.75
(120.65)
1.31
(33.3)
78 -124 33 27.00
(685.8)
10.00
(254)
9.58
(243.3)
10.52
(260.4)
.25
(6.35)
6.63
(168.4)
4.75
(120.65)
1.31
(33.3)
MX Card
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31

Amp Frame
Size
A
in (mm)
B
in (mm)
C (w/MX)
in (mm)
C (w/MII)
in (mm)
D
in (mm)
E
in (mm)
F
in (mm)
G
in (mm)
125 180 34 19.00
(482.6)
17.25
(438.2)
11.77
(298.9)
12.77
(324.4)
16.46
(418.0)
14.00
(355.6)
2.88
(73.2)
5.75
(146.0)
181 477 35 27.67
(702.8)
17.25
(438.2)
10.86
(275.8)
11.80
(299.7)
24.27
(616.5)
21.75
(552.45)
2.88
(73.2)
5.75
(146.0)
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32

Amp Frame
Size
A
in (mm)
B
in (mm)
C (w/MX)
in (mm)
C (w/MII)
in (mm)
D
in (mm)
E
in (mm)
F
in (mm)
G
in (mm)
478 - 838 36 35.32
(897.2)
20.25
(514.4)
11.77
(299.0)
12.71
(322.8)
31.52
(800.6)
29.00
(736.6)
3.25
(82.6)
6.88
(174.6)

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33
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

Mechanical Drawings
34
Figure 16 - Keypad Bezel Mounting Dimensions Bezel

35
3 Installation
3 INSTALLATION
Control Board Layout
36
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.

3 INSTALLATION
Control & Power Schematics
37
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.
3 INSTALLATION
38
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 60/75C 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.

3 INSTALLATION
Control Board Basic Wiring
39
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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40
3.3.4 Control Board Layout
Figure 18 Control Board Layout

START
DI 1
S/DI
COM
DI2
DI3
DI2/D3
COM
NO1
RC1
NC1
NO2
RC2
NC2
NC3
RC3
NO3
BIPC 300050-00-01
SN
Gnd
120V
Control
Relay Output
R1, R2, R3
Digital Inputs
Start, DI1,
DI2, DI3
Modbus
Serial Port
SCR 6
CT Input

LED Display &
Keypad
Analog Output
& Config Jumper
CT Burden
Selector Switch
Analog
Input
& Config
Jumper
SCR 3
SCR 5
SCR 1
SCR 4
SCR 2
Serial
Number
120V
Control
CPU Heart Beat LED
Serial Com LEDs
Shield
Ground
Terminating
Resistor
Reset
Button
Conn 3
Conn 2
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41
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

3 INSTALLATION
42
Figure 19 Power Schematic for RBX Integral Bypass Power Stack, 3 Amps to 96 Amps

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43
Figure 20 Control Schematic for RBX Integral Bypass Power Stack, 3 Amps to 96 Amps

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45

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46
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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48

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50
Figure 27 Power Schematic for RBX with ATL Separate Bypass 3 96 Amp
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51
Figure 28 Control Schematic for RBX with ATL Separate Bypass 3 to 96 Amp

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52
Figure 29 Power Schematic for RBX with ATL Separate Bypass 97 Amps and up

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53
Figure 30 Control Schematic for RBX with ATL Separate Bypass 97 Amp and up

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54
Figure 31 Power Schematic for RCX No Bypass 3 to 124 Amp

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55
Figure 32 Control Schematic for RCX with No Bypass 3 to 124 Amp

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56
Figure 33 Power Schematic for RCX with No Bypass 125 to 840 Amp

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57
Figure 34 Power Schematic for RCX with No Bypass 125 to 840 Amp

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Installation Procedures
58
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

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
CTs 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).
CT Input, White wire (+)
CT Input Black wire (-)
3 INSTALLATION
59
Table 14 CT Ratios and Burden Switch Settings
CT Ratio Minimum
FLA (A rms)
Maximum
FLA (A rms)
Switch 6
Position 1
Switch 6
Position 2
2 3 Off Off
3 4 Off On
4 9 On Off
72
(4 wraps
288:1)
9 16 On On
3 4 Off Off
4 5 Off On
5 12 On Off
96
(3 wraps
288:1)
12 21 On On
4 7 Off Off
7 8 Off On
8 18 On Off
144
(2 wraps
288:1)
18 32 On On
8 14 Off Off
14 16 Off On
16 32 On Off
288
36 64 On On
24 42 Off Off
42 50 Off On
50 108 On Off
864
108 190 On On
37 64 Off Off
64 76 Off On
76 165 On Off
1320
(2 wraps
2640)
165 290 On On
73 128 Off Off
128 151 Off On
151 330 On Off
2640
330 590 On On
73 140 Off Off
140 165 Off On
165 361 On Off
2880
361 640 On On
105 190 Off Off
190 225 Off On
225 490 On Off
3900
490 870 On On
160 280 Off Off
280 330 Off On
330 720 On Off
5760
720 1280 On On
223 390 Off Off
390 465 Off On
465 1000 On Off
8000
1000 1800 On On
400 700 Off Off
700 840 Off On
840 1800 On Off
14400
Mult.
CT-CT
Combinations
1800 3200 On On
800 1400 Off Off
1400 1680 Off On
1680 3600 On Off
28800
Mult.
CT-CT
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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61
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
Motor
L1
L2
L3
T1
T2
T3
5
2
4
6
3
1

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62
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
Motor
2
5
3
6
1
4
T6 T3
T4
T1 T5
T2
L3
L2
L1

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.
3 INSTALLATION
63
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 SCRs were not bypassed. While bypassed, the
SCRs 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 SCRs 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
3 INSTALLATION
64
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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3.6.3 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
FRONT VIEW DETAIL SIDE VIEW DETAIL
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

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
FRONT VIEW SIDE VIEW DETAIL
MUST BE A 3" (MIN.)
SPACE BETWEEN CT
AND TOP OF LUG
CUSTOMER MUST FASTEN CT
TO POWER WIRE WITH TWO 1/4"
NYLON WRAPS TO PREVENT
MOVEMENT DURING RUNNING
Dot, or X,
White Wire

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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
conductor

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

(mm2)
Slot width-0.047 inch
(1.2mm) or less and slot
length inch (6.4mm) or
less
Slot width-over 0.047
inch (1.2mm) or slot
length over inch
(6.4mm) or less

Split- bolt
connectors

Other connectors
18 10 (0.82 5.3) 20 (2.3) 35 (4.0) 80 (9.0) 75 (8.5)
8 (8.4) 25 (2.8) 40 (4.5) 80 (9.0) 75 (8.5)
6 4 (13.3 21.2) 35 (4.0) 45 (5.1) 165 (18.6) 110 (12.4)
3 (26.7) 35 (4.0) 50 (5.6) 275 (31.1) 150 (16.9)
2 (33.6) 40 (4.5) 50 (5.6) 275 (31.1) 150 (16.9)
1 (42.4) -- -- 50 (5.6) 275 (31.1) 150 (16.9)
1/0 2/0 (53.5 64.4) -- -- 50 (5.6) 385 (43.5) 180 (20.3)
3/0 4/0 (85.0 107.2) -- -- 50 (5.6) 500 (56.5) 250 (28.2)
250 350 (127 177) -- -- 50 (5.6) 650 (73.4) 325 (36.7)
400 (203) -- -- 50 (5.6) 825 (93.2) 375 (36.7)
500 (253) -- -- 50 (5.6) 825 (93.2) 375 (42.4)
600 750 (304 380) -- -- 50 (5.6) 1000 (113.0) 375 (42.4)
800 1000 (406 508) -- -- 50 (5.6) 1100 (124.3) 500 (56.5)
1250
2000
(635 1010) -- -- -- -- 1100 (124.3) 600 (67.8)
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 50C. 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 50C. 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 sites 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.

3 INSTALLATION
68
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

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.
Red Wire
Ground Wire
Remote Cable
3 INSTALLATION
69
3.10.1.3 Mounting The Keypad
Figure 42 Mounting Remote Keypads
KPMXLCDSKP
Part of GKT-100008-00
MD-100001-00
GKT-100008-00

Note: See Figure 16 for mounting dimensions and hole locations
3 INSTALLATION
70
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

3 INSTALLATION
71
Figure 43 Power Schematic for RBX integral Bypass Power Stack for Single Phase Operation

3 INSTALLATION
72

73
4 Keypad Operation
4 KEYPAD OPERATION
Standard LED Keypad and Display
74
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
PARAM DOWN UP ENTER
RESET

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
Ready
Accelerating or Kicking
Accelerating or Kicking with ramp 2
Up to Speed
Run Done with Accel ramp but not yet Up to
Speed.
Decelerating Motor
Overload Alarm The motor overload level is
between 90% and 100%.
Overload Fault The motor overload level has
reached 100%.
Overload Lockout A start is not allowed until the
motor overload level cools below 60%.
Control Power Lockout A start is not allowed
because the control power is too low.
Lock out State
Phase order meter showing ABC
Phase order meter showing CBA
Phase order meter showing Single Phase
xxx xxx = overload content.
xx xx = Parameter code.
xx xx = Alarm code. If the condition persists,
a fault will occur.
xx xx = Fault code.
Instantaneous Overcurrent
Default Flashes when parameter defaults
are loaded.
Heater/Anti-windmill Mode
Energy Saver
In reflash mode
In reflash mode, programming
In reflash mode, verifying
In reflash mode, complete
4 KEYPAD OPERATION
75
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).
4 KEYPAD OPERATION
76
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.
4 KEYPAD OPERATION
77
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.

4 KEYPAD OPERATION
78

79
5 Troubleshooting
5TROUBLESHOOTING
80
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
Control voltage absent. Check for proper control voltage
input. Verify fuses and wiring.
Display Blank, CPU Heartbeat LED
on MX board not blinking.
MX control board problem. Consult factory.
Fault Displayed. Fault Occurred. See fault code troubleshooting table
for more details.
Start/Stop control input problems. Verify that the start/stop wiring and
start input voltage levels are correct.
Start command given but nothing
happens.
Control Source parameters (QST 04-
05, P4-5) not set correctly.
Verify that the parameters are set
correctly.
Check input supply for inline
contactor, open disconnects, open
fuses, open circuit breakers, or
disconnected wiring.
Verify that the SCR gate wires are
properly connected to the MX control
board.
On medium voltage systems, verify
wiring of the voltage feedback
measurement circuit.
NOL or No Line is displayed and a
start command is given, it will fault
in F28.
No line voltage has been detected by
the MX when a start command is
given..
See fault code troubleshooting table
for more details.
5 TROUBLESHOOTING
81
5.2.2 During starting, motor rotates but does not reach full speed
for more details.
Maximum Motor Current setting
(QST 07, P7) set too low.
Review acceleration ramp settings.
Motor loading too high and/or current
not dropping below 175% FLA
indicating that the motor has not
come up to speed.
Reduce load on motor during
starting.
Motor FLA (QST 01, P1) or CT ratio
(FUN 03, P68) parameter set
incorrectly.
Verify that Motor FLA and CT ratio
parameters are set correctly.
Abnormally low line voltage. Fix cause of low line voltage.
Display shows Accel or Run.
A mechanical or supplemental brake
is still engaged.
Verify that any external brakes are
disengaged.
Motor Hums before turning
Initial current to low Increase initial current

FLA or CT incorrect Verify FLA or CTs
5.2.3 Acceleration not operating as desired
Ramp time (QST 08, P8) too short. Increase ramp time.
Initial current (QST 06, P6) set too
high.
Decrease Initial current.
Maximum current (QST07, P7) set
too high.
Decrease Maximum current.
Kick start current (CFN10, P13) too
high.
Decrease or turn off Kick current.
Kick start time (CFN11, P14) too
long.
Decrease Kick time.
incorrectly.
Motor accelerates too quickly.
Starter Type parameter (FUN 07,
P64) set incorrectly.
Verify that Starter Type parameter is
set correctly.
Maximum Motor Current setting
(QST 07, P7) set too low.
Review acceleration ramp settings.
Increase max current
Motor loading too high. Reduce load on motor during
starting.
incorrectly.
Abnormally low line voltage. Fix cause of low line voltage.
Motor accelerates too slowly
Ramp time to long Decrease ramp time
5TROUBLESHOOTING
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5.2.4 Deceleration not operating as desired
Decel Time (CFN17, P18) set to
short.
Increase Decel Time. Motor stops too quickly.
Decel Begin and End Levels CFN
15-16, P16-17) set improperly.
Increase Decel Begin and/or Decel
End levels.
Decel time seems correct but motor
surges (oscillates) at beginning of
deceleration cycle.
Decel Begin Level (CFN15, P16) set
too high.
Decrease Decel Begin Level until
surging is eliminated.
Decel time seems correct but motor
stops before end of deceleration
cycle.
Decel End Level (CFN16, P17) set
too low.
Increase Decel End Level until motor
just stops at the end of the
deceleration cycle.
Decel End Level (CFN16, P17) set
too high.
Decrease Decel End Level until water
hammer is eliminated.
Water hammer still occurs at end of
cycle.
Decel Time (CFN17, P18) too short. If possible, increase Decel Time to
decelerate system more gently.
Motor speed drops sharply before
decel
Decel begin level to low. Increase the Decel Begin Level until
drop in speed is eleminated.
5.2.5 Motor stops unexpectedly while running
for more details.
Verify start command input signal is
present or serial communications
start command is present.
Ready Displayed. Start command lost.
Check any permissives that may be
wired into the run command
(Start/Stop)
Control voltage absent. Check for proper control voltage
input. Verify wiring and fuses.
Display Blank, Heartbeat LED on
MX board not blinking.
MX control board problem. Consult factory.

5 TROUBLESHOOTING
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5.2.6 Metering incorrect
CTs installed or wired incorrectly. Verify correct CT wiring and verify
that the CTs are installed with all the
White dots towards the input line
side.
CT ratio parameter (FUN 03, P68) set
incorrectly.
Verify that the CT ratio parameter is
set correctly.
Power Metering not reading
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
side.
Energy Saver active. Turn off Energy Saver if not desired.
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.
Motor Current or Voltage meters
fluctuating with steady load.
Other equipment on same power feed
causing power fluctuations and/or
distortion.
Fix cause of power fluctuations
and/or distortion.
Voltage Metering not reading
correctly.
Rated Voltage parameter (FUN 05,
P66) set incorrectly.
Verify that Rated Voltage parameter
is set correctly.
incorrectly.
set correctly.
set correctly.
Current Metering not reading
correctly.
side.
incorrectly.
set correctly.
set correctly.
Ground Fault Current Metering not
reading correctly.
side.

5TROUBLESHOOTING
84
5.2.7 Other Situations
If input phasing correct, exchange
any two output wires.
Motor Rotates in Wrong Direction Phasing incorrect
If input phasing incorrect, exchange
any two input wires.
Erratic Operation Loose connections Shut off all power and check all
connections.
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 Overheats
Motor cooling obstructed/damaged Remove cooling air obstructions.
Check motor cooling fan.
Fan power supply lost Verify fan power supply, check fuses.
Fan wiring problem Check fan wiring.
Starter cooling fans do not operate
(When Present)
Fan failure Replace fan
Voltage/Current output jumper (JP1)
not set correctly.
Set jumper to give correct output.
Wiring problem Verify output wiring.
Analog Output Function parameter
(I/O 12, P50) set incorrectly.
Verify that the Analog Output
Function parameter is set correctly.
Analog Output Offset and/or Span
parameters (I/O 13-14, P51-52) set
incorrectly.
Verify that the Analog Output Span
and Offset parameters are set
correctly.
Load on analog output too high. Verify that load on analog output
meets MX control analog output
specifications.
Analog Output not functioning
properly
Ground loop or noise problems. Verify correct grounding of analog
output connection to prevent noise
and/or ground loops from affecting
output.
Keypad cable not plugged in properly
or cable damaged.
Verify that the remote keypad cable
has not been damaged and that it is
properly seated at both the keypad
and the MX Control board.
Display interface board (when
present) not firmly plugged in.
Verify that the display interface
board (if present) is firmly attached
to MX control card.
Remote Keypad does not operate
correctly.
Remote display damaged. Replace remote display.
5 TROUBLESHOOTING
85
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
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.
F01 UTS Time Limit Expired
Evaluate UTS timer setting and, if acceptable, increase UTS timer setting
(QST 09, P9).
The MX motor thermal overload protection has tripped.
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 CTs and starter.
F02 (F OL) Motor Thermal Overload
Trip
Reset overload when content falls below 15%.
Input phase rotation is not ABC and Input Phase Sensitivity parameter
(FUN 04, P67) is set to ABC only.
Verify correct phase rotation of input power. Correct wiring if necessary.
F10 Phase Rotation Error, not
ABC
Verify correct setting of Input Phase Sensitivity parameter (FUN 04, P67).
Input phase rotation is not CBA and Input Phase Sensitivity parameter
(FUN 04, P67) is set to CBA only.
Verify correct phase rotation of input power. Correct wiring if necessary.
F11 Phase Rotation Error, not
CBA
Verify correct setting of Input Phase Sensitivity parameter (FUN 04, P67).
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
F12 Low Line Frequency
Line power quality problem / excessive line distortion.
Line frequency above 72 Hz was detected.
Verify input line frequency.
If operating on a generator, check generator speed governor for
malfunctions.
F13 High Line Frequency
Line power quality problem / excessive line distortion.
5TROUBLESHOOTING
86
Three-phase power has been detected when the starter is expecting single-
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.
F14 Input power not single
phase
Verify that the SCR gate wires are properly connected to the MX control
board.
Single-phase power has been detected when the starter is expecting three-
phase power.
Verify that input power is three phase. Correct wiring if necessary.
board.
F15 Input power not three
phase
On medium voltage systems, verify wiring of the voltage feedback
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.
F21 Low Line L1-L2
On medium voltage systems, verify wiring of the voltage measurement
circuit.
time (PFN 09, P32).
F22 Low Line L2-L3
time (PFN 09, P32).
F23 Low Line L3-L1
High voltage above the Over voltage Trip Level parameter setting (PFN
time (PFN 09, P32).
F24 High Line L1-L2
Line power quality problems/ excessive line distortions.
5 TROUBLESHOOTING
87
time (PFN 09, P32).
F25 High Line L2-L3
time (PFN 09, P32).
F26 High Line L3-L1
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.
F27 Phase Loss
Check Gate and Cathode connections to MX board
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.
F28 No Line
During operation, the MX controller detected a very high level of current
in one or more phases.
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.
F30 I.O.C.
(Instantaneous
Overcurrent Current)
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).
F31 Overcurrent
Check motor for a jammed or an overload condition.
5TROUBLESHOOTING
88

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).
F34 Undercurrent
Check system for cause of under current condition.
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.
F37 Current Imbalance
Check motor for internal problems.
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.
F38 Ground Fault
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.
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.
F39 No Current at Run
Check for inline contactor or disconnect.
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.
F40 Shorted / Open SCR
Verify the motor wiring. (Verify dual voltage motors for correct wiring
configuration).

5 TROUBLESHOOTING
89
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.
F41 Current at Stop
The MX electronic power stack OL protection has detected an 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.
F47 Stack Protection Fault
(stack thermal overload)
Motor load exceeds power stack rating. Consult factory
A digital input has been programmed as a Bypass/2M Contactor Feedback
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.
F48 Bypass /2M Contactor
Fault
Verify that the bypass contactor(s) are actually not damaged or faulty.
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).
F50 Control Power Low
Check wiring between control power source and starter.
Indicates that the MX control board self-diagnostics have detected a
problem with one or more of the current sensor inputs.
Verify that no actual current is flowing through any of the starters CTs
when the starter is not running.
F51 Current Sensor Offset
Error
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.
DI#1 has been programmed as a fault type digital input and the input
indicates a fault condition is present.
F60 External Fault on DI#1
Input
Verify wiring and level of input.

5TROUBLESHOOTING
90
DI#2 has been programmed as a fault type digital input and input indicates
a fault condition is present.
Input
DI#3 input has been programmed as a fault type digital input and input
indicates a fault condition is present.
input
Based on the Analog Input parameter settings, the analog input level has
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.
F71 Analog Input Level Fault
Trip.
Verify correct grounding of analog input connection to prevent noise or
ground loops from affecting input.
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.
F81 SPI Communication Fault
Route keypad cables away from high power and/or high noise areas to
reduce possible electrical noise pickup.
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.
F82 Modbus Timeout Fault
Examine remote system for cause of communication loss.
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.
F94 CPU Error SW fault
Fault can also occur if the MX control has detected an internal software
problem. Consult factory.

5 TROUBLESHOOTING
91
The non-volatile user parameter values have been found to be corrupted.
Typically occurs when the MX control is re-flashed with new software.
Perform a Factory Parameter reset and then properly set all user
parameters before resuming normal operation.
F95 CPU Error Parameter
EEPROM Checksum
Fault
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
Watchdog Fault
The MX control has detected an internal software problem. Consult
factory.
F98 CPU Error The MX control has detected an internal CPU problem. Consult factory.
The non-volatile program memory has been corrupted. F99 CPU Error Program
EPROM Checksum Fault
Consult factory. Control software will need to be reloaded in to the MX
control card before normal operation can resume.

5TROUBLESHOOTING
92
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.
5 TROUBLESHOOTING
93
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

5TROUBLESHOOTING
94
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 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

95
6 Appendices

96
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

97
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

98
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
Manufacturers Name: Benshaw, Inc.
Manufacturers 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

99
Appendix B Fault Codes
See Section 7 for Troubleshooting Solutions
Fault
Code
Description Controlled
Fault Stop
Shunt Trip
Fault
Auto-Reset
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

100
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
Code
Description Notes
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

101
Alarm
Code
Description Notes
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.

102
Appendix D Spare Parts

Consult Factory

103
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

BENSHAW PRODUCTS
Low Voltage Solid State Reduced Voltage Starters
RSD/RSM6 - SSRV Non or Separate Bypass
RDB/RMB6 - SSRV Integral Bypass
RSM7 - SSRV + DC Injection Braking
RSM10 - SSRV + Reversing
RSM11 - SSRV + DC Injection Braking + Reversing
RSM10/12TS - SSRV Two Speed
WRSM6 - SSRV Wound Rotor
SMRSM6 - SSRV Synchronous
DCB3 - Solid State DC Injection Braking
Medium Voltage Solid State Reduced Voltage Starters
5kV - Induction or Synchronous to 10,000HP
7.2kV - Induction or Synchronous to 10,000HP
15kV - Induction or Synchronous to 60,000HP
Low Voltage - AC Drives
Standard Drives to 1000HP
Custom Industrial Packaged Drives
HVAC Packaged Drives
18 Pulse/IEEE 519 Compliant Drives
RSC Series Contactors
SPO/SPE/SPD Motor Protection Relays
Enclosed Full Voltage, Wye Delta, Two Speed
Part Winding and Reversing Starters
Custom OEM Controls
Sales and Service
United States
Pittsburgh, Pennsylvania
Indianapolis, Indiana
Syracuse, New York
Boston, Massachusetts
Charlotte, North Carolina
Birmingham, Alabama
Los Angeles, California
Detroit, Michigan
Milwaukee, Wisconsin
Phoenix, Arizona
Seattle, Washington
Denver, Colorado
Houston, Texas
Minneapolis, Minnesota
Newark, New Jersey
Canada
Listowel, Ontario
Toronto, Ontario
Montreal, Quebec
Calgary, Alberta
South America
Sao Paulo, Brazil
Santiago, Chile
Lima, Peru
Bogota, Columbia
Beunos Aires, Argentina
Santa Cruz, Bolivia
Guayaquil, Ecuador
Mexico
Shanghai
Australia
Singapore
BENSHAW Inc.
1659 East Sutter Road
Glenshaw, PA 15116
Phone: (412) 487-8235
Fax: (412) 487-4201
BENSHAW West
14715 North 78th Way
Suite 600
Scottsdale, AZ 85260
Phone: (480) 905-0601
Fax: (480) 905-0757
BENSHAW High Point
EPC Division
645 McWay Drive
High Point, NC 27263
Phone: (336) 434-4445
Fax: (336) 434-9682
BENSHAW Mobile
CSD Division
5821 Rangeline Road Suite 202
Theodore, AL 36582
Phone: (251) 443-5911
Fax: (251) 443-5966
BENSHAW Pueblo
Trane Division
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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RediStart Solid State Starter

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