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TRANSCRIPT
RediStart MX3Low Voltage Solid State Motor Control
Instruction Manual
890003-06-00
Carrier RediStart MX3 Instruction Manual
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Carrier RediStart MX3 Instruction Manual
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Table of Contents
Section 1 - OverviewOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Current Ramp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
RediStart MX3 Keypad Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Keypad LEDs and Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Control Card Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4I/O Card Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section 2 - MX3 ControlOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Motor Thermal Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7CT Ratios. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Section 3 - Technical DataSupply Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 4 - Receiving and InstallationOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Wiring Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Section 5 - Operating and ProgrammingOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Keypad Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Power-Up Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
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Main Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Fault Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Applying Power to the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Programming the RediStart MX3
ISM Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15CFN Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15FUN Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Passcode Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Fault Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Event Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Changing Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Parameter Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Section 6 - TroubleshootingGeneral Troubleshooting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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1 - OverviewThe Carrier RediStart MX3 is a microprocessor controlled solid state reduced voltage starter for three phase induction motors. The starter is connected “Inside the Delta” on Carrier’s six lead chiller motor. The RediStart MX3 operates on a user programmed current ramp for optimal motor control and protection. This type of operation is referred to as closed loop current control. The motor is accelerated from the initial current setting to the maximum current setting during the defined ramp time. When the motor is up to full speed, the SCRs are then bypassed utilizing bypass contactors.
Current Ramp The current ramp profile is defined by a line going from the initial current setting to the maximum current setting, in a time defined by the ramp time setting. All three parameters that define the profile have default values set, but may be adjusted.
The initial current is entered as a percent of motor Rated Load Amps (RLA), has a default of 125%, and a range of 50-400%.
The maximum current is entered as a percent of motor Locked Rotor Amps (LRA), has a default of 55%, and a range of 30-75%.
The ramp time is entered in seconds, has a default of 15, and a range of 0-30.
As the current ramps toward the maximum setting, increasing starting torque is developed to accelerate the motor to full speed.
NOTE: Even though maximum current is specified, this maximum will only be reached if the load requires it to achieve full speed. Ramp time is also a factor in determining whether or not maximum current is reached.
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Standard Features • Bypass contactors
• LCD and LED status and diagnostics
• Solid State Motor Overload
• Instantaneous electronic over-current trip
• Open/Shorted SCR Detection
• Single Phase Protection
• Phase rotation protection (ABC only)
• Current regulated, closed loop acceleration control
• Full fault annunciation
• Accumulated Event Recorder (99 events)
• Accumulated Fault Recorder (9 faults)
• Programmable metering display (amps, volts, freq., overload content, P.F.)
• Plain English operation via LCD display interface
• Adjustable ramp time
• Adjustable initial and maximum current
Keypad Display
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Table 1: Keypad LEDs and Key Functions
LED / Key Indication / Function
STOP LED On Stopped
STOP LED Flashing Faulted state
RUN LED On Running up to speed
RUN LED Flashing Running, but not up to speed, (ramping, or maximum current reached.)
ALARM LED Flashing Alarm condition exists. If condition persists, a fault occurs.
START Key Not operational. A start may only be initiated through the ICVC.
UP Arrow Key
Increase the value of a numeric parameter
Select the next value of an enumerated parameter
Advance through a list of parameters within a group
Advance through Fault or Event lists
When viewing the Main screen, allows selection of a different meter value for viewing
DOWN Arrow Key
Decrease the value of a numeric parameter
Select the previous value of an enumerated parameter
View previous parameters listed within a group
View previous displayed Fault or Event
When viewing the Main screen, allows selection of a different meter value for viewing
LEFT Arrow KeyCycle next or previous numeric parameter while editing parameter values
When in Menu mode, allows scrolling in the opposite direction of the MENU Key
MENU Key
Cycle between the Main Screen, and all available parameter groups
Press to jump to top of the menu when viewing parameters
Aborts and discards any change being made to a parameter value while programming
ENTER Key
Store the change of a parameter value
When viewing the Fault log, Scroll through information stored when a fault occurs
When viewing the Event log, Scroll through information stored when an event occurs
Scroll through all active alarms when an Alarm condition exists
STOP / RESET Key
A start is normally initiated through the ICVC. Pressing the STOP/RESET key will however initiate an emergency stop of the starter if configured to do so by the factory.
Fault conditions are normally reset through the ICVC, but may also be reset by pressing the STOP / RESET Key.
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RediStart MX3 Control Card Layout
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I/O Card Layout
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2 - MX3 ControlThe RediStart MX3 consists of two PC cards, mounted one on top of the other. The cards should not be separated, and only installed or replaced as a set. The top card is refererred to as the Control Card, and the bottom card as the I/O Card.
The Control Card generates the gating signals for the SCRs, controls the keypad interface, SIO bus interface, relay outputs, and monitors the digital inputs.
The I/O Card provides additional relay outputs and digital inputs and the differential ground fault inputs.
The following sections explain the adjustments and configurations necessary for proper operation of the starter.
Motor Thermal Overload
The MX3 performs an electronic thermal overload calculation to model the heat buildup in the motor, expressed as a percentage. When the overload content reaches 100%, the MX3 produces an overload fault and stops the motor, after which the overload content begins to decrease exponentially.
The MX3 prevents the ICVC from resetting the overload fault until the overload content has cooled below 90%.
CT Ratios
Table 2: Current Transformer CT1 - CT3
StarterFrame Size
(Amps)
Motor RLA Range
(Amps)CT Ratio
200 Amps 95-135 Amps 864:1
200 Amps 136-200 Amps 2640:1
300 Amps 201-231 Amps 2640:1
300 Amps 232-300 Amps 2640:1
480 Amps 301-340 Amps 2640:1
480 Amps 341-480 Amps 3900:1
600 Amps 481-580 Amps 3900:1
600 Amps 581-600 Amps 3900:1
740 Amps 601-740 Amps 3900:1
1250 Amps 741-855 Amps 5760:1
1250 Amps 856-1250 Amps 5760:1
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LED Indication
Table 3: LED Indicators
Card LED Indicator
Control Card LED1 Power - On when control voltage is present
Control Card LED2 SIO Bus Receive
Control Card LED3 SIO Bus Transmit
Control Card LED8 CPU - Blinks once per second
I/O Card LED1 CPU - On when voltage is present
I/O Card LED3 Power - Blinks once per second
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3 - Technical DataSupply Voltage LINE POWER: Three Phase, 200 - 600V, 23Hz - 72Hz
CONTROL VOLTAGE: Single Phase, 120V, 50-60Hz: +/-25%
Relay Outputs
Table 4: Relay Outputs
Reference Card Rating Terminal Contact Function
R1 Control 3A at 250VAC/30VDC
TB2-1 N.O.
ALARMTB2-2 Common
TB2-3 N.C.
R2 Control 3A at 250VAC/30VDC
TB2-4 N.O.
OIL PUMPTB2-5 Common
TB2-6 N.C.
R3 Control 16A at 250VAC/30VDC
TB2-7 N.O.
SHUNT TRIPTB2-8 Common
TB2-9 N.C.
R4 I/O 5A at 120VAC / 3A at 240 VACJ20-1B N.O.
1CR StartJ20-1A Common
R5 I/O 5A at 120VAC / 3A at 240 VACJ20-2B N.O.
UTSJ20-2A Common
R6 I/O 5A at 120VAC / 3A at 240 VACJ20-3B N.O. Evaporator
Water PumpJ20-3A Common
R7 I/O 5A at 120VAC / 3A at 240 VACJ20-4B N.O. Condenser
Water PumpJ20-4A Common
R8 I/O 5A at 120VAC / 3A at 240 VACJ20-5B N.O.
Tower Fan #1J20-5A Common
R9 I/O 5A at 120VAC / 3A at 240 VACJ20-6B N.O.
Tower Fan #2J20-6A Common
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Digital Inputs
Table 5: Digital Inputs
Reference Card Voltage Terminal Function
Start Control 120 VAC TB3-1 1CR
DIN#1 Control 120 VAC TB3-2 Shunt Trip Fuse Feedback
DIN#2 Control 120 VAC TB3-3 Spare
DIN#3 Control 120 VAC TB3-4 Spare
120V Common Control Neutral TB3-5 Common for Start, DIN#1, DIN#2, DIN#3
DIN#4 I/O 24 VAC J21-1B Spare Safety
DIN#5 I/O 24 VAC J21-1A Ice Build
DIN#6 I/O 24 VAC J21-2B Remote Start
DIN#7 I/O 24 VAC J21-2A Spare
24V Common I/O Neutral J21-3A Common for DIN#4, DIN#5, DIN#6, DIN#7
DIN#8 I/O 120VAC J21-4B Inside Delta Startup Lockout
120V Common I/O Neutral J21-4A Common for DIN#8
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4 - Receiving and InstallationThe Carrier RediStart MX3 has been packaged to protect it from damage caused by normal handling during shipment. Mishandling during shipment, however, may have caused damage to the system. Unpack and inspect the unit as soon as it is received and check for any shipping damage. If damage is suspected, notify the carrier immediately. Any damage reports must be filed by the customer since all shipments are F.O.B. shipping point unless otherwise specified.
Safety Precautions WARNING: Disconnect all phases before working on equipment, touching motor terminals, or touching control equipment parts. Equipment is at line voltage when AC power is connected. Death or serious injury may result.
WARNING: Lock the Motor Disconnect open before servicing or inspecting machine components. Motor is not mechanically isolated from main power. Death or serious injury may result.
The National Electrical Code requires that all equipment, (starter, motor, operator station, etc.) be properly grounded. An incoming disconnect must be locked open before wiring or servicing this starter, motor, or other related equipment. This equipment must only be serviced by qualified personnel fully familiar with the equipment.
Short circuit protection is provided by a circuit breaker sized properly for the particular motor starting application. Standard interrupting capacity is 30K amps. Optional 65K Amps interrupting capacity is available upon request.
Installation Guidelines
Standard NEMA 1 starters must be installed indoors in an area that is not exposed to direct water spray. Do not install in areas where the ambient temperature falls below 0°C or exceeds 40°C unless this was noted at the time of order placement and special precautions were taken to protect against these abnormal temperatures.
CAUTION: Do not attempt to megger the Redistart MX3 starter. Equipment damage may result.
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Wiring Guidelines The National Electrical Code requires that an approved circuit disconnecting device be installed in series with the incoming AC supply and mounted in a location readily accessible to personnel installing or servicing this equipment. A circuit breaker is supplied with the Carrier Redistart MX3 starter to isolate power from the motor terminals. A separate disconnect must be provided by others in order to isolate the starter from power.
CAUTION: Do not connect Power Factor Correction capacitors (PFCs) between the RediStart MX3 and the motor. Equipment damage may result.
PFCs must be connected ahead of the starter. The up-to-speed output contact, which is available with each Redistart MX3, should be used to properly sequence the capacitors after full motor speed has been reached. If ordered from the factory with PFCs, the PFCs will be prewired and sequenced as indicated above.
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5 - Operating and ProgrammingThe Redistart MX3 has been fully tested before leaving the factory, to ensure a rapid and problem free start-up. Before applying power to the starter, consult the start-up check list below.
• Open the main circuit breaker (CB1) on the starter.
• Inspect Starter and remove any foreign matter.
• Ensure that all electrical connections are per the schematic supplied with the starter.
• Ensure that all connections are properly torqued.
• Apply incoming three phase power to the starter.
• Turn on auxiliary circuit breakers CB2 and CB3, then wait 30 seconds.
• Turn on main circuit breaker (CB1).
• Adjust parameters on the LCD Keypad Display if required. The starter is normally factory set allowing the starter to be operated immediately. (Refer to the following: Programming the MX3, and Changing Parameters).
Keypad Display The door mounted keypad features a 32-character alphanumeric LCD display. All starter functions can be accessed by the keypad. The keypad allows easy access to starter programming with parameter descriptions on the LCD display.
Power Up Screen On power up, the software part numbers are displayed for a few seconds. The display then changes to the Main Screen.
Main Screen The Main screen is used to indicate the status of the starter:
• Running / Not Running
• Current state of the starter
• Values of Meter 1 and Meter 2.
Ready Ia= 0AStopped Va=480V
The Main screen indicates the status of the starter on the left, and displays two selectable meters on the right. The meters are selected by the Meter 1 and Meter 2 parameters. See FUN01 and FUN02 in Table 9 for the list of available meters.
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Fault Screen When a fault condition occurs, the Main Screen on the Display is replaced with the Fault screen. The Fault screen displays the fault number and name of the fault. The Main Screen is not shown again until the fault condition is reset.
Fault ##Fault Name
NOTE: For a list of all Fault Codes, refer to Table 11 in Section 6 of this manual
When a fault occurs, the STOP LED flashes.
Applying Power to the Motor
Once the motor start sequence has been initiated by the starter, fine tuning of the set-up parameters may be required.
On start-up, the motor should begin to rotate immediately, and should not experience a stall condition. Increase the initial current setting in the CFN menu if a stall condition does occur. Decrease the initial current parameter if the motor begins to rotate too fast.
The Ramp Time parameter can also be adjusted to extend or decrease the acceleration time if required. To make initial acceleration occur faster, decrease the Ramp Time parameter in the CFN. To extend the time of initial acceleration, increase the Ramp Time parameter.
Table 6: Status Messages on Top Line of Display
Display Description
No Line L1, L2, L3 not present
Ready Starter ready to run
Alarm A fault condition is present. If it continues, a fault occurs.
Run Starter is running
Table 7: Status Message on Bottom Line of Display
Display Description
Stopped Starter is stopped, no faults
Accel Starter is accelerating the load
Run Starter is in Run mode, ramp time has expired
UTS Starter is up to speed
Dry Run Starter is in Dry Run mode
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Programming the Redistart MX3The Redistart MX3 may require programming before it can properly control your application. Press the Menu Key on the keypad to access the parameters.
The parameters are organized into three menus; the ISM menu, the CFN menu, and the FUN menu. Each press of the Menu Key advances the display to the next menu. Additional presses of the Menu Key provide access to the Fault Log and the Event Log.
ISM Menu The ISM menu contains the same set of parameters that are present in the ISM Setup screen on the ICVC. Normally, these parameters should be changed through the ICVC. When they are saved on the ICVC, the values are copied to the RediStart MX3 and will be reflected on the RediStart MX3 display. The values of these parameters may be changed on the starter's display, but if they are, they must also be changed on the ICVC. Otherwise, the ICVC will report an ISM Configuration Conflict fault the next time the chiller is powered up.
CFN Menu The CFN menu contains the current ramp profile parameters. These parameters are not available on the ICVC and may only be configured through the starter's display.
FUN Menu The FUN menu contains parameters to configure what and how information is displayed on the starter's display, and to select the ratio of the CTs used by the starter. The CT ratio should be set appropriately at the factory and should not need adjusting.
Passcode Protection The RediStart MX3 comes from the factory configured so that the parameters cannot be changed using the door-mounted keypad without first entering the proper code into the Passcode parameter in the FUN menu. The code is set at the factory to be the same as the password required to access the ISM Configuration Settings on the ICVC.
To remove passcode protection, enter the proper code into the passcode parameter. To re-apply passcode protection when changes being made to the parameters are complete, you must again enter a code into the Passcode parameter. The same, or a new code, may be used. If a new code is entered, only that new code will be able to disable password protection.
NOTE: Be sure to make note of the passcode, and retain for future reference. Without the proper passcode, the ability to alter parameters will be unavailable unless accessed by a Carrier Representative.
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Changing Parameters
The sequence for changing any parameter is similar to the following example.
To change the Motor RLA from 10 Amps to 30 Amps:
From the Main Screen:
Ready Ia= 0.0AStopped Va=4160V
Press [MENU] key and the display will show the ISM screen:
ISM: Jump Code00 1
Press [UP] key once to Motor RLA (QST 01):
ISM: Motor RLA01 10 Amp
Press [ENTER] key once, the cursor start to flash in the one’s place:
ISM: Motor RLA01 10 Amp
Press [LEFT] key once, the cursor flashes in the ten’s place:
ISM: Motor RLA01 10 Amp
Press [UP] arrow to increase the value, for a value of 30, press twice:
ISM: Motor RLA01 30 Amp
Press [ENTER] to store the value.
ISM: Motor RLA01 30 Amp
Press [UP] arrow to change another parameter in ISM.
Press [MENU] to change another parameter in another group.
Press [LEFT] arrow to return to the Main Screen.
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NOTE: The following parameters may be set differently than their defaults by the factory
Table 8: Parameter Reference
Parameter Number Description Range Units Default
ISM01 Motor RLA 10 - 5000 Arms 200
ISM02 Current Imbalance 5 - 40 % 15
ISM03 Current Imbalance Delay 1 - 10 Sec 5
ISM04 Voltage Imbalance 1 - 10 % 10
ISM05 Voltage Imbalance Delay 1 - 10 Sec 5
ISM06 Over Voltage Threshold 105-115 % 115
ISM07 Under Voltage Threshold 85-95 % 85
ISM08 Over/Under Voltage Delay 1 - 10 Sec 5
ISM09 Motor LRA 100 - 60000 Arms 1000
ISM10 Motor LRA Start Delay 1 - 10 Cycles 5
ISM11 Starter LRA 100 - 60000 Arms 2000
ISM12 Enable Single Cycle Dropout Enable / Disable - DISABLE
ISM13 Ground Fault Enable Enable / Disable - ENABLE
ISM14 Ground Fault Current Threshold 1 - 25 Arms 15
ISM15 GF Persistence 1 - 10 Cycles 5
ISM16 GF Start Delay 1 - 20 Cycles 10
ISM17 Line Frequency 50, 60 Hz 60
ISM18 Enable Frequency Faults Enable / Disable - DISABLE
ISM19 System Voltage 100- 13800 Vrms 480
CFN01 Initial Current 50 - 400 %RLA 125
CFN02 Maximum Current 30 - 75 %LRA 55
CFN03 Ramp Time 0 - 30 Sec 15
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FUN01FUN02
Meter #1 DisplayMeter #2 Display
1: Avg. Current2: L1 Current3: L2 Current4: L3 Current5: Current Imbal%6: Ground Current7: Avg. Voltage8: L1-L2 Voltage9: L2-L3 Voltage10: L3-L1 Voltage11: Overload%12: Power Factor13: Watts14: VA15: vars16: kW Hours17: MW Hours18: Phase Order19: Line Frequency20: Analog Input21: Analog Output22: Run Days23: Run Hours24: Starts25: Peak Starting Current26: Last Start Duration
- -
FUN03 CT Ratio
288:1, 864:1,2640:1, 3900:1,5760:1, 8000:1,
14400:1,28800:1,
50:5, 150:5,250:5, 400:5,600:5, 800:5,
2000:5, 5000:5
- 2640:1
FUN04 Time and Date Format
mm/dd/yy 12hmm/dd/yy 24hyy/mm/dd 12hyy/mm/dd 24hdd/mm/yy 12hdd/mm/yy 24h
- mm/dd/yy 24h
FUN05 Time - - Present Time
FUN06 Date - - Present Date
FUN07 Passcode - - Off
FL1-FL9 Fault Log (9 Faults) - - -
E01 - E99 Event Log (99 Events) - - -
Table 8: Parameter Reference
Parameter Number Description Range Units Default
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Fault Log The fault log viewing menu (designated by FLx: on the top left) allows you to view the last 9 recorded faults along with data collected at the time of each fault.
FL#: Fault##NNNNNNNNN
FL# = Fault Log Number, FL1 is the most recent, FL9 is the oldest faultFault# = Fault CodeNNNN = Fault Name, or the condition when the fault occurred
NOTE: For a list of all Fault Codes, refer to Table 11 in Section 6 of this manual
Press [MENU] until the FL1 parameter is displayed
Pressing the [UP] and [DOWN] buttons navigate through faults in the log
When the fault to be viewed is displayed on the screen, press the [ENTER] key repeatedly. This will cycle through the steps below to indicate the condition the starter was in when the fault occurred.
Table 9: Viewing the Fault Log
Enter Step
1 Fault Description
2 Status when fault occurred: Run, Stopped, Accel, etc.
3 The L1 current at the time of the fault
4 The L2 current at the time of the fault
5 The L3 current at the time of the fault
6 L1-2 voltage at the time of the fault
7 L2-3 voltage at the time of the fault
8 L3-1 voltage at the time of the fault
9 kW at the time of the fault
10 Frequency at the time of the fault
11 Ground current at the time of the fault
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Event Log The event log viewing menu (designated by Exx: on the top left) allows you to view the last 99 recorded events and faults along with the state of the starter when the event occurred, and the date and time that the event occurred.
An event is anything that changes the present state of the starter. Examples of events include a start, stop, overload alarm or fault.
E##: Event ###Event
Press [MENU] until the E01 parameter is displayed.
Pressing [UP] or [DOWN] will scroll through the last 99 events, and display the event or fault code on top, and the event or fault that altered the starter's state on the bottom.
Pressing [ENTER] displays the starter state condition at the time of event.
Press [ENTER] again to display the time of the event.
Press [ENTER] again to display the date that the event occurred.
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6 - Troubleshooting
General Troubleshooting Guidelines
If problems are experienced during start-up of new equipment, the following should be verified:
Ensure all metallic particles and foreign matter has been removed from the starters introduced by cutting holes, wiring, etc. If necessary use a low pressure, high volume air hose to clean printed circuit cards and system components. Use a vacuum to remove debris from the enclosure.
Inspect all components for damage caused by shipping, installation or environmental factors.
Thoroughly inspect every connection point in the system. Gently tighten and confirm all control and power wire connections. Check all the bolts and screws on the solid state starter to verify tightness.
Note that a current imbalance trip in the starter could be caused by a variety of problems. If tripping persists, verify the AC power feeding the unit has properly balanced voltages prior to start and during the starting sequence while the chiller is accelerating.
Verify power meets nameplate requirements. (Refer to equipment nameplate for voltage/amperage/frequency ratings).
Typically if a problem occurs with the motor starter, a fault or event message will be displayed on the chiller control panel and motor starter. Refer to chiller display and “Diagnostic and Troubleshooting Guide” first, then refer to starter troubleshooting guide. The event recorder will log all stops/starts and fault or trips. There is additional information on fault codes in the following pages.
The starter is designed to always have power applied to the RediStart MX3 circuit boards for troubleshooting purposes. Caution is necessary therefore, as power will be present in the starter even though the main circuit breaker CB1 is disconnected.
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Table 10: General Troubleshooting
Condition PossibleCause Correction
Motor does not start / No output to motor
Display blank, CPU Heartbeat LED on Control Card not blinking
Control voltage absent Check for proper control voltage input. Verify FU1, 2, 3, and CB2
Control Card problem Consult factory
Fault Displayed Fault occurred See Fault Code troubleshooting tables for additional details
Start command given but nothing happens
1CR control input problem Verify that 1CR wiring and start input voltage levels are correct
Incorrect control settings Verify that the parameters are set cor-rectly
Motor not connected properly Inspect wiring and correct as required
“No Line” is displayed and a start command is given, fault F28 occurs.
No line voltage has been detected by the MX3 when a start command is given
Check input supply for inline contac-tor, open disconnects, open fuses, open circuit breakers, or discon-nected wiring
Verify that SCR gate wires are prop-erly connected to the Control Card
See fault code troubleshooting tables for additional details
During Start, motor rotates but does not reach full speed
Fault displayed Fault occurred See Fault Code troubleshooting tables for additional details
Display shows Accel or Run
Maximum Motor Current setting is too low Review acceleration ramp settings
Motor loading too high and/or current not dropping, indicating that the motor has not come up to speed
Reduce load on motor during starting
Motor RLA or CT ratio parameter set incorrectly
Verify motor RLA and CT ratio param-eters are set correctly
Abnormally low line voltage Correct cause of low line voltage
Motor “hums” before turning
Initial current too low Increase initial current
Motor RLA is incorrect Review motor RLA set point
CT ratio is incorrect Review CT ratio set point
Starter not accelerating as desired
Motor accelerates to quickly
Ramp time is too short Increase Ramp Time setting
Initial current set too high Decrease Initial Current setting
Maximum current set too high Decrease Maximum Current setting
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Motor accelerates too slowly
Maximum Motor Current parameter set too low
Review acceleration ramps parame-ters
Motor loading too high Reduce load on motor during start
Motor RLA or CT ratio parameter set incorrectly
Verify motor RLA and CT ratio param-eters are set correctly
Abnormally low line voltage Correct cause of low line voltage
Ramp time too long Decrease Ramp Time setting
No display / LEDs on Control Card illuminated
No display
Loose or defective display cable Check cable connecting Control Card and display
Defective display Replace display
Defective Control Card Replace MX3 card set
Motor stops unexpectedly while running
Fault displayed Fault occurred See Fault Code troubleshooting tables for additional details
Ready displayed Start command lost
Verify start command input signal is present or serial communications start command is present
Check 1CR input circuit
Display blank, Hearbeat LED on Control Card not blinking
Control voltage absent Check for proper control voltage input. Verify wiring and fuses.
Control Card problem Consult factory
Circuit Breaker (CB1) Trips
CB1 trips
Shunt trip activated by starter Check for fault/event codes on dis-play. Reset starter and breaker.
ICVC trip activated shunt trip Check for fault/event codes on dis-play. Reset starter and breaker.
Magnetic trip activated breaker Increase magnetic trip level setting if possible
Metering Incorrect
Power Metering not reading correctly
CTs installed or wired incorrectly
Verify correct CT wiring, and that CTs are installed with all white dots toward the input line side: CT1=L1 CT2=L2 CT3=L3
CT ratio parameter set incorrectly Verify proper CT ratio parameter set-tings
Table 10: General Troubleshooting
Condition PossibleCause Correction
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PF Meter not reading correctly CTs installed or wired incorrectly
Verify correct CT wiring, and that CTs are installed with all white dots toward the input line side: CT1=L1 CT2=L2 CT3=L3
Motor Current or Voltage meters fluctuating with steady load
Loose connections Remove all power and check all connections
SCR faultVerify that SCR gate leads are con-nected properly, and that SCRs are not damaged
Load is not steady Verify the load is steady and that there are not mechanical issues
Other equipment on same power feed is causing fluctuation and/or distortion
Correct cause of power fluctuations and/or distortions
Current Metering not reading correctly
CT ratio parameter set incorrectly Verify proper parameter settings
CTs installed or wired incorrectly
Verify correct CT wiring, and that CTs are installed with all whits dots toward the input line side: CT1=L1 CT2=L2 CT3=L3
Ground Fault Current Metering not reading correctly CTs installed or wired incorrectly
Verify correct CT wiring and verify that the ground fault CTs are installed properly
OTHER Conditions
Erratic operation Loose connections Remove all power and check all connections
Motor overheats
Motor overloaded Reduce motor load
Too many starts per hour Allow for adequate motor cooling between starts.
High ambient temperature Reduce ambient temperature or provide for better cooling
Acceleration time too long Reduce starting load and/or review acceleration ramp settings
Motor cooling obstructed/damaged Remove any cooling obstructions
Remote Keypad/Display does not operate correctly
Keypad cable not properly connected, or cable is damaged
Verify that the remote keypad cable is not damaged, is properly connected at both ends
Remote Keypad/Display is damaged Replace Remote Keypad/Display
Table 10: General Troubleshooting
Condition PossibleCause Correction
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Table 11: Fault Codes
Fault Code / Name Condition / Possible Cause Correction
0 - No Fault No fault occurred
01 - Starter Acceleration Fault
Up To Speed fault: Motor never reached full speed
Increase maximum current setting and verify that motor FLA and LRA are set cor-rectly in the ICVC.
Weak incoming voltage, brown-out, et al. Inspect and correct
Motor stalled or overloaded Inspect and correct
02 - Motor Overload Motor overloadOnce the motor has cooled, restart and monitor for overload conditions. Verify ICVC and starter settings.
10 - Phase Rotation Error Phase sequence not ABC Swap any two incoming lines.
12 - Low Line FrequencyLine frequency is less than 46Hz on a 50Hz system, or less than 56Hz on a 60Hz system
Check line frequency
13 - High Line FrequencyLine frequency greater than 54Hz on a 50Hz system or greater than 64Hz on a 60Hz system
Check line frequency
20 - Voltage Imbalance A voltage imbalance has occurred Verify line voltages
21 - Low Line Line voltage too low Verify line voltages
24 - High Line Line voltage too high Verify line voltages
27 - Phase Loss Phase loss detected Verify line votagesCheck gate lead connections
28 - No Line Line voltage dropped during chiller start-up sequence Verify line voltages
29 - Single Cycle Dropout A single cycle dropout of line voltage has occurred Verify line voltages
30 - I.O.C. (Shunt Trip CB1) Starter Output is shorted Inspect and Correct
31 - Overcurrent 1 Current exceeded 110% of RLA at runVerify correct RLA settings
Verify loading of chiller
32 - Overcurrent 2 Motor Locked Rotor current exceeded
Verify correct Motor Locked Current set-tings
Verify the motor shaft rotates freely
33 - Overcurrent 3 (Shunt Trip CB1) Starter Locked Rotor current exceeded
Verify correct Starter Locked Current set-tings
Verify the motor shaft rotates freely
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37 - Current Imbalance
Line 1,2, or 3 current is out of balance Inspect and increase current imbalance level in ICVC
Failed SCRs
Failed SCRs
Replace complete defective phase assembly (1,2, or 3) if possible. If not pos-sible, refer to Benshaw Service Note SN0046 “Spring Bar Clamp Replacement”
Refer to Benshaw Service Note SN0002 “Testing SCRs”
Poor connections or improper wiring between SCRs
Refer to wiring diagram. Inspect and cor-rect, verify that all red and white gate con-nections are secure.
Poor connection in motor or motor failure Inspect connections. Inspect and test motor for shorts or open windings.
Defective or improper current transformers
Test for continuity and verify properly sized current transformers
38 - Ground Fault (Shunt Trip CB1) A ground fault has occurred Inspect and test motor winding and wiring.
39 - No Current at Run No motor connection or CTs disconnected Verify all connections
40 - Shorted / Open SCR (Shunt Trip CB1) One or more SCRs have failed in an open
or shorted state
Replace complete defective phase assembly (1,2, or 3) if possible. If not pos-sible, refer to Benshaw Service Note SN0046 “Spring Bar Clamp Replacement”
Refer to Benshaw Service Note SN0002 “Testing SCRs”
41 - Current at Stop (Shunt Trip CB1) Current present while stopped Inspect for shorting conditions
47 - Power Stack Overtemperature A Power Stack Overtemperature condition has been detected
Check the motor for jammed or overloaded condition
Verify that the CT ratio (FUN 03) is correct
Motor load exceeds power stack rating.Consult Benshaw Service
48 - 2M / Bypass Contactor Fault 2M / Bypass Fault. All bypasses did not close when commanded.
Inspect bypass contactor coil and auxiliary contact wiring. Correct or replace as required.
50 - Control Power Low
Control voltage too low (below 90V) Verify proper control voltage and correct as required.
Loss of incoming power Inspect and correct as required.
Fuses FU1,2,3 or CB2 open Inspect and correct as required.
Table 11: Fault Codes
Fault Code / Name Condition / Possible Cause Correction
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51 - Current Sensor Offset Error A problem with one or more of the current sensor inputs has been detected
Verify that the motor RLA and CT ratio are correct
Verify that no current is flowing through any of the starter’s CTs when the starter is not running
Consult Benshaw Service if condition persists
58 - Shunt Trip Fuse Shunt Trip Fuse blown (DIN #1) Replace FU4
59 - High Compressor Pressure Cutout
A high compressor pressure condition exists Verify proper compressor pressure.
70 - 1M Fault
The starter received a start command over the SIO bus, but not the 120VAC start command
Check the control wiring feeding the start input on the starter
The 120VAC start command went low without receiving a stop command over the SIO bus
Check the control wiring feeding the start input on the starter
71 - 1M/2M Stop Fault (Shunt Trip CB1)
The starter received a 120VAC start com-mand without receiving a start command over the SIO bus
Check the control wiring feeding the start input on the starter
The starter received a stop command over the SIO bus, but the 120VAC start command remained high
Check the control wiring feeding the start input on the starter
75 - Emergency Stop (Shunt Trip CB1)
Stop Key was pressed on the starter keypad -
78 - Invalid ISM ConfigurationISM configuration parameters were set on the ICVC to values beyond the ranges accepted by the starter
Verify ISM configuration parameters on the ICVC are within the ranges accepted by the starter
Table 11: Fault Codes
Fault Code / Name Condition / Possible Cause Correction
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84 - CPU to I/O Comm Fault
Contact Benshaw Service
85 - I/O Card - SW Version Fault
86 - I/O Card - Current Offset Fault
87 - I/O Card - RTC Fault
88 - I/O Card - Internal Fault
89 - I/O Card - SW Watchdog
90 - I/O Card - Internal Fault
91 - I/O Card - EPROM Checksum
94 - CPU - SW Fault
95 - CPU - EEPROM Checksum
96 - CPU - Illegal Instruction Trap
97 - CPU - SW Watchdog Fault
98 - CPU - Spurious Interrupt
99 - CPU - EPROM Checksum
Table 11: Fault Codes
Fault Code / Name Condition / Possible Cause Correction
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Revision History
Revision Date ECO Number
- 06/09/09 2377
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