BENSHAW RediStart MX2 SEP User manual

Software Version: 810027-01-00
Hardware Version: 300063-01
2008 Benshaw Inc.
©
890040-01-00
Solid State Starter
SEP
Synchronous Control
RediStart TM
User Manual
MX SEP Models
2
Benshaw retains the right to change specifications and illustrations in text without prior notification. The contents of this document may
not be copied without the explicit permission of Benshaw.

TRADEMARK NOTICE
Benshaw and are registered trademarks of Benshaw Incorporated.
UL is a trademark of Underwriters Laboratories, Incorporated.
Important Reader Notice
Congratulations on the purchase of your new Benshaw RediStart MX2SEP controller. This manual contains the information to install and
program the MX2SEP controller. The MX2SEP controller is a standard version controller.
This manual may not cover all of the applications of the RediStart MX2SEP. Also, it may not provide information on every possible contingency
concerning installation, programming, operation, or maintenance specific to the RediStart MX2SEP Series Controllers.
The content of this manual will not modify any prior agreement, commitment or relationship between the customer and Benshaw. The sales
contract contains the entire obligation of Benshaw. The warranty enclosed within the contract between the parties is the only warranty that
Benshaw will recognize and any statements contained herein do not create new warranties or modify the existing warranty in any way.
Any electrical or mechanical modifications to Benshaw products without prior written consent of Benshaw will void all warranties and may also
void cUL listing or other safety certifications, unauthorized modifications may also result in product damage operation malfunctions or personal
injury.
Incorrect handling of the controller may result with an unexpected fault or damage to the controller. For best results on operating the RediStart
MX2SEP controller, carefully read this manual and all warning labels attached to the controller before installation and operation. Keep this
manual on hand for reference.
Do not attempt to install, operate, maintain or inspect the controller until you have thoroughly read this manual and related documents carefully
and can use the equipment correctly.
Do not use the controller until you have a full knowledge of the equipment, safety procedures and instructions.
This instruction manual classifies safety instruction levels under "WARNING" and "CAUTION".
Electrical Hazard that could result in injury or death.
Caution that could result in damage to the starter.
Highlight marking an important point in the documentation.
Please follow the instructions of both safety levels as they are important to personal safety.
High Voltage
Motor control equipment and electronic controllers are connected to hazardous line voltages. When servicing starters and electronic
controllers, there may be exposed components with housings or protrusions at or above line potential. Extreme care should be taken
to protect against shock.
Stand on an insulating pad and make it a habit to use only one hand when checking components. Always work with another person
in case an emergency occurs. Disconnect power before checking controllers or performing maintenance. Be sure equipment is
properly grounded. Wear safety glasses whenever working on electronic controllers or rotating machinery.

Safety Precautions
Electric Shock Prevention
•While power is on or controller is running, do not open the front cover. You may get an electrical shock.
•This controller contains high voltage which can cause electric shock resulting in personal injury or loss of life.
•Be sure all AC power is removed from the controller before servicing.
•Do not connect or disconnect the wires to or from controller when power is applied.
•Make sure ground connection is in place.
•Always install the controller before wiring. Otherwise, you may get an electrical shock or be injured.
•Operate the switches with dry hands to prevent an electrical shock.
•Risk of Electric Shock - More than one disconnect switch may be required to de-energize the equipment before servicing.
Injury Prevention
•Service only by qualified personnel.
•Make sure power-up restart is off to prevent any unexpected operation of the motor.
•Make certain proper shield installation is in place.
•Apply only the voltage that is specified in this manual to the terminals to prevent damage.
Transportation and Installation
•Use proper lifting gear when carrying products, to prevent injury.
•Make certain that the installation position and materials can withstand the weight of the controller. Refer to the installation information in this
manual for correct installation.
•If parts are missing, or controller is damaged, do not operate the RediStart MX2SEP.
•Do not stand or rest heavy objects on the controller, as damage to the controller may result.
•Do not subject the controller to impact or dropping.
•Make certain to prevent screws, wire fragments, conductive bodies, oil or other flammable substances from entering the controller.
Trial Run
•Check all parameters, and ensure that the application will not be damaged by a sudden start-up.
Emergency Stop
•To prevent the machine and equipment from hazardous conditions if the controller fails, provide a safety backup such as an emergency brake.
Disposing of the RediStart MX2SEP
•Never dispose of electrical components via incineration. Contact your state environmental agency for details on disposal of electrical components
and packaging in your area.
i
SAFETY PRECAUTIONS

Table of Contents
1 INTRODUCTION ............................................2
2 TECHNICAL SPECIFICATIONS ...................................8
2.1 General Information ...........................................8
2.2 Electrical Ratings .............................................8
2.2.1 Terminal Points and Functions........................................8
2.2.2 Measurements and Accuracies ........................................9
2.2.3 List of Motor Protection Features ......................................9
2.3 Environmental Conditions........................................10
2.4 Altitude Derating .............................................10
2.5 Approvals .................................................10
2.6 Certificate of Compliance ........................................10
3 INSTALLATION .............................................12
3.1 Before You Start..............................................12
3.1.1 Inspection....................................................12
3.1.2 Installation Precautions ............................................12
3.1.3 Safety Precautions ...............................................12
3.2 Installation Considerations .......................................13
3.2.1 Site Preparation ................................................13
3.2.2 EMC Installation Guidelines .........................................13
3.3 Mounting Considerations ........................................14
3.4 Wiring Considerations ..........................................15
3.4.1 Wiring Practices ................................................15
3.4.2 Considerations for Control and Power Wiring...............................15
3.4.3 Considerations for Signal Wiring ......................................15
3.4.4 Meggering a Motor ..............................................15
3.4.5 High Pot Testing ................................................15
3.5 Power and Control Drawings ......................................16
3.5.1 MX2 ATL Synchronous Brushtype (Field Control) Solid State......................16
3.5.2 MX2 ATL Synchronous Brushtype with contactors ............................17
3.5.3 MX2 ATL Synchronous Brushless ......................................18
3.6 Power Wiring ...............................................19
3.6.1 Recommended Incoming Line Protection .................................19
3.6.2 Recommended Wire Gauges .........................................19
3.6.3 Power Wire Connections ...........................................19
3.6.4 Compression Lugs...............................................19
3.6.5 Torque Requirements for Power Wiring Terminations ..........................20
3.7 Control Card Layout ...........................................21
3.8 Control Wiring ..............................................22
3.8.1 Control Power .................................................22
3.8.2 Output Relays .................................................22
3.8.3 Digital Input Wiring Options ........................................23
3.8.4 Analog Output .................................................24
3.8.5 SW1 DIP Switch ................................................24
3.9 Remote LCD Keypad/Display .....................................25
3.9.1 Remote Display ................................................25
3.9.2 Display Cutout.................................................25
3.9.3 Installing Display ...............................................26
ii
TABLE OF CONTENTS

4 KEYPAD OPERATION .........................................28
4.1 Introduction ................................................28
4.2 Standard Keypad and Display .....................................28
4.3 Viewing Parameter Values for the Standard Keypad .........................28
4.4 Changing Parameter Values .......................................29
4.5 Messages Displayed ...........................................30
4.5.1 Power Up ....................................................31
4.5.2 Stopped .....................................................31
4.5.3 Running.....................................................31
4.5.4 Alarm Condition................................................31
4.5.5 Lockout Condition...............................................32
4.5.6 Faulted Condition ...............................................32
4.5.7 Quick Meters ..................................................32
4.6 Jump Code ................................................33
4.7 Restoring Factory Parameter Settings .................................33
4.8 Resetting a Fault .............................................33
4.9 2x16 Remote LCD Keypad........................................34
4.10 Description of the LEDs on the Keypad................................34
4.11 Description of the Keys on the Remote LCD Keypad ........................35
4.12 Alphanumeric Display .........................................36
4.12.1 Parameter Group Screens ..........................................37
4.12.2 Meter Pages ..................................................38
4.12.3 Fault Log Screen ...............................................38
4.12.4 Fault Screen ..................................................39
4.12.5 Lockout Screen ................................................39
4.12.6 Alarm Screen .................................................39
4.13 Procedure for Setting Data .......................................40
5 PARAMETER GROUPS .........................................44
5.1 Introduction ................................................44
5.2 LED and LCD Display Parameters Cross Reference & Control Mode Reference .........45
5.3 LED Display Parameters .........................................46
5.4 LCD Display Parameters.........................................49
5.4.1 Quick Start Group ...............................................49
5.4.2 Control Function Group ...........................................50
5.4.3 Protection Group ...............................................50
5.4.4 I/O Group ...................................................51
5.4.5 Function Group ................................................52
5.4.6 LCD Fault Group ...............................................53
5.4.7 LED Fault Group ...............................................53
6 PARAMETER DESCRIPTION .....................................56
6.1 Parameter Descriptions .........................................56
7 THEORY OF OPERATION .......................................86
7.1 Control Modes of Synchronous Motor Operation...........................86
7.1.1 Brush Type (Field Control) Synchronous Motor Operation .......................86
7.1.2 Brushless Type Synchronous Motor Operation ..............................87
7.1.3 Current Follower ...............................................87
7.2 Use Hall Effect Current Sensor .....................................88
7.2.1 Analog Input ..................................................88
iii
TABLE OF CONTENTS

7.3 Simplified I/O Schematics........................................90
7.4 Remote Modbus Communications ...................................91
7.4.1 Supported Commands ............................................91
7.4.2 Modbus Register Addresses .........................................91
7.4.3 Cable Specifications ..............................................91
7.4.4 Terminating Resistors .............................................91
7.4.5 Grounding ...................................................91
7.4.6 Shielding ....................................................91
7.4.7 Wiring......................................................92
7.5 Dynamic Braking .............................................94
8 TROUBLESHOOTING & MAINTENANCE .............................96
8.1 Safety Precautions ............................................96
8.2 Preventative Maintenance ........................................96
8.2.1 General Information..............................................96
8.2.2 Preventative Maintenance ..........................................96
8.3 General Troubleshooting Charts ....................................97
8.3.1 Motor does not start, no output to motor ..................................97
8.3.2 During starting, motor rotates but does not reach full speed ......................98
8.3.3 Motor stops unexpectedly while running .................................98
8.3.4 Metering incorrect (Hall Effect) .......................................99
8.3.5 Other Situations ................................................100
8.4 Fault Code Table .............................................101
8.5 SCR Testing ................................................106
8.5.1 Resistance....................................................106
8.5.2 Voltage .....................................................106
8.6 Field Discharge Resistor Sizing .....................................106
8.7 Built In Self Test Functions .......................................107
8.7.1 Powered BIST Tests: .............................................107
8.8 SCR Replacement .............................................108
8.8.1 Typical Stack Assembly............................................108
8.8.2 SCR Removal..................................................108
8.8.3 SCR Installation ................................................108
8.8.4 SCR Clamp ...................................................109
8.8.5 Tightening Clamp ...............................................109
8.8.6 Testing SCR...................................................109
APPENDIX A ALARM CODES .....................................112
APPENDIX B FAULT CODES ......................................114
APPENDIX C SPARE PARTS ......................................115
APPENDIX D EU DECLARATION OF CONFORMITY .......................116
APPENDIX E MODBUS REGISTER MAP ...............................117
APPENDIX F PARAMETER TABLES ..................................122
iv
TABLE OF CONTENTS

1Introduction
1

1INTRODUCTION
Using this Manual
Layout This manual is divided into 10 sections. Each section contains topics related to the section. The sections
are as follows:
•Introduction
•Technical Information
•Installation
•Keypad Operation
•Parameters
•Parameter Description
•Applications
•Theory of Operation
•Troubleshooting & Maintenance
•Appendices
Symbols There are 2 symbols used in this manual to highlight important information. The symbols appear as the
following:
Electrical Hazard warns of situations in which a high voltage can cause physical injury, death
and/or damage equipment.
Caution warns of situations in which physical injury and/damage to equipment may occur by means
other than electrical.
Highlight mark an important point in the documentation.
2
1- INTRODUCTION
HAZARD OF ELECTRIC SHOCK, EXPLOSION, OR ARC FLASH
Only qualified personnel familiar with low voltage equipment are to perform work described in this set of instructions.
Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E.
Turn off all power before working on or inside equipment.
Use a properly rated voltage sensing device to confirm that the power is off.
Before performing visual inspections, tests, or maintenance on the equipment, disconnect all sources of electric power.
Assume that circuits are live until they have been completely de-energized, tested, and tagged. Pay particular attention to
the design of the power system. Consider all sources of power, including the possibility of backfeeding.
Replace all devices, doors, and covers before turning on power to this equipment.
Failure to follow these instructions will result in death or serious injury.
DANGER

Benshaw Services
General Information Benshaw offers its customers the following:
•Start-up services
•On-site training services
•Technical support
•Detailed documentation
•Replacement parts
zNOTE: Information about products and services is available by contacting Benshaw, refer to
page 4.
Start-Up Services Benshaw technical field support personnel are available to customers with the initial start-up of the
RediStart MX2SEP. Information about start-up services and fees are available by contacting Benshaw.
On-Site Training Services Benshaw technical field support personnel are available to conduct on-site training on RediStart MX2
SEP 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 page 4.
Documentation Benshaw provides all customers with:
•Operations manual.
•Wiring diagram.
All drawings are produced in AutoCAD© format. The drawings are available on standard CD / DVD or
via e-mail by contacting Benshaw.
On-Line Documentation All RediStart MX2SEP documentation is available on-line at http://www.benshaw.com.
Replacement Parts Spare and replacement parts can be purchased from Benshaw Technical Support.
Software Number This manual pertains to the software version numbers 810027-01-00.
Hardware Number This manual pertains to the hardware version numbers 300063-01.
Publication History See page 127.
Warranty Benshaw provides a 1 year standard warranty with its controllers. An extension to the 3 year warranty
is provided when a Benshaw or Benshaw authorized service technician completes the installation and
initial start up. The warranty data sheet must also be signed and returned. The cost of this service is not
included in the price of the Benshaw controllers and will be quoted specifically to each customers
needs. All recommended maintenance procedures must be followed throughout the warranty period to
ensure validity. This information is also available by going online to register at www.benshaw.com.
3
1- INTRODUCTION

Contacting Benshaw
Contacting Benshaw Information about Benshaw products and services is available by contacting Benshaw at one of the
following offices:
Technical support for the RediStart MX2SEP Series is available at no charge by contacting Benshaw’s
customer service department at one of the above telephone numbers. A service technician is available
Monday through Friday from 8:00 a.m. to 5:00 p.m. EST.
zNOTE: 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
•Voltage of motor attached to Benshaw product
•FLA of motor attached to Benshaw product
•A brief description of the application
•Field voltage and current rating of motor
4
1- INTRODUCTION
Benshaw Inc. Corporate Headquarters
1659 E. Sutter Road
Glenshaw, PA 15116
Phone: [phone]
Tech Support: [phone]
Fax: [phone]
Benshaw High Point
EPC Division
645 McWay Drive
High Point, NC 27263
Phone: [phone]
Fax: [phone]
Benshaw Canada Controls Inc.
550 Bright Street East
Listowel, Ontario N4W 3W3
Phone: [phone]
Tech Support: [phone] (BEN-SHAW)
Fax: [phone]
Benshaw Mobile
CSD Division
5821 Rangeline Road, Suite 202
Theodor, AL 36582
Phone: [phone]
Fax: [phone]
Benshaw West
14715 North 78th Way, Suite 600
Scottsdale, AZ 85260
Phone: [phone]
Fax: [phone]
Benshaw Pueblo
Trane Division
1 Jetway Court
Pueblo, CO 81001
Phone: [phone]
Fax: [phone]

Interpreting Model Numbers
Example of Model Number: MX2SEP-125VDC-50A-3-S-C
A Controller with 125VDC field voltage, MX2SEP control, 50A at bridge, 3 phase bridge, solid-state ,open Chassis.
5
1- INTRODUCTION
MX2SEP-125VDC-50A-3-S-C
C = Open Chassis
1 = Single phase bridge
3 = Three phase bridge
S = Solid State
M = Mechanical (contactors)
Current Rating of Bridge
Voltage rating of field (125 or 250 VDC)
MX2 Control
Figure 1: RediStart MX2 SEP Series Model Numbers

General Overview of a Synchronous Field Controller
General Overview The RediStart MX2SEP synchronous field controller is a microprocessor based controller for single or
three-phase field supply. The sync controller can be custom designed for specific applications. A few of the
features are:
•Solid state design.
•Closed-loop current control.
•Programmable operating parameters.
•Programmable metering.
Each MX2SEP can operate within applied line voltage and frequency values of 100VAC to 600VAC
(optional 1000VAC) and 23 to 72Hz.
The field controller can be programmed for synchronous motor fields. The RediStart MX2SEP can also
protect the motor and its load from damage that could be caused by incorrect phase order wiring.
The controller continually monitors the amount of field current being delivered to the motor. This protects the
motor from overheating or drawing excess current.
Features The enhanced engineering features of the starter include:
•Multiple frame sizes
•Universal voltage operation
•Universal frequency operation
•Phase rotation protection
•Regulated current control
•Electronic over/under current protection
•Single phase protection
•Programmable metering
•Passcode protected
•Programmable Relays
•Analog output with digital offset and span adjustment
•Analog input with digital offset and span adjustment
•Voltage and Current Accuracy of 3%
6
1- INTRODUCTION
6

2 Technical Specifications

2TECHNICAL SPECIFI CATIONS
Technical Specifications
2.1 General Information
The physical specifications of the starter vary depending upon its configuration. The applicable motor current determines the
configuration and its specific application requirements.
Specifications are subject to change without notice.
This document covers the control electronics and several power sections:
•MX2SEP control card
•RC Power Stacks, Continuous operation, NO bypass
Electrical Ratings
2.2 Electrical Ratings
2.2.1 Terminal Points and Functions
8
2- TECHNICAL SPECIFICATIONS
Function Terminal
Block Terminal Number Description
Control Power TB1 G, ground
N, 120VAC neutral
N, 120VAC neutral
L, 120VAC line
L, 120VAC line
96 – 144 VAC input, 50/60 Hz
45VA required for control card
Relay 1 (R1) TB2 NO1:Normally Open Contact
RC1:Common
NC1: Normally Closed Contact
Relay Output, SPDT form C
NO Contact (resistive) NC Contact(resistive)
5A at 250VAC 3A at 250VAC
5A at 125VAC 3A at 125VAC
5A at 30VDC 3A at 30VDC
1250VA 750VA
Relay 2 (R2) TB2 NO2: Normally Open Contact
RC2: Common Contact
NC2: Normally Closed Contact
Relay Output, SPDT form C
NO Contact (resistive) NC Contact(resistive)
5A at 250VAC 3A at 250VAC
5A at 125VAC 3A at 125VAC
5A at 30VDC 3A at 30VDC
1250VA 750VA
Relay 3 (R3) TB2 NO3: Normally Open Contact
RC3: Common Contact
NC3: Normally Closed Contact
10A at 250VAC
10A at 125VAC
10A at 30VDC
2500VA
Digital Inputs TB3 1: Start
2: DI1
3: DI2
4: DI3
5: Common
120VAC digital input
2500V optical isolation
4mA current draw
Off: 0-35VAC
On: 60-120VAC
Serial Comm TB4 1: B+
2: A-
3: COM
Modbus RTU serial communication port.
RS-485 interface
19.2k baud maximum
2500V Isolation
Analog I/O
(Hall Effect input) TB5 1: Ain Power 2: M
3: Common
4: Ground (Sheild)
5: Aout
6: Common
7: Shield
Input:
Voltage or Current
Voltage: 0-10VDC, 67KWimpedance
Current: 0-20mA, 500Wimpedance
Output:
Voltage or Current
Voltage: 0-10VDC, 120mA maximum
Current: 0-20mA, 500Wload maximum
Display RJ45 Door Mounted Display Connector
Table 1: Terminals
8

2.2.2 Measurements and Accuracies
2.2.3 List of Motor Protection Features
•ANSI 27 / 59 – 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 37 – Undercurrent detection (Off or 5 to 100% and time 0.1 to 90.0 sec. in 0.1 sec. intervals)
•ANSI 47 – Phase rotation (selectable ABC, CBA, Insensitive, or Single Phase)
•ANSI 48 – Incomplete Sequence
•ANSI 51 – Overcurrent detection (Off or 50 to 800% and time 0.1 to 90.0 sec. in 0.1 sec. intervals)
•ANSI 56 – Field Application
•ANSI 74 – Alarm relay output available
•ANSI 81 – Over / Under Frequency
•ANSI 94 – Tripping
•ANSI 95 – Reluctance torque sync
•ANSI 96 – Autoloading
•Single Phase Protection
•Shorted SCR detection
9
2- TECHNICAL SPECIFICATIONS
Function Terminal
Block Terminal Number Description
SCR J6 to J11 1: Gate
2: Cathode SCR gate Connections
Wire Gauge: The terminals can support 1- 14 AWG wire or 2-16 AWG wire or smaller.
Torque Rating: The terminals on the control card have a torque rating of 5.0-inch lb. or 0.56Nm. This MUST be followed or damage will occur to the terminals.
Refer to the Control Card Layout on page 21.
Table 1: Terminals
Internal Measurements
Hall Effect Input Conversion: True RMS, Sampling @ 1.562kHz
Range: 1-1000A
Line Voltage Inputs Conversion: True RMS, Sampling @ 1.562kHz
Range: 100VAC to 1000VAC 23 to 72 Hz
Metering Current
Slip %
Voltage
Line Frequency
Run Time
Analog Input
Analog Output
0 – 40,000 Amps ± 3%
0.0 – 100%
0 – 1250 Volts ± 3%
23 – 72 Hz ± 0.1 Hz
± 3 seconds per 24 hour period
Accuracy ± 3% of full scale (10 bit)
Accuracy ±2% of full scale (12 bit)
zNOTE: Percent accuracy is percent of full scale of the given ranges, Current = Current
Setpoint, Voltage = 1000V
Table 2: Measurements and Accuracies

Environmental Conditions
2.3 Environmental Conditions
Altitude Derating
2.4 Altitude Derating
Benshaw's starters are capable of operating at altitudes up to 3,300 feet (1000 meters) without requiring altitude derating. Table 3
provides the derating percentage to be considered when using a starter above 3,300 feet (1000 meters).
Approvals
2.5 Approvals
MX2SEP Control Card is UL, cUL Recognized
Certificate of Compliance
2.6 Certificate of Compliance
CE Mark, See Appendix D on page 116.
10
2- TECHNICAL SPECIFICATIONS
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.
Table 3: Altitude Derating
Operating Temperatures -10°C to +40°C (14°F to 104°F)enclosed
-10°C to +50°C (14°F to 122°F)open
Storage Temperatures -20°C to +70°C (-4°F to 155°F)
Humidity 0% to 95% non condensing
Altitude 1000m (3300ft) without derating
Maximum Vibration 5.9m/s2(19.2ft/s2) [0.6G]
Cooling (Natural convection) or Fan Forced
Table 4: Environmental Ratings

3Installation

3INSTALLATION
Before You Start
3.1 Before You Start
3.1.1 Inspection
Before storing or installing the RediStart MX2SEP Series sync controller, thoroughly inspect the device for possible shipping damage.
Upon receipt:
•Remove the controller 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 controller 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 controller and ensure that the correct amperage and input voltage for the application has
been purchased.
•The numbering system for a chassis is shown below.
3.1.2 Installation Precautions
Installation of some models may require halting production during installation. If applicable, ensure that the controller is installed when
production can be halted long enough to accommodate the installation. Before installing the controller, ensure:
•The wiring diagram (supplied separately with the controller) is correct for the required application.
•The controller is the correct current rating and voltage rating for the motor..
•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.
3.1.3 Safety Precautions
To ensure the safety of the individuals installing the sync controller, 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 13).
•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 Power Ratings for the fault rating on pages 19.
•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 controller are wearing ALL protective eyewear and clothing.
•Ensure the controller 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 controller should be inspected and replaced if damaged.
12
3- INSTALLATION

Installation Considerations
3.2 Installation Considerations
3.2.1 Site Preparation
General Information
Before the sync controller 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 controller 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 contrtoller NEMA/CEMA rating. For optimal performance, the installation site must
meet the appropriate environmental and altitude requirements.
3.2.2 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 15.
Filtering To comply with Conducted Emission Limits (CE requirement), a high voltage (1000V or greater) 0.1 uF capacitor
should be connected from each input line to ground at the point where the line enters the cabinet.
13
3- INSTALLATION

Mounting Considerations
3.3 Mounting Considerations
Provisions should be made to ensure that the temperature inside the enclosure never rises above 50°C. If the temperature inside the
enclosure is too high, the starter can be damaged or the operational life can be reduced. As a general rule of thumb, the following
ventilation guidelines can be followed.
The field supply produces 4 watts of heat per amp of current and 26 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. 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.
14
3- INSTALLATION
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.)
401 to 600 amps 2 x 4” fan (230 cfm) 2 x 6” grills (28 sq.in.)
601 to 700 amps 2 x 6” fan (470 cfm) 2 x 6” grills (28 sq.in.)
> 700 amps Consult factory Consult Factory
Table 5: Ventilation Requirements