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RediStart MX3Low Voltage Solid State Motor Control

Instruction Manual

890003-06-00

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.


TB2-4 N.O.

OIL PUMPTB2-5 Common

TB2-6 N.C.


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


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


Tower Fan #1J20-5A Common


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:


Press [LEFT] key once, the cursor flashes in the ten’s place:


Press [UP] arrow to increase the value, for a value of 30, press twice:


Press [ENTER] to store the value.


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



6 L1-2 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




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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




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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.




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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


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


The starter received a stop command over the SIO bus, but the 120VAC start command remained high


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




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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




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Revision History

Revision Date ECO Number

- 06/09/09 2377


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BENSHAW Inc.1659 East Sutter RoadGlenshaw, PA 15116Phone: 412-487-8235Fax: 412-487-4201

BENSHAW West14715 North 78th WaySuite 600Scottsdale, AZ 85260Phone:480-905-0601Fax: 480-905-0757

BENSHAW Canada550 Bright StreetListowel, OntarioN4W 3W3Phone:519-291-5112Fax: 519-291-2595

For Technical Support7 Days a Week24 Hours a Day800-203-2416

Visit us at:http:/www.benshaw.com

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