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BENSHAW EMX4e-0024B User Manual

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Low Voltage
Soft Starter
User Guide
EMX4e
710-21918-00A
Software Version (200-102-202-102)
© 2019 Benshaw, Inc
Benshaw retains the right to change specications and illustrations in text without prior notication.
The contents of this document may not be copied without hte explicit permission of Benshaw.

Table of Contents

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BENSHAW EMX4e-0024B Specifications

General IconGeneral
BrandBENSHAW
ModelEMX4e-0024B
CategoryController
LanguageEnglish

Summary

About This Manual

Disclaimer

States examples are illustrative and information is subject to change without notice.

Caution Statements

Electrical Shock Risk

Warns about severe electric shock risk from specific locations and stresses grounding requirements.

Unexpected Operation

Warns about accidental starts, unexpected starter operation, and mechanical damage from restarts.

System Design

Feature List

Details product features: setup, interface, energy efficiency, models, and protection.

Model Code

Explains the structure of the EMX4e model code for identification and selection.

Model Selection

Guides on selecting the correct soft starter size based on motor and application requirements.

Current Ratings

Provides IEC ratings for various models under different operating conditions.

Dimensions and Weights

Lists physical dimensions and weights for different EMX4e models.

Physical Installation

Illustrates recommended spacing for installing multiple starters and solid surface mounting.

Accessories

Describes available expansion cards for added functionality and communication options.

Remote Keypad

Details the use and compatibility of the remote keypad with EMX4e starters.

Finger Guard Kit

Explains the purpose and IP rating of the finger guard kit for terminal protection.

Soft Starter Management Software

Describes PC software for managing starters, including real-time and offline capabilities.

Main Contactor

Recommends using a main contactor for starter protection and how to control it.

Circuit Breaker

Discusses using a shunt trip circuit breaker as an alternative to a main contactor for isolation.

Power Factor Correction

Explains how to use the EMX4e to control power factor correction capacitors.

Short Circuit Protection Devices (SCPD)

Details Type 1 and Type 2 coordination for fuses and semiconductor fuses.

IEC Coordination with Short Circuit Protection Devices

Provides fuse selection recommendations for IEC Type 1 and Type 2 coordination.

UL Coordination with Short Circuit Protection Devices

Lists standard fault short circuit current ratings and maximum fuse ratings for UL compliance.

High Fault Short Circuit Current Ratings

Details high fault short circuit current ratings and recommended fuse classes for 480 VAC.

Circuit breakers – High fault short circuit current

Lists circuit breaker models for high fault short circuit current protection at 480 VAC.

Fuse Selection for Type 2 Coordination

Explains using semiconductor fuses for Type 2 coordination and provides I²t values.

Specifications

Lists detailed electrical, mechanical, and environmental specifications for the EMX4e.

Protection

Specifies IP ratings for different model ranges.

Heat dissipation

Provides heat dissipation figures during start and run for various model ranges.

Motor Overload Protection

Details default motor overload protection settings.

Certification

Lists certifications obtained by the product.

Operational life (internal bypass contacts)

States the operational life of internal bypass contacts.

Disposal Instructions

Advises on proper disposal of electrical components.

Installation

Command Source

Explains how to set the command source for starting and stopping the EMX4e.

Setup Procedure Overview

Outlines the steps for configuring the EMX4e for a specific application.

Inputs

Describes the control inputs and provides a warning against applying external voltage.

Input Terminals

Details the terminal connections for motor thermistor, reset, start/stop, and programmable inputs.

Motor Thermistor

Explains how to connect motor thermistors and the starter's response to resistance changes.

Reset/Starter Disable

Explains the function of the reset input and its configuration.

Start/Stop

Details the two-wire control requirement for starting and stopping the EMX4e.

Programmable Inputs

Describes how programmable inputs can be used to control the starter.

USB Port

Explains the use of the USB port for file transfer and parameter management.

Outputs

Details the available outputs and their functions.

Analog output

Explains how to connect the analog output to monitor motor performance.

Main Contactor Output

Describes the operation of the main contactor output and its control.

Programmable Outputs

Explains how programmable outputs can report starter status or control equipment.

Control Voltage

Shows how to connect the control voltage supply based on the voltage being used.

UL Compliant Installation

Specifies requirements for UL compliant installations regarding control circuit protection.

Power Terminations

Details power termination methods, cable size, torque, and connector types.

Wiring connectors

Recommends compression connectors and lists part numbers for different cable types.

Motor Connection

Explains the required in-line (three-wire) connection for the EMX4e to the motor.

Typical Installation

Illustrates a typical installation wiring diagram with a main contactor and control voltage supply.

Quick Setup

Describes the Quick Setup menu for easy configuration of common applications.

Setup Tools

Command Source

Explains how to set the command source via Setup Tools or parameter 1A.

Commissioning

Allows starting and stopping the starter via the local keypad for initial setup.

Run simulation

Simulates motor operation to confirm correct installation and wiring.

Load/Save Settings

Allows users to reset parameters, load, or save settings to an internal file.

USB Save & Load

Enables saving/loading parameter settings and event logs via a USB drive.

Network Address

Details how to configure IP address, gateway, and subnet mask for Ethernet networking.

Digital I/O State

Displays the current state of fixed and programmable inputs and outputs.

Analog I/O State

Shows the state of the motor thermistor input and the analog output value.

Serial Number & Rating

Displays the product name, serial number, and model number.

Software Versions

Reports the version of each software component installed in the starter.

Thermistor Reset

Explains how to disable the thermistor input if it's no longer needed.

Reset Thermal Model

Allows resetting the motor's thermal model, with a caution for emergency use only.

Logs

Event Log

Stores details of recent trips, warnings, and configuration changes.

Counters

Stores statistics on starter operation like hours run and number of starts.

QR Code

Generates a QR code for quick access to starter information via a smartphone app.

Keypad and Feedback

The Keypad

Details the local and remote keypads, including buttons and status LEDs.

Remote Keypad

Explains how to use the remote keypad for controlling the starter.

Lighten/Darken the Display

Describes how to adjust the display backlight brightness on both keypads.

Starter status LEDs

Explains the meaning of the Ready, Run, Trip, and Local status LEDs.

Displays

Details the information shown on the starter's display screens at power-up and during operation.

Starter status screen

Explains the starter status screen showing running current and status.

Current

Describes the current screen showing real-time line current on each phase.

Last Start Information

Provides details of the most recent successful start, like duration and current.

User configurable screen

Allows configuring the display to show important application information.

Performance Graph

Displays real-time operating performance, typically motor current.

Operation

Start, Stop and Reset Commands

Explains how to start, stop, and reset the EMX4e using various command sources.

Command Override

Details how to override the command source using a programmable input.

Emergency Mode

Describes the emergency mode which allows the motor to run ignoring trip conditions.

Auxiliary Trip

Explains how to use an external trip circuit to stop the soft starter and motor.

Typical Control Methods

Provides common application starting and stopping method settings as a starting point.

Soft Start Methods

Explains different soft start methods like Constant Current and Current Ramp.

Constant Current

Details the Constant Current soft start method, ideal for specific start current requirements.

Constant Current with Current Ramp

Describes Current Ramp soft starting for varying loads or limited supplies.

Timed voltage ramp

Explains Timed Voltage Ramp (TVR) starting for gradual voltage application.

Adaptive Control for Starting

Details Adaptive Control for starting, which adjusts current to start the motor within a specified time.

Fine-tuning Adaptive Control

Guides on adjusting adaptive control gain for smoother starts and stops.

Stop Methods

Covers Coast to Stop and Timed Voltage Ramp Soft Stop methods.

Programmable Parameters

Main Menu

Explains how to access and navigate the main menu for parameter adjustments.

Altering Parameter Values

Guides on how to change parameter values using the keypad and save/cancel actions.

Adjustment Lock

Describes how to prevent unauthorized parameter changes using the adjustment lock.

Parameter List

Provides a comprehensive list of programmable parameters with default settings.

Motor Details

Details parameters for Command Source, Motor Full Load Current, and Locked Rotor Time.

Motor Start/Stop

Lists parameters for configuring start modes, ramp times, and current limits.

Protection Levels

Lists parameters for setting various protection trip levels and delays.

Protection Actions

Defines how the starter's response to protection events (trip, reset, log).

Inputs

Details parameters for configuring digital and programmable inputs.

Relay Outputs

Lists parameters for configuring the function and timing of relay outputs.

Analog Output

Lists parameters for configuring the analog output signal.

Display

Lists parameters for display language, temperature scale, and graph settings.

Communications Card

Parameters for configuring Modbus, DeviceNet, and Profibus communication settings.

Advanced

Parameters for fine-tuning adaptive control and other advanced settings.

Pump Input Configuration

Parameters for configuring pressure, flow, and depth sensors for pump applications.

Flow Protection

Parameters for setting high and low flow trip levels and delays.

Pressure Protection

Parameters for setting high and low pressure trip levels and delays.

Pressure Control

Parameters for controlling soft start based on pressure readings.

Depth Protection

Parameters for setting trip levels and delays for depth protection.

Thermal Protection

Parameters for temperature trip levels.

Pump Trip Action

Defines the starter's response to faults detected by pump sensors.

Application Examples

Smart Card - Pump Protection

Details an example of using the smart card for pump protection with external sensors.

Smart Card - Level Controlled Pump Activation

Shows how to use the smart card for pump activation based on water levels.

Troubleshooting

Protection Responses

Explains how the starter responds to protection conditions and how to reset.

Trip Messages

Lists possible causes and suggested solutions for various display trip messages.

EEPROM fail

Addresses errors loading data from EEPROM to RAM on keypad power-up.

Excess start time

Explains conditions causing excess start time trips.

Firing Fail Px

Discusses SCR firing failures and potential causes.

Flow Sensor

Addresses faults detected with the flow sensor.

Flow Switch

Explains issues related to the flow switch sensor.

Frequency

Discusses trips related to mains frequency deviations.

Heatsink overtemperature

Addresses heatsink overtemperature issues and causes.

High Flow

Explains causes for high flow protection activation.

High Pressure

Explains causes for high pressure protection activation.

Input A trip

Addresses programmable input trips for Input A and B.

Instantaneous overcurrent

Discusses instantaneous overcurrent trips and their causes.

Internal fault x

Addresses internal faults indicated by a number.

Internal fault 88

Addresses internal faults related to firmware/hardware mismatch.

Keypad disconnected

Discusses issues with keypad detection and connection.

Phase loss

Addresses phase loss detection during pre-start checks or run state.

Shorted SCR or Bypass

Discusses short circuits detected in SCRs or bypass contactors.

Low Control Volts

Addresses issues with low internal control voltage.

Low Flow

Explains causes for low flow protection activation.

Low Pressure

Explains causes for low pressure protection activation.

Low Water

Explains causes for depth protection activation.

Motor connection

Addresses issues with motor connection detection and configuration.

Motor overload

Discusses motor overload causes and troubleshooting.

Motor thermistor

Addresses issues with the motor thermistor input.

Network communication

Discusses network communication problems.

Not ready

Explains conditions causing the starter to be in a 'Not Ready' state.

Overcurrent

Explains causes for overcurrent trips based on set levels and delays.

Parameter out of range

Addresses issues with invalid parameter values or data loading errors.

Phase sequence

Discusses invalid phase sequence detection and correction.

Power loss

Addresses issues related to loss of mains supply during operation.

Pressure Sensor

Addresses faults detected with the pressure sensor.

Rating Capacity

Discusses operating beyond the starter's safe capacity.

RTD Circuit

Addresses faults detected with RTD sensors or temperature protection.

SCR Itsm

Discusses SCR current surge rating exceedance.

SCR overtemperature

Addresses SCR overtemperature issues.

Starter communication

Discusses communication problems with optional expansion cards.

Starts per hour

Addresses the situation where the maximum number of starts per hour has been reached.

Thermistor circuit

Addresses issues with the thermistor circuit, such as low resistance or short circuit.

Time-overcurrent

Discusses time-overcurrent trips due to high current during running.

Undercurrent

Explains causes for undercurrent conditions.

VZC Fail Px

Addresses internal faults indicated by VZC Fail Px.

General Faults

Describes situations where the starter does not operate as expected without tripping.

Starter "Not Ready"

Explains causes for the 'Not Ready' status, like active reset input or simulation mode.

"Simul" on display

Addresses the display showing 'Simul' indicating simulation mode is active.

Keypad unresponsive

Troubleshoots unresponsive keypad buttons, checking command source and local LED.

Control input unresponsive

Troubleshoots control input response, checking command source and wiring.

No start command response

Troubleshoots no start response, checking restart delay, motor temperature, reset input, and network signals.

Remote keypad 'awaiting data'

Addresses 'awaiting data' message on remote keypad, checking cable.

Incorrect motor starting

Troubleshoots motor control issues during starting, checking FLC, PFC, and harmonics.

Motor does not reach full speed

Troubleshoots motor not reaching full speed, checking start current, load, and profiles.

Soft stop ends too quickly

Addresses soft stops ending too quickly, suggesting review of settings.

Adaptive Control start variation

Explains initial Adaptive Control behavior and learning process.

Parameter settings not stored

Troubleshoots inability to store parameter settings, checking SAVE, EXIT, and Adjustment Lock.

USB Full

Addresses USB drive full errors, checking free space and file system compatibility.

USB Missing

Troubleshoots USB drive not being detected.

File Missing

Addresses missing files required for USB functions.

File Not Valid

Addresses invalid files for USB functions.

File Empty

Addresses USB files found but empty or with incorrect content.

Rating Not Valid

Addresses invalid Model Rating parameter mismatch.

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