Rockwell Automation VSM500 User Manual

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Installing and Operating the VSM500™ Integrated Drive/Motor Version 3.0

Instruction Manual

D2-3400-3

The information in this manual is subject to change without notice.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

Throughout this manual, the following notes are used to alert you to safety considerations:

ATTENTION:Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss.

Important: Identifies information that is critical for successful application and understanding of the product. The thick black bar shown on the outside margin of this page will be used throughout this instruction manual to

signify new or revised text or figures.

ATTENTION:Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, and/or service this equipment.

Read and understand this instruction manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:After disconnecting input power, wait five minutes and check with a voltmeter to insure that DC bus capacitors are discharged. The voltmeter should read zero volts. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:High voltage and rotating parts can cause serious or fatal injury. Installation, operation, and maintenance of electrical machinery should be performed by qualified personnel. Make sure that the motor and equipment are grounded and protected in accordance with the National Electric and local codes. See NEMA MG-2 safety standard.

ATTENTION:The user is responsible for conforming with all applicable local, national, and international codes. Failure to observe this precaution could result in personal injury and/or damage to, or destruction of, the equipment.

DeviceNet™ is a trademark of the Open DeviceNet Vendor Association. VSM500™ and Reliance™ are trademarks of Rockwell Automation.

Checklist Installation Checklist

Chapter 1 Step 1 - Identify Your Unit

1.1 VSM500 Standard Unit....................................................................................1-2

1.1.1 Standard Unit Display Description......................................................... 1-2

1.1.2 Standard Unit Reverse LED Description............................................... 1-2

1.1.3 Standard Unit Communications LED Description.................................. 1-3

1.2 VSM500 Local Operator Control Unit.............................................................. 1-3

1.2.1 Local Operator Control Unit Key Descriptions.......................................1-4

1.2.2 Local Operating Control Unit Display Description ................................. 1-4

1.2.3 Local Operating Control Unit Reverse LED Description........................ 1-4

1.2.4 Local Operator Control Unit Communications LED Description............ 1-4

1.2.5 Operating the Unit Using the Local Operator Controls..........................1-5

1.3 Option Kits.......................................................................................................1-5

Chapter 2 Step 2 - Plan the Installation

2.1 Wire Routing Guidelines..................................................................................2-3

2.2 Handling and Lifting Guidelines....................................................................... 2-4

Chapter 3 Step 3 - Mount the Unit

3.1 Mounting Guidelines for Reliance Face-Mounted Motors ...............................3-1

3.2 Mounting Dimensions for NEMA Frames ........................................................ 3-2

ONTENTS

Chapter 4 Step 4 - Install External Components

4.1 Installing an AC Input Disconnect....................................................................4-1

4.2 Installing Branch Circuit Protection..................................................................4-1

4.3 Installing Input Isolation Transformers............................................................. 4-2

Chapter 5 Step 5 - Wire AC Power to the Unit and Ground the Unit

5.1 Grounding the Unit .......................................................................................... 5-3

Chapter 6 Step 6 - Install an Emergency Stop

6.1 Compliance with Machinery Safety Standard EN 60204-1: 1992.................... 6-1

Chapter 7 Step 7 - Wire the Control Signal Terminal Block

7.1 Wiring Function Loss .......................................................................................7-4

7.2 Wiring the Analog Output ................................................................................ 7-5

7.3 Wiring the Relay Control Output...................................................................... 7-6

7.4 Wiring RPM or %Load Display ........................................................................ 7-7

7.5 Wiring the Speed Reference ........................................................................... 7-7

7.5.1 Wiring the Preset Speed Inputs ............................................................7-8

7.5.2 Wiring the Speed Reference Signal Potentiometer............................... 7-9

7.5.3 Wiring an External Speed Reference (0 to 10 VDC or 4 to 20 mA) ....7-10

7.6 Wiring Start / Stop Control............................................................................. 7-12

7.7 Wiring Forward / Reverse Control .................................................................7-13

7.8 Wiring Reset Control .....................................................................................7-14

Contents

Chapter 8 Step 8 - Verify the Setup and Adjust Switches if Required

8.1 Adjusting the Maximum Speed ................. ....... ...... ....... ...................................8-3

8.2 Adjusting the Acceleration / Deceleration Time ...............................................8-4

8.3 Modifying the Setup Using the Setup Slide Switch ..........................................8-5

8.3.1 Power-Up Start (Position 1)...................................................................8-6

8.3.2 Speed Reference Select (Position 2).....................................................8-6

8.3.3 Relay Control Output - Running or Faulted (Position 3) ........................8-7

8.3.4 Auto Restart (Position 4)........................................................................8-7

8.3.5 Torque Curve (Position 5)......................................................................8-8

8.3.6 Stop Type (Position 6) ...........................................................................8-9

8.3.7 Reverse Disable (Position 7).................................................................8-9

8.3.8 Minimum Speed Select (Position 8).......................................................8-9

8.3.9 Start Mode Select (Position 9).............................................................8-11

8.3.10Parameter Mode for DeviceNet Option (Position 10) ..........................8-11

Chapter 9 Step 9 - Check the Installation

9.1 Checking the Installation with the Power Off....................................................9-1

9.2 Checking the Direction of Motor Rotation ........................................................9-2

9.3 Attaching the Cover..........................................................................................9-2

9.3.1 Rotating the Cover.................................................................................9-3

9.4 Checking the Speed Reference.......................................................................9-4

Chapter 10 Step 10 - Set the Operating Speed

Chapter 11 Diagnostics and Troubleshooting

11.1 Fault Codes and Corrective Actions...............................................................11-2

11.2 Troubleshooting Tables..................................................................................11-5

11.3 Replacement Parts........................................... ...... ....... ...... ....... ...... ....... ...... .11-7

11.4 Replacement Part Compatibilit y.... ...... ...... ....... ...... ....................................... .11-9

Chapter 12 Maintenance Guidelines

12.1 General Unit Maintenance .............................................................................12-1

12.2 Motor Maintenance ........................................................................................12-1

Appendix A Technical Specifications...........................................................................................A-1

Appendix B Product Features...................................................................................................... B-1

Appendix C VSM500 System Diagram........................................................................................C-1

Appendix D Installation Record ...................................................................................................D-1

Appendix E Replacing the Drive Section or the Motor Section ................................................... E-1

Appendix F CE Conformity....... ....... ...... ....... ...... ....... ...................................... ....... ...... ....... ...... .. F-1

Index ..................................... ...... ....... ...... ....... ...... ....................................... ...... ....... ..Index-1

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

List of Figures

Figure 1.1 – VSM500 Standard Unit.........................................................................1-2

Figure 1.2 – VSM500 Local Operator Control Unit...................................................1-3

Figure 1.3 – Local Operator Controls Key Functions................................................1-4

Figure 2.1 – Component Location ............................................................................2-1

Figure 2.2 – Access Clearances...............................................................................2-2

Figure 2.3 – Wire Routing Locations ........................................................................2-3

Figure 3.1 – NEMA Frame Mounting Dimensions ....................................................3-2

Figure 5.1 – Removing the Cover............................................................................. 5-2

Figure 5.2 – AC Input Power Connections ...............................................................5-2

Figure 7.1 – Control Signal Terminal Block ..............................................................7-1

Figure 7.2 – Typical Control Signal Connections for Standard Units and

Local Operator Control Units Set Up for Terminal Block Control ......... 7-2

Figure 7.3 – Typical Control Signal Connections for Local Operator Control Units..7-3

Figure 7.4 – Function Loss Control Wiring ...............................................................7-4

Figure 7.5 – Analog Output Wiring ...........................................................................7-5

Figure 7.6 – Relay Control Output Wiring.................................................................7-6

Figure 7.7 – RPM or %Load Display Wiring .............................................................7-7

Figure 7.8 – Preset Speed Input Wiring.................................................................... 7-8

Figure 7.9 – Speed Reference Potentiometer Wiring...............................................7-9

Figure 7.10 – 0 to 10 VDC External Speed Reference Wiring................................7-10

Figure 7.11 – 4 to 20 mA External Speed Reference Wiring..................................7-11

Figure 7.12 – Start / Stop Control Wiring................................................................7-12

Figure 7.13 – Forward / Reverse Control Wiring .................................................... 7-13

Figure 7.14 – Reset Control Wiring ........................................................................7-14

Contents

Figure 8.1 – Factory Settings for the Setup Rotary Switches and Slide Switch .......8-2

Figure 8.2 – Maximum Speed Rotary Switch ...........................................................8-3

Figure 8.3 – Acceleration / Deceleration Rotary Switch ...........................................8-4

Figure 8.4 – Setup Slide Switch Selections.............................................................. 8-5

Figure 8.5 – Torque Curves......................................................................................8-8

Figure 8.6 – Wiring Minimum Speed ......................................................................8-10

Figure 9.1 – Changing the Definition of Forward and Reverse................................. 9-2

Figure 9.2 – Rotating the Cover................................................................................ 9-3

III

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

List of Tables

Table 1.1 – Model Number Format...........................................................................1-1

Table 1.2 – VSM500 Option Kits ..............................................................................1-5

Table 4.1 – Required AC Branch Circuit Protection .................................................4-1

Table 4.2 – Input Line Reactors................................................................................ 4-2

Table 7.1 – Fixed Preset Speed Selections.............................................................. 7-8

Table 8.1 – Auto Restartable Faults......................................................................... 8-8

Table 11.1 – Fault Codes and Corrective Actions .................................................11-2

Table 11.2 – Display Not On...................................................................................11-5

Table 11.3 – Motor Will Not Start............................................................................11-5

Table 11.4 – Motor Rotates but Does Not Accelerate to Full Speed......................11-5

Table 11.5 – Motor Stops While Running...............................................................11-5

Table 11.6 – Motor Runs, But Not with Expected Performance.............................11-6

Table 11.7 – Replacement Parts for 460 VAC Units .............................................. 11-7

Table 11.8 – Replacement Parts for 230 VAC Units .............................................. 11-8

Table 11.9 – Replacement Parts for 115 VAC Units .............................................. 11-8

Table 11.10 – Replacement Bearings .................................................................... 11-9

Table 11.11 – Replacement Part Compatibility ...................................................... 11-9

Contents

Installing and Operating the VSM500 Integrated Drive/Motor, Veresion 3.0

HECKLIST

Installation Checklist

This manual describes how to install, troubleshoot, and maintain the VSM500 unit. Use the following checklist to guide you through the installation process.

Read Manual

Section(s)

1.1

1.2

2.0

4.0

4.1

4.2

4.3

9.0

9.1

9.2

9.3

9.4

❑ Step 1

❑ Step 2

❑ Step 3 ❑ Step 4

❑ Step 5 ❑ Step 6 ❑ Step 7 ❑ Step 8 ❑ Step 9

❑ Step 10

Installation Procedure

Identify your unit 1.0

Understand how the

operates

Understand how the

operates

unit

Plan the installation

If your installation must be in compliance with the European Community Electromagnetic Compatibility Standards,

refer to Appendix F before proceeding. Mount the unit 3.0 Install external components

AC input disconnect

Branch circuit protection

Input isolation transformers Wire AC power to the unit and ground the unit 5.0 Install an emergency stop 6.0 Wire the control signal terminal str ip 7.0 Verify the setup and adjust it if required 8.0 Check the installation

Perform power-off checks

Verify the direction of motor rotation

Attach the cover

Check the speed reference Set the operating speed 10.0

standard unit

local operator control

Installation Checklist

If problems occur during unit operation, refer to chapter 11 for troubleshooting guidelines.

Getting Assistance from Reliance Electric

If you have any questions or problems with the products described in this instruction manual, contact your local Re liance Electric sales office. For tech nical assistance, note the unit’s model number and call 1-800-726-8112.

Checklist-1

Checklist-2

Max Speed Switch

0 = 1500 RPM (50 Hz) 1 = 1800 RPM (60 Hz) (Default)

2 = 2100 RPM (70 Hz)

3 = 2400 RPM (80 Hz)

4 = 2700 RPM (90 Hz)

5 = 3000 RPM (100 Hz) 6 = 3300 RPM (110 Hz) 7 = 3600 RPM (120 Hz)

Setup Slide Switch

Power-Up Start Disabled

1> Spd Ref from Operator C ontrols

Relay Output Control: Ru nning

Auto Restart Disabled

Variable Torque Curve

Coast-to-Rest Stop

Reverse Enabled

0 Hz Minimum Speed

1> Start from Operator C ontrols

2> Parameter Settings f rom Setup Switches

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

1> Switches 2 and 9 are used only with local operator control units. 2> Switch 10 is used only with the DeviceNet Communication Option board.

Power-Up Start Enabled

23 54 768

Analog Spd Ref from Terminal Block

Relay Output Control: Faulted

Auto Restart Enabled Constant Torque Curve Ramp-to-Rest Stop Reverse Disabled (Reverse Lockout)

Min Spd from Terminal Bloc k In put s Start from Terminal Block

109

Parameter Settings fr om EEPROM Memory

= Default Setting (OFF Position)

Top View of Unit With Cover Removed

Display Board Connector

Accel / Decel Switch

0 = 1 sec accel / 5 sec decel 1 = 5 sec (Default)

2 = 10 sec

3 = 15 sec

4 = 20 sec

5 = 30 sec

6 = 60 sec 7 = 90 sec

(Stop to Max Spd)

AC Input Power Connections

DC Bus (Do Not Wire)

- DBR (Do Not Wire)

AC Inputs

Ground

Control Signal Terminal Block Connections

RPM

%LOAD

Momentary 3-Wire Start

+ -

REV

+10VDC

FWD

Connect to external device such as PLC input.

Standard Unit

1 10 Volt Reference

2 0 to 10V Spd Ref Input 3 4 to 20 mA Spd Ref Input 4 Common 5 0 to 10V Output

7 24V DC 8 Speed Preset 2

9 Speed Preset 1 10 Speed Preset 0 11 Function Loss 12 RPM / %Load Display 13 24V DC 14 Forward/Reverse 15 Reset 16 Start

17 Stop 18 24 DC Common 19 N.O. Relay 20 Relay Common

= N.O. Momentary Contact = N.C. Momentary Contact = Maintained Contact - Closed = Maintained Contact - Open

Local Operator Control Unit

+ -

RPM

%LOAD

Connect to external device such as PLC input.

1 10 Volt Reference

2 0 to 10V Spd Ref Input 3 4 to 20 mA Spd Ref Input 4 Common 5 0 to 10V Output 6 Common6 Common 7 24V DC 8 Speed Preset 2

9 Speed Preset 1 10 Speed Preset 0 11 Function Loss 12 RPM / %Load Display

13 24V DC 14 Forward/Reverse 15 Reset 16 Start 17 Stop 18 24 DC Common 19 N.O. Relay

20 Relay Common

Maintained 2-Wire Start

16 17

1> The jumper between te rm inals 7 and 11 must be removed when wiring the Function Loss input. See s ec t ion 7.1 for more information.

2> An external 0 to 10 volt or 4 t o 20 mA speed reference sou rc e c an be connected. See section 7.5.3 for more information.

3> block inputs, the jumper bet w een terminals 13 and 17 must be removed when wiring the Stop input. See section 7.6 for more informa t ion.

To stop the unit using the ter m inal

Important:

HAPTER

Step 1 - Identify Your Unit

The VSM500™ integrated drive/motor is an AC drive integrally mounted with an inverter duty motor. Each unit consists of a drive section and a motor section.

The drive section is a single- or three-phase input, three-phase output inverter providing open loop V/Hz regulation. It houses the PC boards and the blower. The motor section is a four-pole, three-phase induction motor.

The unit’s default setup suits a wide range of applications. Two rotary switches and a 10-position slide switch on the Regulator board are used to adjust the setup, if required.

VSM500 units are identified by model number. This number appears on the shipping label and on the unit’s nameplate. Table 1.1 shows the format of this number and what it indicates.

Table 1.1 – Model Number Format

nn n a a n n n n

Horsepower

1 = 1 HP 2 = 2 HP 3 = 3 HP 5 = 5 HP

Frame

0 = 56 1 = 140 2 = 180

Regulator

X = CT / VT

Display

S = Standard W = Operator Controls

Input Voltage

1 = 1-Phase, 115 VAC 2 = 3-Phase, 230 VAC 3 = 1-Phase, 230 VAC 4 = 3-Phase, 460 VAC

CE Certification

0 = Without Mains Filter

Enclosure Type

0 = Drive Section Only 1 = Standard

Mounting

1 = C-face and Foot

Standard units, described in section 1.1, provide remote operator control. Local operator control units, described in section 1.2, provide local (default) or remote (user option) control.

Step 1 - Identify Your Unit

1-1

1.1 VSM500 Standard Unit

The standard unit, shown in figure 1.1, provides a local display for speed or %load, and diagnostic information. A control signal terminal block in the drive section connects to a user-supplied remote operator control station.

Motor Section

Drive Section

Display

Figure 1.1 – VSM500 Standard Unit

1.1.1 Standard Unit Display Description

The four-character, seven-segment display shows the drive’s output speed in RPM or %load, and displays active fault codes. Speed in RPM is the default display. To display %load, see section 7.4.

If a fault occurs, the unit displays the corresponding fault code. Refer to chapter 11 for more information about fault codes and corrective actions.

1.1.2 Standard Unit Reverse LED Description

The REVERSE LED indicates the requested direction of motor rotation:

LED Status Definition

OFF The requested direction of motor rotation is forward.

(The VSM500 unit is shipped with the forward direction defined as CCW shaft rotation as viewed from the motor shaft end.)

ON The requested direction of motor rotation is reverse.

(The VSM500 unit is shipped with the reverse direction defined as CW shaft rotation as viewed from the motor shaft end.)

Reverse LED

Communications LED

1-2

Note that if the motor is turning and you request a change to motor direction, the LED turns on or off immediately even though it may take some time for the motor to decelerate and begin turning in the opposite direction.

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

1.1.3 Standard Unit Communications LED Description

Motor Section

Drive Section

Display

Reverse LED

Local Operator Controls

Communications LED

The communications LED (COMM) is used only with the VSM500 DeviceNet option. Refer to the VSM500 DeviceNet Option Board instruction manual, D2-3463, for more information about this LED.

1.2 VSM500 Local Operator Control Unit

The local operator control unit (see figure 1.2) provides local start, stop, forward, reverse, reset, and speed control functions. The controls replace the Start, Stop, Reset, and F or war d / Re v erse i nput sig nals a t the te rminal b loc k. F or lo cal con trol, y ou do not wire to these inputs.

V ersion 3.0 and later units provide the option to control the unit from the terminal block instead of the local operator controls. In this case, you wire to the Start, Stop, Reset,

and Forward / Reverse input signals at the terminal block. Note that the red

used to stop the unit when the unit is set up for local (local operator controls) or remote

can be (terminal block) control. See section 8.3.9, Start Mode Select, for a description of this option.

The local operator control unit receives its speed reference from the keypad (default) or the analog input terminals (user option). Refer to section 8.3.2 for more information.

key

Step 1 - Identify Your Unit

Figure 1.2 – VSM500 Local Operator Control Unit

1-3

1.2.1 Local Operator Control Unit Key Descriptions

Figure 1.3 shows each key’s function.

Use the FORWARD/REVERSE key to toggle the direction of motor rotation.

Use the START key to apply power to the motor section.

Use the STOP key to turn off the drive section output to the motor section.

Figure 1.3 – Local Operator Controls Key Functions

Use the RESET key to reset any active faults or cancel an Auto Restart sequence.

Press the UP ARROW key once to display the current speed reference.

Hold this key down to increase the speed reference value. The longer this key is pressed, the faster the reference value will change.

Press the DOWN ARROW key once to display the current speed reference.

Hold this key down to decre a se the speed reference value. The longer this key is pressed, the faster the reference value will change.

1.2.2 Local Operating Control Unit Display Description

The four-character, seven-segment display shows output speed in RPM or %load, the current speed reference, and active fault codes. Speed in RPM is the default display. To display %load, see section 7.4.

If a fault occurs, the unit displays the corresponding fault code. Refer to chapter 11 for more information about fault codes and corrective actions.

1-4

1.2.3 Local Operating Control Unit Reverse LED Description

The REVERSE LED indicates the requested direction of motor rotation:

LED Status Definition

OFF The requested direction of motor rotation is forward.

(The VSM500 unit is shipped with the forward direction defined as CCW shaft rotation as viewed from the motor shaft end.)

ON The requested direction of motor rotation is reverse.

(The VSM500 unit is shipped with the reverse direction defined as CCW shaft rotation as viewed from the motor shaft end.)

Note that if the motor is turning and the key is pressed, the LED turns on or off immediately even though it may take some time for the motor to decelerate and begin turning in the opposi te direc ti on.

1.2.4 Local Operator Control Unit Communications LED Description

The communications LED (COMM) is used only with the VSM500 DeviceNet option. Refer to the VSM500 DeviceNet Option Board instruction manual, D2-3463, for more information about this LED.

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

1.2.5 Operating the Unit Using the Local Operator Controls

Desired Action User Steps

Start the unit. Stop the unit.

Change the direction of motor rotation. Clear faults.

Decrease the speed reference.

Display the current speed reference

Display the speed in RPM No action required; speed in RPM is the default display based on status of

Display %load Close contact on terminal 12 (see section 7.4) Increase the speed reference.

Cancel Auto Restart sequence.

If the unit is set up for terminal block control (see section 8.3.9), the and

If the unit is using a preset speed reference (see section 7.4.1) or terminal block speed reference (see

section 8.3.2), pressing the or key will have no effect on unit operation.

Press the green key. Press the red key.

Press the key. Press the key. Press the key until the speed reference displayed is the desired value. The

longer the key is held down, the faster the value decreases. Press the or key once.

The display returns to indicating speed in RPM or %load after three to five seconds. (Note that holding down either key will change the speed reference.)

terminal 12 (see section 7.4). If the or keys are not pressed for several seconds , the dis pla y returns

to indicating actual motor speed in RPM.

Press the key until the speed reference displayed is the desired value. The longer the key is held down, the faster the value increases.

Press the key.

RESET

keys are not functional.

Important:

If the local operator controls are disconnected from or connected to the unit after power up, the unit will stop due to a non-resettable fault. Refer to chapter 11 for information about faults.

1.3 Option Kits

Table 1.2 lists the VSM500 option kits.

Drive Input Rating

115V, 230V Single Phase

230V, 460V Three Phase

Table 1.2 – VSM500 Option Kits

CE Filter Option Kit DeviceNet

Communication

VSM-CE-1I VSM-CE-1E

VSM-CE-3I VSM-CE-3E

Option KitInternal Mount External Mount

DNVSM500

Step 1 - Identify Your Unit

1-5

1-6

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

Accel/Decel Switch

Display Board Connector

Ground

Control Signal Terminal Block

Max Speed Switch

Setup Slide Switch

AC Input Power Terminal Block

Top View of Unit with

Drive Section Cover Removed

HAPTER

Step 2 - Plan the Installation

ATTENTION:Only qualified electrical personnel, familiar with the

construction and operation of this equipment and the hazards involved,

It is the user’s responsibility to ensure that this equipment is installed properly according to this manual and in conformance with all applicable codes. Consult your local inspecting agency for information about any local, national, or international codes that may apply.

should install, adjust, operate, and/or service this equipment. Read and understand this instruction manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:This equipment is at line voltage when AC power is connected. Disconnect and lockout all ungrounded conductors of the AC power line before working on the unit. Failure to observe these precautions could result in severe bodily injury or loss of life.

Review all installation and wiring instructions thoroughly before proceeding. Throughout the installation procedures, use figure 2.1 to locate wiring termination points and setup switches.

If the VSM500 unit installation must be in compliance with the European Community Electromagnetic Compatibility Standards, refer to appendix F before proceeding.

Figure 2.1 – Component Location

Step 2 - Plan the Installation

2-1

Planning the installation is necessary to ensure you have acceptable environmental and operating conditions for the unit. Read and follow the requirements given below before proceeding with the installation:

•

Locate the unit where it will have unrestricted clearance as shown in figure 2.2.

•

Locate the unit where it will be kept clean (away from oil, coolants, or airborne contaminants). The VSM500 unit has an IP54/Type 12 rating. An IP rating designates the enclosure’s level of protection. The first number in the rating (5) indicates that the VSM500 unit is dust-resistant. The second number (4) indicates that the unit is splashproof.

•

Mount the unit on a flat surface.

•

Verify that the ambient temperature will remain between 0°C to 40°C (32°F to

F).

104

•

Verify that the relative humidity will be between 5% and 95%, non-condensing.

•

For installations above 1000 meters (3300 feet), refer to appendix A for derating guidelines.

•

Verify that there will be adequate clearance for opening the cover. See figure 2.2.

•

Verify that there will be adequate clearance for blower intake. See figure 2.2.

12.50

Front View

Clearance

1.30

10.25

Figure 2.2 – Access Clearances

Top View

Blower IntakeCover

Clearance

1.00

2-2

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

Control Signal Terminal Block

AC Input Power

Control Signal

AC Input Power

Wiring

Top View

Side View

Ground

Control Signal

Wiring

Control Signal

Wiring

AC Input Power

Wiring

AC Input Power

Wiring

Terminal Block

2.1 Wire Routing Guidelines

The VSM500 unit is shipped from the factory with plastic conduit plugs installed. These plugs must be removed. Before wiring, replace these plugs with appropriate 3/4-inch NPT connectors having a similar enclosure rating. After wiring, seal unused routing holes using permanent, user-supplied 3/4-inch NPT plugs. Seal all threaded connections. Route the power and control wiring as shown in figure 2.3.

Step 2 - Plan the Installation

Figure 2.3 – Wire Routing Locations

2-3

2.2 Handling and Lifting Guidelines

Follow these handling and lifting guidelines:

•

In the case of assemblies on a common base, carefully lift the assembly by a sling around the base or by other lifting means on the base.

•

When designing the lifting means, take care to assure lifting in the intended direction.

•

Do not lift the unit by the plastic blower cover.

•

Do not use any lifting means under the drive section.

•

Do not lift attached equipment by lifting the motor.

•

Do not use the VSM500 unit as a step.

2-4

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

HAPTER

Step 3 - Mount the Unit

Mount the unit on a foundation sufficiently rigid to prevent excessive vibration. The unit may be mounted at any orientation. After carefully aligning the VSM500 unit with the driven machinery, bolt securely in place.

When the unit is mounted vertically, it may be necessary to use additional guards to prevent foreign objects from falling into the motor openings and striking rotating parts.

Mounting dimensions are provided on the following pages of this chapter.

3.1 Mounting Guidelines for Reliance Face-Mounted Motors

Use the following guidelines when mounting Reliance 56C and 140C face-mounted motors:

•

Before mounting a C-face motor to the mating flange, be sure both surfaces and all mounting holes are smooth and free of debris.

•

When mounting into a quill-type reducer, make sure the input and output shafts are coated with an anti-seize compound suitable for the application.

•

When mounting through a flexible coupling, make sure that there is adequate clearance between the driven equipment shaft, the coupling interface, and the motor shaft. Insufficient clearance may result in binding of the shafting and premature bearing failure.

•

Always slide the motor tenon into the mating flange to its full depth before tightening the mounting bolts. Do not allow the motor to hang by the shaft extension while assembling it to the driven equipment (for example, a quill input gear case) as this may bend or crease the shaft and damage any seals that are present.

•

Make sure to use the proper mounting bolts. For 56C and 140C motors, these should be 9.5 mm (0.38 in) and sized for length such that engagement into the motor flange does not exceed 14.3 mm (0.563 in).

For example, a gearcase with a 9.5 mm (0.38 in) flange thickness requires a bolt that is 9.5 mm (0.38 in) + 14.3 mm (0.56 in). That is, 23.8 mm (0.94 in) should be the maximum bolt length. Since 23.8 mm (0.94 in) is not a standard bolt length, a

22.2 mm (0.88 in) bolt or a 25.4 mm (1.0 in) bolt with a lock washer can be used.

Important:

Using a bolt that is too long may cause damage to the motor resulting in premature failure and/or a loose assembly.

Step 3 - Mount the Unit

3-1

3/4 Conduit

Both Sides

45°

Face Runout & Eccentricity .004 Max. T.I.R. Shaft Runout .002 Max. T.I.R.

3.2 Mounting Dimensions for NEMA Frames

6.00

.75

S - Key Width/Height ES - Key Length

H - Diameter Through

* Denotes Control Wiring Ports ** Denotes Input Power Port Opposite Side

Figure 3.1 – NEMA Frame Mounting Dimensions

4.50

6.01

Short Cover

7.86

Std. Cover

Dimensions in inches (mm)

Frame Size A 2E H D BF AJ AK U AH S ES

56C 6.71

(170)

143TC 145TC

182TC 184TC

6.71

(170)

8.50

(216)

5.50

(140)

5.50

(140)

7.50

(191)

0.34 (8.6)

3.50 (89)

4.50

(114)

3/8-16 5.88

(149)

3/8-16 5.88

(149)

1/2-13 7.25

(184)

4.50

(114)

4.50

(114)

8.50

(216)

0.625 (15.9)

0.875 (22.3)

1.125 (28.6)

2.06 (52)

2.12 (54)

2.62 (67)

.19 SQ

(4.8)

.19 SQ

(4.8)

.25 SQ

(6.4)

Dimensions in inches (mm)

Frame Size BC BB BA B 2F 1 2F 2 EV C P BV

56C -0.19

(-4.8)

143TC 0.12

(3.0)

145TC 0.12

(3.0)

182TC 0.12

(3.0)

184TC 0.12

(3.0)

0.12 (3.0)

0.25 (6.4)

2.75 (70)

3.50 (89)

6.50

(165)

6.50

(165)

6.50

(165)

6.50

(165)

6.50

(165)

3.00 (76)

4.00

(102)

4.00

(102)

4.50

(114)

4.50

(114)

5.00

(127)

5.00

(127)

5.00

(127)

5.50

(140)

5.50

(140)

0.47 (12)

0.50 (13)

15.90 (404)

16.46 (418)

15.96 (405)

18.75 (476)

19.75 (502)

8.38

(213)

8.38

(213)

8.38

(213)

8.80

(224)

8.80

(224)

10.14 (258)

10.64 (270)

12.39 (315)

13.39 (340)

1.25 (32)

1.50 (38)

3-2

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

Step 4 - Install External Components

Install external components using the guidelines in the following sections.

4.1 Installing an AC Input Disconnect

HAPTER

ATTENTION:

provided i n the i ncomi ng po wer lines . Failure to observ e thi s prec aution

An AC input disconnect must be provided in the incoming power lines in accordance with NEC/CEC guidelines.

could result in severe bodily injury or loss of life.

The NEC and CEC require that an input disconnect be

4.2 Installing Branch Circuit Protection

ATTENTION:

be provided to protect input power wiring. The input fuse ratings listed

Install the required, user-supplied branch circuit protection fuses according to NEC/CEC guidelines. Refer to table 4.1 for recommended fuse ratings.

Model Number Input Voltage Unit HP

1_X_4_1_ 460 VAC 1 HP 2.3 A 3.5 A 2_X_4_1_ 460 VAC 2 HP 3.7 A 6.0 A 3_X_4_1_ 460 VAC 3 HP 5.7 A 9.0 A 5_X_4_1_ 460 VAC 5 HP 9.0 A 15.0 A 1_X_2_1_ 230 VAC 1 HP 4.5 A 7.0 A 2_X_2_1_ 230 VAC 2 HP 7.6 A 12.0 A 1_X_3_1_ 230 VAC (1-Phase) 1 HP 5.8 A 9.0 A 2_X_3_1_ 230 VAC (1-Phase) 2 HP 14.0 A 20.0 A 1_X_1_1_ 115 VAC 1 HP 14.0 A 20.0 A

Recommended fuse type: UL Class J or CC, 600 V, time delay.

in table 4.1 are applicable for one VSM500 unit per branch circuit. No other load can be applied to that fused branch circuit. Failure to observe this precaution could result in severe bodily injury or loss of life.

The NEC/CEC requires that upstream branch protection

Table 4.1 – Required AC Branch Circuit Protection

NEC Amps Input

Input

Current

Rating

Fuse

Step 4 - Install External Components

4-1

4.3 Installing Input Isolation Transformers

ATTENTION:

recommended system KVA (100 KVA for 460 VAC three-phase, 5%

Depending upon the requirements of the application, the VSM500 unit may require input isolation transformers to help eliminate the following:

•

Damaging AC line voltage transients from reaching the VSM500 unit.

•

Line noise from the VSM500 unit being fed back to the incoming power source.

An isolation transformer or line reactors of 3% drive input impedance should be used between the distribution source and the VSM500 unit in situations such as the following:

•

The power distribution system feeding the VSM500 unit contains power factor correction capacito rs.

•

The power distribution system feeding the VSM500 unit connects with heavy industrial equipment that causes instantaneous line distribution shorts such as arc welders, line-commutated thyristor converters, or line-started AC induction motors greater than 50 HP (37 KVA).

•

The distribution transformer is rated more than 100 KVA for 460 VAC with less than 5% impedance.

impedance) requires using an isolation transformer, a line reactor, or other means of adding similar impedance. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

Distribution system capacity above the maximum

•

The distribution system is prone to frequent power outages or transient power interruptions or significant voltage spikes.

Refer to table 4.2 for the appropriate line reactor for your unit.

Table 4.2 – Input Line Reactors

VSM500 Unit Input Line Reactor

Rated

HP Input Voltage Inductance

1 460V, 3-Phase 6.5 mH 4.0 608895-63D 2 460V, 3-Phase 3.0 mH 8.0 608895-63F 3 460V, 3-Phase 2.5 mH 12.0 608895-63H 5 460V, 3-Phase 1.5 mH 18.0 608895-63K 1 230V, 3-Phase 1.5 mH 8.0 608895-63E 2 230V, 3-Phase 0.8 mH 18.0 608895-63J

A power-disconnecting device must be installed between the power line and the primary of the transformer. If the power-disconnecting device is a circuit breaker, the circuit breaker trip rating must be coordinated with the in-rush current (10 to 12 times full load current) of the transformer.

Amps Reliance Part No.

4-2

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

HAPTER

Step 5 - Wire AC Power to the Unit and

Ground the Unit

ATTENTION:If the distribution system capacity exceeds the unit’s

maximum symmetrical fault short-circuit current of 10,000 amps,

Observe the following guidelines when wiring AC power:

additional impedance should be added to the AC line supplying the unit to limit available current in the event of a fault. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:The unit is intended to be commanded by control input signals that will start and stop the motor. A device that routinely disconnects then reapplies input power to the unit for the purpose of starting and stopping the motor should not be used. If it is necessary to use this method for starting and stopping, or if frequent cycling of power is unavoidable, make sure that it does not occur more than once a minute. Failure to observe this precaution could result in damage to equipment.

•

The terminal block accepts up to 3.31 mm2 (12 AWG) wire.

•

The recommended tightening torque is 1.3 Nm (12 in-lb).

•

Verify that the input power to the unit corresponds to the unit voltage and frequency and that the input supply is of sufficient capacity to support the input current requirements. Refer to appendix A, Technical Specifications.

•

Size the AC line conductors for the unit rating and in accordance with all applicable local, national, and international codes.

Step 5 - Wire AC Power to the Unit and Ground the Unit

5-1

Use the following procedure to wire AC power to the unit. Grounding instructions are provided in section 5.1.

Step 1. Remove the cover by loosening the four cover screws. Note that the display

ribbon cable is designed to disconnect from the main unit when the cover is removed as shown in figure 5.1.

Cover Screws (4)

Display Board Ribbon Cable Connector

Figure 5.1 – Removing the Cover

Step 2. For three-phase input: Connect the incoming three-phase AC line to

terminals R, S, and T, as shown in figure 5.2.

For single-phase input: Connect the incoming single-phase AC line to any two of the terminals R, S, T shown in figure 5.2.

Drive Section with Cover Off

DC Bus

[Not Used]

AC Inputs

AC Input Terminal Block

Ground

5-2

Figure 5.2 – AC Input Power Connections

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

5.1 Grounding the Unit

ATTENTION:

national, and international codes applicable to the grounding of this

Connect the ground wire brought in with the incoming AC power to the unit’s grounding screw (see figure 5.2). This grounding conductor must run unbroken from the unit to earth ground. The recommended tightening torque is 2.6 Nm (32 in-lb).

equipment. Failure to observe this precaution could result in severe bodily injury or loss of life.

The user is responsible for conforming with all local,

Step 5 - Wire AC Power to the Unit and Ground the Unit

5-3

5-4

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

HAPTER

Step 6 - Install an Emergency Stop

ATTENTION:

stop circuit outside of the VSM500 unit circuitry. This circuit must disable

Depending upon the requirements of the application, the VSM500 unit can be set up to provide either a coast-to-rest (default) or a ramp-to-rest (user option) operational stop. The unit’s Function Loss input provides an additional coast-to-rest operational stop.

In addition to the operational stop, the user must provide a hardwired emergency stop external to the unit. The emergency stop circuit must contain only hardwired electromechanical components. Operation of the emergency stop must not depend on electronic logic (hardware or software) or on the communication of commands over an electronic network or link.

the system in case of improper operation. Uncontrolled machine operation may result if this procedure is not followed. Failure to observe this precaution could result in bodily injury.

The user must provide an external, hardwired emergency

6.1 Complia nce with Machinery Safety Standard EN 60204-1: 1992

This section applies to users who must comply with EN 60204-1: 1992, Electrical equipment of industrial machines, part 9.2.5.4, Emergency Stop.

The VSM500 coast-to-rest stop is a category 0 operational stop. The ramp-to-rest stop is a category 1 operational stop.

The required external hardwired emergency stop must be either a category 0 or 1 stop, depending on the user’s risk assessment of the associated machinery. In order to fully comply with EN 60204-1: 1992, part 9.2.5.4, at least one of the system’s stop methods must be a category 0 stop.

Step 6 - Install an Emergency Stop

6-1

6-2

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

HAPTER

Step 7 - Wire the Control Signal

Terminal Block

The following sections describe how to wire the control signal terminal block shown in figure 7. 1.

Refer to either figure 7.2 (standard units or local operator control units set up for terminal block control) or figure 7.3 (local operator control units) before you begin wiring. These figures show typical wiring connections and the sections in this chapter where the signals are described in detail.

Note the following when wiring the terminal block:

•

The terminal block is isolated from the input power.

•

Route the control wires separately from the power wires.

•

The terminal block accepts 0.326 mm2 (22 AWG) through 3.31 mm2 (12 AWG) wire.

•

The maximum lead length is 300 meters (1000 ft).

•

The maximum tightening torque is 0.8 Nm (7 in-lb).

0 to 10V Speed Reference Input

4 to 20mA Speed Reference Input

1> The jumper between terminals 7

and 11 must be removed when wiring the Function Loss input. See section 7.1 for more information.

10 Volt Reference

Common

0 to 10V Output

Common

24V DC Speed Preset 2 Speed Preset 1

Speed Preset 0

Function Loss

RPM / %Load Display

24V DC

Forward/Reverse

Reset

Start Stop

24V DC Common

N.O. Relay

Relay Common

Control Signal Terminal Block

2> Important: To stop the unit using the

1 2

4 5 6 7 8

10 11 12

13 14

15 16 17 18 19

terminal block inputs, the jumper between terminal s 13 and 17 must be removed when wiring the Stop input . See section 7.6 for more information.

Step 7 - Wire the Control Signal Terminal Block

Figure 7.1 – Control Signal Terminal Block

7-1

Drive Section with Cover Removed

Maintained 2-Wire

Start

+10VDC

REV

FWD

RPM

16 17

%LOAD

1 10 Volt Reference

2 0 to 10V Speed Reference Input 3 4 to 20 mA Speed Reference Input 4 Common 5 0 to 10V Output 6 Common 7 24V DC 8 Speed Preset 2

9 Speed Preset 1 10 Speed Preset 0 11 Function Loss

12 RPM / %Load Display 13 24V DC 14 Forward/Reverse 15 Reset 16 Start 17 Stop 18 24V DC Common 19 N.O. Relay 20 Relay Common

Control Signal Terminal Block Connections

Standard Unit

N.O. Momentary Contact

N.C. Momentary Contact

Maintained Contact - Closed

Maintained Contact - Open

1> The jumper between terminals 7 and 11

must be removed when wiring the Function Loss input. See section 7.1 for more information.

2> An external 0 to 10 vo lt or 40 to 20 mA spee d

reference source can be connected. See section 7.5.3 for more information.

: To stop the unit using the

Important

terminal block inputs, the jumper between terminals 13 and 17 must be removed when wiring the Stop input. See section 7.6 for more information.

User Wiring for Standard Units

Signal

Function Loss 7.1 Analog Output 7.2 Relay Control Output 7.3 RPM / %Load Display 7.4 Speed Reference (

select one

) Preset Speeds 7.5.1 Speed Potentiometer 7.5.2 External Speed Reference (0 to 10 VDC or 4 to 20 mA)

Start 7.6 Stop 7.6 Forward / Reverse 7.7 Reset 7.8

Refer to

Section

7.5.3

7-2

Figure 7.2 – T ypical Control Signal Connections for Standard Units and Local Operator Control Units Set Up

for Terminal Block Control

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

Drive Section with Cover Removed

RPM

%LOAD

1 10 Volt Reference

2 0 to 10V Speed Reference Input 3 4 to 20 mA Speed Reference Input 4 Common 5 0 to 10V Output 6 Common 7 24V DC 8 Speed Preset 2

9 Speed Preset 1 10 Speed Preset 0 11 Function Loss

12 RPM / %Load Display 13 24V DC 14 Forward/Reverse 15 Reset 16 Start 17 Stop 18 24V DC Common 19 N.O. Relay 20 Relay Common

Control Signal Terminal Block Connections

Local Operator Control Unit

N.O. Momentary Contact

N.C. Momentary Contact

Maintained Contact - Closed

Maintained Contact - Open

1> The jumper between terminals 7 and 11

must be removed when wiring the Function Loss input. See section 7.1 for more information.

2> An external 0 to 10 volt or 40 to 20 mA

speed reference source can be connected. See section 7.5.3 for more information.

To stop the unit using the

Important:

terminal block inputs, the jumper between terminals 13 and 17 must be removed when wiring the Stop input. See section 7.6 for more information.

User Wiring for Local Operator Control Units

Signal Refer to

Function Loss 7.1 Analog Output 7.2 Relay Control Output 7.3 RPM / %Load Display 7.4 Speed Reference (

select one

)

(default = local operator controls)

Preset Speeds 7.5.1

Speed Potentiometer 7.5.2

External Speed Reference (0 to 10 VDC or 4 to 20 mA)

Section

7.5.3

Figure 7.3 – Typical Control Signal Connections for Local Operator Control Units

Step 7 - Wire the Control Signal Terminal Block

7-3

7.1 Wiring Function Loss

For the unit to run, you must maintain a signal at the Function Loss input (the connection between control terminals 7 and 11). If the Function Loss signal is not present, the unit turns off the power devices and coasts to rest. To restart the unit, you must restore the Function Loss signal, clear any faults, and reassert the Start command.

The unit ships from the factory with a jumper between terminals 7 and 11 which provides the Function Loss signal. The Function Loss input should be wired in series with the drive’s external interlocks as shown in figure 7.4. In this case, remove the jumper before making the connections.

Important:

Function Loss provides an operational stop. It does not fulfill the requirements of an emergency stop. Refer to chapter 6 for information regarding emergency stop requirements.

1 2 3 4 5

10 11

6 7

24V DC

8 9

Function Loss

User-Supplied Function Loss

Pushbutton

User-Supplied Safety Interlocks

13 14 15 16 17

18 19 20

7-4

= N.C. Momentary Contact

Maintained Contact - Closed

Figure 7.4 – Function Loss Control Wiring

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

7.2 Wiring the Analog Outp ut

The analog output provides a 0 to 10 VDC signal to a user-supplied metering device. This output indicates speed (default) or %load (user option), based on the status of input terminal 12.

If you select speed indication, 0 to 10 V = 0 to the maximum speed as defined by the maximum speed rotary switch. (Refer to chapter 8 for a description of the rotary switch.)

If you select %load indication, 0 to 10 V = 0 to 200% load. Wire to the analog output as shown in figure 7.5.

1 2 3

4 5 6 7 8

9 10 11 12 13 14 15 16 17 18

0 to 10V Output Common

Step 7 - Wire the Control Signal Terminal Block

Figure 7.5 – Analog Output Wiring

7-5

7.3 Wiring the Relay Control Output

A single form A relay on the terminal block can be used to indicate the unit is running (default) or has faulted (user option) based on the setup slide switch setting. Refer to the setup slide switch description in chapter 8.

Wire to the relay control output as shown in figure 7.6.

1 2 3 4 5 6 7 8 9

12 13 14 15 16 17

Connect to External Device Such as PLC Input

N.O. Relay Relay Common

7-6

Figure 7.6 – Relay Control Output Wiring

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

7.4 Wiring RPM or %Load Display

The RPM or %Load Display input (control terminal 12) selects the type of information displayed by the analog output and the built-in display , speed in RPM or %load. Wire a switch between control terminals 12 and 13 as shown in figure 7.7.

1 2

3 4 5 6 7 8 9

%Load

RPM

12 13 14 15 16 17 18 19 20

RPM or %Load Display

24V DC

Figure 7.7 – RPM or %Load Display Wiring

7.5 Wiring the Speed Reference

standard VSM500 unit

The

•

Seven preset speeds

•

An external 0 to 10 VDC or 4 to 20 mA speed reference source

VSM500 unit with local operator controls

The reference options:

•

The local operator controls (using the keys)

•

Seven preset speeds (the keys are not used)

•

An external 0 to 10 VDC or 4 to 20 mA speed reference source (the keys are not used)

Select the option that is the most suitable for your application. The following sections provide wiring information for each option except the local operator controls. Refer to section 1.2 for information on the local operator controls.

provides two motor speed reference options:

provides three motor speed

Step 7 - Wire the Control Signal Terminal Block

7-7

7.5.1 Wiring the Preset Speed Inputs

Control terminals 8, 9, and 10 select seven preset speeds as shown in table 7.1. Note that if you select a preset speed that is greater than the maximum speed setting (based on the rotary switch setting), the unit uses the maximum speed setting value.

Important:

Slide switch position 8 defines whether terminals 8, 9, and 10 are used as presets (default) or to define the unit’s minimum speed (user option). Refer to section 8.3.8 for information about using terminals 8, 9, and 10 to select minimum speed.

Table 7.1 – Fixed Preset Speed Selections

Selected Speed Reference

Terminal 8

Status

Terminal 9

Status

Terminal 10

Status Standard Unit

Local Operator

Control Unit

Open Open Open Analog speed reference Local operator control Open Open Closed Preset 1 - 300 RPM (10 Hz) Open Closed Open Preset 2 - 600 RPM (20 Hz)

Open Closed Closed Preset 3 - 900 RPM (30 Hz) Closed Open Open Preset 4 - 1200 RPM (40 Hz) Closed Open Closed Preset 5 - 1500 RPM (50 Hz) Closed Closed Open Preset 6 - 1800 RPM (60 Hz) Closed Closed Closed Preset 7 - 2100 RPM (70 Hz)

To use the preset speeds to set the speed reference, wire to terminals 8, 9, and 10 as shown in figure 7.8.

7-8

= Maintained Contact - Open

Figure 7.8 – Preset Speed Input Wiring

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

11 12 13 14 15 16 17 18 19 20

2 3 4 5 6 7 8 9

24V DC

Speed Preset 2 Speed Preset 1

Speed Preset 0

7.5.2 Wiring the Speed Reference Signal Potentiometer

Control terminal 1 provides a 10 VDC reference for use with the user-supplied 5 kΩ potentiometer. Perf orm the following procedure to wire the potentiometer as the speed reference (refer to figure 7.9):

Step 1. Mount the speed reference potentiometer at an appropriate

operator-accessible location, less than 300 meters (1000 feet) from the VSM500 unit.

Step 2. Connect one end of the potentiometer to control terminal 1 (10V reference)

and the other end to control terminal 4 (signal common).

Step 3. Connect the potentiometer’s wiper to control terminal 2 (speed reference

input).

+10VDC

10V Reference

0 to 10V Speed Reference Input

3 4

Common

5 6 7 8 9

12 13 14 15 16 17

18 19 20

Figure 7.9 – Speed Reference Potentiometer Wiring

Step 7 - Wire the Control Signal Terminal Block

7-9

7.5.3 Wiring an External Sp eed Reference (0 to 10 VDC or 4 t o 20 mA)

The terminal block provides both 0 to 10 VDC and 4 to 20 mA inputs. Use only one of these inputs for the external speed reference. The other input must remain unconnected.

0 to 10 VDC External Speed Reference

To use an external 0 to 10 VDC signal to set the speed reference, connect the signal leads as shown in figure 7.10. 0 to 10 VDC = minimum speed to maximum speed.

2 3 4

0 to 10 V Speed Reference Input

Common

5 6 7 8 9

12 13 14 15 16 17 18 19 20

0 to 10 VDC

Figure 7.10 – 0 to 10 VDC External Speed Reference Wiring

7-10

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

4 to 20 mA External Speed Reference

To use an external 4 to 20 mA signal to set the speed reference, connect the signal leads as shown in figure 7.11. 4 to 20 mA = minimum speed to maximum speed.

3 4

4 to 20 mA Speed Reference Input

Common

5 6 7 8 9

12 13 14 15 16 17

18 19 20

4 to 20 mA

Figure 7.11 – 4 to 20 mA External Speed Reference Wiring

Step 7 - Wire the Control Signal Terminal Block

7-11

7.6 Wiring Start / Stop Control

Important:

The system looks for an open-to-closed transition at the Start input before starting the unit unless you have the Power-Up Start switch (setup slide switch 1, see section

8.3.1) set to ON. If you use a maintained start device and power to the unit is lost, you must open and reclose the start device before the unit will start again. Both the Stop and the Function Loss input signals must be present and there must be no active faults for the unit to start.

In order for the unit to run, you must maintain a signal at the Stop input. If the signal is interrupted, the unit coasts to rest (default) or ramps to rest (user option). To restart the unit, you must restore the signal and reassert the Start input.

The unit ships from the factory with a jumper on the Stop input terminals (terminals 13 and 17) which permits the unit to be started. To stop the unit using the terminal block inputs, you must remove the factory jumper and install appropriate stop wiring.

Figure 7.12 illustrates wiring for a maintained 2-wire and for a momentary 3-wire Start / Stop control.

1 2 3 4 5 6 7 8 9

11 12 13 14 15 16 17 18 19

This applies only to standard units and local operator control units set up for terminal block control (setup slide switch position 9 = ON, see section

8.3.9).

1 2 3 4 5 6 7 8 9

24V DC

14 15

Start Stop

N.O N.C.

16 17

Start

Stop

20 20

7-12

Maintained 2-Wire Momentary 3-Wire

= Maintained Contact - Open

= N.O. Momentary Contact = N.C. Momentary Contact

Important:

terminal block inputs, the jumper between terminals 13 and 17 must be removed when wiring the Stop input.

Figure 7.12 – Start / Stop Control Wiring

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

To stop the unit using the

7.7 Wiring Forward / Reverse Control

Important:

The Forward / Reverse input (the connection between terminals 13 and 14) defines the requested direction of motor rotation. If the input is open, the requested direction is forward. Switching the Forward / Reverse input causes the motor to ramp to rest and then accelerate in the opposite direction. Note that the VSM500 unit is shipped with the forward direction defined as CCW shaft rotation as viewed from the motor shaft end.

Figure 7.13 shows the Forward / Reverse control wiring for the VSM500 unit. If you disable (lock out) reverse using the setup slide switch, do not wire to this input because the drive ignores any transition on this input. Refer to the setup slide switch description in chapter 8.

This applies only to standard units and local operator control units set up for terminal block control (setup slide switch position 9 = ON, see section

8.3.9).

1 2

3 4 5 6 7 8

9 10 11 12

24V DC

Forward/Reverse

REV

13 14 15

FWD

16 17 18

Step 7 - Wire the Control Signal Terminal Block

Figure 7.13 – Forward / Reverse Control Wiring

7-13

7.8 Wiring Reset Control

Important:

An open-to-closed transition at the Reset input (control terminal 15) clears a fault once the appropriate corrective action has been taken. After clearing the fault, you must reassert the Start command in order to restart the unit.

Wire a normally-open (N.O.) pushbutton between control terminals 15 and 13 as shown in figure 7.14. Refer to chapter 11, Diagnostics and Troubleshooting, for more information on faults.

This applies only to standard units and local operator control units set up for terminal block control (setup slide switch position 9 = ON, see section

8.3.9).

1 2

3 4 5 6 7 8 9

11 12 13

24V DC

14 15

Reset

16 17 18

19 20

7-14

= N.O. Momentary Contact

Figure 7.14 – Reset Control Wiring

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

HAPTER

Step 8 - Verify the Setup and

Adjust Switches if Required

The VSM500 unit is set up using two rotary switches and a 10-position slide switch mounted on the printed circuit board as shown in figure 8.1. Figure 8.1 shows the setting selections and the factory defaults. Normally , no adjustments will be needed to the facto ry settin gs .

If your application requires adjustment to these settings, refer to the following sections in this chapter. If no adjustment is needed, go to chapter 9 to complete the installation procedure.

ATTENTION:Only qualified personnel familiar with the construction and operation of this equipment and the hazards involved should install,

adjust, operate, and/or service this equipment. Read and understand this instruction manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

A T TENT IO N:All adjustments to these components should be made with power removed. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:After disconnecting input power wait five minutes and check with a voltmeter to insure that DC bus capacitors are discharged. The voltmeter should read zero volts. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION:The cover screws must be securely tightened in order to properly ground the cover . Verify that all four cover screws are tight before applying power to the unit. Failure to observe this precaution could result in severe bodily injury or loss of life.

Review all setup instructions thoroughly before making any adjustments or applying power to the unit.

After changing the setup, go to chapter 9 to complete the installation.

Before making any adjustments to the unit, be sure to take the following precautions:

Step 1. Turn off, lockout, and tag AC input power to the unit. Step 2. Wait five minutes. Then remove the cover and use a voltmeter to verify that

the DC bus capacitors are discharged. The voltmeter should read zero volts. Refer to figure 5.2 for the DC bus test points.

Step 8 - Verify the Setup and Adjust Switches if Required

8-1

0 = 1500 RPM (50 Hz)

1 = 1800 RPM (60 Hz) (D efault)

2 = 2100 RPM (70 Hz) 3 = 2400 RPM (80 Hz)

4 = 2700 RPM (90 Hz)

5 = 3000 RPM (100 Hz)

6 = 3300 RPM (110 Hz) 7 = 3600 RPM (120 Hz)

Max Speed Switch

(SW2)

(See section 8.1)

Setup Slide Switch

Power-Up Start Disabled

1> Speed Reference From Operator Controls

Relay Control Output: Running

Auto Restart Disabled

Variable Torque Curve

Coast-to-Rest Stop

Reverse Enabled

0 Hz Minimum Speed

1> Start from Operator Controls

2> Parameter Settings from Setup Switches

(SW3)

(See section 8.3)

O N

4532

867 910

0 = 1 sec accel / 5 sec decel

1 = 5 sec (Default) 2 = 10 sec 3 = 15 sec 4 = 20 sec 5 = 30 sec 6 = 60 sec 7 = 90 sec

Accel/Decel Switch

(SW1)

(See section 8.2)

Power-Up Start Enabled Analog Speed Reference From Terminal Block Relay Control Output: Faulted Auto Restart Enabled Constant Torque Curve Ramp-to-Rest Stop Reverse Disabled (Reverse Lockout) Minimum Speed From Terminal Block Inputs Start from Terminal Block Parameter Settings from EEPROM Memory

8-2

= Default Setting (Off Position) 1> Switches 2 and 9 apply to local operator control units only.

2> Switch 10 is used with the DeviceNet Communication option only.

Figure 8.1 – Factory Settings for the Setup Rotary Switches and Slide Switch

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

8.1 Adjusting t he Maximum Speed

ATTENTION:

and all drive-train mechanisms are capable of safe operation at maximum

The maximum speed rotary switch limits the speed reference to the unit. Regardless of what speed reference is supplied, the unit will not command a speed greater than the value selected by this rotary switch.

Range: Default:

To set the maximum speed: Step 1. To

speed. Failure to observe this precaution could result in severe bodily injury or loss of life.

1500 RPM (50 Hz) to 3600 RPM (120 Hz)

1800 RPM (60 Hz)

increase

higher position number.

The user is responsible for ensuring that driven machinery

0 = 1500 RPM (50 Hz)

Figure 8.2 – Maximum Speed Rotary Switch

the maximum speed, turn the maximum speed rotary switch to a

1 = 1800 RPM (60 Hz) (Default) 2 = 2100 RPM (70 Hz) 3 = 2400 RPM (80 Hz)

4 = 2700 RPM (90 Hz)

5 = 3000 RPM (100 Hz) 6 = 3300 RPM (110 Hz) 7 = 3600 RPM (120 Hz)

-or-

decrease

To lower position number.

Step 2. Connect the display board ribbon cable and replace the cover. Verify that all

four cover screws are in place and tightened. Step 3. Apply AC input power. Step 4. Set the operator’s speed reference signal to maximum.

Standard units:

external speed reference device.

Local operator control units:

reference and the key to decrease the speed reference. Step 5. Use a handheld tachometer to monitor motor speed.

Step 6. Repeat the adjustment procedure until the desired maximum speed is

obtained. Note that changes to the maximum speed setting are recognized

only while the drive is stopped.

Important:

If speed is errati c or not a s ex pected, v erify t hat only one of the speed ref ere nce inputs (0 to 10 VDC or 4 to 20 mA) has been wired.

the maximum speed, turn the maximum speed rotary switch to a

Use the speed potentiometer or other user-supplied

Use the key to increase the speed

Step 8 - Verify the Setup and Adjust Switches if Required

8-3

8.2 Adjusting the Acceleration / Deceleration Time

The acceleration / deceleration time is the amount of time it takes the motor to ramp from stop to the maximum speed setting of the unit. This is also the amount of time it takes the motor to ramp from the maximum speed setting to stop.

0 = 1 sec accel / 5 sec decel 1 = 5 sec (Default) 2 = 10 sec

3 = 15 sec

4 = 20 sec

5 = 30 sec 6 = 60 sec 7 = 90 sec

Figure 8.3 – Acceleration / Deceleration Rotary Switch

Range: Default:

1, 5, 10, 15, 20, 30, 60, 90 seconds

5 seconds

Note that if the operator speed reference setting is less than the maximum speed value, the acceleration / deceleration ramp time is proportionately less than the acceleration / deceleration setting.

Assume: Max Speed = 1800 RPM Operating Speed = 900 RPM Accel/Dece l Time Setting = 30 Seconds

Use the following formula:

Operating Speed x Accel/Decel Time Setting = Time to Operating Speed

Max Speed

900 x 30 = 15

1800

Accel Time = the time required to accelerate from stop to MAX SPEED.

Decel Time = the time required to decelerate from MAX SPEED to stop.

Example

1800 RPM

900 RPM

SPEED

It will take 15 seconds to ramp from stop to 900 RPM

To adjust the acceleration / deceleration time: Step 1. To

increase

the acceleration / deceleration time, turn the accel / decel rotary switch

to a higher position number.

-or-

decrease

the acceleration / deceleration time, turn the accel / decel rotary

switch to a lower position number.

Step 2. Connect the display board ribbon cable and replace the cover. Verify that all

four cover screws are in place and tightened.

8-4

TIME

15 Sec 30 Sec

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

Step 3. Apply AC input power.

Minimum Speed From Terminal Block Inputs

Reverse Disabled (Reverse Lockout)

Ramp-to-Rest Stop

0 Hz Minimum Speed

Reverse Enabled

Coast-to-Rest Stop

867

Analog Speed Reference From Terminal Block

Constant Torque Curve

Auto Restart Enabled

Power-Up Start Enabled

Relay Control Output: Faulted

1> Speed Reference From Operator Controls

Relay Control Output: Running

Power-Up Start Disabled

Variable Torque Curve

Auto Restart Disabled

4532

910

Start from Terminal Block Parameter Settings from EEPROM Memory

= Default Setting (OFF position)

1> Switches 2 and 9 apply to local operator control units only.

1> Start from Operator Controls

2> Parameter Settings from Setup Switches

2> Switch 10 is used with the DeviceNet Communication option only.

Step 4. Set the desired operating speed.

Standard units: Use the speed potentiometer or other user-supplied

external speed reference device.

Local operator control units: Use the key to increase the speed

reference and the key to decrease the speed reference. Step 5. Repeat the adjustment procedure until the desired acceleration / deceleration

time is obtained. Note that changes to the acceleration / deceleration time

are recognized only while the drive is stopped. Important: If speed is erratic or not as expected, verify that only one of the speed reference

inputs (0 to 10 VDC or 4 to mA) has been wired.

8.3 Modifying the Setup Using the Setup Slide Switch

The switches in the 10-position setup slide switch define the characteristics of the VSM500 unit as shown in figure 8.4. The switches are preset at the factory to suit a wide range of applications and normally do not need to be changed. The following sections describe how to modify the setup to suit your specific application, if required.

Important: Changes to the slide switch settings are recognized only while the drive is

stopped.

Step 8 - Verify the Setup and Adjust Switches if Required

Figure 8.4 – Setup Slide Switch Selections

8-5

8.3.1 Power-Up Start (Position 1)

A TTENTION:

motor section automatically at drive power up. When this feature is enabled,

Important:

The switch at position 1 enables or disables the power-up start function. When this function is enabled, output power is applied to the motor section automatically at power up if all power-up start permissive conditions are met. These conditions are:

•

No faults are active.

•

The terminal strip function loss input is closed.

For terminal block control:

•

above, the terminal strip Start and Stop inputs must be closed.

For local operator control:

•

have to press the green key.

Settings (Position 1):

the user must ensure that automatic start up of the driven equipment will not cause injury to the operating personnel or damage to the driven equipment. In addition, the user is responsible for providing suitable audible or visual alarms or other devices to indicate that this function is enabled and the drive may start at any moment. Failure to observe this precaution could result in severe bodily injury or loss of life.

If AC power is lost, the drive will restart without command when power is returned. Under these circumstances, it is the responsibility of the user to ensure that a dangerous condition does not exist when lost AC power returns.

Enabling this feature causes output power to be applied to the

In addition to the start permissive conditions listed

The unit will simulate a start signal edge; you do not

OFF position = Power-Up Start Disabled (Default) ON position = Power-Up Start Enabled

8.3.2 Speed Reference Select (Position 2)

Important:

The switch at position 2 is used to select whether the unit gets its speed reference from the operator controls or from the analog input terminals. If this switch is set to the OFF position, the speed reference will come from the operator controls. If this switch is set to the ON position, the speed reference will come from the analog input terminals,

and the and keys are not functional.

Settings (Position 2):

OFF position = Speed Reference from Operator Controls (Default) ON position = Speed Reference from Analog Input Terminals

This applies only to local operator control units.

8-6

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

8.3.3 Relay Control Output - Running or Faulted (Position 3)

The switch at position 3 specifies the type of status indication provided by the normally open (N.O.) relay control output (control terminals 19 and 20). See section 7.3 for a description of control terminals 19 and 20. The relay can be used to indicate that the unit is running (power is applied to the motor section) or has faulted (an active drive fault exists).

Relay Control

Switch 3 Position State of Unit

OFF (Unit running indication selected)

ON (Unit faulted indication selected)

Settings (Position 3):

OFF position = Unit Running Indication (Default) ON position = Unit Faulted Indication

Running Closed Stopped Open

No Faults Closed

Active Fault Open

Output Status

8.3.4 Auto Restart (Position 4)

ATTENTION:

automatically after auto-restartable faults (see table 8.1) have shut down

The switch at position 4 enables or disables the auto-restart function. If the auto-restart function is enabled, the unit shuts down as usual upon the detection of a fault, waits five seconds, and attempts to start automatically. If the fault reoccurs, the drive section again waits five seconds before trying to start, up to a maximum of four attempts within a five minute period. If the drive section fails all these attempts, it remains in the faulted state and displays the fault it is attempting to clear.

While the unit is counting down the five-second restart period, the display flashes the following pattern to warn of the impending automatic restart of the drive:

If the Reset input is asserted (or the key is pressed) during the countdown, the auto-restart process is canceled. Table 8.1 lists the auto-restartable faults.

the unit. When this feature is enabled, the user must ensure that automatic restart of the driven equipment will not cause injury to operating personnel or damage to the driven equipment. Failure to observe this precaution could result in severe bodily injury or loss of life.

Enabling this feature causes the unit to restart

..... ..... ..... .....

RESET

Step 8 - Verify the Setup and Adjust Switches if Required

8-7

Table 8.1 – Auto Restartable Faults

Fault Code Descri p t i o n

Settings (Position 4):

OFF position = Auto-Restart Disabled (Default) ON position = Auto-Restart Enabled

8.3.5 Torque Curve (Position 5)

The switch at position 5 selects either a variable torque curve or a constant torque curve. The variable torque selection provides a squared V/Hz curve and 110% electronic thermal overload and 110% current limit for one minute. The constant torque selection provides a linear V/Hz curve and 150% electronic thermal overload and 150% current limit for one minute.

Overcurrent

Overload

High bus voltage

Low bus voltage

Overtemperature

8-8

460 V

Output

Voltage

Figure 8.5 – Torque Curves

Settings (Position 5):

OFF position = Variable Torque Curve (Default) ON position = Constant Torque Curve

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

Base

Frequency

8.3.6 Stop Type (Position 6)

The switch at position 6 selects how the motor will stop when the Stop input is asserted (or the red key is pressed). A coast-to-rest stop turns off the transistor power device drivers. A ramp-to-rest stop continues to switch the transistor power

device drivers until the output frequency equals 0 Hz (decelerating the motor at a rate based on the accel / decel switch setting), and then turns off the power device drivers.

Settings (Position 6):

OFF position = Coast-to-Rest (Default) ON position = Ramp-to-Rest

8.3.7 Reverse Disable (Position 7)

The switch at position 7 enables or disables reverse rotation of the motor. It is factory-set to enable a forward-to-reverse change of motor direction. If this switch is in the ON position, the reverse direction is disabled (locked out). In other words, the motor can run in the forward direction only.

Settings (Position 7):

OFF position = Reverse Enabled (Forward/reverse change allowed; default) ON position = Reverse Disabled (Reverse direction prohibited)

8.3.8 Minimum Speed Select (Position 8)

ATTENTION:

The user is responsible for assuring safe conditions for operating

The switch at position 8 is used to select whether the minimum speed will be 0 RPM (0 Hz) or will be determined by the preset inputs (terminals 8, 9, and 10 on the control terminal block).

Important:

Settings (Position 8):

OFF position = 0 RPM (0 Hz) Minimum Speed (Default) ON position = Minimum Speed from the Control Terminal Block

personnel by providing suitable guards, audible or visual alarms, or other devices to indicate that the drive is operating or may operate at or near zero speed. Failure to observe this precaution could result in severe bodily injury or loss of life.

Slide sw itch posi tion 8 define s wheth er terminal s 8, 9, a nd 10 are used as presets (default) or to define the unit’s minimum speed (user option). If you select the ON position (Minimum Speed from the Control Signal Terminal Block), you cannot use the speed reference presets. See section 7.5.1 for information about the preset speed inputs.

The VSM500 unit can operate at and maintain zero speed.

Step 8 - Verify the Setup and Adjust Switches if Required

8-9

When the switch in position 8 is ON, the minimum speed will be determined as shown in the following table:

Control Terminal Block Slide Switch Position 8 = ON

Terminal 8

Status

Open Open Open 0 RPM (0 Hz) Open Open Closed 150 RPM (5 Hz) Open Closed Open 300 RPM (10 Hz)

Open Closed Closed 600 RPM (20 Hz) Closed Open Open 900 RPM (30 Hz) Closed Open Closed 1200 RPM (40 Hz) Closed Closed Open 1500 RPM (50 Hz) Closed Closed Closed 1800 RPM (60 Hz)

Terminal 9

Status

Terminal 10

Status Minimum Speed Setting

1 2 3 4 5 6 7 8 9

24V DC Min Speed 2

Min Speed 1 Min Speed 0

11 12 13 14 15 16 17 18 19

8-10

= Maintained Contact - Open

Figure 8.6 – Wiring Minimum Speed

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

8.3.9 Start Mode Select (Position 9)

Important:

This switch applies only to the local operator control units.

The switch at position 9 is used to select whether the unit is controlled from the operator controls or from the terminal block.

Note that if the unit is set up for terminal block control (Start Mode Select = ON), the

RESET

and

keys remai ns activ e.

Settings (Position 9)

OFF position = Control from the Operator Controls (default) ON position = Control from t he Terminal Block

Important:

The drive will not start when power is applied after changing this setting. The start command must be reasserted in order to start the drive.

8.3.10 Parameter Mode for DeviceNet Option (Position 10)

Important:

The switch at position 10 is used to select whether the unit gets its parameter settings from the rotary switches and setup slide switch (SW1, SW2, and SW3) or from the EEPROM memory. Refer to the DeviceNet Option board instruction manual (D2-3463) for information on installing and configuring the DeviceNet Option board.

This switch applies only to the DeviceNet Communication option.

This s witch setting is read when power is applied.

Settings (Position 10)

OFF position = Parameter Settings from the Rotary Switches and Setup Slide

Switches (SW1, SW2, and SW3).

ON position = Parameter Settings from the EEPROM Memory.

Step 8 - Verify the Setup and Adjust Switches if Required

8-11

8-12

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

HAPTER

Step 9 - Check the Installation

ATTENTION:

construction and operation of this equipment and the hazards involved,

To ensure safe operation, check the installation with the power off before operating the unit. When power is first applied, the direction of rotation, operator speed reference, and operation under load should be tested.

should install, adjust, operate, and/or service this equipment. Read and understand this manual in its entirety before proceeding. Failure to observe these precautions could result in severe bodily injury or loss of life.

Only qualified electrical personnel, familiar with the

9.1 Checking the Installation with the Power Off

ATTENTION:

check with a voltmeter to insure that DC bus capacitors are discharged.

Perform the following checks of the unit installation with the power off: Step 1. Turn off, lockout, and tag AC input power to the unit. Step 2. If an input disconnect is installed, make sure it is in the OFF position. Step 3. Wait five minutes after disconnecting power and verify that the DC bus has

The voltmeter should read zero volts. Failure to observe these precautions could result in severe bodily injury or loss of life.

discharged to zero volts. See figure 5.2 for the test points used to measure DC bus voltage.

After disconnecting input power wait five minutes and

Step 9 - Check the Installation

Step 4. Check that any interlocks installed around the driven machine are

operational. Step 5. Check that there is adequate clearance around the unit. Refer to figure 2.2. Step 6. Check that the wiring to the control signal terminal strip and to the power

terminals is correct (figures 5.2 and 7.1 through 7.14). Step 7. Check the setup slide switch and the rotary switches are set correctly. Step 8. Check that user-supplied branch circuit protection is properly installed and

correctly rated. Step 9. Check that incoming AC power is correctly rated. Step 10. Check that the rating of the transformer (if used) matches the unit

requirements and that the transformer is connected for the proper voltage. Step 11. Check that a properly sized ground wire is installed and that a suitable earth

ground is used. Verify that all ground leads are run unbroken.

9-1

9.2 Checking the Direction of Moto r Rotation

The VSM500 unit is shipped with the forward direction defined as counterclockwise (CCW) shaft rotation as viewed from the motor shaft end. If this is appropriate for your application, go to section 9.3, Attaching the Cover.

If this is not appropriate for your application, do one of the following:

•

Change the direction by using the Forward / Reverse input to select the appropriate direction.

-or-

•

Change the definition of forward and reverse by swapping the U/T1 and W/T3 connectors as shown in figure 9.1.

3 T

/ W

1 T

/ U

2 T

Top View of Unit with

Drive Section Cover Removed

Figure 9.1 – Changing the Definition of Forward and Reverse

9.3 Attaching the Cover

ATTENTION:

properly ground the cover . Verify that all four cover screws are tight before

The cover can be rotated 180° to allow the display and local operator controls to be in the correct orientation regardless of the mounting position. Before attaching the cover, determine the proper cover orientation. If the cover must be rotated, follow the procedure in section 9.3.1.

Before reattaching the cover, be sure the display board ribbon cable is securely connected, then position the cover and tighten the screws. The tightening torque limit for the cover screws is 1.3 to 1.7 Nm (11 to 15 in-lb). Verify that all four screws are securely tightened before applying power.

applying power to the unit. Failure to observe this precaution could result in severe bodily injury or loss of life.

The cover screws must be securely tightened in order to

Switch Motor Leads Labeled U/T1 and W/T3 to Change Direction of Motor Rotation.

9-2

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

9.3.1 Rotating the Cover

Cover Screws (4)

Display Board Ribbon Cable Connector

Before rotating the cover, take the following precautions: Step 1. Turn off, lockout, and tag AC input power to the drive. Step 2. Remove the cover by loosening the four cover screws. Note that the display

board ribbon cable is designed to disconnect when the cover is removed. Step 3. W ait fiv e minutes after disconnecting power and verify that DC bus voltage is

zero. See figure 5.1 for the location of the DC bus test points. Refer to figure 9.2 and use the following procedure to rotate the cover:

Step 1. Remove the display board ribbon cable from the display board. You will need

to insert a small screwdriver into the cable latch to release it from the board. Step 2. Insert the display board ribbon cable into the opposite side of the display

board. Push the cable in until it clicks. V erify the connection by lightly tugging

on the cable. Step 3. Rotate the cover. Step 4. Connect the display board ribbon cable together. Step 5. Position the cover and tighten the four cover screws. The tightening torque

limit for the cover screws is 1.3 to 1.7 Nm (11 to 15 in-lb). Verify that all four

screws are securely tightened before applying power.

Step 9 - Check the Installation

Figure 9.2 – Rotating the Cover

9-3

9.4 Checking the Speed Reference

ATTENTION:

electrical circuits to be exposed. Stay clear if the unit must be running.

Use the following procedure to check the speed reference: Step 1. Uncouple the driven equipment from the motor section, if possible. Step 2. Turn power on to the unit. Step 3. Set the operator speed reference signal to zero. Note that when the unit is

Step 4. Press the user-installed Start button (section 7.6) or the green key on

Step 5. Vary the speed reference while running the motor unloaded across the speed

Step 6. If the motor operates satisfactorily, proceed to step 8.

Disconnect, lockout, and tag the power source if contact must be made. Failure to observe these precautions could result in severe bodily injury or loss of life.

powered up the first time, it uses the factory-set minimum speed setting as the speed reference.

For terminal block speed reference:

user-supplied external speed reference device.

For local operator control speed reference:

the speed reference.

local operator control units.

range. Use a handheld tachometer to check the speed.

If the motor does not operate satisfactorily, continue with step 7.

The following procedures require rotating parts and/or

Use the sp ee d po t e nt i om e ter or other

Use the key to decrease

Step 7. If the motor does not operate satisfactorily:

a. Check that the speed reference is wired correctly. See section 7.5, Wiring

the Speed Reference.

b. If the speed reference is correct, and the motor does not operate

satisfactorily , refer to chapter 8, Verify the Setup and Adjust the Switches if Required.

Step 8. If the motor operates satisfactorily:

a. Press the user-installed Stop button (section 7.6) on standard units or the

red key on the local operator control units. b. Remove power from the unit. c. Couple the driven equipment to the motor section.

9-4

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

HAPTER

Step 10 - Set the Operating Speed

Before starting the unit, set the operating speed as follows: For standard units: Use the speed potentiometer or other user-supplied external

speed reference device. For local operator control units: As shipped from the factory, the local operator

control unit receives its speed reference from the keypad. Use the key to increase the speed reference and the key to decrease the speed reference.

To use the analog input terminals for the speed reference, setup switch 2 (Speed Reference Select) must be in the ON position. In this case, the keys are not

used. Refer to section 8.3.2 for more information. At subsequent power ups, the unit will use the last speed reference setting selected

before power was removed. Important: If speed is errati c or not a s ex pected, v erify t hat only one of the speed ref ere nce

inputs (0 to 10 VDC or 4 to 20 mA) has been wired.

Step 10 - Set the Operating Speed

10-1

10-2

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

Diagnostics and Troubleshooting

ATTENTION:Only qualified personnel familiar with the construction and

operation of this equipment and the hazards involved should install,

Use the following flowchart to troubleshoot the unit.

A T TENT IO N:After disconnecting input power, wait five minutes and check with a voltmeter to insure that DC bus capacitors are discharged. The voltmeter should read zero volts. Failure to observe these precautions could result in severe bodily injury or loss of life.

ATTENTION:If a megohmmeter (megger) is used, make certain that all leads are disconnected between the motor and the drive. This will prevent damage to electronic circuitry due to high voltage generated by the megger. Use three wires to megger to ground. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

HAPTER

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Diagnostics and Troubleshooting

11-1

Observe the following precautions when troubleshooting the unit:

•

Stop the unit using either the Stop input or Function Loss input.

•

Disconnect, tag, and lockout AC power before working on the unit.

•

Verify that there is no voltage present at AC input terminals R/L1, S/L2, and T/L3. Refer to figure 5.2 for the location of the terminals.

•

Wait five minutes and verify that the DC bus has discharged to zero volts. See figure

5.2 for the location of the DC bus test points.

11.1 Faul t Codes and Corrective Action s

The following table describes normal operational faults that may be corrected by the user. For standard units, the corrective action assumes that a Reset pushbutton is wired between control terminals 15 and 13, as described in section 7.8.

If a fault occurs, do the following: Step 1. Try to clear the fault first by pressing the Reset pushbutton (or key on

local operator control units). If the fault reoccurs, continue with step 2.

Step 2. Refer to table 11.1 to identify the fault code and the possible causes. Important: Contact Reliance if the displayed fault code is not in table 11.1. Step 3. Perform the corrective action(s). Step 4. Clear the fault by pressing the Reset pushbutton (or key).

Table 11.1 – Fault Codes and Corrective Actions

Fault

Code Fault Description Fault Cause Corrective Action

Turn off power to the unit. Verify the cable connection between the Regulator board and the DeviceNet option board. Turn power on to the unit.

Reset parameters to default values and cycle power.

Turn off power to the unit. Verify the keypad cable connection. Turn power on to the unit.

Communication Loss Communication cable between

the DeviceNet option board and the drive disconnected or opened.

Parameter Checksum Contents of the EEPROM is

corrupted.

Keypad Cable Disconnected

Keypad cable disconnected while unit under power.

RESET

11-2

X DeviceNet Communication

Fault where X = E, F, L, P, or U.

Keypad Cable Connected Keypad cable connected while

unit under power.

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

Refer to the VSM500 DeviceNet Option Board manual, D2-3463.

Turn off power to the unit. Verify the keypad cable connection. Turn power on to the unit.

Table 11.1 – Fault Codes and Corrective Actions (Continued)

Fault

Code Fault Description Fault Cause Corrective Action

Keypad Redundant Start Keypad hardware malfunction. Turn power off to the unit. Verify

the keypad cable connection. Turn power on to the unit.

Function Loss Open connection on Function

Loss control terminal block inputs (terminals 7 and 11).

Check and restore the Function Loss connection on the control terminal block (see section 7.1). Check the external sensors wired into the Function Loss string.

High Bus Voltage High input line.

Check in put line to ve rify v oltage is within operating

Deceleration time too fast.

specifications. Increase deceleration time using

Overhauling load.

the accel/decel rotary switch (see section 8.2).

EEPROM Drive ID Contents of the EEPROM is

corrupted.

Reset parameters to default values and cycle power. If fault persists, replace unit.

Low Bus Voltage Low input line

Temporary loss of input line.

Check in put line to ve rify v oltage is within operating specifications.

Overcurrent (Current exceeded 200% of

Shaft rotation blocked.

Check for obstructions to shaft rotation.

rated current.)

Excessive driven load.

Reduce excessive load. Increase accel / decel time using the accel/decel rotary switch (see section 8.2).

Unit Overtemperature Operating environment is too

Diagnostics and Troubleshooting

Input power is not correctly wired to the unit.

Motor section ground fault.

hot.

Blower is blocked or not operating.

Excessive driven load.

Verify input wiring is correctly connected (see section 5.0).

Ohm out motor section to check for ground fault. Replace motor section if a ground fault is detected.

Check the application site and verify the ambient temperature is within the operating specification.

Check for blower obstruction. Replace blower if required.

Reduce load or make sure unit matches the application requirement.

11-3

Table 11.1 – Fault Codes and Corrective Actions (Continued)

Fault

Code Fault Description Fault Cause Corrective Action

Electronic Thermal Overload The electronic thermal overload will trip when the current to the motor has exceeded either 110% (variable torque V/Hz cu rve

Excessive current to the motor for an extended time due to excessive load or short circuit.

Check for obstructions to shaft rotation. Reduce the driven load. Verify input wiring is correctly connected (see section 5.0). Check for blower obstruction.

Replace blower if required. selected) or 150% (constant torque V/Hz curve selected) of the motor rated current for 60 seconds.

TB Redundant Start Regulator board malfunction. Turn off power to unit. Verify the

keypad cable connection. Turn

power on to the unit.

=NNN Internal Fault

(NNN = a number from 0 to

Regulator board failure. Replace Regulator board.

Internal faults cannot be reset.

999) The display flashes the fault code on and off at 1/2 second intervals to indicate an internal fault.

11-4

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

11.2 Troubleshooting Tables

Use the following tables to troubleshoot the unit. If you cannot resolve the problem using these tables, systematically replace the drive section and the motor section one at a time with a corresponding drive section or motor known to be operating correctly. If the problem is not corrected, contact Reliance.

Table 11.2 – Display Not On

Possible Cause Corrective Action

Unit is not receiving input power. Check input power wiring and connections (see

section 5.0). Check main power supply.

Display ribbon cable is not connected securely. Open the cover and verify the cable connection by

lightly tugging on the cable at each end. If the cable is disconnected, push the cable in until it clicks.

Display ribbon cable is damaged. Replace ribbon cable.

Table 11.3 – Motor Will Not Start

Possible Cause Corrective Action

Drive section has faulted. See section 11.1. Unit is not receiving input power. Check input power wiring and connections (see

section 5.0). Check main power supply .

Start input is not asserted. Check terminal board wiring. Assert Start input on

standard unit (see section 7.6) or press green key on local operator control unit.

Function Loss input wiring is missing or incorrectly wired.

Stop input is open. Close Stop input. Faults have not been cleared. Fault code is displayed. Clear the faults by pressing the Reset pushbutton

Check Function Loss wiring (see section 7.1).

(wired between control terminals 13 and 15, see section 7.8) on standard units or pressing the

RESET

key on local operator control units.

Table 11.4 – Motor Rotates but Does Not Accelerate to Full Speed

Possible Cause Corrective Action

Maximum speed is set too low. Increase maximum speed by turning the maximum

speed rotary switch to a higher position (see section

8.1). Unit is receiving incorrect speed reference. Verify speed reference wiring (see section 7.5). Excessive load. Reduce load; make sure the unit matches the

application requirement.

Table 11.5 – Motor Stops While Running

Possible Cause Corrective Action

Drive section has faulted. See section 11.1.

Diagnostics and Troubleshooting

11-5

Table 11.6 – Motor Runs, But Not with Expected Performance

Symptom Corrective Action

Motor accelerates too slowly. Check accel / decel switch setting (see section 8.2).

Verify applied voltage. Verify input wiring.

Reduce load. Motor accelerates too quickly. Check accel / decel switch setting (see section 8.2). Motor acceleration / deceleration is not smooth. Check the motor coupling to load. Motor stops too slowly or too quickly.

Check Stop Type slide switch selection (see section

8.3.6). Check accel / decel switch setting (see section 8.2)

Blower does not operate.

Check wiring. Verify that blower can rotate freely. Verify that input voltage is correct.

Replace blower.

High amps; %load indicates > 100%

Verify load is not excessive. Verify input line voltages.

Runs hot

Clean unit. Check input power connections (see section 5.0). Check input power phases. Check input fuses. Check power supply.

Check blower.

Noisy

Check bearings; replace if necessary. Check unit mounting (alignment, etc.).

Runs in wrong direction. Refer to section 9.3 (Checking the Direction of Motor

Rotation). Erratic speed

Verify ground connection (see section 5.1). Verify that only one of the speed reference inputs

(0-10 VDC or 0-20 mA) has been wired (see section

7.5.3). Verify that there is no noise on the analog reference

signal. Check the speed reference setting and wiring.

11-6

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

11.3 Replacement Parts

Tables 11.7 through 11.9 list the replacement parts for the VSM500 unit. Table 11.10 lists replacement bearings for the motor section.

Table 11.7 – Replacement Parts for 460 VA C Units

Replacement Part 1 HP Unit 2 HP Unit 3 HP Unit 5 HP Unit

Drive Section - 460 VAC, 3-Phase, with Display

Drive Section - 460 VAC, 3-Phase, with Operator Controls

Motor Section - 460 VAC, 3-Phase, NEMA 56

Motor Section - 460 VAC, 3-Phase, NEMA 140

Motor Section - 460 VAC, 3-Phase, NEMA 180

Blower 164454 164454 22650-002-01 22650-002-01 Blower Cover 164408 164408 164409 164409 Cover with Display (includes display

cable) Cover with Display and Operator

Controls (includes display cable) Optional Short Cover with Display

(includes displ ay cable)

Optional Short Cover with Display and Operator Controls (includes display

cable) Regulator Board 194458 194458 194458 194458 Display Cable (Long) 184314 184314 184314 184314

The short cover cannot be used with the DeviceNet Communication option.

10XS4000 21XS4000 32XS4000 52XS4000

10XW4000 21XW4000 32XW4000 52XW4000

J56Z5411 - - -

J14Z5411 J14Z5421 - -

- - J18Z5431 J18Z5451

194431 194431 194431 194431

194432 194432 194432 194432

195083 195083 195083 195083

195084 195084 195084 195084

Diagnostics and Troubleshooting

11-7

Table 11.8 – Replacement Parts for 230 VA C Units

Replacement Part 1 HP Unit 2 HP Unit

Drive Sec tion - 230 VAC, 3-Phase with Display 10XS20 00 21XS2000 Drive Sec tion - 230 VAC, 3-Phase with Operator

10XW2000 21XW2000

Controls Drive Sec tion - 230 VAC, 1-Phase with Display 10XS30 00 21XS3000 Drive Sec tion - 230 VAC, 1-Phase with Operator

10XW3000 21XW3000

Controls Motor Section - 230 VAC, 1- and 3-Phase

J56Z5211 -

NEMA 56 Motor Section - 230 VAC, 1- and 3-Phase

J14Z5211 J14Z5221

NEMA 140 Blower 164454 164454 Blower Cover 164408 164408 Cover with Display (includes display cable) 194431 194431 Cover with Display and Operator Controls

194432 194432

(includes displ ay cable) Optional Short Cover with Display (includes

display cable)

Optional Short Cover with Display and Operator Control (includes display cable)

195083 195083

195084 195084

Regulator Board 194458 194458 Display Cable (Long) 184314 184314

The short cover cannot be used with the DeviceNet Communication option.

11-8

Table 11.9 – Replacement Parts for 115 VAC Units

Replacement Part 1 HP Unit

Drive Sec tion - 115 VAC, 1-Phase with Display 10XS1000 Drive Section - 115 VAC, 1-Phase with Operator Controls 10XW1000 Motor Section - 115 VAC, 1-Phase NEMA 56 J56Z5111 Motor Section - 115 VAC, 1-Phase NEMA 140 J14Z5111 Blower 164454 Blower Cover 164408 Cover with Display (includes display cabl e) 194431 Cover with Display and Operator Controls (includes display cable) 194432

Optional Short Cover with Display (includes display cable) Optional Short Cover with Display and Operator Controls

(includes displ ay cable)

195083 195084

Regulator Board 194458 Display Cable (Long) 184314

The short cover cannot be used with the DeviceNet Communication option.

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

Table 11.10 – Replacement Bearings

Motor Frame Part Number Quantity Description

56 or 140 416821-56-F 2 6205 ball bearings; double seals with

180 416821-56F

416821-56G

1 1

Chevron SRI #2 grease; ABEC 1 tolerances; AFBMA-3 internal tolerances.

11.4 Replacement Part Compatibility

Table 11.11 – Replacement Part Compatibility

Replacement Part VSM500

Description Ve rsion Version 1.0 Version 2.0 Version 3.0

Control Board Replacement Kit 1.0 Compatible Not Compatible Not Compatible

2.0 Not Compatible Compatible Not Compatible

3.0 Not Compatible Not Compatible Compatible

Cover with Display Only 1.0 Compatible Compatible

2.0 Compatible Compatible

3.0

Cover with Display and Operator Controls

1.0 Compatible Compatible

2.0 Compatible Compatible

3.0

The DeviceNet Communication LED is not present on the Version 1.0 or 2.0 cover assembly.

The DeviceNet Communication LED will be illuminated while the unit is powered.

Compatible

Compatible Compatible

Compatible

Compatible Compatible

Compatible

1 1

Diagnostics and Troubleshooting

11-9

11-10

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

HAPTER

Maintenance Guidelines

ATTENTION:

operation of this equipment and the hazards involved should install,

Use the guidelines in this chapter to maintain the unit.

ATTENTIO N:

with a voltmeter to insure that DC bus capacitors are discharged. The voltmeter should read zero volts. Failure to observe these precautions could result in severe bodily in jury or loss of life.

ATTENTION:

started, turn off, lockout, and tag power source before proceeding. Failure to observe this precaution could result in bodily injury.

ATTENTION:

become hot, which may cause injury.

Only qualified personnel familiar with the construction and

After discon necting in put powe r, w ait fiv e minut es and chec k

To insure that the driven equipment is not unexpectedly

The surface temperature of the drive and motor may

12.1 General Unit Maintenance

Check the following at regular intervals:

•

Make sure the exterior is kept dry and free of dust, grease, oil, and dirt.

•

Make sure the terminal connections, assembly screws, bolts, and nuts are tight.

12.2 Motor Maintenance

Maintenance Guidelines

•

Make sure the unit is securely mounted to minimize vibration.

Enclosed motors require minimal attention. At regular intervals, verify that external air passages of the motor do not become clogged with foreign material that will restrict the flow of air.

The ball bearings are deep-grooved, double-shielded bearings with sufficient lubricant packed into the bearings. You do not need to re-lub r ic ate the bearings.

12-1

12-2

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

Technical Specifications

Unit Ratings

Input Ratings

AC line voltage:

•

M/N __X_4_1_380 to 460 VAC, 3-phase

•

M/N __X_2_1_200 to 230 VAC, 3-phase

•

M/N __X_3_1_200 to 230 VAC, 1-phase

•

M/N __X_1_1_115 VAC, 1-phase

AC line frequency:

•

48 to 62 Hz

AC line voltage variation:

•

+/-10%

PPENDIX

AC line current:

M/N Input Voltage Unit HP Input Current

1_X_4_1_ 460 VAC 1 HP 2.3 A rms continuous 2_X_4_1_ 460 VAC 2 HP 3.7 A rms continuous 3_X_4_1_ 460 VAC 3 HP 5.7 A rms continuous 5_X_4_1_ 460 VAC 5 HP 9.0 A rms continuous 1_X_2_1_ 230 VAC 1 HP 4.5 A rms continuous 2_X_2_1_ 230 VAC 2 HP 7.6 A rms continuous 1_X_3_1_ 230 VAC, 1-phas e 1 HP 5.8 A rms continuous 2_X_3_1_ 230 VAC, 1-phase 2 HP 14 A rms continuous 1_X_1_1_ 115 VAC 1 HP 14 A rms continuous

Max allowable AC line distribution KVA:

•

100 KVA maximum for 115 VAC to 460 VAC distribution input.

Output Ratings

Horsepower ratings:

•

1, 2, 3 and 5 HP at 460 VAC

•

1, 2 HP at 230 VAC

•

1 HP at 115 VAC

Technical Specifications

A-1

Output voltage:

•

M/N __X_4_1_ 380 to 460 VAC, 3-phase

•

M/N __X_2_1_ 200 to 230 VAC, 3-phase

•

M/N __X_3_1_ 200 to 230 VAC, 3-phase

•

M/N __X_1_1_ 115 VAC, 3-phase

Maximum continuous output current:

Output Current

M/N Input Voltage Unit HP

1_X_4_1_ 460 VAC 1 HP 1.7 A 2_X_4_1_ 460 VAC 2 HP 3.2A 3_X_4_1_ 460 VAC 3 HP 4.5 A 5_X_4_1_ 460 VAC 5 HP 6.9 A 1_X_2_1_ 230 VAC 1 HP 3.4 A 2_X_2_1_ 230 VAC 2 HP 6.4 A 1_X_3_1_ 230 VAC, 1-phase 1 HP 3.4 A 2_X_3_1_ 230 VAC, 1-phase 2 HP 6.4 A 1_X_1_1_ 115 VAC 1 HP 6.8 A

(Motor Rated Amps)

Maximum output current:

Maximum Output

Current

M/N Input Voltage Unit HP

1_X_4_1_ 460 VAC 1 HP 2.55 A 2_X_4_1_ 460 VAC 2 HP 4.8 A 3_X_4_1_ 460 VAC 3 HP 6.75 A 5_X_4_1_ 460 VAC 5 HP 10.35 A 1_X_2_1_ 230 VAC 1 HP 5.1 A 2_X_2_1_ 230 VAC 2 HP 9.6 A 1_X_3_1_ 230 VAC, 1-phase 1 HP 5.1 A 2_X_3_1_ 230 VAC, 1-phase 2 HP 9.6 A 1_X_1_1_ 115 VAC 1 HP 10.2 A

Important: Maximum current ratings above are for the CT rating. When VT is

selected, the maximum output current will be limited to 110%.

Output frequency:

•

0 to 120 Hz

Carrier frequency:

•

8 kHz

(150% Rated Amps)

A-2

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

Operating Performance

Frequency regulation:

•

1% (1% of base speed, 180 to 1800 RPM, constant torque)

Speed range:

•

20:1 (90 to 1800 RPM, constant torque)

Voltage regulation:

•

3% of maximum rated voltage

Input power dip ride-through time:

•

500 msec minimum

Drive efficiency:

•

>95% (at rated amps, 115 to 460 V, 60 Hz)

Operating Specifications

Operating temperature:

•

0 to 40°C (32°F to 104°F) ambient

Storage temperature:

•

-40°C to 85°C (-40°F to 185°F)

Altitude:

•

1000 meters (3300 feet maximum) without derating. For every 91.4 meters (300 feet) above 1000 meters, derate the current by 1%.

Above 3000 meters (10,000 feet), consult your Reliance Sales Office.

Humidity:

•

5% to 95%, non-condensing

Service factor:

•

1.0

Mechanical Specifica ti o ns

Motor enclosure type:

•

Totally enclosed, 24 VDC blower cooled (TEBC)

Required airflow:

•

Required clearance for blower intake = 1 in

Protection rating:

•

Drive section is NEMA Type 12, motor is IEC IP54

Technical Specifications

A-3

Nominal power dissipation for motor and drive combined:

Input Voltage Unit HP Nominal Watts Loss

460 VAC 1 HP 150 W 460 VAC 2 HP 250 W 460 VAC 3 HP 350 W 460 VAC 5 HP 550 W 230 VAC 1 HP 150 W

230 VAC 2 HP 250 W 230 VAC, 1-phase 1 HP 150 W 230 VAC, 1-phase 2 HP 260 W 115 VAC, 1-phase 1 HP 180 W

Weight:

Input Voltage Unit HP Weight

460 VAC 1 HP 38 lb

460 VAC 2 HP 49 lb

460 VAC 3 HP 59 lb

460 VAC 5 HP 59 lb

230 VAC 1 HP 38 lb

230 VAC 2 HP 49 lb 230 VAC, 1-phase 1 HP 38 lb 230 VAC, 1-phase 2 HP 49 lb 115 VAC, 1-phase 1 HP 38 lb

A-4

Shock:

•

15 G Operational, 30 G Non-Operational

Vibration:

•

1.0 G Operational, 2.5 G Non-Operational

Drive Protection/Fault Detection

Output overcurrent:

•

Trip level = 200% of max peak rated current

Output ground fault:

•

Trip level = 200% of max peak rated current DC bus overvoltage:

Line Voltage Trip Level

460 VAC 830 VDC 230 VAC 415 VDC 115 VAC 208 VDC

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

Communication Fault (DeviceNet Option):

•

Trip on communication loss or malfunction

Motor thermal overload:

•

Trip time = 1 minute at 150% of rated current (CT)

•

Trip time = 1 minute at 110% of rated current (VT)

DC bus undervoltage:

Line Voltage Trip Level

460 VAC 435 VDC 380 VAC 358 VDC 230 VAC 218 VDC 115 VAC 109 VDC

I/O Specifications

Important:

Analog inputs

0 to 10 V

4 to 20 mA

Analog output

0 to 10 V

Logic inputs (Stop, Start, Reset, Fwd/Rev, RPM/%Load, Function Loss, Preset Speed)

24 VDC sourcing inputs

Relay output (1 form A N.O. contact) isolated

Maximum current (resistive or inductive): 1 A Minimum current: 10 mA Maximum voltage: 28 VDC, 250 VAC

All signals are isolated from the incoming 3-phase power.

Input impedance: 50 kΩ Resolution: 0.11%

Input impedance: 250 Ω Resolution: 0.14%

Minimum load resistance: 2 kΩ Resolution: 0.4%

Maximum input voltage: 28.8 VDC Input current @ 24 VDC: 10 mA Maximum OFF state voltage: 5 VDC Minimum ON state voltage: 15 VDC

Technical Specifications

A-5

A-6

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

PPENDIX

Product Features

The following features are standard on every VSM500 unit:

•

Totally enclosed standard NEMA frame sizes with C-face and foot mounting. IEC frames and flanges are available.

•

PWM (pulse-width modulated) drive section with a microprocessor-based V/Hz regulator.

•

Design B inverter-duty motor section:

Class F non-hygroscopic insulation system resists heat, oil, and water.

Double-shielded bearings.

•

Four-character, seven-segment LED display to indicate speed, %load, and diagnostic information.

•

0 to 10 VDC or 4 to 20 mA analog input for remote speed reference from a PLC or process controller.

•

0 to 10 VDC analog output to provide remote speed or %load indication.

•

Seven selectable preset speeds.

•

Form A contact output to indicate drive running or drive faulted condition.

•

500 ms power dip ride-through time.

•

Protection features, including sensing for overtemperature, overcurrent, high DC bus voltage, low DC bus voltage, and surge suppression.

•

Conduit cover can be rotated 180° to provide the appropriate display view in each application.

•

User-selectable coast-to-rest (default) or ramp-to-rest (user option) stop.

•

User-selectable variable torque (default) or constant torque (user option) operation.

•

8 kHz carrier frequency for quiet operation.

•

Complies with UL 1995.

B.1 New Features in Version 3.0

Additional start mode selection.

•

from either the operator controls or the terminal block.

Terminal block stop input.

•

stop key are active for all start mode selections.

Zero speed operation

•

to zero.

. The minimum speed has been reduced from 90 RPM (3 Hz)

Local operator control units can be controlled

The terminal block stop input and local operator control

Product Features

B-1

•

Storage temperature range extended. The storage temperature rating has been extended from 70°C to 85°C.

•

CE Mark. The unit now conforms to the EMC and LVD directives for CE. An optional line filter is required.

•

CE Line Filter Option. Single- and three-phase line filters can be mounted internally or are packaged for external mounting.

•

DeviceNet Communication Option. A DeviceNet Option Board, purchased separately, is installed inside the unit. Refer to the DeviceNet Option board instruction manual, D2-3463, for more information.

•

Drive Parameters Added. Drive display parameters and drive program parameters can be viewed or changed through a DeviceNet connection. Refer to the DeviceNet Communication Option Board instruction manual, D2-3463, for more information.

B.2 Application/Installation Considerations

Keep the following in mind if you are planning to upgrade your unit or are considering additional options:

•

If you are replacing a Version 1.0 or 2.0 unit with a Version 3.0 unit, keep in mind that:

•

The minimum speed has been reduced from 90 RPM (3 Hz) to 0 RPM (0 Hz).

•

The terminal block stop input must be present for local operator control units.

•

The DeviceNet communication option is not available for Version 1.0 or 2.0 units.

•

The CE filter option is compatible with any version of the VSM500 integrated drive/motor; however, only Version 3.0 meets the CE requirement.

•

The short cover has been replaced by a tall cover.

B-2

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

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PPENDIX

VSM500 System Diagram

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VSM500 System Diagram

Figure C.1 – VSM500 System Diagram

C-1

C-2

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

PPENDIX

Installation Record

Model Number:

Record the switch settings for your setup in the diagrams below:

0 = 1500 RPM (50 Hz)

1> Speed Ref erence From Operator Controls

2> Parameter Settings from Setup Switches

1 = 1800 RPM (60 Hz)(Default)

2 = 2100 RPM (70 Hz)

3 = 2400 RPM (80 Hz) 4 = 2700 RPM (90 Hz) 5 = 3000 RPM (100 Hz) 6 = 3300 RPM (110 Hz) 7 = 3600 RPM (120 Hz)

(SW2)

Power-Up Start Disabled

Relay Control Output: Running

Auto Restart Disabled

Variable Torque Curve

Coast-to-Rest Stop

Reverse Enabled

0 Hz Minimum Speed

1> Start from Operator Controls

1 23

0 = 1 sec accel / 5 sec decel

Accel/Decel SwitchMax Speed Switch

Power-Up Start Enabled

O N

Analog Speed Reference From Terminal Block Relay Control Output: Faulted Auto Restart Enabled

Constant Torque Curve Ramp-to-Rest Stop Reverse Disabled (Reverse Lockout)

Minimum Speed From Terminal Block Inputs Start from Terminal Block Parameter Settings from EEPROM Memory

1 = 5 sec (Default) 2 = 10 sec

3 = 15 sec 4 = 20 sec 5 = 30 sec 6 = 60 sec 7 = 90 sec

(SW1)

Setup Slide Switch

SW3

(

1> Switches 2 and 9 apply only to local operator control units.

2> Switch 10 is used only with the DeviceNet Communication Option.

Installation Record

)

D-1

D-2

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

M4 x 10mm Screws

M4 x 50mm Screw

Motor Lead Faston Connectors

M5 x 50mm Screws (See figure E.2)

M5 x 22mm Screw

Blower Cover

(U, V, W)

PPENDIX

Replacing the Drive Section or

the Motor Section

ATTENTION:Only qualified personnel familiar with the construction and

operation of this equipment and the hazards involved should install,

Before beginning the replacement procedure, be sure to take the following precautions:

ATTENTION:All adjustments to these components should be made with power removed. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: After disconnecting input power, wait five minutes and check with a voltmeter to insure that DC bus capacitors are discharged. The voltmeter should read zero volts. Failure to observe this precaution could result in severe bodily injury or loss of life.

Step 1. Turn off, lockout, and tag AC input power to the unit. Step 2. Wait five minutes. Then remove the cover and use a voltmeter to verify that

Refer to figure E.1 and use the following procedure to replace the drive section or the motor section of the VSM500 unit.

Replacing the Drive Section or the Motor Section

the DC bus capacitors are discharged. The voltmeter should read zero volts. Refer to figure 5.2 in chapter 5 for the DC bus test points.

Figure E.1 – Replacing the Drive Section or the Motor Section

E-1

Step 1. Loosen, but do not remove, the M5 x 22mm screw located on the top of the

motor section.

Step 2. Using a 4 mm T-handle hex driver, remove the four M5 x 50mm socket head

cap screws that secure the drive section and the motor section together. Step 3. Slide the drive section away from the motor section. Step 4. Disconnect the motor lead Faston connectors. Step 5. Replace either the drive section or the motor section. Step 6. Reconnect the Faston motor leads. The wires are labeled on both the motor

and drive sections. Connect U to U, V to V, and W to W. Step 7. Slide the drive section onto the motor section. Verify that the slot in the top of

the drive section fits securely around the screw on the motor section. Step 8. Remove the three screws from the blower cover. Remove the blower cover. Step 9. Secure the drive section to the motor section using the four M5 x 50mm

screws removed in step 2. See figure E.2 for the hole locations. Tighten

screws first to 1.5 Nm (13 in-lb). Then torque to 3.9 Nm (35 in-lb) using a

cross-rotational pattern.

M5 x 50mm

Screws

Drive Section End

(Blower Cover Removed)

Figure E.2 – Hole Location

M5 x 50mm

Screws

Step 10. Tighten the M5 x 22mm screw on top of the motor section. Torque to 2.3 Nm

(20 in-lb). Step 11. Place the M4 x 50mm screw (top screw) into the blower cover. Slide the

blower cover over the blower using the screw to aid alignment. Insert and

tighten the bottom two M4 x 10mm screws on the blower cover. Torque

blower cover screws to 2.3 Nm (20 in-lb). Important: The blower covers on the 1 and 2 HP units have a spacer on the top

M4 x 50 mm screw. Verify that this spacer is in place before attaching the blower cover.

E-2

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

PPENDIX

CE Conformity

This unit is a component intended for implementation in machines or systems for the industrial environment. It is CE marked for conformity to the Low Voltage (LV) Directive 73/23/EEC when installed as described. It also has been tested to meet the Council Directive 89/336 Electromagnetic Compatibility (EMC). The standards used for this testing are LV: EN50178, EN60204-1, EMC: EN61800-3, EN50081-1, EN50082-2.

Important: The conformity of the drive and filter to any standard does not guarantee

that the entire installation will conform. Many other factors can influence the total installation and only direct measurements can verify total conformity. It is therefore the responsibility of the machine manufacturer to ensure that the conformity is met.

Copies of the Declaration of Conformity (DOC) may be obtained by contacting the Rockwell AutoFax service at 440-646-7777.

F.1 Essential Requirements for a Conforming EMC

Installation

The following items are requred for CE conformance:

•

A CE filter (see table 1.2) must be installed to reduce conducted emissions.

•

Grounding of equipment and cable shields must be solid, with low impedance connections.

•

All control and signal wiring must use shielded cable or be in grounded metal conduit.

F.2 Low Voltage Directive 73/23/EEC Compliance

This product complies with Low Voltage Directive 72/23/EEC when conforming with the following installation requirements:

Review ATTENTION statements throughout this manual prior to installing the product. Install the product with a fixed connection to the earth. The use of residual-current-

operated protective devices (RCDs) or ground fault indicators is not recommended. If unavoidable, the VSM500 unit is compatible with type B RCDs only.

Install the product in an appropriate or suitable enclosure.

CE Conformity

F-1

F-2

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

NDEX

AC input disconnect, installing, 4-1 AC input power terminal block

connections, 5-2 location, 2-1 tightening torque, 5-1 wiring, 5-1

Accel / decel switch

adjusting, 8-4 location, 2-1, 8-2

Analog output

selecting RPM or %load, 7-7

wiring, 7-5 Application/installation considerations, B-2 Assistance from Reliance Electric, Checklist -1 Auto restart switch

adjusting, 8-7

location, 8-2

Branch circuit protection, installing, 4-1

Declaration of Conformity, F-1 Default switch settings, 8-2 DeviceNet communication option

description, B-2 option kit model number, 1-5 parameter mode selection, 8-11

Display

local operator control unit, 1-4 selecting RPM or %load, 7-7

standard unit, 1-2 Display board connector, location, 2-1 Drive section

description, 1-1

replacing, E-1

Emergency stop, installing, 6-1 EN 60204-1 compliance, 6-1

CE conformity, F-1 CE filter option kits, 1-5 COMM LED, 1-3, 1- 4 Communications (COMM) LED, 1-3, 1-4 Control signal terminal block

location, 2-1, 7-2, 7-3 wiring, 7-1 to 7-14

Cover

attaching, 9-2 clearance, 2-2 opening, 5-2 rotating, 9-3

Index

Fault codes, 11-2 to 11-4 Faults, clearing, 1-5, 11-2 Features, B-1

new features in version 3.0, B-1 Forward control

reverse dis able switch, 8-9

wiring, 7-13 Function loss, wiring, 7-4

Grounding, 5-3

Handling and lifting guidelines, 2-4

Index-1

Identifying your unit, 1-1 to 1-5 Input isolation transformers, installing, 4-2 Input line reactors, 4-2 Installation

AC input disconnect, 4-1 AC input power, 5-1 branch circuit protection, 4-1 check with power off, 9-1 checklist, Checklist -1 considerations, B-2 emergency stop, 6-1 grounding, 5-3 input isolation transformers, 4-2 mounting, 3-1 to 3-2 planning, 2-1 to 2-2 wire routing guidelines, 2-3

Installation record, D-1

LED, communications (COMM), 1-3, 1-4, 11-9 LED, reverse, 1-2, 1-4 Local operating control unit

display, 1-4 reverse LED, 1-4

Local operator control unit

communications (COMM) LED, 1-4 general information, 1-3 key descriptions, 1-4 using terminal block control, 1-3 using the operator controls, 1-3, 1-5

Low Voltage Directive compliance, F-1

NEMA frames, mounting dimensions, 3-2

Operating speed, setting, 10-1 Option kits, 1-5

Power-up start switch

adjusting, 8-6

location, 8-2

Relay control output

switch, 8-7

wiring, 7-6 Replacement part compatibility, 11-9 Replacement parts, 11-7 Reset control, wiring, 7-14 Reverse control

reverse disable, 8-9

wiring, 7-13 Reverse LED, 1-2, 1-4 Rotary switches

adjusting the accel / decel time using, 8-4

adjusting the maximum speed using, 8-3

Maintenance guidelines, 12-1 Maximum speed rotary switch

adjusting, 8-3

location, 2-1, 8-2 Minimum speed, setting, 8-9 Model number format, 1-1 Motor maintenance, 12-1 Motor rotation, changing the direction of, 9-2 Motor section

description, 1-1

replacing, E-1 Mounting dimensions, 3-2

Index-2

Setup slide switch, location, 2-1 Slide switch, setup

auto restart, 8-7 minimum speed select, 8-9 parameter mode for DeviceNet option, 8-11 power-up start, 8-6 relay control output, 8-7 reverse disable, 8-9 speed reference select, 8-6 start mode select, 8-11 stop type, 8-9 torque curve, 8-8

Specifications, A-1 to A-5

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

Speed reference

0 to 10 VDC external speed reference,

wiring, 7-10

4 to 20 mA external speed reference, wiring, 7-

11 checking, 9-4 preset speed inputs, 7-8 signal potentiometer, 7-9 wiring, 7-7 to 7-11

Standard unit

communications (COMM) LED, 1-3 general information, 1-2 reverse LED, 1-2

Start control, wiring, 7-9, 7-12 Starting the unit

using local operator controls, 1-3, 1-5 using terminal block control, 7-12

Stop control

stop type, 8-9 stop type switch location, 8-2 wiring, 7-12

Stopping the unit

using local operator controls, 1-3, 1-5 using terminal block control, 1-3, 7-12

Switch

accel / decel, 8-4 maximum speed, 8-3 setup, 8-5 to 8-11

System diagram, C-1

Wire routing guidelines, 2-3 Wire size

AC input power terminal terminal block, 5-1 control signal terminal block, 7-1

Wiring diagrams, Checklist -2, 7-2, 7-3, 7-4 to 7-14

Technical assistance, Checklist -1 Tightening torque

AC input power terminal block, 5-1 blower cover screws, E-2 control signal terminal block, 7-1 cover screw s , 9-2 drive section screws, E-2 ground screw, 5-3

Torque curve

selecting, 8-8 switch location, 8-2

Troubleshooting, 11-1 to 11-6

Verifying the setup, 8-1

Index

Index-3

Index-4

Installing and Operating the VSM500 Integrated Drive/Motor, Version 3.0

U.S. Drives Technical Support

Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives

Rockwell Automation VSM500 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual