Rockwell Automation VSM500 User Manual

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

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Rockwell Automation VSM500 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual