BENSHAW RSi GM2 Series User manual

RSi GM2 Series
Variable Frequency Drive
1.0to 15HP - 230V
1.0to 15HP - 460V
Instruction Manual
890054-00-00
© 2020Benshaw Inc.
Benshaw retains the right to change specifications and illustrations in text without prior notification. The contents of this document may
not be copied without the explicit permission of Benshaw.

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iii
Safety Information
tion
Safety Information
Read and follow all safety instructions in this manual precisely to avoid unsafe operating conditions,
property damage, personal injury, or even death.
Safety Symbols in This Manual
Indicates an imminently hazardous situation which, if not avoided, will result in severe
injury or even death.
Indicates a potentially hazardous situation which, if not avoided, could result in injury or
even death.
Indicates a potentially hazardous situation which, if not avoided, could result in minor
injury or property damage.
Safety Information
•Never remove the product cover or touch the internal printed circuit board (PCB) or
any contact points when the power is on. Also, do not start the product when the cover
is open. This may cause an electrical shock due to the exposure of high voltage
terminals or live parts.
•Even if the power is off, do not open the cover unless it is absolutely necessary like for
the wiring operation or for regular inspection. Opening the cover may still cause an
electrical shock even after the power is blocked because the product has been charged
for a long period of time.
•Wait at least 10 minutes before opening the covers and exposing the terminal
connections. Before starting work on the inverter, test the connections to ensure all DC
voltage has been fully discharged. Otherwise it may cause an electrical shock and result
in personal injury or even death.
•Make sure to install ground connection between the equipment and the motor for safe
use. Otherwise it may cause an electrical shock and result in personal injury or even
death.
•Do not turn on the power if the product is damaged or faulty. If you find that the
product is faulty, disconnect the power supply and have the product professionally
repaired.
•The inverter becomes hot during operation. Avoid touching the inverter until it has
cooled to avoid burns. Avoid touching the inverter until it has cooled to avoid burns.

iv
Safety Information
•Do not allow foreign objects, such as screws, metal chips, debris, water, or oil to get
inside the inverter. Allowing foreign objects inside the inverter may cause the inverter
to malfunction or result in a fire.
•Do not operate the switch with wet hands. Otherwise it may cause an electrical shock
and result in personal injury or even death.
•Check the information about the protection level for the circuits and devices.
The connection terminals and parts below have electrical protection class 0. This means
that the protection class of the circuit depends on basic insulation and there is a
danger of electric shock if the basic insulation is not working properly. Therefore, take
the same protective measures as handling the power line when connecting wires to the
terminals or the device below, or when installing or using the devices.
- Multi-function (digital) Input: P1–P5, CM
- Analog Input/Output: VR, V1, I2, AO
- Digital Output: 24, A1/B1/C1, A2/C2
- Communication: S+/ S-
- Fan
•The protection level of this equipment is electrical protective class 1.
•Do not change the inside of the product at your own discretion. This may result in
injury or damage to the product due to failure or malfunction. Also, products changed
at your own discretion will be excluded from the product warranty.
•Do not use the inverter for single phase motor operation as it has been designed for
three phase motor operation. Using a single phase motor may damage the motor.
•Do not place heavy objects on top of electric cables. Heavy objects may damage the
cable and result in electric shock.
Note
Following IEC 60439-1, the maximum allowed short-circuit current at the power
source is 100kA. Based on the selected breaker, the GM2 inverter is suitable for use in
circuits capable of delivering up to a maximum of 100 kA symmetrical current at the
drive's maximum rated voltage.

v
Table of Contents
Table of Contents
Preparing the Installation........................................................................................ 1
Product Identification ............................................................................................................... 1
Part Names ................................................................................................................................... 2
Installation Considerations ..................................................................................................... 4
Selecting the Installation Site ................................................................................................ 5
Cable Selection............................................................................................................................ 7
Installing the Inverter .............................................................................................. 8
Mounting the Inverter ............................................................................................................10
Wiring……………………………………………………………………………………………………………...13
Post-Installation Checklist.....................................................................................................26
Test Run .......................................................................................................................................28
Perform Basic Operations......................................................................................29
About the Keypad ....................................................................................................................29
About the Display................................................................................................29
Operation Keys .....................................................................................................30
Control Menu........................................................................................................32
Learning to Use the Keypad.................................................................................................33
Group and Parameter Code Selection.........................................................33
Navigating Directly to Different Codes (Jump Codes) ..........................34
Setting Parameter Values .................................................................................35
Actual Application Examples................................................................................................36
Acceleration Time Configuration...................................................................36
Frequency Reference Configuration.............................................................37
Jog Frequency Configuration..........................................................................38
Parameter Initialization......................................................................................39
Frequency Setting (Keypad) and Operation (via Terminal Input)......40
Frequency Setting (Potentiometer) and Operation (Terminal Input)41
Frequency setting with (internal) potentiometer and start command with the
keypad [RUN] key...............................................................................................43
Monitoring the Operation.....................................................................................................45
Output Current Monitoring .............................................................................45
Trip Condition Monitor......................................................................................46
Learning Basic Features .........................................................................................49

Table of Contents
vi
Frequency Reference Configuration..................................................................................51
Set the Frequency Reference from the Keypad - Direct Input ...........51
Set the Frequency Reference from the Keypad - Using [▲] and [▼] keys 51
Set the Frequency Reference using the V1 Terminal .............................52
Set the Frequency Reference using V0, Built-in Potentiometer.........57
Setting the Reference Frequency using Input Current (I2) ..................57
Setting the Frequency Reference using RS-485 Communication .....59
Frequency Hold by Digital Input ........................................................................................59
Multi-step Frequency Configuration.................................................................................60
Command Source (Start/Stop) Configuration...............................................................62
Setting the Keypad as a Command Input Device....................................62
Setting the Terminal Block as a Command Input Device - Fwd/Rev Run
Commands............................................................................................................62
Setting the Terminal Block as a Command Input Device - Run and Rotation
Direction Commands........................................................................................63
Setting RS-485 Communications as a Command Input Device.........64
Forward or Reverse Run Prevention..................................................................................64
Power-on Run............................................................................................................................65
Reset and Restart .....................................................................................................................66
Setting Acceleration and Deceleration Times................................................................67
Acc/Dec Time Based on Maximum Frequency.........................................67
Acc/Dec Time Based on Operating frequency .........................................68
Multi-step Acc/Dec Time Configuration .....................................................69
Acc/Dec Time Switch Frequency....................................................................71
Acc/Dec Pattern Configuration ...........................................................................................72
Stopping the Acc/Dec Operation ....................................................................................74
V/F Control ...............................................................................................................................74
Linear V/F Pattern Operation ..........................................................................74
Square Reduction V/F Pattern Operation...................................................76
User V/F Pattern Operation .............................................................................77
Torque Boost ...........................................................................................................................78
Manual Torque Boost.........................................................................................78
Auto Torque Boost..............................................................................................79
Motor Output Voltage Adjustment ................................................................................80
Start Mode Setting................................................................................................................80
Accelerating Start ................................................................................................80
DC Braking At Start.............................................................................................80
Initial Excitation (Pre-excite) ............................................................................82
Stop Mode Setting ................................................................................................................82

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Table of Contents
Deceleration Stop................................................................................................82
DC Braking After Stop........................................................................................83
Free Run Stop........................................................................................................84
Power Braking.......................................................................................................84
Frequency Limit ......................................................................................................................85
Frequency Limit Using Maximum Frequency and Start Frequency ..85
Frequency Limit Using Upper and Lower Limit Frequency Values....85
Frequency Jump...................................................................................................86
2nd Operation Mode..............................................................................................................87
Multi-function (digital) Input Terminal Control..........................................................88
Fire Mode Operation ............................................................................................................90
Learning Advanced Features .................................................................................92
Operating with Auxiliary References.................................................................................94
Jog Operation............................................................................................................................98
Jog Operation 1-Forward .................................................................................98
Jog Operation 2-Fwd/Rev Jog by Multi-function (digital) Terminal 99
Up-down Operation ............................................................................................................. 100
3-Wire Operation .................................................................................................................. 102
Safe Operation mode........................................................................................................... 103
Dwell Operation..................................................................................................................... 105
Slip Compensation Operation .......................................................................................... 107
PID Control .............................................................................................................................. 108
Basic PID Operation......................................................................................... 108
Pre-PID Operation............................................................................................ 113
PID Operation Sleep mode ........................................................................... 113
PID Switching (PID Openloop)..................................................................... 114
Auto-tuning............................................................................................................................. 115
Sensorless Vector Control for Induction Motors .................................................... 118
Sensorless Vector Control Operation Setting for Induction Motors119
Sensorless Vector Control Operation Guide for Induction Motors 122
Kinetic Energy Buffering - KEB....................................................................................... 124
Energy Saving Operation ................................................................................................. 127
Manual Energy Saving Operation............................................................... 127
Automatic Energy Saving Operation......................................................... 127
Speed Search Operation .................................................................................................. 128
Auto Restart Settings......................................................................................................... 131

Table of Contents
viii
Operational Noise Settings (Carrier Frequency Settings).................................... 133
2nd Motor Operation........................................................................................................ 134
Commercial Power Source Transition ......................................................................... 135
Cooling Fan Control........................................................................................................... 136
Input Power Frequency and Voltage Settings ......................................................... 136
Parameter Save.................................................................................................................... 137
Parameter Initialization..................................................................................................... 137
Parameter Lock.................................................................................................................... 138
Changed Parameter Display ........................................................................................... 139
Timer Settings ...................................................................................................................... 139
Brake Control........................................................................................................................ 140
Multi-function (digital) relay On/Off Control ........................................................... 141
Press Regeneration Prevention...................................................................................... 142
Analog output...................................................................................................................... 143
Voltage Analog Output .................................................................................. 143
Digital Output ...................................................................................................................... 146
Multi-function (digital) relay Settings....................................................... 146
Trip Output to Multi-function (digital) relay .......................................... 151
Multi-function (digital) relay Terminal Delay Time Settings............. 152
Base Block.............................................................................................................................. 153
Learning Protection Features ..............................................................................154
Motor Protection................................................................................................................... 154
Electronic Thermal Motor Overheating Prevention (ETH)................. 154
Overload Trip and Early Warning ............................................................... 156
Stall Prevention and Flux Braking............................................................... 158
Inverter and Sequence Protection .................................................................................. 162
Input/Output open-phase protection....................................................... 162
External Trip Signal .......................................................................................... 163
Inverter Overload Protection........................................................................ 164
Speed Reference Loss ..................................................................................... 164
Dynamic Braking (DB) Configuration ........................................................ 167
Under Load Fault and Warning ................................................................... 169
Fan Fault Detection.......................................................................................... 170
Lifetime diagnosis of Components ............................................................ 171
Low Voltage Fault............................................................................................. 172
Output Block by Multi-function (digital) Terminal............................... 172
Trip Status Reset ............................................................................................... 173

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Table of Contents
Operation Mode on Option Card Trip...................................................... 173
No Motor Trip.................................................................................................... 174
Low Voltage Trip 2 ........................................................................................... 174
Inverter pre-overheat warning .................................................................... 175
Torque Detection Protection Action ......................................................... 176
RS-485 Communication Features........................................................................179
Communication Standards ................................................................................................ 179
Communication System Configuration......................................................................... 181
Communication Line Connection............................................................... 181
Setting Communication Parameters ......................................................... 182
Setting Start command and Frequency ................................................... 183
Command Loss Protective Operation....................................................... 184
Setting Virtual Multi-function (digital) Input.......................................... 184
Saving Parameters Defined by Communication ................................... 185
Total Memory Map for Communication .................................................. 185
Parameter Group for Data Transmission ................................................. 185
Communication Protocol ................................................................................................... 186
Modbus-RTU Protocol.................................................................................... 186
WinDRIVE ................................................................................................................................. 189
Compatible Common Area Parameter.......................................................................... 192
GM2 Expansion Common Area Parameter.................................................................. 195
Monitoring Area Parameter (Read Only)................................................. 195
Control Area Parameter (Read/ Write) ..................................................... 199
Memory Control Area Parameter (Read and Write)............................ 200
Table of Functions ................................................................................................202
Operation Group ................................................................................................................... 202
Drive Group (PAR→dr) ........................................................................................................ 204
Basic Function Group (PAR→bA)..................................................................................... 207
Advanced Function Group (PAR→Ad)........................................................................... 211
Control Function Group (PAR→Cn)................................................................................ 216
Input Terminal Block Function Group (PAR→In)....................................................... 219
Output Terminal Block Function Group (PAR→OU)................................................. 223
Communication Function Group (PAR→CM) ............................................................. 227
Application Function Group (PAR→AP)........................................................................ 231

Table of Contents
x
Protection Function Group (PAR→Pr)......................................................................... 233
2nd Motor Function Group (PAR→M2)...................................................................... 237
Troubleshooting ...................................................................................................239
Trip and Warning................................................................................................................... 239
Faults ..................................................................................................................... 239
Warning Messages........................................................................................... 242
Troubleshooting Faults ....................................................................................................... 243
Other Faults ............................................................................................................................. 245
Maintenance..........................................................................................................248
Periodic Inspection Summary......................................................................................... 248
Periodic Inspection Items................................................................................................. 249
Storage.................................................................................................................................... 252
Disposal .................................................................................................................................. 252
Technical Specification ........................................................................................253
Input and Output Specification ..................................................................................... 253
Product Specification Details.......................................................................................... 255
External dimensions........................................................................................................... 257
Terminal Screw Specification.......................................................................................... 261
Braking Resistor Specification........................................................................................ 262
Continuous Current Derating......................................................................................... 263
Heat Emission....................................................................................................................... 266
Remote Keypad Option.................................................................................................... 267

GM2 Series VFD
Preparing the Installation
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1
Preparing the Installation
This chapter provides details on product identification, part names, correct installation and cable
specifications. To install the inverter correctly and safely, carefully read and follow the instructions.
Product Identification
The GM2 Inverter is manufactured within a range of 1 HP ~ 15 HP (Normal Duty) and 0.5 HP ~ 10
HP (Heavy Duty) for both 240V or 480V input voltage ratings. Product model and specifications are
detailed on the label. Check the product specification before installing the product and make sure
that it is suitable for the intended use. For more detailed product specifications, refer to 11.1 input
and Output Specification on page 253.
Note
Open the packaging and check the product name and model. Verify that the product is
free from defects. If the product is found to be faulty, contact your supplier.
Label

Preparing the Installation
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GM2 Series VFD
Part Names
See the assembly diagram below to identify names and locations of parts on the inverter. Detailed
images may vary between product groups.
ND: 1.0 HP ~ 7.5 HP, 240V/480V
HD: 0.5 HP ~ 5.0 HP
HD: 0.4 kW ~ 4.0 kW

GM2 Series VFD
Preparing the Installation
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3
ND: 10 HP ~ 15 HP, 240V/480V
HD: 7.5 HP ~ 10 HP
HD: 5.5 kW ~ 7.5 kW

Preparing the Installation
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4
GM2 Series VFD
Installation Considerations
Inverters are composed of various precision electronic devices and the installation environment can
significantly impact the lifespan and reliability of the product. The table below details the ideal
installation and operating conditions for the inverter.
Items
Description
Ambient
temperature*
Normal Duty: 14°F ~ 104°F (-10~40)
Heavy Duty: 14°F ~ 122°F (-10~50)
Ambient
humidity
Less than 95% relative humidity (no condensation)
Storage
temperature
-4°F ~ 149°F (-20~65°C)
Environmental
factors
An environment free from corrosive or flammable gases, oil residue, and
dust
Operating
altitude
Vibration
Lower than 3,280 ft (1,000 m) above sea level
(Apply derating of 1% on voltage/output current for every 328 ft. (100m)
above 3,280 ft. (1,000 m), maximum of 13123 ft. (4,000m).
Less than 1G (9.8 m/sec2)
Air Pressure
70–106 kPa
* The ambient temperature is the temperature measured at a point 2” (5 cm) from the surface of
the inverter.
Do not allow the ambient temperature to exceed the allowable range while operating the
inverter.

GM2 Series VFD
Preparing the Installation
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Selecting the Installation Site
When selecting an installation location consider the following points:
•The location must be free from vibration, and the inverter must be installed on a wall that can
support the inverter’s weight.
•The inverter can become very hot during operation. Install the inverter on a surface that is fire-
resistant or flame-retardant and with sufficient clearance around the inverter to allow air to
circulate.
•Make sure that sufficient air circulation is provided around the product. When installing the
product inside the panel, carefully consider the position of the product's cooling fan and the
ventilation louvers. The product must be placed for the cooling fan to discharge heat
satisfactorily during the operation.

Preparing the Installation
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6
GM2 Series VFD
•If you are installing multiple inverters in one location, side-by-side mounting is acceptable with
minimal spacing (~2.5mm) between inverters. Do not install the cover (option) shown in
diagram.
•If you are installing multiple inverters of different ratings, provide sufficient clearance above and
below and to side walls to meet the clearance specifications of the larger inverter.

GM2 Series VFD
Preparing the Installation
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7
Cable Selection
When you install power and signal cables in the terminal blocks, only use cables that meet the
required specification for the safe and reliable operation of the product. Refer to the following
information to assist you with cable selection.
•Wherever possible use cables with the largest cross-sectional area for main power
wiring to ensure that voltage drop does not exceed 2%.
•Use copper cables rated for 600 V, 75for power terminal wiring.
•Use copper cables rated for 300 V, 75for control terminal wiring.
Ground Cable and Power Cable Specification
Capacity
Ground
Power Terminal Wiring
Terminal
Block Size
mm2
AWG
mm2
AWG
kW
HP
R/S/T
U/V/W
R/S/T
U/V/W
3–Phase
200 V
0.4
0.5
4
12
1.5
1.5
16
16
M3
0.75
1.0
1.5
2.0
4
12
4
2.5
12
14
M4
2.2
3.0
4
5.0
6
10
6
6
10
10
M4
5.5
7.5
6
10
16
10
6
8
M4
7.5
10
3–Phase
400 V
0.4
0.5
2.5
14
1.5
1.5
16
16
M3.5
0.75
1.0
1.5
2.0
2.2
3.0
4
5.0
6
10
2.5
2.5
14
14
M4
5.5
7.5
6
10
10
6
8
10
M4
7.5
10
Signal (Control) Cable Specifications
Terminals
Control Terminal Wiring
Without Crimp Terminal
Connectors
With Crimp Terminal
Connectors
mm2
AWG
mm2
AWG
P1 ~ P5, CM, 24
0.8
18
0.5
20
A1/B1/C1/A2/C2,
VR/V1/I2/AO/CM,
S+/S-

Installing the Inverter
8
GM2 Series VFD
890054-00-00
Installing the Inverter
This chapter describes the physical and electrical installation methods, including mounting and
wiring of the inverter. Refer to the flowchart and basic configuration diagram provided to
understand the procedures and installation methods to be followed to install the product correctly.
DIN Rail Mounting
The inverters include provisions for standard DIN rail (35mm x 7.5mm) mounting. If using DIN rail,
skip section 2.1, Panel / Wall Mounting.
Panel / Wall Mounting Installation Flowchart
The flowchart lists the sequence to be followed during installation. Install the product following the
flowchart and to test the operation. For more information on each step, refer to the pages below.
Product Identification (p.1Ref.)
Select the Installation Location (p.4Ref.)
Mounting the Inverter (p.10 Ref.)
Wiring the Ground Connection (p.15 Ref.)
Power and Signal Wiring (12)
Power and Signal Wiring (p.16 Ref.)
Post-Installation Checks (p.26 Ref.)
Turning on the Inverter
Parameter Configuration (p.35 Ref.)
Testing (p.28)

9
GM2 Series VFD
890054-00-00
Installing the Inverter
Basic Configuration
The diagram below shows the basic system configuration. Use the diagram for reference when
configuring the system by connecting the product with peripheral devices. Ensure that the product
has a suitable rating for the configuration and that all the required peripherals and optional devices
(brake unit, reactors, noise filters, etc.) are available.
•Note that the illustrations in this user manual may represent the product with the
inverter cover removed or the circuit breaker removed for explanation. When operating
the inverter, make sure to follow the instructions of user manual after fully installing the
necessary parts, such as the cover and circuit breaker.
•Do not start or stop the inverter with a magnetic contactor. This may cause damage to
the inverter.
•If the inverter is damaged and loses control, the machine may cause a dangerous
situation. Install an additional safety device such as an emergency brake to prevent
these situations.
•High levels of current draw during power-on can affect the system. Ensure that
correctly rated circuit breakers are installed to operate safely during power-on
situations.
•Reactors can be installed to improve the power factor. If the input power exceeds 10
times of inverter capacity (KVA rating), a line reactor must be installed within 30 ft
(9.14m) from the inverter input.

Installing the Inverter
10
GM2 Series VFD
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Mounting the Inverter
Mount the inverter on a wall or inside a panel following the procedures provided below. Before
installation, ensure that there is sufficient space to meet the clearance specifications, and that there
are no obstacles impeding the cooling fan’s air flow.
Select a wall or panel suitable to support the installation. Refer to 11.3 External Dimensions
on page 257 and check the inverter’s mounting bracket dimensions.
Use a level to draw a horizontal line on the mounting surface, and then carefully mark the
mounting holes.
Drill the two upper mounting bolt holes, and then mount the inverter with the top mounting
bolts. Do not fully tighten the bolts at this time. Fully tighten the mounting bolts after the
inverter has been mounted.
With the inverter temporarily installed, mark the location for the bottom mounting bolts.
Remove the inverter and drill holes for the bottom mounting bolts.
Mount the inverter on a wall or inside a panel using all mounting bolts. Fully tighten the upper
mounting bolts, then install two lower mounting bolts and tighten fully. Ensure that the
inverter is placed flat on the mounting surface, and that the installation surface can securely
support the weight of the inverter.