BENSHAW RSi GX Series User manual

2005 Benshaw Inc.
©
890030-01-01
Sensorless Vector
Variable Frequency Drive
RSi GX Series
Hardware Manual
1.0 to 5.0HP - 230V
1.0 to 5.0HP - 460V
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.

TRADEMARK NOTICE
Benshaw and are registered trademarks of Benshaw Incorporated.
ModBUS is a registered trademark of Schneider Electric.
DeviceNet is a registered trademark of the Open DeviceNet Vendor Association (ODVA).
Metasys is a registered trademarkof Johnson Controls, Inc.
UL is a trademark of Underwriters Laboratories, Incorporated.

Safety Precautions
i
SAFETY PRECAUTIONS
1. Do not remove the front cover when input power is connected. Doing so can result in electric
shock.
2. Do not operate the drive with the front cover removed. Electric shock can occur due to the
exposed high voltage terminals and capacitor.
3. Do not remove the cover except for routine inspections or wiring, even if the input power is
not applied. The capacitor will remain charged for a long time even when the power is not
applied.
4. This drive contains high voltage which can cause electric shock resulting in personal injury or
loss of life.
5. Be sure all AC power is removed from the drive before servicing.
6. Wait at least 10 minutes after turning off the AC power for the bus capacitor to discharge.
Measure the DC Bus charge between B+ and B- terminals, ensure DC voltage is below 45V
before proceeding.
7. Do not connect or disconnect the wires to or from drive when power is applied.
8. Do not operate the switches with wet hands. Doing so can result in electric shock.
9. Electric shock can occur if the cable coating is damaged or if heavy objects than can
cause excess stressare put on the cable.
1. Service only by qualified personnel.
2. Install the drive on a non-flammable surface. Do not place flammable material nearby.
Otherwise, fire could occur.
3. Make sure power-up restart is off to prevent any unexpected operation of the motor.
3. Do not use a higher grounding method than the Type 3 grounding method.
4. Disconnect the input power if the drive gets damaged. Otherwise, it could result in a
secondary accident and fire.
5. Make certain proper shield installation is in place.
6. Never connect the input power leads to the output terminals of drive.
7. Risk of Electric Shock - More than one disconnect switch may be required to
de-energize the equipment before servicing.
8. Do not allow lint, paper, wood chips, dust, metallic chips or other foreign matter into
the drive. Otherwise, fire or accident could occur.
9. Incorrectly connecting the polarity (+/-) of the terminals can damage the drive.
WARNING
CAUTION

TABLE OF CONTENTS
1 INTRODUCTION ...................................2
1.1 Inspection ...................................5
1.2 Model Numbers ...............................5
1.3 Connection of Peripheral Devices to the Drive ..............6
1.4 Drive Components ..............................7
1.5 Product Assembly/Disassembly ......................8
2 TECHNICAL SPECIFICATIONS ..........................10
2.1 Technical Data ................................10
2.2 Environmental Specifiactions ........................12
2.3 Electrical Specifications ...........................12
2.4 Altitude Derating ...............................13
2.5 Thermal Derating...............................13
2.6 RSi001GX (200/400V) ............................14
2.7 RSi002GX (200/400V) ............................15
2.8 RSi003GX (200/400V) ............................16
2.9 RSi005GX (200/400V) ............................17
3 RECEIVING AND INSTALLATION ........................20
3.1 Preliminary Inspection............................20
3.2 Installation Precautions ...........................20
3.3 Temperature Derating Information.....................22
3.4 Basic Wiring Diagram ............................23
3.5 Power Terminals ...............................24
3.6 Control Circuit Terminals ..........................25
3.6.1 Wiring Input and Output Power Terminals ...............26
3.6.2 Interference Supression Measures.....................29
3.6.3 Wires and Terminal lugs .........................30
3.6.4 Power and Motor Connection .......................31
3.7 PNP/NPN selection and connector for communication option.....32
3.8 Recommended Breakers ...........................32
3.9 Recommended AC Reactors.........................33
3.9.1 Keypad .................................... 33
ii
TABLE OF CONTENTS

4 Operation ........................................36
4.1 Keypad and Parameter Group Setting ...................36
4.1.1 Keypad Description .............................36
4.2 Parameter Setting and Adjustment .....................37
4.2.1 Moving to other Groups ..........................37
4.2.2 How to Change the Codes in a Group ..................38
4.2.3 Parameter Setting .............................. 39
4.2.4 Monitoring of Operation Status ......................41
4.3 Frequency Setting and Basic Operation ..................43
4.4 Operation with the Keypad and Control terminal ............46
4.4.1 Operation with Control terminal .....................46
4.4.2 Operation with Keypad ..........................46
5 Parameter List .....................................48
5.1 Drive Group..................................48
5.2 Function Group 1 [FU1] ...........................49
5.3 Function Group 2 [FU2] ...........................51
5.4 Input/Output Group [I/O] .........................54
6 Parameter Descriptions ................................58
6.1 Drive Group..................................58
6.2 Function Group 1 ...............................65
6.3 Function Group 2 ...............................83
6.4 I/O Group...................................111
7 Remote Communication ...............................130
7.1 Introduction ..................................130
7.1.1 Features ................................... 130
7.1.2 Connection Guide for RS485 Communication with PC , PLC and RS232/485
............................................ 130
7.1.3 Before Installation ..............................130
7.2 Specification..................................131
7.2.1 Performance Specification .........................131
7.2.2 Hardware Specification...........................131
7.2.3 Communication Specification .......................131
7.3 Installation...................................131
7.3.1 Connecting the Communication Line ...................131
iii
TABLE OF CONTENTS

7.4 Operation ...................................132
7.4.1 Operating Steps ............................... 132
7.5 Communication Protocol (MODBUS-RTU) ................132
7.5.1 Supported function code ..........................132
7.5.2 Exception code................................ 132
7.5.3 Baudrate ................................... 132
7.6 Parameter code list <Common area> ...................133
7.6.1 Troubleshooting RS485 Communications ................141
7.7 ASCII Code List................................142
8 Troubleshooting & Maintenance ..........................144
8.1 Protective Functions .............................144
8.2 Fault Remedy .................................146
8.3 Precautions forMaintenance and Inspection................148
8.4 Check Points .................................148
8.5 Replacement Parts ..............................148
8.6 Troubleshooting ...............................149
8.6.1 Motor Overheats ..............................150
8.6.2 Motor Speed is not equal to the Command Frequency .........151
8.6.3 Motor Does Not Run Smoothly ......................152
8.6.4 Motor Does Not Run ............................153
8.7 How to Check Power Components.....................154
8.8 Daily and Periodic Inspection Items ....................155
9 Options .........................................158
9.1 Short Circuit Fuse / Braking Resistor ...................158
10 EU DECLARATION OF CONFORMITY .....................160
iv
TABLE OF CONTENTS

1 Introduction
1

Using This Manual
Layout This manual is divided into 7 sections. Each section contains topics
related to the section. The sections are as follows:
•Introduction
•Technical Specifications
•Installation
•Connection
•Troubleshooting & Maintenance
•Interference Suppression Measures
•Appendices
Symbols There are 2 symbols used in this manual to highlight important
information. The symbols appear as the following:
Electrical Hazard that warns of situations in which a high voltage
can cause physical injury, death and/or damage equipment.
Caution that warns of situations in which physical injury
and/damage to equipment may occur by means other than electrical.
Highlight marking an important point in the documentation.
2
1 - INTRODUCTION

Benshaw Services
General Information Benshaw offers its customers the following:
•Start-up services
•On-site training services
•Technical support
•Detailed documentation
•Replacement parts
zNOTE: Information about products and services is available by
contacting Benshaw, refer to page 4.
Start-Up Services Benshaw technical field support personnel are available to do startup
and conduct on-site training on the starter operations and
troubleshooting.
On-Site Training Services Benshaw technical field support personnel are available to conduct
on-site training on starter operations and troubleshooting.
Technical Support Benshaw technical support personnel are available (at no charge) to
answer customer questions and provide technical support over the
telephone. For more information about contacting technical support
personnel, refer to Contacting Benshaw on page 4.
Documentation Benshaw provides all customers with:
•Hardware Manual - Production # 890030-01-xx
On-Line Documentation All documentation is available on-line at http://www.benshaw.com.
Replacement Parts Spare and replacement parts can be purchased from Benshaw.
Publication History Refer to the Revision History in the appendices.
3
1 - INTRODUCTION

Contacting Benshaw
Contacting Benshaw Information about Benshaw products and services is available by
contacting Benshaw at one of the following offices:
Benshaw Inc. Corporate Headquarters
1659 E. Sutter Road
Glenshaw, PA 15116
United States of America
Phone: [phone]
Fax: [phone]
Benshaw Canada Controls Inc.
550 Bright Street. E.
Listowel, Ontario N4W 3W3
Canada
Phone: [phone]
Fax: [phone]
Benshaw West
14715 North 78th Way, Suite 600
Scottsdale, AZ 85260
United States of America
Phone: [phone]
Fax: [phone]
E-mail:[email protected]
[email protected]
Technical support for RSi GX Series is available at no charge by
contacting Benshaw’s customer service department at one of the
above telephone numbers. A service technician is available Monday
through Friday from 8:00 a.m. to 5:00 p.m. EST.
zNOTE: An on-call technician is available after normal business
hours and on weekends by calling Benshaw and following the
recorded instructions.
To help assure prompt and accurate service, please have the
following information available when contacting Benshaw:
•Name of Company
•Telephone number where the caller can be contacted
•Fax number of caller
•Benshaw product name
•Benshaw model number
•Benshaw serial number
•Name of product distributor
•Approximate date of purchase
•System Voltage
•FLA of motor attached to Benshaw product
•A brief description of the application
4
1 - INTRODUCTION

Inspection
1.1 Inspection
Before storing or installing the RSi GX, thoroughly inspect the device for possible shipping
damage. Upon receipt:
•Remove the starter from its package and inspect exterior for shipping damage. If damage
is apparent, notify the shipping agent and your sales representative.
•Open the enclosure and inspect the starter for any apparent damage or foreign objects.
Ensure that all of the mounting hardware and terminal connection hardware are properly
seated, securely fastened, and undamaged.
•Ensure all connections and wires are secured.
•Read the technical data label affixed to the starter and ensure that the correct horsepower
and input voltage for the application has been purchased.
•If you will store the drive after receipt, place it in its original packaging and store in a
clean, dry place free from direct sunlight or corrosive fumes, where the ambient
temperature is not less than -20°C (-4°F) or greater than +65°C (+149°F).
•Depending on the type of unit you have purchased, check that you have received all the
necessary parts. The delivery package should include the unit itself, this manual and a
Quick Start Guide. The Quick Start Guide gives a summary of the installation
instructions. It is not meant to be a substitute for the User Manual, rather it is meant to be
a supplement to the manual.
Interpreting Model Numbers
1.2 Model Numbers
The model number of the RSi GX drive appears on the shipping carton label and on the
technical data label affixed to the model. Read the technical data label affixed to the drive
and ensure that the correct horsepower and input voltage for the application has been
purchased. The numbering system for a Benshaw RSi GX drive is shown below.
5
1 - INTRODUCTION
Benshaw Drive
Applicable constant torque motor capacity
For example, 005 = 5HP
Series name of drive
Input voltage
2 = 230V, three-phase
4 = 460V, three-phase
Enclosure Type
B = NEMA 1 / I 31P
B
2
GX
005
RSi
Figure 1: RSi GX Drive Model Numbers

Basic Configuration
1.3 Connection of Peripheral Devices to the Drive
The following devices are required to operate the drive. Proper peripheral devices must be
selected and correct connections made to ensure proper operation. An incorrectly applied
or installed drive can result in system malfunction or reduction in product life as well as
component damage. You must read and understand this manual thoroughly before
proceeding.
6
1 - INTRODUCTION
AC Source Supply
Use the power supply within the
permissible range of drive input power
rating (Refer to page 10).
MCCB or Earth
leakage circuit
breaker (ELB)
Select circuit breakers with care. A large
inrush current may flow in the drive at
power on.
Magnetic
Contactor
Install it if necessary. When installed, do
not use it for the purpose of starting or
stopping. Otherwise, it could lead to
reduction in product life.
Reactors
The reactors must be used when the power
factor is to be improved or the drive is
installed near a large power supply system
(1000kVA or more and wiring distance
within 10m).
Installation and
wiring
To operate the drive with high performance
for a long time, install the drive in a proper
place in the correct direction and with
proper clearances. Incorrect terminal wiring
could result in the equipment damage.
To motor
Do not connect a power factor capacitor,
surge suppressor or radio noise filter to the
output side of the drive.

Drive Components
1.4 Drive Components
7
1 - INTRODUCTION
Status LED Display
RUN Button
ENTER Button
NPN, PNP Select Switch
Ground Terminal
Cooling Fan
Drive Nameplate
Control Signal Terminals
Connection for Remote Option
/
Parameter Copying
STOP/RESET Button
Detachable Keypad
Power Terminals
4-Way Button
(Up/Down/Left/Right)

Product Assembly/Disassembly
1.5 Product Assembly/Disassembly
To remove the front cover, press both of the indented sides of the cover lightly and pull up.
To change the drive fan, press both sides of the bottom cover lightly and pull out to the
side. Disconnect the fan wire.
8
1 - INTRODUCTION
Press this part lightly and pull up.
Press this part and pull out

2 Technical Specifications
9

Technical Data
2.1 Technical Data
1) Indicates the maximum applicable motor capacity when using a 4-pole motor.
2) Rated capacity is based on 220V for 200V class and 440V for 400V class.
3) Refer to when Carrier frequency setting (H39) is above 3kHz.
4) Max frequency setting range is extended to 300Hz when H40 (Control mode select) is
set to 3 (SVC).
5) Maximum output voltage cannot be higher than the input voltage. It can be
programmable below input voltage.
10
2 - TECHNICAL SPECIFICATIONS
Drive Type (RSixxxGX-2) 001 002 003 005
Motor
Rating1
HP 1235
KW 0.75 1.5 2.2 3.7
Output
Ratings
Capacity[kVA]21.9 3.0 4.5 6.1
FLA [A]35 8 12 16
Max. Frequency 400 [Hz]4
Max. Voltage 3f200 - 230V5
Input
Ratings
Rated Voltage 3f200 - 230 VAC (+10%, -15%)
Rated Frequency 50 - 60 [Hz] (±5%)
Cooling Method Forced Cooling
Weight [kg] 0.77 1.12 1.84 1.89
230V Class (1.0 - 5.0HP)
Drive Type (RSixxxGX-4) 001 002 003 005
Motor
Rating1
HP 1235
KW 0.75 1.5 2.2 3.7
Output
Ratings
Capacity[kVA]21.9 3.0 4.5 6.1
FLA [A]32.5 4 6 8
Max. Frequency 400 [Hz]4
Max. Voltage 3f380 - 480V5
Input
Ratings
Rated Voltage 3f380 - 480 VAC (+10%, -15%)
Rated Frequency 50 - 60 [Hz] (±5%)
Cooling Method Forced Cooling
Weight [kg] 0.77 1.12 1.84 1.89
400V Class (1.0 - 5.0HP)

11
2 - TECHNICAL SPECIFICATIONS
Control Method V/F, Sensorless vector control
Frequency Setting Resolution Digital command: 0.01Hz
Analog command: 0.06Hz (Max freq.: 60Hz)
Frequency Accuracy Digital command: 0.01% of Max output frequency
Analog command: 0.1% of Max output frequency
V/F Pattern Linear, Squared, User V/F
Overload Capacity 150% per 1 min.
Torque Boost Manual/Auto torque boost
Dynamic
Braking
Max braking
torque 20% 1)
Time / %ED 150% 2) when using optional DB resistor
1) Means average braking torque during Decel to stop of a motor.
2) Refer to Chapter 9 for DB resistor specification.
Control
Operation Mode Keypad/ Terminal/ Communication option/ Remote keypad
selectable
Frequency Setting Analog: 0 ~ 10[V], -10 ~ 10[V], 0 ~ 20[mA]
Digital: Keypad
Operation Features PID, Up-down, 3-wire
Input
Multi-function
terminal
P1~P8
NPN / PNP selectable (See page 3-6)
FWD/REV RUN, Emergency stop, Fault reset,
Jog operation, Multi-step Frequency-High, Mid, Low,
Multi-step, Accel/Decel-High, Mid, Low, DC braking at stop,
2nd motor select, Frequency UP/Down, 3-wire operation,
External trip A, B, PID-drive (v/f) operation bypass,
Option-drive (v/f) operation bypass, Analog Hold,
Accel/Decel stop
Output
Open collector
terminal Fault output and drive
status output
Less than DC 24V 50mA
Multi-function
relay
(N.O., N.C.)
Less than AC250V 1A,
Less than DC 30V 1A
Analog output 0 - 10 Vdc (less than10mA): Output Freq, Output Current,
Output Voltage, DC link selectable
Operation
Trip
Over Voltage, Under Voltage, Over Current, Ground Fault current
detection, drive Overheat, Motor Overheat, Output Phase Open,
Overload Protection, Communication Error, Loss of Speed
Command, Hardware Fault, Fan trip
Alarm Stall prevention, overload
Momentary Power Loss
Below 15 msec: Continuous operation (should be within rated input
voltage, rated output power.)
Above 15 msec: Auto restart enable
Protection Function

Environmental Specifications
2.2 Environmental Specifiactions
Electrical Specifications
2.3 Electrical Specifications
12
2 - TECHNICAL SPECIFICATIONS
Protection degree IP 20, NEMA TYPE 1 (Option)
Ambient temperature -10°C to +50°C (non-freezing)
Storage temperature -20°C to +65°C (-4°F to 149°F)
Humidity 0% to 95% RH (non-condensing)
Altitude Max. 1,000m (3300ft) without derating
Maximum vibration 5.9 m/s2(19.2 ft/s2) [0.6G] or less
Cooling Natural convection (1HP models)
Fan cooling (2HP and larger models)
Atmospheric pressure 70 to 106 kPa
Location Protected from corrosive gas, combustible gas, oil
mist or dust
Table 1
200VAC Models 400VAC Models
Voltage input 3f200 - 230VAC -10%, -15% 3f380 - 480VAC +10%, -15%
Line frequency 50 / 60Hz ±5%
DC bus voltage for:
Overvoltage trip
Dynamic Brake
activation
Nominal undervoltage
(UV) trip
407VDC
391VDC
202VDC
805VDC
780VDC
510VDC
Control system Voltage Vector pulse width modulation (PWM)
Carrier frequency = 4, 6, 8, 12, and 16kHz
Output voltage 0 to 100% of line voltage, Three-phase
Overload capacity 150% of rated rms for 60 seconds
Rated output frequency 50/60Hz ±5%
Frequency range 0 to 1000Hz
Frequency stability
±0.02Hz from 0 to 300Hz (digital)
±0.01Hz from 300 to 1000Hz (digital)
0.1% (analog) over 24 hours ±10°C change
Frequency setting Digital: keypad (0 to 10VDC, -10 to 10VDC, 0 to 20mA)
Agency listings UL and cUL Listed, CE Mark
Table 2

Altitude Derating
2.4 Altitude Derating
Benshaw VFDs are capable of operating at altitudes up to 3,300 feet (1000 meters) without
requiring an altitude derate. Table 3 provides the derating percentage to be considered
when using a drive above 3,300 feet (1000 meters).
zNote: For derating above 10,000ft consult Benshaw.
Thermal Derating
2.5 Thermal Derating
The ambient operating temperature range of the RSi GX is as follows:
•NEMA 1 0-40°C
13
2 - TECHNICAL SPECIFICATIONS
Altitude Percent Derating (Amps)
3,300 feet 1,006 meters 0.0%
4,300 feet 1,311 meters 3.0%
5,300 feet 1,615 meters 6.0%
6,300 feet 1,920 meters 9.0%
7,300 feet 2,225 meters 12.0%
8,300 feet 2,530 meters 15.0%
9,300 feet 2,835 meters 18.0%
Table 3: Altitude Derating

Dimensions
2.6 RSi001GX (200/400V)
14
2 - TECHNICAL SPECIFICATIONS
RUN
ENT
RESET
STOP
SET
RUN
FWD
REV
W1 A
A
H1
Æ
W1
B
H
D
W
Model [HP] [kW] W
[mm]
W1
[mm]
H
[mm]
H1
[mm]
D
[mm] FA [mm]
B
[mm] [Kg]
RSi001GX-2/4 1.0 0.75 70
(2.76)
65.5
(2.58)
128
(5.04)
119
(4.69)
130
(5.12) 4.0 4.5 (0.18)
4.0
(0.16)
0.77
(1.70lb)
zNote: For single phase operation consult factory.
Unit: mm (inches)