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Variable Speed AC Motor Drives SM-Basic Installation and Operation Manual - PDF Free Download
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Bartholomew Mills
1 ELECTRIC MOTORS, GEARMOTORS AND DRIVES Variable Speed AC Motor Drives SM-Basic Installation and Operation Manual
2 We, EC Declaration of Conformity In accordance with EN45014:1998 Leeson Electric Corporation 2100 Washington Street Grafton, Wisconsin USA declare under sole responsibility that the following equipment to which this declaration relates, meets the essential health and safety requirements and is in conformity with the relevant sections of the applicable EC standards and other normative documents. If changes are made to the product that is covered by this declaration of conformity, the declaration of conformity is no longer valid. Equipment Type: AC Variable Frequency Motor Drives: EC Directives: By virtue of this conformity, the products are deemed to comply with the provisions of the Council of European Communities Directives listed, provided installations are carried out in accordance with the manufacturer s instructions. 1) Low Voltage Directive 73/23/EEC as amended 93/68/EEC 2) Electromagnetic Compatibility Directive 89/336/EEC as amended 92/31/EEC Harmonized Standards Used: EN *: Electromagnetic Compatibility Generic Emission Standard; Part 2: Industrial Environment EN *: Electromagnetic Compatibility Generic Emission Standard; Part 2: Industrial Environment EN50178; 1998 Electronic Equipment for use in Power Installations * with suitable filters that are properly installed Authorized Representative: Ms. Elisa Basso Leeson Electric International Phone: (+39) Via Caduti Di Sabbiuno 11/D-E Fax: (+39) Anzola Emilia Bologna Italy Dated this 2 st day of May Peter F. Hennig Senior Design Engineer Revision: 00, 5/02/2000
3 Manual Number: IMSN01 TABLE OF CONTENTS 1.0 GENERAL SM-Basic DIMENSIONS SM-Basic MODEL DESIGNATION CODE SM-Basic SPECIFICATIONS SM-Basic RATINGS INSTALLATION INPUT AC POWER REQUIREMENTS POWER WIRING SM-Basic POWER WIRING DIAGRAM CONTROL WIRING SM-Basic CONTROL WIRING DIAGRAMS INITIAL POWER UP AND MOTOR ROTATION PROGRAMMING THE SM Basic DRIVE PARAMETER MENU DESCRIPTION OF PARAMETERS TROUBLESHOOTING SM-Basic DISPLAY MESSAGES USER SETTING RECORD... 41
4 THE SM-Basic SUB-MICRO DRIVE INPUT POWER TERMINALS GROUND LUG ELECTRONIC PROGRAMMING MODULE (EPM) 2-DIGIT LED DISPLAY PROGRAMMING BUTTONS CONTROL TERMINAL STRIP OUTPUT (MOTOR) TERMINALS
5 1.0 GENERAL 1.1 PRODUCTS COVERED IN THIS MANUAL This manual covers the Leeson Electric Corporation SM-Basic Series Variable Frequency Drive. 1.2 PRODUCT CHANGES Leeson Electric Corporation reserves the right to discontinue or make modifications to the design of its products without prior notice, and holds no obligation to make modifications to products sold previously. Leeson Electric Corporation also holds no liability for losses of any kind which may result from this action. 1.3 WARRANTY Leeson Electric Corporation warrants the SM-Basic AC motor control to be free of defects in material and workmanship for a period of twelve months from the date of sale to the user, or eighteen months from the date of shipment, which ever occurs first. If an SM-Basic motor control, under normal use, becomes defective within the stated warranty time period, contact Leeson Electric's Service Department for instructions on obtaining a warranty replacement unit. Leeson Electric Corporation reserves the right to make the final determination as to the validity of a warranty claim, and sole obligation is to repair or replace only components which have been rendered defective due to faulty material or workmanship. No warranty claim will be accepted for components which have been damaged due to mishandling, improper installation, unauthorized repair and/or alteration of the product, operation in excess of design specifications or other misuse, or improper maintenance. Leeson Electric Corporation makes no warranty that its products are compatible with any other equipment, or to any specific application, to which they may be applied and shall not be held liable for any other consequential damage or injury arising from the use of its products. This warranty is in lieu of all other warranties, expressed or implied. No other person, firm or corporation is authorized to assume, for Leeson Electric Corporation, any other liability in connection with the demonstration or sale of its products. 1.4 RECEIVING Inspect all cartons for damage which may have occurred during shipping. Carefully unpack equipment and inspect thoroughly for damage or shortage. Report any damage to carrier and/or shortages to supplier. All major components and connections should be examined for damage and tightness, with special attention given to PC boards, plugs, knobs and switches. 1.5 CUSTOMER MODIFICATION Leeson Electric Corporation, its sales representatives and distributors, welcome the opportunity to assist our customers in applying our products. Many customizing options are available to aid in this function. Leeson Electric Corporation cannot assume responsibility for any modifications not authorized by its engineering department. 1
6 2.0 SM-Basic DIMENSIONS 0.38" H R W 0.38" 0.18" D 0.69" P 0.19" Dia. Slot Mounting Tab Detail HP INPUT VOLTAGE MODEL H W D P R /208/ / /208/ / / /208/ / / /208/ / / / / / /
7 3.0 SM-Basic MODEL DESIGNATION CODE 4.0 SM-Basic SPECIFICATIONS Storage Temperature -20 to 70 C Ambient Operating Temperature 0 to 50 C (up to 6 khz carrier, derate above 6 khz) Ambient Humidity < 95% (non-condensing) Altitude 3300 ft (1000 m) above sea level (without derating) Input Line Voltages 120/208/240 Vac single phase, 208/240 Vac three phase Input Voltage Tolerance +10%, -15% Input Frequency Tolerance 48 to 62 Hz Output Wave Form Sine Coded PWM Output Frequency 0-99 Hz Carrier Frequency 4 khz to 10 khz Service Factor 1.00 (up to 6 khz carrier, derate above 6 khz) Efficiency Up to 98% Power Factor (displacement) 0.96 or better Overload Current Capacity 150% for 60 seconds, 180% for 30 seconds Speed Reference Follower Speed Potentiometer, 0-10 VDC (must be isolated) 1 Power Supply for Auxiliary Relay 50 ma at 12 VDC Digital Output Circuit rated 50 ma and 30 VDC max (to drive auxiliary relay) 1 1 WARNING: Control terminals are not isolated from line voltage! Do not touch! 3
8 5.0 SM-Basic RATINGS MODEL NUMBER INPUT OUTPUT MODEL (120/208/240 Vac, Hz) (0-200/230 Vac) HEAT LOSS FOR MOTORS RATED HP kw INPUT PHASE CURRENT (AMPS) (NOTE 1) POWER (kva) CURRENT (AMPS) (NOTE 1) WATTS (NOTE 3) /3.5/ /1.6/ /5.3/ /2.5/ /9.1/ /4.6/ /12.3/ /6.2/ NOTE 1: The first current rating listed is for 120 Vac input, the second current rating is for 208 Vac input, and the third current rating is for 240 Vac input. 120 Vac input yields 230 Vac output. MODEL NUMBER INPUT OUTPUT MODEL (208/240 Vac, Hz) (0-200/230 Vac) HEAT LOSS FOR MOTORS RATED HP kw INPUT PHASE CURRENT (AMPS) (NOTE 1) POWER (kva) CURRENT (AMPS) (NOTE 1) WATTS (NOTE 3) / / / / / / / / / / / / / / / / / NOTE 1: Models are rated for use with single and three phase input. NOTE 2: The higher current rating is for 208 Vac input and the lower current rating is for 240 Vac input. NOTE 3: Values are worst-case (not typical) for 6 khz carrier frequency at full speed and full load. 4
9 6.0 INSTALLATION NOTE! SM-Basic drives are intended for inclusion within other equipment, by professional electrical installers. They are not intended for stand-alone operation. WARNING! DRIVES MUST NOT BE INSTALLED WHERE SUBJECTED TO ADVERSE ENVIRONMENTAL CONDITIONS SUCH AS: COMBUSTIBLE, OILY, OR HAZARDOUS VAPORS OR DUST; EXCESSIVE MOISTURE OR DIRT; VIBRATION; EXCESSIVE AMBIENT TEMPERATURES. CONSULT AC TECHNOLOGY FOR MORE INFORMATION ON THE SUITABILITY OF A DRIVE TO A PARTICULAR ENVIRONMENT. WARNING! Hazard of electrical shock! The SM-Basic control terminals are not isolated from line voltage! Line voltage is present between the control terminals and ground. Do not touch! Disconnect input power and wait three minutes before making connections to the control terminals. Devices (such as switches, pushbuttons, potentiometers, relays, etc) and wiring connected to the control terminals are hot to ground and must have an insulation rating of at least 240 Vac or a dielectric rating of at least 1500 volts to prevent damage to equipment and/or injury to personnel. SM-Basic models are suitable for UL pollution degree 2 environment only, and MUST be installed in an electrical enclosure which will provide complete mechanical protection and will maintain the internal temperature within the drive s ambient operating temperature rating. All drive models MUST be mounted in a vertical position for proper heatsink cooling. Maintain a minimum spacing around the drive of at least one inch on each side and two inches on the top and bottom. Allow more spacing if the drive is mounted next to other heat-producing equipment. Do not mount drives above other drives or heat producing equipment. Fans or blowers should be used to insure proper cooling in tight quarters. In order to properly size an enclosure, the heat generated by the drive(s) must be known. Refer to the HEAT LOSS column in Section SM-Basic RATINGS. An enclosure manufacturer can then determine the required enclosure size based on the total heat generated inside the enclosure (from the drive(s) and other heat sources), the maximum allowable temperature inside the enclosure, the maximum ambient temperature outside the enclosure, and the enclosure properties. The SM-Basic Series is UL approved for solid state motor overload protection. Therefore, a separate thermal overload relay is not required for single motor applications. 5
10 6.1 INSTALLATION AFTER A LONG PERIOD OF STORAGE WARNING! Severe damage to the drive can result if it is operated after a long period of storage or inactivity without reforming the DC bus capacitors! If input power has not been applied to the drive for a period of time exceeding three years (due to storage, etc), the electrolytic DC bus capacitors within the drive can change internally, resulting in excessive leakage current. This can result in premature failure of the capacitors if the drive is operated after such a long period of inactivity or storage. In order to reform the capacitors and prepare the drive for operation after a long period of inactivity, apply input power to the drive for 8 hours prior to actually operating the motor. 6.2 EXPLOSION PROOF APPLICATIONS Explosion proof motors that are not rated for inverter use lose their certification when used for variable speed. Due to the many areas of liability that may be encountered when dealing with these applications, the following statement of policy applies: Leeson Electric Corporation inverter products are sold with no warranty of fitness for a particular purpose or warranty of suitability for use with explosion proof motors. Leeson Electric Corporation accepts no responsibility for any direct, incidental or consequential loss, cost, or damage that may arise through the use of its AC inverter products in these applications. The purchaser expressly agrees to assume all risk of any loss, cost, or damage that may arise from such application. Leeson Electric Corporation or Leeson Electric Corporation s engineering department will not knowingly approve applications involving explosion proof motors. 6
11 7.0 INPUT AC POWER REQUIREMENTS WARNING! Hazard of electrical shock! Capacitors retain charge after power is removed. Disconnect incoming power and wait until the voltage between terminals B+ and B- is 0 VDC before servicing the drive. The input voltage must match the nameplate voltage rating of the drive. Voltage fluctuation must not vary by greater than 10% overvoltage or 15% undervoltage. NOTE: Drives with dual input voltage ratings must be programmed for the proper supply voltage (refer to Parameter 01 - LINE VOLTAGE SELECTION in Section DESCRIPTION OF PARAMETERS). The drive is suitable for use on a circuit capable of delivering not more than 5,000 RMS symmetrical amperes at the drive s rated voltage. Three phase voltage imbalance must be less than 2.0% phase to phase. Excessive phase to phase imbalance can cause severe damage to the drive. Motor voltage should match line voltage in normal applications. The drive s maximum output voltage will equal the input voltage. Use extreme caution when using a motor with a voltage rating which is different from the input line voltage. 7.1 INPUT VOLTAGE RATINGS SM-Basic Series drives are rated for 120/208/240 Vac, single phase, Hz input. The drive will function with input voltage of 120 Vac (+10%, -15%), at 48 to 60 Hz, or with input voltage of 208 to 240 Vac (+ 10%, - 15%), at 48 to 62 Hz. SM-Basic Series drives are rated for 208/240 Vac, single phase, Hz input. The drive will function with input voltages of 208 to 240 Vac (+10%, -15%), at 48 to 62 Hz. SM-Basic Series drives are rated for 208/240 Vac, three phase, Hz input. The drive will function with input voltages of 208 to 240 Vac (+ 10%, - 15%), at 48 to 62 Hz. NOTE: Parameter 01 - LINE VOLTAGE SELECTION must be programmed according to the applied input voltage. See Section DESCRIPTION OF PARAMETERS. 7.2 INPUT FUSING AND DISCONNECT REQUIREMENTS A circuit breaker or a disconnect switch with fuses must be provided in accordance with the National Electric Code (NEC) and all local codes. The SM-Basic drive is capable of withstanding up to 150% current overload for 60 seconds. Select a fuse or magnetic trip circuit breaker rated at 1.5 times the input current rating of the drive (the minimum fuse size should be 10 amps, regardless of input current rating). Refer to Section SM-Basic RATINGS. 7
12 Minimum voltage rating of the protection device should be 250 Vac for 120/208/240 Vac and 208/ 240 Vac rated drives. UL Class CC fast-acting, current limiting type fuses should be used when input fusing is required. Select fuses with low I 2 T values, rated at 200,000 AIC. Recommended fuses are Bussman KTK-R. Similar fuses with equivalent ratings by other manufacturers may also be acceptable. 8.0 POWER WIRING WARNING! Hazard of electrical shock! Capacitors retain charge after power is removed. Disconnect incoming power and wait until the voltage between terminals B+ and B- is 0 VDC before servicing the drive. Note drive input and output current ratings and check applicable electrical codes for required wire type and size, grounding requirements, over-current protection, and incoming power disconnect, before wiring the drive. Size conservatively to minimize voltage drop. Strip off 0.20 to 0.25 inches of insulation for input power, output power, and DC Bus wiring. The input power, output power, and DC Bus terminals must be tightened to a torque of 4.0 to 4.5 lb-in. Input fusing and a power disconnect switch or contactor MUST be wired in series with terminals L1, L2, and L3 for three phase input models. For 208/240 Vac single phase input models, use terminals L1 and L2. For 120 Vac single phase input models, use terminals L1 and N. This disconnect must be used to power down the drive when servicing, or when the drive is not to be operated for a long period of time, but should not be used to start and stop the motor. Repetitive cycling of a disconnect or input contactor (more than once every two minutes) may cause damage to the drive. 8.1 WIRING FOR SINGLE PHASE OR THREE PHASE INPUT If the drive is rated for 120/208/240 Vac single phase input, wire the input to terminals L1 and N for 120 Vac voltage, or wire to terminals L1 and L2 (do not wire to N) for 208/240 Vac input voltage. Refer to Section SM-Basic POWER WIRING DIAGRAM. If the drive is rated for 208/240 Vac single phase input, wire the input to terminals L1 and L2. If the drive is rated for three phase input, wire the input to terminals L1, L2, and L3. All three power output wires, from terminals T1, T2, and T3 to the motor, must be kept tightly bundled and run in a separate conduit away from all other power and control wiring. Do not install contactors or disconnects between the drive and motor without consulting Leeson Electric Corporation for more information. 8
13 9.0 SM-Basic POWER WIRING DIAGRAM THREE PHASE INPUT (where applicable) 120 Vac SINGLE PHASE INPUT (where applicable) L1 L2 L3 L1 L2 N 208/240 Vac SINGLE PHASE INPUT (where applicable) OUTPUT (ALL) T1 T2 T3 B- B+ L1 L2 L3* 3 PHASE AC MOTOR + DC BUS VOLTAGE WARNING! Do not connect incoming AC power to output terminals T1, T2, or T3. Severe damage to the drive will result. NOTES: 1. WIRE AND GROUND IN ACCORDANCE WITH NEC OR CEC, AND ALL APPLICABLE LOCAL CODES. 2. Motor wires MUST be run in a separate steel conduit away from control wiring and incoming AC power wiring. 3. Do not install contactors between the drive and the motor without consulting Leeson Electric Corporation for more information. Failure to do so may result in drive damage. 4. Use only UL and CSA listed and approved wire. 5. Minimum wire voltage ratings: 300 V for 120, 208 and 240 Vac systems. 6. Wire gauge must be based on a minimum of 125% of the rated input/output current of the drive, and a minimum 75 C insulation rating. Use copper wire only. 7. Strip off 0.20 to 0.25 inches of insulation for input power, output power, and DC Bus wiring. 9
14 10.0 CONTROL WIRING WARNING! Hazard of electrical shock! The SM-Basic control terminals are not isolated from line voltage! Line voltage is present between the control terminals and ground. Do not touch! Disconnect input power and wait three minutes before making connections to the control terminals. Devices (such as switches, pushbuttons, potentiometers, relays, etc) and wiring connected to the control terminals are hot to ground and must have an insulation rating of at least 240 Vac or a dielectric rating of at least 1500 volts to prevent damage to equipment and/or injury to personnel CONTROL WIRING VS. POWER WIRING External control wiring MUST be run in a separate conduit away from all other input and output power wiring. If control wiring is not kept separate from power wiring, electrical noise may be generated on the control wiring that will cause erratic drive behavior. Use twisted wires or shielded cable rated for 300 VDC minimum (do not ground the shield) SURGE SUPPRESION ON RELAYS Current and voltage surges and spikes in the coils of contactors, relays, and solenoids, near or connected to the drive, can cause erratic drive operation. Snubbers should be used on any coils associated with the drive. For AC loads, snubbers should consist of a resistor and a capacitor in series across the coil. For DC loads, a free-wheeling or flyback diode should be placed across the coil START/STOP CONTROL There are various control schemes that allow for 2-wire and 3-wire Start/Stop circuits. Refer to the wiring diagrams in Section SM-Basic CONTROL WIRING DIAGRAMS SPEED REFERENCE SIGNALS SPEED POT Connect the wiper to terminal TB-5, and connect the high and low end leads to terminals TB-6 and TB-3, respectively. The speed pot can be 5kΩ up to 10kΩ VDC Wire the positive to terminal TB-5 and the negative to terminal TB-3. The 0-10 VDC signal must be isolated, as the control terminals are at line voltage potential. DO NOT connect the low side of the speed pot or 0-10 VDC signal to ground. 10
15 10.5 SPEED REFERENCE SELECTION If a speed pot is to be used to control the drive speed, terminal TB-13A, 13B, or 13C (Parameter 10, 11, or 12) may be programmed as the input select for the speed pot. When that TB-13 terminal is then closed to TB-11, the drive will follow the speed pot input. If the speed pot is not selected on the terminal strip using TB-13A, 13B, or 13C, speed control will default to STANDARD mode, which is governed by the setting of Parameter 05 - STANDARD SPEED SOURCE. The STANDARD SPEED SOURCE can be the s and t buttons on the front of the drive, PRESET SPEED #1 (Parameter 31), or a speed pot. PRESET SPEEDS TB-13A can be programmed to select PRESET SPEED #1, TB-13B to select PRESET SPEED #2, and TB-13C to select PRESET SPEED #3. There are a total of seven preset speeds, which are activated by different combinations of contact closures between TB-13A, 13B, 13C and TB-11. Refer to Parameters in Section DESCRIPTION OF PARAMETERS. JOG TB-13B can be programmed to select either JOG FORWARD or JOG REVERSE. The Jog speed is set by PRESET SPEED #2. Close TB-13B to TB-11 to JOG, and open the contact to STOP. WARNING! When operating in JOG mode, the STOP signal and the AUXILIARY STOP function (see Parameters 10-12) WILL NOT stop the drive. To stop the drive, remove the JOG command. JOG REVERSE will operate the drive in reverse rotation even if ROTATION DIRECTION (Parameter 17) is set to FORWARD ONLY. NOTE: If the drive is commanded to JOG while running, the drive will enter JOG mode and run at PRESET SPEED #2. When the JOG command is removed, the drive will STOP. MOTOR OPERATED POT (MOP) / FLOATING POINT CONTROL TB-13B and TB-13C are required for this function, which controls the drive speed using normally open contacts wired to the terminal strip. Program TB-13B for DECREASE FREQ, and program TB-13C for INCREASE FREQ. Closing the contacts between the TB-13 terminals and TB-11 will cause the speed setpoint to increase or decrease until the contact is opened. The INCREASE FREQ function will only operate while the drive is running. NOTE: If TB-13A, TB-13B, and TB-13C are all programmed to select speed references, and two or three of the terminals are closed to TB-11, the higher terminal has priority and will override the others. For example, if TB-13A is programmed to select a speed pot, and TB-13C is programmed to select PRESET SPEED #3, closing both terminals to TB-11 will cause the drive to respond to PRESET SPEED #3, because TB-13C overrides TB-13A. 11
16 10.7 DRIVE STATUS DIGITAL OUTPUTS There is one open-collector output at terminal TB-14. The open-collector circuit is a current-sinking type rated at 30 VDC and 50 ma maximum. The open-collector output can be programmed to indicate any one of the following: RUN, FAULT, INVERSE FAULT, FAULT LOCKOUT, AT SPEED, ABOVE PRESET SPEED #3, CURRENT LIMIT, AUTO SPEED MODE, and REVERSE. Refer to Parameter 06 in Section DESCRIPTION OF PARAMETERS. DIODE SNUBBER (RECOMMENDED) SCN TERMINAL STRIP TB-11 TB-14 RELAY COIL WARNING! Hazard of electrical shock! The SCN control terminals are not isolated from line voltage! Line voltage is present between the control terminals and ground. Do not touch! Only use relays with an insulation rating of at least 240 Vac or a dielectric rating of at least 1500 volts to prevent damage to equipment and/or injury to personnel. NOTE: When the optional remote keypad is used, TB-14 is wired to the remote keypad and cannot be used for status indication. 12
17 11.0 SM-Basic CONTROL WIRING DIAGRAMS 11.1 TWO-WIRE START/STOP CONTROL WARNING! Hazard of electrical shock! The SM-Basic control terminals are not isolated from line voltage! Line voltage is present between the control terminals and ground. Do not touch! Disconnect input power and wait three minutes before making connections to the control terminals. Devices (such as switches, pushbuttons, potentiometers, relays, etc) and wiring connected to the control terminals are hot to ground and must have an insulation rating of at least 240 Vac or a dielectric rating of at least 1500 volts to prevent damage to equipment and/or injury to personnel A 13B 13C 14 RUN SPEED POT COMMON SPEED POT INPUT SPEED POT POWER SUPPLY DIGITAL INPUT REFERENCE TB-13A FUNCTION SELECT (RUN REVERSE) TB-13B FUNCTION SELECT TB-13C FUNCTION SELECT OPEN-COLLECTOR OUTPUT SPEED POT NOTES: MAINTAINED RUN/STOP CONTACT (FORWARD) MAINTAINED RUN/STOP CONTACT (REVERSE) 1. Close TB-1 to TB-11 to RUN, and open to STOP. TB-1 functions as a RUN input for two-wire start/stop circuits, and a STOP input for three-wire start/stop circuits. Refer to Section If reverse direction is required, set ROTATION (Parameter 17) to FORWARD AND REVERSE (02), and program TB-13A (Parameter 10) to RUN REVERSE (05). Close TB-13A to TB-11 to RUN in the reverse direction, and open to STOP. 3. For speed pot control, set STANDARD SPEED SOURCE (Parameter 05) to SPEED POT (03). 13
18 11.2 THREE-WIRE START/STOP CONTROL WARNING! Hazard of electrical shock! The SM-Basic control terminals are not isolated from line voltage! Line voltage is present between the control terminals and ground. Do not touch! Disconnect input power and wait three minutes before making connections to the control terminals. Devices (such as switches, pushbuttons, potentiometers, relays, etc) and wiring connected to the control terminals are hot to ground and must have an insulation rating of at least 240 Vac or a dielectric rating of at least 1500 volts to prevent damage to equipment and/or injury to personnel A 13B 13C 14 STOP SPEED POT COMMON SPEED POT INPUT SPEED POT POWER SUPPLY DIGITAL INPUT REFERENCE TB-13A FUNCTION SELECT (START REVERSE) TB-13B FUNCTION SELECT TB-13C FUNCTION SELECT (START FORWARD) OPEN-COLLECTOR OUTPUT SPEED POT REV FWD MOMENTARY STOP CONTACT MOMENTARY START CONTACT NOTES: 1. Program TB-13C (Parameter 12) for START FORWARD (05). 2. If reverse direction is required, set ROTATION (Parameter 17) to FORWARD AND REVERSE (02), and program TB-13A (Parameter 10) for START REVERSE (06). 3. Momentarily close TB-13C to TB-11 to START in the forward direction, or close TB-13A to TB-11 to START in the reverse direction. Momentarily open TB-1 to TB-11 to STOP the drive. 4. For speed pot control, set STANDARD SPEED SOURCE (Parameter 05) to SPEED POT (03). 14
19 11.3 PRESET SPEEDS (WITH TWO-WIRE START/STOP CONTROL) WARNING! Hazard of electrical shock! The SM-Basic control terminals are not isolated from line voltage! Line voltage is present between the control terminals and ground. Do not touch! Disconnect input power and wait three minutes before making connections to the control terminals. Devices (such as switches, pushbuttons, potentiometers, relays, etc) and wiring connected to the control terminals are hot to ground and must have an insulation rating of at least 240 Vac or a dielectric rating of at least 1500 volts to prevent damage to equipment and/or injury to personnel A 13B 13C 14 RUN SPEED POT COMMON SPEED POT INPUT SPEED POT POWER SUPPLY DIGITAL INPUT REFERENCE TB-13A FUNCTION SELECT (PRESET SPEED #1) TB-13B FUNCTION SELECT (PRESET SPEED #2) TB-13C FUNCTION SELECT (PRESET SPEED #3) OPEN-COLLECTOR OUTPUT SPEED POT MAINTAINED RUN/STOP CONTACT NOTES: 1. For preset speed control, all or some of the TB-13 terminals must be programmed as preset speed selects. If only two or three preset speeds are required, only two of the TB-13 terminals must be used. Refer to the table in the description of Parameters in Section Program the PRESET SPEEDS (Parameters 31-37) to the desired values. 3. If speed pot control is desired when none of the preset speeds are selected (all preset speed selects are open to TB-11), set STANDARD SPEED SOURCE (Parameter 05) to SPEED POT (03). 15
20 12.0 INITIAL POWER UP AND MOTOR ROTATION WARNING! DO NOT connect incoming AC power to output terminals T1, T2, and T3! Severe damage to the drive will result. Do not continuously cycle input power to the drive more than once every two minutes. Damage to the drive will result. WARNING! Hazard of electrical shock! The SM-Basic control terminals are not isolated from line voltage! Line voltage is present between the control terminals and ground. Do not touch! Capacitors retain charge after power is removed. Disconnect input power and wait until the voltage between terminals B+ and B- is 0 VDC before making control connections or servicing the drive. WARNING! Severe damage to the drive can result if it is operated after a long period of storage or inactivity without reforming the DC bus capacitors! If input power has not been applied to the drive for a period of time exceeding three years (due to storage, etc), the electrolytic DC bus capacitors within the drive can change internally, resulting in excessive leakage current. This can result in premature failure of the capacitors if the drive is operated after such a long period of inactivity or storage. In order to reform the capacitors and prepare the drive for operation after a long period of inactivity, apply input power to the drive for 8 hours prior to actually operating the motor. Before attempting to operate the drive, motor, and driven equipment, be sure all procedures pertaining to installation and wiring have been properly followed. If possible, disconnect the driven load from the motor. Verify that the drive input terminals (L1, L2, and L3 or N) are wired to the proper input voltage per the nameplate rating of the drive. Energize the incoming power line. The LED display will flash a two-digit number (15 in the example below) that identifies the parameter version contained in the drive ("15" actually means parameter version 315). The display should then read - -", which indicates that the drive is in a STOP condition. This is shown below: Apply input power Display flashes parameter version (00-99) Display then reads "- -" 16
21 Follow the procedure below to check the motor rotation. This procedure assumes that the drive has been powered up for the first time, and that none of the parameters have been changed. 1. Use the t button to decrease the speed setpoint to 0 Hz. The left decimal point will illuminate as the speed setpoint is decreased. Once 0 Hz is reached, the display will toggle between 00 and - -, which indicates that the drive is in a STOP condition with a speed setpoint of 0 Hz. 2. Give the drive a START command. This can be done using one of several wiring methods described in Section SM-Basic CONTROL WIRING DIAGRAMS. Once the START command is issued, the display will read 00, indicating that the drive is in a RUN condition with a speed setpoint of 0 Hz. 3. Use the s button to increase the speed setpoint until the motor starts to rotate. The left decimal point will light as the speed setpoint is increased. 4. If the motor is rotating in the wrong direction, give the drive a STOP command and remove power from the drive. Wait three minutes for the bus capacitors to discharge, and swap any two of the motor wires connected to T1, T2, and T3. NOTE: The drive is phase insensitive with respect to incoming line voltage. This means that the drive will operate with any phase sequence of the incoming three phase voltage. Therefore, to change the motor rotation, the phases must be swapped at the drive output terminals or at the motor. 17
22 13.0 PROGRAMMING THE SM-Basic DRIVE The drive may be programmed by one of two methods: using the three buttons and 2-digit LED display on the front of the drive, or programming the Electronic Programming Module (EPM) using the optional EPM Programmer. This section describes programming the drive using the buttons and display, which are shown below: BUTTONS DISPLAY Mode To enter the PROGRAM mode to access the parameters, press the Mode button. This will activate the PASSWORD prompt (if the password has not been disabled). The display will read 00 and the upper right-hand decimal point will be blinking, as shown below: Press Mode Display reads "00" Right decimal point blinks Use the s and t buttons to scroll to the password value (the factory default password is 25 ) and press the Mode button. Once the correct password value is entered, the display will read "01", which indicates that the PROGRAM mode has been accessed at the beginning of the parameter menu (01 is the first parameter), and the upper right decimal point will turn on solid. This is shown below: Use s and t to scroll to the password value Press Mode to enter password Parameter menu is accessed at the first parameter Upper right decimal point turns on solid. 18
23 NOTE: If the display flashes Er, the password was incorrect, and the process to enter the password must be repeated. Use the s and t buttons to scroll to the desired parameter number. In the example below, Parameter 19 is being displayed, which is the ACCELERATION TIME of the drive: Use s and t to scroll to the desired parameter number Once the desired parameter number is found, press the Mode button to display the present parameter setting. The upper right-hand decimal point will begin blinking, indicating that the present parameter setting is being displayed, and that it can be changed by using the s and t buttons. Press Mode to display present parameter setting (present example setting is 15) Right decimal point blinks Use s and t to change setting (example setting changed to 30) Press Mode to store new setting Pressing the Mode will store the new setting and also exit the PROGRAM mode. To change another parameter, press the Mode key again to re-enter the PROGRAM mode (the parameter menu will be accessed at the parameter that was last viewed or changed before exiting). If the Mode key is pressed within two minutes of exiting the PROGRAM mode, the password is not required access the parameters. After two minutes, the password must be entered in order to access the parameters again. 19
24 13.2 ELECTRONIC PROGRAMMING MODULE (EPM) Every SM-Basic Series drive has an Electronic Programming Module (EPM) installed on the main control board. The EPM stores the user s parameter settings and special OEM default settings (if programmed). The EPM is removable, allowing it to be installed in another drive for quick set-up. For example, if a drive is being replaced with a new one, the EPM can be taken out of the first drive and installed in the new drive. Downtime is minimized because the new drive does not require programming - it is ready to run when the EPM is installed. The SM-Basic Series drive contains two or three sets of parameter values, depending on whether the drive has been programmed with optional OEM default settings. The first set of values is the factory default settings, which are permanently stored on the main control board and cannot be changed. The second set of values is the user settings, which are stored in the EPM. When the drive leaves the factory, the user settings are the same as the factory default settings, but the user settings can be changed to configure the drive for a particular application. The optional third set of values is the OEM default settings, which are also stored in the EPM. OEM default settings are typically used in cases where many drives are used for the same application, which requires that all of the drives have the same parameter settings. The OEM default settings cannot be changed without the optional EPM Programmer. The drive can be programmed to operate according to the user settings or the OEM default settings (see Parameter 48 in Section 15.0). NOTE: The drive will not operate without the EPM installed. The drive will display F1 if the EPM is missing or damaged. WARNING! Do not remove the EPM while power is applied to the drive. Damage to the EPM and/or drive may result. An EPM Programmer is available as an option from SM-Basic, which has the ability to quickly and easily program many SM-Basic drives for the same configuration. Once a master EPM is programmed with the desired parameter settings, the EPM Programmer can copy those settings to other EPMs, allowing many drives to be configured very quickly. Please consult the EPM Programmer Instruction Manual or contact the factory for more information. If the OEM settings in the EPM become corrupted, the drive will operate normally, until an attempt is made to perform a RESET OEM using Parameter 48 - PROGRAM SELECTION. The drive will then flash GF to indicate that the OEM settings are no longer valid. This will require that the EPM be re-programmed using the optional EPM Programmer. If the OEM settings and the user settings are both corrupted, the drive will display GF immediately and the drive will require a RESET 60 or RESET 50 using Parameter 48 - PROGRAM SELECTION. Once the RESET is performed, the parameters can then be programmed individually to match the OEM default settings. This will allow the drive to operate as if it were in OEM mode, even though it is actually operating in USER mode. Refer to Parameter 48 in Section DESCRIPTION OF PARAMETERS. NOTE: The drive will also display GF if a RESET OEM or OPERATE WITH OEM SETTINGS is attempted when the drive is not equipped with the OEM default option. 20
25 14.0 PARAMETER MENU FACTORY NO. PARAMETER NAME RANGE OF ADJUSTMENT DEFAULT (NOTE 1) 01 LINE VOLTAGE HIGH (01), LOW (02) HIGH (01) 02 CARRIER FREQUENCY 4kHz (01), 6 khz (02), 8 khz (03), 10 khz (04) 6 khz (02) 03 START METHOD NORMAL (01), START ON POWER UP (02), NORMAL (01) START WITH DC BRAKE (03), AUTO RESTART WITH DC BRAKE (04), FLYING RESTART 1 (05), FLYING RESTART 2 (06), FLYING RESTART 3 (07) 04 STOP METHOD COAST (01), COAST WITH DC BRAKE (02), COAST (01) RAMP (03), RAMP WITH DC BRAKE (04) 05 STANDARD SPEED KEYPAD (01), PRESET #1 (02), KEYPAD (01) SOURCE SPEED POT (03) 06 TB-14 OUTPUT NONE (01), RUN (02), FAULT (03), NONE (01) INVERSE FAULT (04), FAULT LOCKOUT (05), AT SET SPEED (06), ABOVE PRESET #3 (07), CURRENT LIMIT (08), AUTO SPEED (09), REVERSE (10), DB BRAKE (11) 10 TB-13A FUNCTION NONE (01), SPEED POT (02), NONE (01) SELECT PRESET SPEED #1 (03), START FORWARD (04), RUN REVERSE (05), START REVERSE (06), EXTERNAL FAULT (07), DB FAULT (08), AUXILIARY STOP (09), ACCEL/DECEL #2 (10) 11 TB-13B FUNCTION NONE (01), SPEED POT (02), NONE (01) SELECT PRESET SPEED #2 (03), DECREASE FREQ (04), JOG FORWARD (05), JOG REVERSE (06), EXTERNAL FAULT (07), DB FAULT (08), AUXILIARY STOP (09), ACCEL/DECEL #2 (10) 12 TB-13C FUNCTION NONE (01), SPEED POT (02), NONE (01) SELECT PRESET SPEED #3 (03), INCREASE FREQ (04), START FORWARD (05), EXTERNAL FAULT (06), DB FAULT (07), AUXILIARY STOP (08), ACCEL/DECEL #2 (09) NOTE 1: Factory defaults are shown for a 60 Hz base frequency. See Parameter 48 for 50 Hz base frequency. 21
26 FACTORY NO. PARAMETER NAME RANGE OF ADUSTMENT DEFAULT (NOTE 1) 14 CONTROL TERMINAL STRIP ONLY (01), TERMINAL STRIP REMOTE KEYPAD ONLY (02) ONLY (01) 17 ROTATION FORWARD ONLY (01), FORWARD FORWARD AND REVERSE (02) ONLY (01) 18 TIME RANGE SELECT x0.1 (01), x1.0 (02), x10.0 (03) x1.0 (02) 19 ACCELERATION TIME SEC 20 SEC 20 DECELERATION TIME SEC 20 SEC 21 DC BRAKE TIME SEC 0 SEC 22 DC BRAKE VOLTAGE 0-30 % 0 % 23 MINIMUM FREQUENCY 0 - MAXIMUM FREQUENCY 0 Hz 24 MAXIMUM FREQUENCY MINIMUM FREQUENCY - 99 Hz 60 Hz 25 CURRENT LIMIT % (NOTE 2) 180 % 26 MOTOR OVERLOAD % 100 % 27 BASE FREQUENCY Hz 60 Hz 28 FIXED BOOST 0-30 % 1 % 29 ACCEL BOOST 0-20 % 0 % 30 SLIP COMPENSATION % 0 % PRESET SPEEDS 0 - MAXIMUM FREQUENCY 0 Hz 38 SKIP BANDWIDTH 0-10 Hz 0 Hz 42 ACCEL / DECEL # SEC 20 SEC 44 PASSWORD CLEAR HISTORY MAINTAIN (01), CLEAR (02) MAINTAIN (01) 48 PROGRAM USER SETTINGS (01), OEM SETTINGS (02), USER SELECTION RESET OEM (03), RESET 60 (04), SETTINGS (01) RESET 50 (05), TRANSLATE (06) 50 FAULT HISTORY (VIEW-ONLY) (N/A) 51 SOFTWARE CODE (VIEW-ONLY) (N/A) 52 DC BUS VOLTAGE (VIEW-ONLY) (N/A) 53 MOTOR VOLTAGE (VIEW-ONLY) (N/A) 54 LOAD (VIEW-ONLY) (N/A) 55 SPEED POT INPUT (VIEW-ONLY) (N/A) 57 TB STRIP STATUS (VIEW-ONLY) (N/A) 58 KEYPAD STATUS (VIEW-ONLY) (N/A) NOTE 1: Factory defaults are shown for a 60 Hz base frequency. See Parameter 48 for 50 Hz base frequency. NOTE 2: If LINE VOLTAGE is set to LOW, maximum setting is 150%. 22
27 15.0 DESCRIPTION OF PARAMETERS 01 LINE VOLTAGE SELECTION This calibrates the drive for the actual applied input voltage, and can be set to HIGH (01) or LOW (02). Refer to the table below for the proper setting depending on the input voltage. RATED INPUT INPUT APPLIED PLIED INPUT PARAMETERR MODEL VOLTAGE PHASE VOLTAGE SETTING SN100S 120 / 208 / 240 Vac Vac or Vac HIGH (01) Vac LOW (02) N 0S 208 / 240 Vac 1 or Vac HIGH (01) 1 or Vac LOW (02) SN / 240 Vac Vac HIGH (01) Vac LOW (02) NOTE: If this parameter is changed while the drive is running, the new value will not take effect until the drive is stopped. 02 CARRIER FREQUENCY This sets the switching rate of the output IGBT s. Increasing the carrier frequency will result in less audible motor noise. Available settings are: 4 khz, 6 khz, 8 khz, and 10 khz. PARAMETER CARRIER MAXIMUM OUTPUT AMBIENT OR OUTPUT SETTING FREQUENCY FREQUENCY DERATE (NOTE 2) 01 4 khz 99 Hz 50 C or 100% 02 6 khz 99 Hz 50 C or 100% 03 8 khz 99 Hz 43 C or 92% khz 99 Hz 35 C or 82% NOTE 1: The SM-Basic drive is fully rated up to 6 khz carrier frequency. If the 8 khz or 10 khz carrier frequency is selected, the drive s ambient temperature rating OR output current rating must be de-rated to the value shown in the table above. NOTE 2: If this parameter is changed while the drive is running, the change will not take effect until the drive is stopped. 23
28 03 START METHOD WARNING! Automatic starting of equipment may cause damage to equipment and/or injury to personnel! Automatic start should only be used on equipment that is inaccessible to personnel. 01 NORMAL: The drive will start when the appropriate contact is closed on the terminal strip. See Section 11 for possible control configurations. 02 START ON POWER UP: The drive will automatically start upon application of input power. 03 START WITH DC BRAKE: When a START command is given, the drive will apply DC BRAKE VOLTAGE (Parameter 22) for the duration of DC BRAKE TIME (Parameter 21) prior to starting the motor to ensure that the motor is not turning. 04 AUTO RESTART WITH DC BRAKING: Upon a START command, after a fault, or upon application of power, the drive will apply DC BRAKE VOLTAGE (Parameter 22) for the duration of DC BRAKE TIME (Parameter 21) prior to starting (or restarting) the motor. 05 FLYING RESTART 1: LOW performance. Slowest synchronization and lowest current level. This setting results in the smoothest synchronization. 06 FLYING RESTART 2: MEDIUM performance. Faster synchronization and higher current level. This setting allows faster synchronization while retaining smoothness. 07 FLYING RESTART 3: HIGH performance. Fastest synchronization and highest current level. This setting allows the fastest synchronization, but sacrifices smoothness. When programmed for auto-restart (settings 04-07), the drive will attempt three restarts after a fault. The interval between restart attempts is 15 seconds for setting 04, and 2 seconds for settings 05, 06 and 07. During the interval between restart attempts, the display will read SP to indicate Start Pending. If all three restart attempts fail, the drive will trip into FAULT LOCKOUT (displayed LC ) and require a manual reset. Refer to Section TROUBLESHOOTING. The FLYING RESTART 1-3 settings allow the drive to start into a spinning load after a fault or upon application of input power. They differ in the time required to find the motor and the amount of current required to synchronize with it. The faster the drive attempts to find the motor, the more current is required. The first two restart attempts will try to start into the spinning load, but the third restart attempt will act like AUTO RESTART WITH DC BRAKING. NOTE: Settings 02 and require a two-wire start/stop circuit to operate. The RUN contact must remain closed for the power-up start and auto-restart functions to operate. 24
29 04 STOP METHOD 01 COAST TO STOP: When a STOP command is given, the drive shuts off the output to the motor, allowing it to coast freely to a stop. 02 COAST WITH DC BRAKE: When a stop command is given, the drive will activate DC braking (after a delay of up to 2 seconds, depending on frequency) to help decelerate the load. Refer to Parameters: 21 - DC BRAKE TIME, and 22 - DC BRAKE VOLTAGE. 03 RAMP TO STOP: When a stop command is given, the drive will decelerate the motor to a stop at the rate determined by Parameter 20 - DECELERATION TIME. 04 RAMP WITH DC BRAKE: When a stop command is given, the drive will decelerate the motor down to 0.2 Hz (at the rate set by Parameter 20 - DECELERATION TIME) and then activate DC braking according to the settings of Parameters 21 - DC BRAKE TIME and 22 - DC BRAKE VOLTAGE. This is used to bring the load to a final stop, as the motor may still be turning slightly after the drive stops. 05 STANDARD SPEED SOURCE This selects the speed reference source when the drive is in STANDARD speed mode. The following speed references can be selected: 01 KEYPAD: Use the s and t buttons to scroll to the desired speed. 02 PRESET SPEED #1: The drive will operate at the frequency set into Parameter SPEED POT: The drive will respond to a speed pot. Refer to Section 11.0 for speed pot wiring. 06 TB-14 OPEN COLLECTOR OUTPUT This selects the status indication for the open-collector output at TB-14. The terms open and close refer to the state of the internal transistor that activates the circuit. When the transistor is closed, TB-14 is at the same potential as TB-2, allowing current to flow. 01 NONE: Disables the open-collector output. 02 RUN: Closes upon a START command. Opens if the drive is in a STOP state, the drive faults, or input power is removed. DC braking is considered a STOP state. 03 FAULT: Closes if there is no fault condition. Opens if the drive faults, or input power is removed. 04 INVERSE FAULT: Closes if the drive faults. Opens if there is no fault condition. 05 FAULT LOCKOUT: Closes when input power is applied. Opens if three restart attempts are unsuccessful, or if input power is removed. 25
30 06 AT SET SPEED: Closes if the drive is within Hz of the speed setpoint. 07 ABOVE PRESET SPEED #3: Closes if the output frequency exceeds PRESET SPEED #3 (Parameter 33). Opens if the output frequency is equal to or less than PRESET SPEED #3. 08 CURRENT LIMIT: Closes if the output current exceeds the CURRENT LIMIT setting. Opens if the output current is equal to or less than CURRENT LIMIT (see Parameter 25). 09 AUTOMATIC SPEED MODE: Closes if an AUTOMATIC (terminal strip) speed reference is active. Opens if a STANDARD (Parameter 5) speed reference is active. 10 REVERSE: Closes when reverse rotation is active. Opens when forward rotation is active (see Parameter 17 - ROTATION DIRECTION). 11 DB BRAKE: TB-14 becomes the "trigger" that activates the optional external Dynamic Braking module. Refer to the instructions included with the Dynamic Braking option. NOTE: If the optional remote keypad is used, TB-14 is wired to the remote keypad and cannot be used for any of the above listed functions. In this case, this parameter should be set to NONE (01). 10 TB-13A FUNCTION SELECT This selects the function of terminal TB-13A. Closing TB-13A to TB-11 (or opening in the case of settings 07 and 09) activates the selected function. The following functions can be selected: 01 NONE: Disables the TB-13A function. 02 SPEED POT: Selects a speed pot as the speed reference input. Refer to Section 11.0 for speed pot wiring. 03 PRESET SPEED #1: Selects PRESET SPEED #1 as the speed reference. The drive will operate at the frequency programmed into Parameter START FORWARD: Sets up the drive for a 3-wire start/stop circuit. Momentarily close TB- 13A to TB-11 to start the drive, and momentarily open TB-1 to TB-11 to stop. 05 RUN REVERSE: Close TB-13A to TB-11 to run in the reverse direction, and open to stop. Close TB-1 to TB-11 to run in the forward direction and open to stop. 06 START REVERSE: Momentarily close TB-13A to TB-11 to start the drive in the reverse direction, and momentarily open TB-1 to TB-11 to stop. Parameter 17 - ROTATION must be set to FORWARD AND REVERSE (02), and TB-13C must be used for START FORWARD. 07 EXTERNAL FAULT: Sets TB-13A as a normally closed external fault input. Open TB-13A to TB-11 to trip the drive. 26
31 08 DB FAULT: Sets TB-13A as a dynamic braking fault input when used with the optional dynamic braking module. When this input is activated by the dynamic braking module, the drive will trip into a "df" fault and the motor will coast to a stop. Refer to the instructions included with the Dynamic Braking option. 09 AUXILIARY STOP: When TB-13A is opened with respect to TB-11, the drive will decelerate to a STOP (even if STOP METHOD is set to COAST) at the rate set into ACCEL/DECEL #2 (Parameter 42). 10 ACCEL/DECEL #2: Selects the acceleration and deceleration time programmed into ACCEL/ DECEL #2 (Parameter 42). NOTE: If the optional remote keypad is used, functions 02, 04, 05, and 06 are disabled. Therefore, if this terminal is not being used for any of the other functions, it should be set to NONE (01). 11 TB-13B FUNCTION SELECT This selects the function of terminal TB-13B. Closing TB-13B to TB-11 (or opening in the case of settings 07 and 09) activates the selected function. The following functions can be selected: 01 NONE: Disables the TB-13B function. 02 SPEED POT: Selects a speed pot as the speed reference input. Refer to Section 11.0 for speed pot wiring. 03 PRESET SPEED #2: Selects PRESET SPEED #2 as the speed reference. The drive will operate at the frequency programmed into Parameter DECREASE FREQ: Closing TB-13B to TB-11 will decrease the speed setpoint until the contact is opened. TB-13C must be programmed for INCREASE FREQ. 05 JOG FORWARD: Close TB-13B to TB-11 to JOG in the forward direction. The drive will run at PRESET SPEED #2 (Parameter 32) when in JOG mode. 06 JOG REVERSE: Close TB-13B to TB-11 to JOG in the reverse direction. The drive will run at PRESET SPEED #2 (Parameter 32) when in JOG mode. WARNING! When operating in JOG mode, the STOP signal and the AUXILIARY STOP function (see Parameters 10-12) WILL NOT stop the drive. To stop the drive, remove the JOG command. JOG REVERSE will operate the drive in reverse rotation even if ROTATION DIRECTION (Parameter 17) is set to FORWARD ONLY. 07 EXTERNAL FAULT: Sets TB-13B as a normally closed external fault input. Open TB-13B to TB-11 to trip the drive. 27
SMVector - Frequency Inverter
SMVector - Frequency Inverter Operating Instructions Contents 1 Safety Information...3 2 Technical Data...5 2.1 Standards and Application Conditions...5 2.2 Ratings...6 2.2.1 NEMA 1 (IP 31) Ratings...6