Rockwell Automation MD60 User Manual

MD60 AC Drive User Manual Version 3.0

Instruction Manual

D2-3499-3

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

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

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

ATTENTION:Identifies information about practices or circumstances that can lead to personal injury or death,

Important: Identifies information that is critical for successful application and

MD60, VS Utilities, and Reliance are trademarks of Rockwell Automation.

property damage, or economic loss.

understanding of the product.

ATTENTION: Only qualified personnel familiar with the construction and operation of this equipment and the hazards involv ed should install, adjust, operate , or service this equipment. Read and understand this document in its entirety before proceeding. Failure to observ e this precaution could result in severe bodily injury or loss of life.

ATTENTION: The drive contains high volt age capacitors that take time to discharge after removal of mains supply. Before working on the drive, ensure isolati on of mains supply from line i nputs [R, S, T (L1, L2, L3)]. Wait three (3) minutes for capacitors to discharge to safe v oltage lev els. Darkened displa y LEDs is not an indication that capacitors ha ve discharged to safe voltage le v els . Failure to observe thi s precaution could result in severe bodily injury or loss of life.

ATTENTION: The drive can operate at and maintain z ero speed. The user is responsible f or assuring safe c onditions fo r operating personnel by providing suitab le guards , audib le or visual alarms, or other devices to indicate that the drive is operating, or may operate, at or near zero speed. Failu re to observe this precaution could result in severe bodily injury or loss of li fe.

ATTENTION: The drive contains ESD- (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing, or repairing the driv e. Erratic machine operation and damage to, or destruction of, equipment can result if this procedure is not f ollowed. Failure to observe this precaution can result in bodily injury.

ATTENTION: The user must provide an external, hardwired emergency stop circuit outside of the drive circu itry . This circuit ry must disable the system in case of improper operation. Uncontrolled machine operation ma y result if this procedure is not followed. Failure to observe this p recaut ion could result in bo dily injury.

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

ATTENTION: An incorrectly applied or installed drive can result in component damage or reduction in product life. Wiring or application errors, such as undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temper atures may result in malfunction of the system.

Chapter 1 Introduction

1.1 Getting Assistance from Reliance Electric..................... 1-1

Chapter 2 About the MD60 Drive

2.1 Identifying the Drive by Model Number.......................... 2-1

2.2 MD60 Drive Ratings, Model Numbers, and Frame

Sizes .............................................................................2-2

2.3 Kits.................................................................................2-3

2.4 Storage Guidelines........................................................2-4

Chapter 3 Mounting the Drive

3.1 General Requirements for the Installation Site.............. 3-1

3.1.1 Operating Conditions........................................... 3-2

3.1.2 Recommended Mounting Clearances .................3-2

3.1.3 Mounting Dimensions for the MD60 Drive........... 3-3

3.2 Mounting the Drive......................................................... 3-4

3.2.1 Protecting the Drive from Debris......................... 3-4

Chapter 4 Grounding the Drive

4.1 RFI Filter Grounding...................................................... 4-2

Chapter 5 Installing Power Wiring

5.1 Opening the Cover......................................................... 5-1

5.2 Verifying Drive AC Input Ratings Match Available

Power...........................................................................5-2

5.2.1 Ungrounded Distribution Systems....................... 5-2

5.2.2 Input Power Conditioning .............. ... ................... 5-4

5.3 Power Wiring Specifications..........................................5-5

5.4 Power Terminal Block Connections ............................... 5-5

5.5 Fuses and Circuit Breakers ........................................... 5-6

5.6 Motor Cable Types Acceptable for 200-600 Volt

Installations ...................................................................5-8

5.7 Reflected Wave Protection............................................5-9

5.8 Output Disconnect.......................................................5-10

CONTENTS

Chapter 6 Installing Control Wiring

6.1 Stop Circuit Requirements.............................................6-1

6.1.1 Compliance with Machinery Safety Standard EN

60204-1:1992...................................................... 6-2

6.2 Motor Start/Stop Precautions......................................... 6-2

6.3 I/O Wiring Recommendations........................................ 6-3

6.3.1 Maximum Cable Length Recommendations........ 6-3

6.4 Wiring the Control Terminal Block................................. 6-4

6.4.1 I/O Wiring Examples............................................6-5

Contents I

6.4.2 Typical Multiple Drive Connection Examples.......6-7

6.5 Start and Speed Reference Control...............................6-8

6.6 Accel/Decel Selection....................................................6-9

Chapter 7 Completing the Installation

7.1 Checking the Installation Before Applying Power to the

Drive ..............................................................................7-1

7.2 Powering Up After Installation is Complete....................7-2

Chapter 8 Using the Integral Keypad to Program and Control the Drive

8.1 Keypad Components .....................................................8-1

8.1.1 Display Description..............................................8-2

8.1.2 LED Descriptions.................................................8-2

8.1.3 Key Descriptions..................................................8-3

8.2 About Parameters................................ ... ... ....................8-4

8.3 How Parameters are Organized ........................... .........8-4

8.4 Viewing and Adjusting Basic (P) and Advanced (A)

Parameters....................................................................8-5

8.5 Viewing the Display (d) Parameters...............................8-6

Chapter 9 Parameter Descriptions

9.1 Basic Program Group Parameters.................................9-2

9.2 Advanced Group Parameters ........................................9-8

9.3 Display Group Parameters...........................................9-27

Chapter 10 Troubleshooting the Drive

10.1Fault Codes..................................................................10-1

10.1.1Manually Clearing Faults...................................10-2

10.1.2Automatically Clearing Faults (Auto Restart

Feature)............................................................10-2

10.2Troubleshooting Tables ................................................10-6

10.2.1Problem: Drive Does Not Start From Terminal Block

Start or Run Inputs ............................................10-6

10.2.2Problem: Drive Does Not Start From Integral

Keypad.............................................................10-7

10.2.3Problem: Drive Does Not Respond to Changes in

Speed Command ................................. .............10-7

10.2.4Problem: Motor and/or Drive Will Not Accelerate to

Commanded Speed ..........................................10-8

10.2.5Problem: Motor Operation is Unstable...............10-8

10.2.6Problem: Drive Will Not Reverse Motor

Direction...........................................................10-9

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

Appendix B Record of User Settings ...................................................B-1

Appendix C Parameters Cross-Referenced by Name ......................... C-1

II MD60 AC Drive User Manual

Appendix D CE Conformance Requirements .......................................D-1

Appendix E Accessories.......................................................................E-1

Appendix F RS485 (MDI) Protocol........................................... .............F-1

Appendix G RJ45 Splitter Cable.......................................................... G-1

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

Contents III

IV MD60 AC Drive User Manual

List of Figures

Figure 2.1 – Identifying the Drive by Model Number..................................2-1

Figure 3.1 – Minimum Mounting Clearances.............................................3-2

Figure 3.2 – Drive Dimensions - Front View..............................................3-3

Figure 3.3 – Drive Dimensions - Bottom View...........................................3-3

Figure 4.1 – Typical Grounding..................................................................4-1

Figure 5.1 – Opening the Cover.................................................................5-1

Figure 5.2 – Removing the Finger Guard..................................................5-2

Figure 5.3 – Jumper Location (A Frame Shown).......................................5-3

Figure 5.4 – Phase-to-Ground MOV Removal...........................................5-3

Figure 5.5 – Power Terminal Block Connections.......................................5-5

Figure 6.1 – Wiring the Control Terminal Block.........................................6-4

Figure 6.2 – I/O Wiring Examples..............................................................6-5

Figure 6.3 – Override Priority for the Speed Reference Command........... 6-8

Figure 6.4 – Accel/Decel Selection............................................................6-9

Figure 8.1 – Integral Keypad .....................................................................8-1

Figure 9.1 – Accel Time 1 (P039)..............................................................9-7

Figure 9.2 – Decel Time 1 (P040)..............................................................9-7

Figure 9.3 – Accel Time 2 (A067)............................................................9-11

Figure 9.4 – Decel Time 2 (A068)............................................................9-12

Figure 9.5 – DC Brake Level (A081)........................................................9-14

Figure 9.6 – S Curve% (A083) Examples................................................9-15

Figure 9.7 – Start Boost (A084)...............................................................9-16

Figure 9.8 – Motor OL Select (A090).......................................................9-17

Figure 9.9 – Derating Guidelines Based on PWM Frequency (A091)

Selection...........................................................................9-18

Figure 9.10 – Drive Status (d006) Bit Definitions..................................... 9-28

Figure 9.11 – Control Source (d012) Bit Definitions ................................9-29

Figure 9.12 – Control Input Status (d013) Bit Definitions.........................9-30

Figure 9.13 – Digital Input Status (d014) Bit Definitions..........................9-30

Figure 9.14 – Comm Status (d015) Bit Definitions...................................9-31

Contents V

VI MD60 AC Drive User Manual

List of Tables

Table 2.1 – Drive Ratings, Model Numbers, and Frame Sizes.................. 2-2

Table 2.2 – Standard Kits..........................................................................2-3

Table 3.1 – Ambient Operating Temperatures and Mounting Clearances. 3-2

Table 3.2 – Mounting Specifications..........................................................3-4

Table 5.1 – Corrective Actions for Input Power Conditions.......................5-4

Table 5.2 – Power Wiring Specifications...................................................5-5

Table 5.3 – Power Terminal Block Specifications......................................5-5

Table 5.4 – Drive, Fuse, and Circuit Breaker Ratings................................5-7

Table 5.5 – Shielded Motor Cable Types Acceptable for 200-600 Volt

Installations..........................................................................5-8

Table 5.6 – Maximum Cable Length Recommendation.............................5-9

Table 6.1 – Recommended Control and Signal Wire................................. 6-3

Table 6.2 – I/O Terminal Block Specifications...........................................6-3

Table 6.3 – Typical Multiple Drive Connection Examples..........................6-7

Table 8.1 – LED Descriptions....................................................................8-2

Table 8.2 – Key Descriptions.....................................................................8-3

Table 8.3 – Viewing and Adjusting Basic (P) and Advanced (A)

Parameters..........................................................................8-5

Table 8.4 – Viewing the Display (d) Parameters........................................8-6

Table 9.1 – Trip Points for Digital Output Relay.......................................9-11

Table 9.2 – Selecting the Reference Source Using Presets....................9-13

Table 10.1 – Fault Descriptions and Corrective Actions..........................10-3

Table 10.2 – Problem: Drive Does Not Start From Terminal Block Start

or Run Inputs ...................................................................10-6

Table 10.3 – Problem: Drive Does Not Start From Integral Keypad........ 10-7

Table 10.4 – Problem: Drive Does Not Respond to Changes in Speed

Command.........................................................................10-7

Table 10.5 – Problem: Motor and/or Drive Will Not Accelerate to

Commanded Speed.......................................................... 10-8

Table 10.6 – Problem: Motor Operation is Unstable................................10-8

Table 10.7 – Problem: Drive Will Not Reverse Motor Direction...............10-9

Contents VII

VIII MD60 AC Drive User Manual

CHAPTER 1

Introduction

This manual is intended for qualified electrical personnel familiar with installing, programming, and maintaining AC drives.

This manual contains information on:

• Installing and wiring the MD60 drive

• Programming the drive

• Troubleshooting the drive

The latest version of this manual is available from

http://www.theautomationbookstore.com or http://www.reliance.com/docs_onl/online_stdrv.htm.

1.1 Getting Assistance from Reliance Electric

If you have any questions or problems with the products described in this instruction manual, contact your local Reliance Electric sales office.

For technical assistance, call 1-800-726-8112. Before calling, please review the troubleshooting section of this manual and check the Reliance Standard Drives website for additional information. When you call this number, you will be asked for the drive model number or catalog number and this instruction manual number.

Introduction 1-1

1-2 MD60 AC Drive User Manual

CHAPTER 2

About the MD60 Drive

This chapter provides information about the MD60 AC drive, including:

• How to identify the drive

• Descriptions of NEMA ratings

2.1 Identifying the Drive by Model Number

Each drive can be identified by its model number, as shown in figure 2.1. The model number is on the shipping label and the drive nameplate. The model number includes the drive and any options. Drive model numbers are provided in table 2.1.

6MD V N - 1P5 1 1 1

6MD = MD60 Drive

A = 1-Phase, 240 VAC V = 1-Phase, 120 VAC B = 3-Phase, 240 VAC D = 3-Phase, 460VAC

N = IP20 (Open)

@115V / 230 VAC

1P5 = 1.5 A, 0.25 HP 2P3 = 2.3 A, 0.5 HP 4P5 = 4.5 A, 1 HP 6P0 = 6.0 A, 1.5 HP 8P0 = 8 A, 2 HP 012 = 12 A, 3 HP 017 = 17.5 A, 5 HP

@460 VAC

1P4 = 1.4 A, 0.5 HP 2P3 = 2.3 A, 1 HP 4P0 = 4 A, 2 HP 6P0 = 6 A, 3 HP 8P7 = 8.7 A, 5 HP

Reserved

0 = Not Filtered 1 = Internal Filter

Reserved

Figure 2.1 – Identifying the Drive by Model Number

About the MD60 Drive 2-1

2.2 MD60 Drive Ratings, Model Numbers, and Frame Sizes

Similar MD60 drive sizes are grouped into frame sizes to simplify re-ordering and dimensioning. Refer to figure 3.2 for the dimensions of each frame size.

Table 2.1 provides MD60 drive ratings, model numbers, and frame sizes.

Table 2.1 – Drive Ratings, Model Numbers, and Frame Sizes

Drive Ratings

Frame

SizeInput Voltage kW HP

115V, 50/60 Hz 1-Phase

230V, 50/60 Hz 1-Phase With Integral EMC Filter

230V, 50/60 Hz 1-Phase No Filter

230V, 50/60 Hz 3-Phase

460V, 50/60 Hz 3-Phase

Output

Current

0.2 0.25 1.5A 6MDVN-1P5101 A

0.37 0.5 2.3A 6MDVN-2P3101 A

0.75 1.0 4.5A 6MDVN-4P5101 B

1.1 1.5 6.0A 6MDVN-6P0101 B

0.2 0.25 1.5A 6MDAN-1P5111 A

0.37 0.5 2.3A 6MDAN-2P3111 A

0.75 1.0 4.5A 6MDAN-4P5111 A

1.5 2.0 8.0A 6MDAN-8P0111 B

0.2 0.25 1.5A 6MDAN-1P5101 A

0.37 0.5 2.3A 6MDAN-2P3101 A

0.75 1.0 4.5A 6MDAN-4P5101 A

1.5 2.0 8.0A 6MDAN-8P0101 B

0.2 0.25 1.5A 6MDBN-1P5101 A

0.37 0.5 2.3A 6MDBN-2P3101 A

0.75 1.0 4.5A 6MDBN-4P5101 A

1.5 2.0 8.0A 6MDBN-8P0101 A

2.2 3.0 12.0A 6MDBN-012101 B

3.7 5.0 17.5 6MDBN-017101 B

0.37 0.5 1.4A 6MDDN-1P4101 A

0.75 1.0 2.3A 6MDDN-2P3101 A

1.5 2.0 4.0A 6MDDN-4P0101 A

2.2 3.0 6.0A 6MDDN-6P0101 B

3.7 5.0 8.7A 6MDDN-8P7101 B

Model Number

2-2 MD60 AC Drive User Manual

2.3 Kits

Table 2.2 lists kits for the MD60 drive. Contact Reliance Electric for more information about these kits.

MD60 Serial Converter and cables MDCOMM-232 VS Utilities Software CD RECOMM-VSUTIL MD60 Serial Converter (includes VS

Utilities Software) NEMA 1/IP30 Kit (contains conduit box and

converter cover) Remote LCD OIM Nema 4x/12 (includes

2.9 meter cable) Remote Handheld OIM (Copy Cat Ke ypad;

includes 1.0 meter cable) Bezel Kit (panel mount for Remote

Handheld OIM) OIM Cable (1.0 meter OIM-to-RJ45 cable) MDCBL-CC1 OIM Cable (2.9 meter OIM-to-RJ45 cable) MDCBL-CC3 RJ45 Cable (2.0 meter RJ45-to-RJ45

cable, male-to-male connectors) Serial Cable (2.0 meter serial cable with a

locking low profile connector to connect to the serial converter and a 9-pin subminiature D female connector to connect to a computer)

RJ45 Splitter Cables See Appendix G Terminating Resistors (RJ45 120 Ohm

resistors; 2 pieces) Terminal Block (RJ45 two-position terminal

block; 5 pieces) Communications Option Kits See Appendix E Dynamic Brake Resistors

EMI Filters

See Appendix E for more information.

Table 2.2 – Standard Kits

Kit Description Model Number

MDCOMM-VSU232

6MD-NM1A 6MD-NM1B

MD4ALCD

MD1CC

MDBZL-N1

MDCBL-RJ45

RECBL-SFC

AK-UO-RJ45-TRI

AK-UO-TB2P

AK-R2-xxx 6MDF-xxx

About the MD60 Drive 2-3

2.4 Storage Guidelines

If you need to store the drive, follow these recommendations to prolong drive life and performance:

• Store the drive within an ambient temperature range of -40° to

+85° C.

• Store the drive within a relative humidity range of 0% to 95%,

non-condensing.

• Do not expose the drive to a corrosive atmosphere.

2-4 MD60 AC Drive User Manual

CHAPTER 3

Mounting the Drive

This chapter provides information that must be considered when planning an MD60 drive installation and provides drive mounting information and installation site requirements.

ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the

hazards involved should install, adjust, operate, or service this equipment. Read and understand this manual and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: Use of power correction capacitors on the output of the drive can result in erratic operation of the motor, nuisance tripping, and/or permanent damage to the drive. Remove pow er correc tion capacitors before proceeding. Failure to observe this precaution could result in damage to, or destruction of, the equipment.

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

3.1 General Requirements for the Installation Site

It is important to properly plan before installing an MD60 drive to ensure that the drive’s environment and operating conditions are satisfactory.

The area behind the drive must be kept clear of all control and power wiring. Pow er connections may create electromagnetic fields that may interfere with control wiring or components when run in close proximity to the drive.

Read the recommendations in the following sections before continuing with the drive installation.

Mounting the Drive 3-1

3.1.1 Operating Conditions

Before deciding on an installation site, consider the following guidelines:

• Protect the cooling fan by avoiding dust or metallic particles.

• Do not expose the drive to a corrosive atmosphere.

• Protect the drive from moisture and direct sunlight.

• Verify that the dr ive location will meet the environmental

conditions specified in table 3.1.

Table 3.1 – Ambient Operating Temperatures and Mounting Clearances

Ambient

Temperature

-10°C (14°F)

40°C (104°F)

50°C (122°F)

Rating requires installation of the MD60 NEMA 1/IP30 Kit.

Enclosure

Rating

IP 20/Open Type Use Mounting Option A

IP 30/NEMA 1/ UL Type 1

IP 20/Open Type Use Mounting Option B

Minimum Mounting

ClearancesMinimum Maximum

(figure 3.1) Use Mounting Option B

(figure 3.1)

3.1.2 Recommended Mounting Clearances

Refer to figure 3.1 for the minimum mounting clearances. Refer to section 3.1.3 for drive mounting dimensions.

25 mm (1.0 in)

120 mm (4.7 in)

Mounting Option A

No clearance required between drives

Mounting Option B

120 mm (4.7 in)

See figure 3.2 for drive dimensions.

Figure 3.1 – Minimum Mounting Clearances

3-2 MD60 AC Drive User Manual

120 mm

(4.7 in)

120 mm

(4.7 in)

3.1.3 Mounting Dimensions for the MD60 Drive

Overall dimensions and weights are illustrated in figures 3.2 and 3.3 as an aid to calculating the total area required by the MD60 drive. Dimensions are in millimeters and (inches). Weights are in kilograms and (pounds). See table 2.1 for drive ratings by frame.

Frame A B

A D

5.5 (0.22)

Front

CDE2FG

Side

NEMA 1/IP30 Kit

A 80 (3.15) 185 (7.28) 136 (5.35) 67 (2.64) 152 (5.98) 59.3 (2.33) 140 (5.51) 1.4 (3.1)

B 100 (3.94) 213 (8.39) 136 (5.35) 87 (3.43) 180 (7.09) 87.4 (3.44) 168 (6.61) 2.2 (4.9)

Figure 3.2 – Drive Dimensions - Front View

Height dimension includes NEMA 1/IP30 Kit; see figure 3.3.

Height dimension without NEMA 1/IP30 Kit.

79.1

40.6

(1.60)

64.1

(2.52)

(3.11)

∅ 22.2

(0.88)

20.7

(0.81)

40.0

(1.57)

59.2

(2.33)

∅ 22.2

(0.88)

25.6

(1.01)

Shipping

Weight

34.0

(1.34)

75.3

(2.96)

35.6

(1.40)

74.3

(2.93)

Frame A Frame B

Figure 3.3 – Drive Dimensions - Bottom View

Mounting the Drive 3-3

3.2 Mounting the Drive

Mount the drive upright on a flat, vertical, and level surface.

• Install on 35 mm DIN rail

• Install with screws (see table 3.2).

Table 3.2 – Mounting Specifications

Minimum Panel

Thickness Screw Size Mounting Torque

1.9 mm (0.0747 in) M4 (#8-32) 1.56-1.96 N-m (14-17 in-lb)

3.2.1 Protecting the Drive from Debris

A plastic top panel is included with the drive. Install the panel to prevent debris from falling through the vents of the drive housing during installation. Remove the panel for IP 20/Open Type applications.

3-4 MD60 AC Drive User Manual

CHAPTER 4

Grounding the Drive

ATTENTION: The following information is merely a guide for proper installation. Rockwell Automation

The drive Safety Ground - must be connected to system ground. Ground impedance must conform to the requirements of

national and local industrial safety regulations and/or electrical codes. The integrity of all ground connections should be periodically checked.

cannot assume responsibility for the compliance or the noncompliance to any code, national, local or otherwise for the proper installation of this drive or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation.

Important:

is installed on an ungrounded system.

Tighten screw after jumper removal.

Jumper Location

For installations within a cabinet, a single safety ground point or ground bus bar connected directly to building steel should be used. All circuits including the AC input ground conductor should be grounded independently and directly to this point/bar.

Grounding the Drive 4-1

R/L1 S/L2 T/L3

Figure 4.1 – Typical Groun ding

Remove the MOV-to-ground jumper if the drive

U/T1 V/T2 W/T3

SHLD

Ground Fault Monitoring

If a system ground fault monitor is to be used, only Type B (adjustable) devices should be used to avoid nuisance tripping.

Safety Ground - (PE)

This is the safety ground for the drive that is required by code. One of these points must be connected to adjacent building steel (girder, joist), a floor ground rod, or bus bar. Grounding points must comply with national and local industrial safety regulations and/or electrical codes.

Motor Ground

The motor ground must be connected to one of the ground terminals on the drive.

Shield Termination - SHLD

Either of the safety ground terminals located on the power terminal block provides a grounding point for the motor cable shield. The motor cable shield connected to one of these terminals (drive end) should also be connected to the motor frame (motor end). Use a shield terminating or EMI clamp to connect the shield to the safety ground terminal. The NEMA 1/IP30 Kit may be used with a cable clamp for a grounding point for the cable shield.

When shielded cable is used for contr o l and signal wiring, the shield should be grounded at the source end only, not at the drive end.

4.1 RFI Filter Grounding

Using single-phase drives with integral filter, or an e xternal filter with any drive rating, may result in relatively high ground leakage currents. Therefore, the filter must only be used in installations

with grounded AC supply systems and be permanently installed and solidly grounded (bonded) to the building power

distribution ground. Ensure that the incoming supply neutral is solidly connected

(bonded) to the same building power distribution ground. Grounding must not rely on flexible cables and should not include any form of plug or socket that would permit inadvertent disconnection. Some local codes may require redundant ground connections. The integrity of all connections should be periodically checked.

4-2 MD60 AC Drive User Manual

Installing Power Wiring

ATTENTION: The user is responsible f or conforming with all applicable local and national codes. Failure

This chapter provides instructions on wiring output wiring to the motor and installing AC input power wiring.

5.1 Opening the Cover

To access the power terminal block: Step 1. Open the cover.

to observe this precaution could result in damage to, or destruction of, the equipment.

ATTENTION: To avoid a possible shock hazard caused by induced voltages, unused wires in the conduit must be grounded at both ends. For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this conduit should be disabled. This will help minimize the possible shock hazard from “cross-coupled” power leads.

a. Press and hold in the tabs on each side of the cover. b. Pull the cov er out and up to release (refer to figure 5.1).

CHAPTER 5

Figure 5.1 – Opening the Cover

Installing Power Wiring 5-1

Step 2. Remove the finger guard (refer to figure 5.2).

a. Press in and hold the locking tab. b. Slide finger guard down and out.

Replace the finger guard when wiring is complete.

BR-

BR+

Power Terminal Block

Finger Guard

Figure 5.2 – Removing the Finger Guard

5.2 Verifying Drive AC Input Ratings Match Available Power

It is important to verity that plant power meets the input power requirements of the drive’s circuitry. Refer to table 5.4 for input power rating specifications. Be sure input power to the drive corresponds to the drive nameplate voltage and frequency.

V/T2T/L3S/L2R/L1 U/T1 W/T3

5.2.1 Ungrounded Distribution Systems

ATTENTION: MD60 driv es contain protective MO Vs

that are referenced to ground. These devices should

To prevent drive damage, the MOVs connected to ground should be disconnected if the drive is installed on an ungrounded distribution system where the line-to-ground voltages on any phase could exceed 125% of the nominal line-to-line voltage.

5-2 MD60 AC Drive User Manual

be disconnected if the drive is installed on an ungrounded distribution system.

Disconnecting MOVs

To disconnect MOVs, you must remove the external jumper located on the lower left side of the front of the drive.

To remove the jumper, use the following procedure and refer to figures 5.3 and 5.4.

Step 1. Open the cover. Step 2. Locate the screw below and to the left of the power

terminal block. Step 3. Turn the screw counterclockwise to loosen. Step 4. Pull the jumper completely out of the drive chassis. Step 5. Tighten the screw to keep it in place.

Important: Tighten screw after jumper removal.

Jumper

Figure 5.3 – Jumper Location (A Frame Shown)

Three-Phase

AC Input

Figure 5.4 – Phase-to-Ground MOV Removal

Installing Power Wiring 5-3

R/L1

S/L2

T/L3

Jumper

123

5.2.2 Input Power Conditioning

The drive is suitable for direct connection to input power within the rated voltage of the drive (see table 5.4). Table 5.1 lists certain input power conditions that may cause component damage or reduction in product life. If any of the conditions exist, install one of the devices listed in the ”Corrective Action” column in table 5.1 on the line side of the drive.

Important: Only one device per branch circuit is required. It

should be mounted closest to the branch and sized to handle the total current of the branch circuit.

Table 5.1 – Corrective Actions for Input Power Conditions

Input Power Condition Corrective Action

Low line impedance (less than 1% line reactance)

Greater than 120 kVA supply transformer Line has power f ac to r correcti o n ca pa ci to rs Line has frequent power interruptions Line has intermittent noise spikes in excess of

6000V (lightning) Phase-to-ground voltage exceeds 125% of

normal line-to-line voltage Ungrounded distribution system

Contact Reliance Electric for application and ordering information.

• Install line reactor

• Install isolation

transformer

• Remove MOV jumper to

ground and install isolation transformer with grounded secondary, if necessary.

5-4 MD60 AC Drive User Manual

5.3 Power Wiring Specifications

Table 5.2 – Power Wiring Specifications

Power Wire Rating Recommended Copper Wire

Unshielded 600V, 75°C (167°F)

15 mils insulated, dry location

THHN/THWN Shielded 600V, 90°C (194°F)

RHH/RHW-2 Shielded Tray rated 600V, 90°C (194°F)

RHH/RHW-2

Belden 29501-29507 or equivalent

Shawflex 2ACD/3ACD or equivalent

5.4 Power Terminal Block Connections

Table 5.3 – Power Terminal Block Specifications

Frame Maximum Wire Size

3.3 mm

5.3 mm

Maximum/minimum sizes that the terminal block will accept. These are not recommendations.

(12 AWG) 0.8 mm2 (18 AWG)

(10 AWG) 1.3 mm2 (16 AWG)

Minimum Wire Size

BR+

BR-

V/T2T/L3S/L2R/L1 U/T1 W/T3

1.7-2.2 Nm (16-19 in-lb)

Torque

Power Terminal Block

Terminal Description

R/L1, S/L2 1-Phase Input R/L1, S/L2,

3-Phase Input

T/L3 U/T1 To Motor U/T1 Switch any two V/T2 To Motor V/T2 W/T3 To Motor W/T3

motor leads to change forward direction.

BR+, BR- Dynamic Brake Resistor Connection

(All ratings 100% rated.) PE Ground

Figure 5.5 – Power Terminal Block Connections

Installing Power Wiring 5-5

5.5 Fuses and Circuit Breakers

The MD60 drive does not provide branch short circuit protection. This product should be installed with either input fuses or an input circuit breaker. National and local industrial safety regulations and/ or electrical codes may determine additional requirements for these installations.

Table 5.4 provides drive ratings and recommended AC line input fuse and circuit breaker information. Both types of short circuit protection are acceptable for UL and IEC requirements. Sizes listed are the recommended sizes based on 40 degree C and the U.S. N.E.C. Other country, state or local codes may require different ratings.

ATTENTION: To guard against personal injury and/ or equipment damage caused by improper fusing or

Fuses

The MD60 drive has been UL tested and approved for use with input fuses. The ratings in table 5.4 are the minimum recommended values for use with each drive rating. The devices listed in this table are provided to serve as a guide.

circuit breaker selection, use only the recommended line fuses/circuit breakers specified in table 5.4.

If fuses are chosen as the desired protection method, refer to the recommended types listed below. If available amp ratings do not match the tables provided, the closest fuse rating that exceeds the drive rating should be chosen.

• IEC – BS88 (British Standard) Parts 1 & 2

2, type gG or equivalent should be used.

• UL Class CC, T or J must be used.

Typical designations include, but may not be limited to the following:

Parts 1 & 2: AC, AD, BC, BD, CD, DD, ED, EFS, EF, FF, FG, GF, GG, GH.

Typical designations include: Type CC - KTK-R, FNQ-R Type J - JKS, LPJ Type T - JJS, JJN

, EN60269-1, Parts 1 &

5-6 MD60 AC Drive User Manual

Circuit Breakers

The “other devices” listings in table 5.4 include both circuit breakers (inverse time or instantaneous trip) and self-protecting motor starters. If one of these is chosen as the desired protection method, the following requirements apply.

• IEC and UL – Both types of devices are acceptable for IEC and

UL installations.

Table 5.4 – Drive, Fuse, and Circuit Breaker Ratings

Drive Ratings

Model Number

100 - 115V AC 1-Phase Input

6MDVN-1P5101 0.2 (0.25) 1.5 90-126 0.75 6.0 10 10 25

6MDVN-2P3101 0.37 (0.5) 2.3 90-126 1.15 9.0 15 15 30

6MDVN-4P5101 0.75 (1.0) 4.5 90-126 2.25 18.0 30 30 50

6MDVN-6P0101 1.1 (1.5) 6.0 90-126 3.0 24.0 40 40 70

200 - 240V AC 1-Phase Input; 0 - 230 V, 3-Phase Output

6MDAN-1P5111 0.2 (0.25) 1.5 180-265 0.75 5.0 10 5 25

6MDAN-2P3111 0.37 (0.5) 2.3 180-265 1.15 6.0 10 10 30

6MDAN-4P5111 0.75 (1.0) 4.5 180-265 2.25 10.0 15 15 50

6MDAN-8P0111 1.5 (2.0) 8.0 180-265 4.0 18.0 30 25 80

200 - 240V AC 3-Phase Input; 0 - 230 V, 3-Phase Output

6MDBN-1P5101 0.2 (0.25) 1.5 180-265 0.75 1.8 3 5 25

6MDBN-2P3101 0.37 (0.5) 2.3 180-265 1.15 2.5 6 5 30

6MDBN-4P5101 0.75 (1.0) 4.5 180-265 2.25 5.2 10 7 50

6MDBN-8P0101 1.5 (2.0) 8.0 180-265 4.0 9.5 15 15 80

6MDBN-012101 2.2 (3.0) 12.0 180-265 5.5 15.5 25 25 115

6MDBN-017101 3.7 (5.0) 17.5 180-265 8.6 21.0 35 30 165

380 - 480V AC 3-Phase Input; 0 - 480 V, 3-Phase Output

6MDDN-1P4101 0.37 (0.5) 1.4 340-528 1.4 1.8 3 3 30

6MDDN-2P3101 0.75 (1.0) 2.3 340-528 2.3 3.2 6 4 40

6MDDN-4P0101 1.5 (2.0) 4.0 340-528 4.0 5.7 10 7 60

6MDDN-6P0101 2.2 (3.0) 6.0 340-528 5.9 7.5 15 10 90

6MDDN-8P7101 3.7 (5.0) 8.7 340-528 8.6 9.0 15 15 145

Output Ratings Input Ratings

kW (HP) Amps

Voltage

Range kVA Amps

; 0 - 230 V, 3-Phase Output

Branch Circuit

Protection

Fuse

Other

Rating

Devices

Power

Dissipation

IP20 Open

Watts

Note: For carrier frequencies above 4 kHz, see figure 9.9.

Installing Power Wiring 5-7

5.6 Motor Cable Types Acceptable for 200-600 Volt Installations

General

A variety of cable types are acceptable for drive installations. For many installations, unshielded cable is adequate provided it can be separated from sensitive circuits. As an approximate guide, allow a spacing of 0.3 meters (1 foot) for every 10 meters (32.8 feet) of length. In all cases, long parallel runs must be avoided. Do not use cable with an insulation thickness less than 15 mils (0.4 mm/0.015 in). Do not route more than three sets of motor leads in a single conduit to minimize “cross talk”. If more than three drive/motor connections per conduit are required, shielded cable must be used.

• UL installations in 50°C ambient must use 600V, 75°C or 90°C

wire.

• For UL installations in 40°C ambient, 600V, 75°C or 90°C wire is

recommended.

• Use copper wire only. Wire gauge requirements and

recommendations are based on 75° when using higher temperature wire.

Unshielded

THHN, THWN or similar wire is acceptable for drive installation in dry environments provided adequate free air space and/or conduit fill rates limits are provided. Do not use THHN or similarl y co at ed wire in wet areas. Any wire chosen must have a minimum insulation thickness of 15 mil and should not have large variations in insulation concentricity.

C. Do not reduce wire gauge

Shielded

Refer to table 5.5 for acceptable shielded motor cable types.

Table 5.5 – Shielded Motor Cable Types Acceptable for 200-600 Volt Installations

Location Rating/Type Description

Standard (Option 1)

600V, 75°C or 90°C (167°F or 194°F) RHH/RHW-2 Belden 2950129507 or equivalent

• Four tinned copper conductors with

XLPE insulation

• Foil shield and tinned copper drain

wire with 85% braid coverage

• PVC jacket

5-8 MD60 AC Drive User Manual

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Rockwell Automation MD60 User Manual

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User Manual