Rockwell Automation MD60 User Manual

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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

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

Location Rating/Type Description

Standard (Option 2)

Class I & II; Division I & II

Tray rated 600V, 75°C or 90°C (167°F or 194°F) RHH/ RHW-2 Shawflex 2ACD/ 3ACD or equivalent

Tray rated 600V, 75°C or 90°C (167°F or 194°F) RHH/ RHW-2

• Three tinned copper conductors with

XLPE insulation

• 5 mil single helical copper tape (25%

overlap min.) with three bare copper grounds in contact with shield

• PVC jacket

• Three tinned copper conductors with

XLPE insulation

• 5 mil single helical copper tape (25%

overlap min.) with three bare copper grounds in contact with shield

• PVC copper grounds on #10 AWG

and smaller

5.7 Reflected Wave Protection

The drive should be installed as close to the motor as possible. Installations with long motor cables may require the addition of external devices, such as reactors, to limit voltage reflections at the motor (reflected wave phenomena). Contact Reliance Electric for recommendations.

The reflected wave data applies to all frequencies 2 to16 kHz. For 240 V ratings, reflected wave effects do not need to be considered.

Table 5.6 – Maximum Cable Length Recommendation

Reflected Wave

380-480V Ratings Motor Insulation Rating Motor Cable Only

1000 Vp-p 15 meters (49 feet)

1200 Vp-p 40 meters (131 feet)

1600 Vp-p 170 meters (558 feet)

Longer cable lengths can be achieved by installing devices on the output of the drive. Consult factory for recommendations.

Installing Power Wiring 5-9

5.8 Output Disconnect

The drive is intended to be commanded by control input signals that will start and stop the motor. A device that routinely disconnects then reapplies output power to the motor for the purpose of starting and stopping the motor should not be used. If it is necessary to disconnect power to the motor while the drive is providing output power, an auxiliary contact should be used to simultaneously disable drive control run commands.

5-10 MD60 AC Drive User Manual

CHAPTER 6

Installing Control Wiring

This chapter describes how to wire the signal and I/O terminal strip for stop, speed feedback, and remote control signals.

To access the control terminal block, remove the drive cover (refer to chapter 5).

Terminal block connections are detailed in figure 6.1.

6.1 Stop Circuit Requirements

ATTENTION: You must provide an external,

hardwired emergency stop circuit outside of the

Depending upon the requirements of the application, the MD60 drive can be configured to provide either a coast-to-rest or a rampto-rest operational stop without physical separation of the power source from the motor. A coast-to-rest stop turns off the transistor power device drivers. A ramp-to-rest stop fires the transistor power device drivers until the motor comes to a stop, and then turns off the power devices.

drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled machine operation can result if this procedure is not followed. Failure to observe this precaution could result in bodily injury.

In addition to the operational stop, you must provide a hardwired emergency stop external to the drive. The emergency stop circuit must contain only hardwired electromechanical components. Operation of the emergency stop must not depend on electronic logic (hardware or software) or on the communication of commands over an electronic network or link.

Note that the hardwired emergency stop you install can be used at any time to stop the drive.

Installing Control Wiring 6-1

6.1.1 Compliance with Machinery Safety Standard EN 60204-1:1992

This section applies to you if you must comply with machinery safety standard EN 60204-1:1992, part 9.2.5.4, Emergency Stop.

The MD60 drive coast-to-rest stop is a category 0 operational stop. The ramp-to-rest stop is a category 1 operational stop. You can also implement a category 2 stop with power maintained to the motor at zero speed.

The required external hardwired emergency stop must be either a category 0 or 1 stop, depending on your risk assessment of the associated machinery. To fully comply with machinery safety standard EN60204-1:1992, part 9.2.5.4, at least one of the two stop methods must be a category 0 stop.

6.2 Motor Start/Stop Precautions

ATTENTION: A contactor or other device that

routinely disconnects and reapplies the AC line to the

drive to start and stop the motor can cause drive hardware damage. The drive is designed to use control input signals that will start and stop the motor . If used, the input device must not exceed one operation per minute or drive damage can occur. Failure to observe this precaution can result in damage to, or destruction of, equipment.

ATTENTION: The drive start/stop control circuitry includes solid-state components. If hazards due to accidental contact with moving machinery or unintentional flow of liquid, gas or solids exist, an additional hardwired stop circuit may be required to remove the AC line to the drive. When the AC line is removed, there will be a loss of any inherent regenerative braking effect that might be present the motor will coast to a stop. An auxiliary braking method may be required.

Important points to remember about I/O wiring:

• Always use copper wire.

• Wire with an insulation rating of 600V or greater is recommended.

• Control and signal wires should be separated from power wires

by at least 0.3 meters (1 foot).

6-2 MD60 AC Drive User Manual

Important: I/O terminals labeled “Common” are not ref erenced to

the safety ground (PE) terminal and are designed to greatly reduce common mode interference.

ATTENTION: Driving the 4-20 mA analog input from a voltage source could cause component damage.

Verify proper configuration prior to applying input signals.

6.3 I/O Wiring Recommendations

Table 6.1 – Recommended Control and Sig nal Wire

Wire Type(s) Description

Belden 8760/ 9460 (or equiv.)

Belden 8770 (or equiv.)

If the wires are short and contained within a cabinet which has no sensitive circuits, the use of shielded wire may not be necessary, but is always recommended.

Table 6.2 – I/O Terminal Block Specifications

Maximum Wire Size1

1.3 mm

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

(16 AWG) 0.13 mm2 (26 AWG)

0.8 mm shield with drain.

0.8 mm shielded for remote pot only.

(18A WG), twisted pair, 100%

(18AWG), 3 conductor,

Minimum Wire Size

0.5 to 0.8 Nm (4.4 in-lb)

Minimum

Insulation

Rating

300 V

60° C

(140° F)

Torque

6.3.1 Maximum Cable Length Recommendations

Do not exceed control wiring length of 30 meters (100 feet). Control signal cable length is highly dependent on electrical environment and installation practices. To improve noise immunity, the I/O terminal block Common must be connected to ground terminal/ protective earth. If using the RS485 port, Terminal 16 should also be connected to ground terminal/protective earth.

Installing Control Wiring 6-3

6.4 Wiring the Control Terminal Block

(1)

Important: I/O Terminal 01

is always a coast-to-stop input except when P036 (Start Source) is set to 3-Wire Control. In threewire control, I/O Terminal 01 is controlled by P037 (Stop Mode). All other sources are controlled by P037 (Stop Mode).

Important: The drive is shipped with a jumper installed between I/O Terminals 01 and 11. Remove this jumper when using I/O Terminal 01 as a stop or enable input.

(2)

Two-wire control shown.

For three-wire control, use a momentary input on I/O Terminal 02 to command a start. Use a maintained input for I/O Terminal 03 to change direction.

30V DC 125V AC 230V AC

Resistive 3.0A 3.0A 3.0A

Inductive 0.5A 0.5A 0.5A

No. Signal Default Description Parameter

R1 Relay N.O. Fault Normally open contact for output relay. A055

R2 Relay Common – Common for output relay.

R3 Relay N.C. Fault Normally closed cont act for output relay. A055

Sink/Source DIP Switch Source (SRC) Inputs can be wired as Sink (SNK) or Source (SRC) via DIP Switch setting.

(1)

01 Stop

Coast

02 Start/Run FWD Not Act ive

03 Dir/Run REV Not Active P036, P037, A095

04 Digital Common –

05 Digital Input 1 Preset 1 Program with A051 (Digi tal In1 Select). A051

06 Digital Input 2 Preset 2 Program with A052 (Digi tal In2 Select). A052

11 +24V DC – Drive supplied power for digital inputs.

12 +10V DC – Drive supplied power for 0-10V external pot entiometer. P038

13 0-10V In

(3)

Not Active

14 Analog Common –

15 4-20mA In

(3)

Not Active

16 RS485 Shield –

(3)

Only one analog frequency source may be connected at a time. If more than one reference is connected at the same time, an undetermined frequency r eference will result.

(

RS485 port is used to conne ct the drive to a personal computer running VS Utilities via a Ser ial Converter module, and for

connection to the Remote Nema 4x/12 or Copy Cat Keypads.

Figure 6.1 – Wiring the Control Terminal Block

P036 (Start Source) Stop I/O Terminal 01 Stop

Keypad Per P 037 Coast

3-Wire Per P037 Per P037

2-Wire Per P037 Coast

RS485 Per P037 Coast

(1)

Stop

Start/Run FWD

Direction/Run REV

Digital Common

Digital Input 1

Digital Input 2

+24V

+24V DC

+10V DC

+10V

0-10V In

Analog Common

4-20mA In

RS485 Shield

01 02 03 04 05 06

11 12 13 14 15 16

(1)

Relay N.O.

Relay Common

Relay N.C.

R1 R2 R3

SRCSNK

R1 R2 R3

SNK SRC

The factory-installed jumper or a normally closed input must be present for the drive to start.

Command comes from the integral keypad by default. To disable reverse operation, see A095 (Reverse Disable).

For digital inputs. Electronically isolated with digital inputs from analog I/O.

For external 0-10V input supply (input impedance = 100k ohm) or potentiometer wiper.

For 0-10V In or 4-20mA In. Analog inputs electrically isolated from digital I/O.

For external 4-20mA input supply (input impedance = 250 ohm).

Terminal should be connected to chassis ground when using the RS485 communications por t.

Typical

SRC Wiring

(2)

Typical

SNK Wiring

RS485

(DSI)

P036

P036, P037

P038

6-4 MD60 AC Drive User Manual

6.4.1 I/O Wiring Examples

Input/Output Connection Example

Potentiometer

1-10k Ohm Pot. Recommended (2 watt minimum)

P038 (Speed Reference) = 2 “0-10V Input”

Analog Input

0 to +10V, 100k ohm impedance

4-20 mA, 100 ohm impedance

2 Wire SRC Control Non-Reversing

P036 (Start Source) = 2, 3 or 4

Input must be active for the drive to run. When input is opened, the drive will stop as specified by P037 (Stop Mode).

If desired, a User Supplied 24 V DC power source can be used. Refer to the “External Supply (SRC)” example.

2 Wire SNK Control NonReversing

Vol ta ge

P038 (Speed Reference) = 2

“0-10V Input”

Common

P038 (Speed Reference) = 3

Common

Current

“4-20mA Input”

Internal Supply (SRC) External Supply (SRC)

Stop-Run

+24V Common

Internal Supply (SNK)

Stop-Run

Figure 6.2 – I/O Wiring Examples

Installing Control Wiring 6-5

Input/Output Connection Example

2 Wire SRC Control - Run

Internal Supply (SRC) External Supply (SRC)

FWD/Run REV

P036 (Start Source) = 2, 3, or 4

Input must be active for the drive to run. When input is opened, the drive will stop as specified by PO37 (Stop Mode).

Stop-Run

Forward

Stop-Run

Reverse

01 02 03

If both Run Forward and Run Reverse inputs are closed at the same time, an undetermined state could occur.

2 Wire SNK Control - Run

Internal Supply (SNK)

FWD/Run REV

Stop-Run

Forward

Stop-Run

Reverse

Stop-Run

Forward

Stop-Run

Reverse

Common

+24V

01 02 03 04

02 03 04

3 Wire SRC Control Non-Reversing

P036 (Start Source) = 1

A momentary input will start the drive. A stop input to I/O Terminal 01 will stop the drive as specified by P037 (Stop Mode).

3 Wire SNK Control - NonReversing

3 Wire SRC Control Reversing

P036 (Start Source) = 1

A momentary input will start the drive. A stop input to I/O Terminal 01 will stop the drive as specified by P037 (Stop Mode). I/O Terminal 03 determines direction.

Internal Supply (SRC) External Supply (SRC)

Stop

Start

+24V

Stop

Start

Common

Internal Supply (SNK)

Stop

Start

01 02 03 04

Internal Supply (SRC) External Supply (SRC)

Stop

Start

Direction

01 02 03

Stop

Start

Direction

+24V Common

Figure 6.2 – I/O Wiring Examples

01 02 03 04

6-6 MD60 AC Drive User Manual

Input/Output Connection Example

3 Wire SNK Control -

Internal Supply (SNK)

Reversing

Stop

Start

Direction

01 02 03 04

Figure 6.2 – I/O Wiring Examples

6.4.2 Typical Multiple Drive Connection Examples

Table 6.3 – Typical Multiple Drive Connection Examples

Input Connection Example

Multiple Digital Input Connections

Customer Inputs can be wired per External Supply (SRC) or Internal Supply (SNK).

Multiple Analog Connections

02 0402 0402 0402

Customer Inputs

Optional Ground Connection

When connecting a single input such as Run, Stop, Reverse or Preset Speeds to multiple drives, it is important to connect I/O Terminal 04 common together for all drives. If they are to be tied into another common (such as earth ground or separate apparatus ground) only one point of the daisy chain of I/O Terminal 04 should be connected.

12 13 14 13 14 13 14 13 14

Remote Potentiometer Optional Ground Connection

When connecting a single potentiometer to multiple drives it is important to connect I/O Terminal 14 common together for all drives. I/O Terminal 14 common and I/O Terminal 13 (potentiometer wiper) should be daisychained to each drive. All drives must be powered up for the analog signal to be read correctly.

Installing Control Wiring 6-7

6.5 Start and Speed Reference Control

The drive speed command can be obtained from a number of different sources. The source is normally determined by P038 (Speed Reference). However, when A051 or A052 (Digital Inx Select) is set to option 2, 4, 5, or 6, and the digital input is active, A051 or A052 will override the speed reference commanded by P038 (Speed Reference). See figure 6.3 for the override priority.

Jog input

enabled and active:

A051 or A052 = 2

Local/Remote input enabled and active:

A051 or A052 = 5

Comm Select input enabled and active:

A051 or A052 = 6

P038 (Speed Reference)

= 4 or 5

A051 / A052

Preset inputs active

Drive will start and run at jog speed.

Yes

Ye s

Yes

Direction comes from

Terminal 03 Dir/Run REV

Start, speed and di rection commands

come from integral keypad.

Start, speed and direction commands

come from RS485 port.

Run as specified by

P038 (Speed Reference).

Start and direction commands come

from P036 (Start Source).

Run as specified by

A071-A073 (Preset Freq 1-3).

Start and direction commands come

from P036 (Start Source).

Run as specified by

P038 (Speed Reference).

Start and direction commands come

from P036 (Start Source).

Figure 6.3 – Override Priority for the Speed Reference Command

6-8 MD60 AC Drive User Manual

6.6 Accel/Decel Selection

The selection of Accel/Decel rates can be made through digital inputs, RS485 communications and/or parameters. See figure 6.4.

Jog input

enabled and active:

A051 or A052 = 2

RS485 port

controls speed

Input is programmed

as Accel 2 & Decel 2

A051 or A052 = 1

Speed is controlled

by (Preset Freq x)

A051 or A052 = 4

P039 (Accel Time 1)/(Decel Time 1)

are used.

Ye s

Yes

A079 (Jog Accel/Decel) used.

A067 (Accel Time 2)/A068 (Decel Time 2)

P039 (Accel Time 1)/P040 (Dec el Time 1);

A067 (Accel Time 2)/A068 (Decel Time 2)

Active when

selected by RS485 port.

is active when input is active.

determined by the active

Preset Frequency.

See A070-A073 (Preset Freq 1-3)

Figure 6.4 – Accel/Decel Selection

Installing Control Wiring 6-9

6-10 MD60 AC Drive User Manual

CHAPTER 7

Completing the Installation

This chapter provides instructions on how to perform a final check of the installation before and after power is applied to the drive.

ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should start and

adjust it. Read and understand this manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.

7.1 Checking the Installation Before Applying Power to the Drive

ATTENTION:The drive contains high voltage

capacitors that take time to discharge after removal of mains supply. Before working on the drive, ensure

isolation of mains suppl y from line in puts [R, S , T (L1, L2, L3)]. Wait three (3) minutes for capacitors to discharge to safe voltage levels. Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels. Failure to observe this precaution could result in severe bodily injury or loss of life.

ATTENTION: Y ou must provide an e xternal, hardwired emergency stop circuit outside of the drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled machine operation can result if this procedure is not followed. Failure to observe this precaution could result in bodily injury.

To verify the condition of the installation:

• Confirm that all inputs are connected to the correct terminals and

are secure.

• Verify that AC line power at the disconnect device is within the

rated value of the drive.

• Verify that any external digital control power is 24 volts DC.

Completing the Installation 7-1

• Verify that the Sink (SNK)/Source (SRC) Setup DIP Switch is set

to match your control wiring scheme. See figure 6.1 for the location of this switch.

Important: The default control scheme is Source (SRC). The

Stop terminal is jumpered (I/O T erminals 01 and 11) to allow starting from the keypad. If the control scheme is changed to Sink (SNK), the jumper must be removed from I/O Term inals 01 and 11 and installed between I/O Terminals 01 and 04.

• Verify that the Stop input is present or the drive will not start.

Important: If I/O Terminal 01 is used as a stop input, the jumper

between I/O Terminals 01 and 11 must be removed.

7.2 Powering Up After Installation is Complete

To verify that the drive is installed correctly and is receiving the proper line voltage, apply AC power and control voltages to the drive.

Become familiar with the integral keypad features bef ore setting any parameters. Refer to chapter 8 for information about the integral keypad and programming the drive. To simplify drive setup, the most commonly programmed parameters are organized in the Basic parameter group.

If a fault code appears on power up, refer to chapter 10, Troubleshooting the Drive, for an explanation of the fault code.

7-2 MD60 AC Drive User Manual

CHAPTER 8

Using the Integral Keypad

to Program and Control

Factory-default parameter values allow the drive to be controlled from the integral keypad. No programming is required to start, stop, change direction, or control speed directly from the integral keypad.

This chapter provides an overview of the integrated keypad and how to use it to program and control the MD60 drive.

Parameter descriptions are provided in chapter 9.

8.1 Keypad Components

the Drive

➊

RUN

FWD

➋

REV

PROGRAM

➍

PROG

➏

MIN. MAX.

Refer to tables 8.1 and 8.2 for the LED and key descriptions noted

by ➊ through ➐.

Using the Integral Keypad to Program and Control the Drive 8-1

➐

Figure 8.1 – Integral Keypad

➎

FAULT

VOLTS AMPS HERTZ

➌

8.1.1 Display Description

The alpha-numeric display indicates the following:

• Parameter number

• Parameter value

• Fault code

8.1.2 LED Descriptions

Refer to figure 8.1 for the location of the LEDs described in table

8.1.

Table 8.1 – LED Descriptions

No. LED LED State Description

RUN Steady Red Indicates the drive is running.

➊

FWD

➋

REV

VOLTS

➌

AMPS HERTZ

PROGRAM Steady Red Indicates the drive is in program

➍

FAULT Flashing

➎

Pot Status Steady

➏

Start Key Status Steady

➐

Flashing Red

Steady Red Indicates the commanded motor

Steady Red Indicates the units of the

Red

Green

Drive has been commanded to change direction. Indicates actual motor direction while decelerating to zero.

direction.

parameter value being displayed.

mode and the parameter value can be changed.

Indicates drive is faulted.

Indicates potentiometer on integral keypad is active.

Indicates Start key on integral keypad is active . The Re v erse ke y is also active unless disabled by A095 (Reverse Disable).

8-2 MD60 AC Drive User Manual

8.1.3 Key Descriptions

Refer to figure 8.1 for the location of the keys described in table 8.2.

Table 8.2 – Key Descriptions

Key Name Description

PROG

Program

• Enter/exit program mode.

• Scroll through parameter

groups.

• Back up one step in

programming menu.

• Cancel a change to a parameter

value.

Up Arrow Down Arrow

• Scroll through P and A

parameters.

• Increase/decrease the value of

a flashing digit.

• In Display Mode, increases/

decreases internal frequency parameter if that parameter is currently controlling the drive commanded speed.

Enter

• Display value of P or A

parameter.

• Save a change to a parameter

value.

• Scroll through display (d)

parameters.

Potentiometer Control drive speed. Default is

active. Controlled by parameter P038.

Start Start the drive. Default is active.

Controlled by parameter P036.

Reverse Reverse direction of the motor.

Default is active. Controlled by parameters P036 and A095.

Stop

• Stop the drive (if drive is

running).

• Clear fault (if drive is stopped).

Controlled by parameter P037.

Using the Integral Keypad to Program and Control the Drive 8-3

8.2 About Parameters

To program the drive for a specific application, you adjust the appropriate parameters. The parameters are used to define characteristics of the drive.

There are three types of parameters:

• Numbered List Parameters

Numbered list parameters allow a selection from two or more options. Each item is represented by a number.

Example: Start Source (P036)

• Bit Parameters

Bit parameters have individual bits associated with features or conditions. If the bit is 0, the feature is off or the condition is false. If the bit is 1, the feature is on or the condition is true.

Example: Drive Status (d006)

• Numeric Parameters

These parameters have a single numerical value (for example,

0.1 volts).

Example: Motor NP Volts (P031) Parameters are also either configurable or tunable, or read-only. Configurable parameters can be adjusted or changed only while

the drive is stopped. Tunable parameters can be adjusted or changed while the drive is

running or stopped.

Read-only parameters cannot be adjusted.

8.3 How Parameters are Organized

Parameters are organized into three Parameter Groups:

• The Basic P arameter Group , (Pnnn) contains the most commonly

used parameters to simplify the start-up process.

• The Advanced Parameter Group (Annn) contains parameters

used for more advanced applications.

• The Display Parameter Group (dnnn) contains parameters that

indicate actual drive conditions.

8-4 MD60 AC Drive User Manual

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

Use the following procedure to view and adjust the Basic and Advanced parameters.

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

Procedure Sample Display

Step 1. Press until the desired

PROG

parameter group is displayed. The PROGRAM LED will turn on to indicate the drive is in program mode.

VOLTS AMPS HERTZ

FAULTPROGRAM

Step 2. Press to scroll

through the parameters in the selected parameter group.

Step 3. Press to view the value

of the displayed parameter.

Step 4. Press or .

The adjustable value will flash on the display.

Step 5. Use to adjust the

value.

Step 6. Press to accept the

value. The value stops flashing.

Step 7. Press to return to the

PROG

parameter number.

VOLTS AMPS HERTZ

FAULTPROGRAM

VOLTS AMPS HERTZ

FAULTPROGRAM

VOLTS AMPS HERTZ

FAULTPROGRAM

VOLTS AMPS HERTZ

FAULTPROGRAM

VOLTS AMPS HERTZ

FAULTPROGRAM

VOLTS AMPS HERTZ

FAULTPROGRAM

To adjust additional parameters, repeat steps 2 through 7. To exit a parameter without saving the value, press instead of

PROG

Using the Integral Keypad to Program and Control the Drive 8-5

8.5 Viewing the Display (d) Parameters

Use the procedure in table 8.4 to view Display parameters.

Table 8.4 – Viewing the Display (d) Parameters

Procedure Sample Display

Step 1. Press to scroll through

PROG

the parameter menus until the

VOLTS AMPS HERTZ

FAULTPROGRAM

Display Group parameters are displayed. The PROGRAM LED will be off to indicate the drive is in display mode.

Step 2. Press to scroll through

the Display Group parameters until the desired Display

VOLTS AMPS HERTZ

FAULTPROGRAM

parameter is displayed.

Step 3. The parameter value will be

displayed 3 seconds after

is released.

VOLTS AMPS HERTZ

FAULTPROGRAM

To view additional Display parameters, press to return to the Display Group parameter list and scroll through the parameter list as described in step 2.

Note that the last user-selected Display parameter is saved when power is removed and is displayed by default when power is re-applied.

8-6 MD60 AC Drive User Manual

CHAPTER 9

Parameter Descriptions

The following information is provided for each parameter along with its description:

Parameter Number: Unique number assigned to each

parameter.

Parameter Name: Unique name assigned to each

Range: Predefined parameter limits or

Default: Factory default setting. See also: Associated parameters that may provide

What the Symbols Mean

Symbol Meaning

The parameters are presented in numerical order in the sections that follow. Refer to Appendix C for a list of parameters crossreferenced by parameter name.

parameter.

selections. Note that a negative Hz value indicates reverse rotation.

additional or related information.

Drive must be stopped before changing parameter value.

32-bit parameter. Parameters marked 32-bit will have two parameter numbers when using RS485 communications and programming software.

Parameter Descriptions 9-1

9.1 Basic Program Group Parameters

The Basic Program Group contains the most commonly used parameters to simplify the start-up process.

P031 Motor NP Volts

Range: 20 VAC to Drive Rated Volts Default: Based on Drive Rating See also: A084

Set to the motor nameplate rated volts.

P032 Motor NP Hertz

Range: 10 to 240 Hz Default: 60 Hz See also: A084

Set to the motor nameplate rated frequency.

P033 Motor OL Current

Range: 0.0 to (Drive Rated Amps x 2) Default: Based on Drive Rating

See also: N/A

Sets the percentage of acceleration or deceleration time that is applied to the ramp as S Curve. Time is added, 1/2 at the beginning and 1/2 at the end of the ramp.

For example: If Accel Time = 10 seconds, and the S Curve% setting is 50%, the S Curve time will be 10 x 0.5 = 5 seconds. Total time will be 10 + 5 = 15 seconds.

50% S Curve

Target

Target/2

1/2 S Curve Time

2.5 Seconds

Total Time to Accelerate = Accel Time + S Curve Time

Accel Time

10 Seconds

1/2 S Curve Time

2.5 Seconds

Figure 9.6 – S Curve% (A083) Examples

Parameter Descriptions 9-15

A084 Start Boost

Range: Settings in% of base voltage at 50% of Motor

Default: 8 = 5.0

See also: N/A

Sets the highest voltage the drive will output.

A089 Current Limit

Range: 0.1 to (Drive Rated Amps x 1.8 ) Default: Drive Rated Amps x 1.8

See also: N/A

Maximum output current allowed before current limiting occurs.

A090 Motor OL Select

Range: 0 = No Derate

Default: 0 = No Derate See also: P032

1 = Minimum Derate 2 = Maximum Derate

Drive provides Class 10 motor overload protection. Settings 0-2 select the derating factor for the I

t overload function. See figure

9.8.

Parameter Descriptions 9-17

No Derat

% of [Motor NP Hertz

1251007

Min Derat

1251007

Motor OL Curent

Figure 9.8 – Motor OL Select (A090)

Max Derat

1251007

613

A091 PWM Frequency

Range: 2.0 to 16.0 kHz Default: 4.0 kHz See also: N/A

Sets the carrier frequency for the PWM output wavef orm. Figure 9.9 provides derating guidelines based on the PWM frequency setting.

Important: Ignoring derating guidelines can cause reduced drive

performance.

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

A092 Auto Restart Tries

Range: 0 to 9 Default: 0

See also: N/A

Enables/disables a software instantaneous (within 100 ms) current trip.

A099 Pro cess Factor (Display Scaling)

Range: 0.1 to 999.9 Default: 30.0

See also: N/A

Enables compensation for the inherent slip in an induction motor. If motor shaft speed decreases significantly under heavy loads, then increase the value of this parameter. Setting this parameter to 0.0 disables this function.

Parameter Descriptions 9-25

A115 Process Time Lo

Range: 0.0 to 99.99 Default: 0.00

See also: N/A

Scales the time value when the drive is running at Minimum Freq. (P034). When set to a value other than zero, Process Display

(D010) indicates the duration of the process.

A116 Process Time Hi

Range: 0.0 to 99.99 Default: 0.00 See also: N/A

Scales the time value when the drive is running at Maximum Freq. (P035). When set to a value other than zero, Process Display (D010) indicates the duration of the process.

9-26 MD60 AC Drive User Manual

9.3 Display Group Parameters

d001 Output Frequency

Range: 0.0 to Maximum Frequency Default: Read Only

See also: N/A

The output current present at terminals T1, T2, and T3 (U , V, and W).

d004 Output Voltage

Range: 0 to Drive Rated Volts Default: Read Only

See also: N/A

A code that represents a drive fault. The codes will appear in these parameters in the order they occur (that is, Fault 1 Code in d007 will contain the more recent fault). Repetitive faults will be recorded only once. Refer to chapter 10 for the fau lt code descriptions.

9-28 MD60 AC Drive User Manual

d010 Process Display

Range: 0.00 to 99999

Default: Read Only See also: d001, A099

The output frequency scaled by A099 (Process Factor). Output Frequency x Process Factor = Process Display

d012 Control Source

Range: 0 to 9

Default: Read Only See also: P036, P038, A051, A052

Displays the active source of the Start Command and Speed Reference, which are normally defined by the settings of P036 (Start Source) and P038 (Speed Reference), but may be overridden by digital inputs. Refer to the flowcharts in section 6.6 and 6.7 for details.

See figure 9.11.

Start Command Digit 0 0 = Keypad 1 = 3-Wire 2 = 2-Wire 3 = 2-Wire Level Sensitive 4 = 2-Wire High Speed 5 = RS485 Port 9 = Jog

Speed Reference Digit 1 0 = Drive Potentiometer 1 = A069 (Internal Frequency) 2 = 0-10V Input 3 = 4-20mA Input 4 = A070-A073 (Preset Frequency x). A051-A052 (Digital InX Select) must be set to 4. 5 = RS485 port 9 = Jog Frequency

Reserved Digit 2

Reserved Digit 3

Figure 9.11 – Control Source (d012) Bit Definitions

Parameter Descriptions 9-29

d013 Control Input Status

Range: 0 = Input Present

Default: Read Only See also: N/A

The status of the control terminal block control inputs. Important: Actual command may come from a source other than

1 = Input Not Present See figure 9.12

the control terminal block.

Start / Run FWD Input (I/O Terminal 02) Digit 0

Direction / Run REV Input (I/O Terminal 03) Digit 1

Stop Input

Reserved Digit 3

The stop input must be present to start the drive. When this

bit is a 1, the drive can be started. When this bit is a 0, the drive will stop.

Figure 9.12 – Control Input Status (d013) Bit Definitions

d014 Digital Input Status

Range: 0 = Input Not Present

Default: Read Only See also: A051, A052

1 = Input Present See figure 9.13.

(Control Terminal 01) Digit 2

The status of the control terminal block digital inputs.

Digital In1 Sel (I/O Terminal 05) Digit 0

Digital In2 Sel (I/O Terminal 06) Digit 1

Reserved Digit 2

Reserved Digit 3

Figure 9.13 – Digital Input Status (d014) Bit Definitions

9-30 MD60 AC Drive User Manual

d015 Comm Status

Range: 0 = Condition False

Default: Read Only See also: A103 through A107

The status of the communications device.

1 = Condition True See figure 9.14.

Receiving Data Bit 0

Transmitting Data Bit 1

RS485 Option Connected Bit 2

Fault Occurred Bit 3

Figure 9.14 – Comm Status (d015) Bit Definitions

d016 Control SW Version

Range: 1.00 to 99.99 Default: Read Only

See also: N/A

The Main Control Board software version.

d017 Drive Type

Range: 1001 to 9999 Default: Read Only

See also: N/A

Used by Rockwell Automation field service personnel.

d018 Elapsed Ru n Ti me

Range: 0 to 9999 Hours Default: Read Only

See also: N/A

The accumulated time drive is outputting power. The time is displayed in 10-hour increments (that is, 1 = 10 hours).

Parameter Descriptions 9-31

d019 Testpoint Data

Range: 0 to FFFF Default: Read Only See also: A102

The present value of the function selected in Testpoint Select (A102).

d020 0 - 10 V Analog Input

Range: 0.0 to 100.0% Default: Read Only

See also: N/A

0 to 1200 C

Displays the present operating temperature of the drive power section.

9-32 MD60 AC Drive User Manual

CHAPTER 10

Troubleshooting the Drive

ATTENTION: The drive contains high voltage capacitors that take time to discharge after removal of mains supply. Before

working on the drive, ensure isolation of mains supply from line inputs [R, S, T (L1, L2, L3)]. Wait three (3) minutes for capacitors to discharge to safe voltage levels. Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels. Failure to observe this precaution could result in severe bodily injury or loss of life.

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.

The MD60 constantly monitors its status and provides the following ways to determine the status of the drive and to troubleshoot problems that may occur:

• LEDs on the drive (refer to figure 8.1 and table 8.1 for a

description of the LEDs)

• Fault codes

10.1 Fault Codes

Faults codes indicate conditions within the drive that require immediate attention. The drive responds to a fault by initiating a coast-to-stop sequence and turning off output power to the motor.

The integral keypad provides visual notification of a fault condition by displaying the following:

• Flashing fault number (code) on the display. (See table 10.1 for

the fault code descriptions.)

• Flashing FAULT LED

In addition, parameters d007-d009 act as a fault log. See the parameter descriptions in chapter 9 for more information.

Troubleshooting the Drive 10-1

10.1.1 Manually Clearing Faults

Step 1. Note the number of the fault code flashing on the display. Step 2. Press on the integral keypad to acknowledge the

fault and remove the fault code from the displa y. This also resets the drive if the fault is cleared.

Step 3. Address the condition that caused the fault. Refer to table

10.1 for a description of the fault and corrective actions. The cause must be corrected before the fault can be cleared.

Step 4. After corrective action has been taken, clear the fault and

reset the drive using one of the following methods:

• Press if P037 (Stop Mode) is set to a value between 0 and 3.

• Cycle drive power.

• Set A100 (Fault Clear) to 1.

• Cycle digital input if A051-A052 (Digital Inx Select) is set to option 7 (Clear Faults).

10.1.2 Automatically Clearing Faults (Auto Restart Feature)

The Auto Restart feature provides the ability for the drive to automatically perform a fault reset followed by a start attempt without user or application intervention. This allows remote or “unattended” operation. This feature can only be used for autoresettable faults (see table 10.1).

When this type of fault occurs, and A092 (Auto Restart Tries) is set to a value greater than “0,” a user-configurable timer, A093 (Auto Restart Delay), begins. When the timer reaches zero, the drive attempts to automatically reset the fault. If the condition that caused the fault is no longer present, the fault will be reset and the drive will be restarted.

To automatically clear an auto-resettable fault and restart the drive:

Step 1. Set A092 (Auto Restart Tries) to a value other than 0. Step 2. Set A093 (Auto Restart Delay) to a value other than 0.

To automatically clear an OverVoltage, UnderVoltage, or Heatsink OverTemp fault without restarting the drive:

Step 1. Set A092 (Auto Restart Tries) to a value other than 0. Step 2. Set A093 (Auto Restart Delay) to 0.

10-2 MD60 AC Drive User Manual

Use caution when enabling this feature since the drive will attempt to issue its own start command based on user-selected programming.

Table 10.1 – Fault Descriptions and Corrective Actions

No. Fault

F2 Auxiliary

Input

F3 Power Loss N DC bus v oltage

F4 UnderVoltage Y DC bus voltage fell

F5 OverVoltage Y DC bus voltage

F6 Motor Stalled Y Drive is unable to

F7 Motor

Overload

Y Auxiliary input interlock

Y Internal electronic

Description Action

Auto-Reset

is open.

remained below 85% of nominal.

below the minimum value.

exceeded maximum value.

accelerate motor.

overload trip.

• Check remote wiring.

• Verify communications

programming for intentional fault.

• Monitor the incoming

AC line for low voltage or line power interruption.

• Check input fuses.

Monitor the incoming AC line for low voltage or line power interruption.

Monitor the AC line for high line voltage or transient conditions. Bus overvoltage can also be caused by motor regeneration. Extend the decel time or install dynamic brake option.

Increase Accel Time x (P039, A067) or reduce load so drive output current does not exceed the current set by parameter A089 (Current Limit).

• An excessiv e motor load

exists. Reduce load so drive output current does not exceed the current set by parameter P033 (Motor OL Current).

• Verify Start Boost

(A084) setting.

Troubleshooting the Drive 10-3

Table 10.1 – Fault Descriptions and Corrective Actions (Continued)

No. Fault

F8 Heatsink

OverTemp

F12 HW

OverCurrent

F13 Ground Fault N A current path to earth

F33 Auto Restart

Tries

F38 Phase U to

Gnd

F39 Phase V to

Gnd

F40 Phase W to

Gnd

F41 Phase UV

Short

F42 Phase UW

Short

F43 Phase VW

Short

Y Heatsink temperature

N The drive output

N Drive unsuccessfully

N A phase to ground fault

N Excessive current has

Description Action

Auto-Reset

exceeds a predefined value.

current has exceeded the hardware current limit.

ground has been detected at one or more of the drive output terminals.

attempted to reset a fault and resume running for the programmed number of Auto Restart T ries in A092.

has been detected between the drive and motor in this phase.

been detected between these two output terminals.

• Check for blocked or

dirty heat sink fins. Verify that ambient temperature has not exceeded 40°C (104 °F) for IP 30/NEMA 1/UL T ype 1 installations or 50°C (122°F) for Open type installations.

• Check fan.

Check programming. Check for excess load, improper Start Boost (A084) setting, DC brake volts set too high, or other causes of excess current.

Check the motor and external wiring to the drive output terminals for a grounded condition.

Correct the cause of the fault and manually clear.

• Check the wiring

between the drive and motor.

• Check motor for

grounded phase.

• Replace drive if fault

cannot be cleared.

• Check the motor and

drive output terminal wiring for a shorted condition.

• Replace drive if fault

cannot be cleared.

10-4 MD60 AC Drive User Manual

Table 10.1 – Fault Descriptions and Corrective Actions (Continued)

No. Fault

F48 Params

Defaulted

F63 SW

OverCurrent

F64 Drive

Overload

F70 Power Unit N Failure has been

F81 Comm Loss N RS485 port stopped

N The drive was

Y Programmed A098

N Drive rating of 150%

Description Action

Auto-Reset

commanded to write default values to EEPROM.

(SW Current Trip) has been exceeded.

for 1 minute has been exceeded.

detected in the drive power section.

communicating.

• Clear the fault or cycle

• Program the drive

Check load requirements and A098 (SW Current Trip) setting.

Reduce load or extend Accel Time.

• Cycle power.

• Replace drive if fault

• If module was not

power to the drive.

parameters as needed.

cannot be cleared.

intentionally disconnected, check wiring to the port . Replace wiring, port expander, module or complete drive as required.

• Check connection.

• A module was

intentionally disconnected.

• Turn off using A105

(Comm Loss Action).

F100 Parameter

Checksum

F122 I/O Board Fail N Failure has been

Refer to section 10.1.2 for information about the Auto Restart Feature.

N The checksum read

from the board does not match the checksum calculated.

detected in the drive control and I/O section.

Set P041 (Reset to Defaults) to option 1 (Reset Defaults).

• Cycle power.

• Replace drive if fault

cannot be cleared.

Troubleshooting the Drive 10-5

10.2 Troubleshooting Tables

Use the following tables to troubleshoot the drive. If you cannot resolve the problem using these tables, contact Reliance Electric.

10.2.1 Problem: Drive Does Not Start From Terminal Block Start or Run Inputs

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

Possible Cause(s) Indication Corrective Action

Drive is faulted Flashing red

FAULT LED

Incorrect programming.

None Check parameter settings.

• P036 (Start Source) is set

to option 0 (Keypad) or option 5 (RS485 Port).

• A051/A052 (Digital Inx

Select) is set to option 5 “Local” and the input is active.

Incorrect input wiring. See figure 6.2 for wiring examples.

None Wire inputs correctly and/or

• 2-wire control requires

Run Forward, Run Reverse or Jog input.

• 3-wire control requires

Start and Stop inputs

• Stop input is always

required.

Clear fault by using one of the following methods:

• Press Stop

• Cycle power

• Set A100 (Fault Clear) to

1 (Clear Faults)

• Cycle digital input if A051/

A052 (Digital Inx Select) is set to option 7 (Clear Fault).

install jumper.

10-6 MD60 AC Drive User Manual

10.2.2 Problem: Drive Does Not Start From Integral Keypad

Table 10.3 – Problem: Drive Does Not Start From Integral Keypad

Cause(s) Indication Corrective Action

Integral keypad is not enabled.

Start Key Status LED is not on.

• Set parameter P036

(Start Source) to option 0 (Keypad).

• Set parameter A051/A052

(Digital Inx Select) is set to option 5 (Local) and activate the input.

I/O Terminal 01 “Stop” input is not present.

None Wire inputs correctly and/or

install jumper.

10.2.3 Problem: Drive Does Not Respond to Changes in Speed Command

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

Cause(s) Indication Corrective Action

No value is coming from the source of the command.

The RUN LED is on and output is 0 Hz.

• Check d012 (Control Source)

for correct source.

• If the source is an analog

input, check wiring and use a meter to check for presence of signal.

• Check d002 (Commanded

Frequency) to verify correct command.

Incorrect reference source is being selected via remote device or digital inputs.

None

• Check d012 (Control Source)

for correct source.

• Check d014 (Digital Input

Status) to see if inputs are selecting an alternate source. Verify settings for A051/A052 (Digital Inx Select).

• Check P038 (Speed

Reference) for the source of the speed reference. Reprogram as necessary.

• Review the Speed Reference

Control chart in section 6.6.

Troubleshooting the Drive 10-7

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

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

Cause(s) Indication Corrective Action

Acceleration time is excessive.

Excess load or short acceleration times force the drive into current limit, slowing or stopping acceleration.

None Reprogram P039 (Accel Time

1) or A067 (Accel Time 2).

None

• Compare d003 (Output

Current) with A089 (Current Limit).

• Remove excess load or

reprogram P039 (Accel Time 1) or A067 (Accel Time 2).

• Check for improper A084

(Start Boost) setting.

Speed command source or value is not as expected.

None

• Verify d002 (Commanded

Frequency).

• Check d012 (Control

Source) for the proper Speed Command.

Programming is preventing the drive output from exceeding limiting values.

None Check P035 (Maximum

Frequency) to ensure that speed is not limited by programming.

10.2.5 Problem: Motor Operation is Unstable

Table 10.6 – Problem: Motor Operation is Unstable

Cause(s) Indication Corrective Action

Motor data was incorrectly entered.

10-8 MD60 AC Drive User Manual

None 1. Correctly enter motor

nameplate data into P031, P032 and P033.

2. Enable A097 (Compensation).

3.Use A084 (Start Boost) to reduce boost level.

10.2.6 Problem: Drive Will Not Reverse Motor Direction.

Table 10.7 – Problem: Drive Will Not Reverse Motor Direction

Cause(s) Indication Corrective Action

Digital input is not selected for reversing control.

Digital input is incorrectly wired.

Motor wiring is improperly phased for reverse.

Reverse is disabled. None Check A095 (Reverse

None Check (Digital Inx Select).

Choose correct input and program for reversing mode.

None Check input wiring. None Switch two motor leads.

Disable).

Troubleshooting the Drive 10-9

10-10 MD60 AC Drive User Manual

APPENDIX A

Technical Specifications

Environment

Altitude: 1000 m (3300 ft) maximum without derating Ambient Operating

Temperature Without Derating:

Storage Temperature (all const.):

Relative Humidity: 0% to 95%, non-condensing Shock (Operating): 15 G peak for 11 ms duration (+/-1.0 ms) Vibration

(Operating):

Control

Carrier Frequency: 2-16 kHz. Drive rating based on 4 kHz. Frequency Accuracy • Digital Input: Within +/-0.05% of set output

Speed Regulation Open Loop with Slip Compensation:

Stop Modes: Multiple programmable stop modes including: Ramp,

Accel/Decel: Two independentl y pro grammable accel and decel

Intermittent Overload

Electronic Motor Overload Protection:

IP 20: -10° C (14° F) to 50° C (122° F) NEMA 1/IP30: -10° C (14° F) to 40° C (104° F)

-40° C (-40° F) to 85° C (185° F)

1 G peak, 5 to 2000 Hz

frequency.

• Analog Input: Within 0.5% of maximum output frequency.

+/-2% of base speed across a 40:1 speed range.

Coast, DC-Brake, Ramp-to-Hold, and S Curve.

times. Each time may be programmed from 0-600 seconds in 0.1 second increments.

• 150% Overload capability for up to 1 minute.

• 200% Overload capacity for up to 3 seconds

Class 10 protection with speed-sensitive response.

Technical Specifications A-1

Input/Output Rating

Output Frequency: 0-240 Hz (Programmable) Efficiency: 97.5% (Typical)

Digital Control Inputs (Inputs Current = 6 mA)

SRC (Source) Mode:

18-24 V = ON 0-6 V = OFF

SNK (Sink) Mode: 0-6 V = ON

18-24 V = OFF

Analog Control Inputs

4-20 mA Analog: 250 ohm input impedance 0-10 V DC Analog: 100k ohm input impedance External Pot: 1-10 k ohms, 2 Watt minimum

Control Output

Programmable Output (form C relay) Resistive Rating: 3.0 A at 30 V DC, 3.0 A at 125 V AC, 3.0 A at

240 V AC

Inductive Rating: 0.5 A at 30 V DC, 0.5 A at 125 V AC, 0.5 A at

240 V AC

Fuses and Circuit Breakers

Recommended Fuse Type:

UL Class J, CC, T or Type BS88; 600 V (550 V) or equivalent.

Recommended

HMCP circuit breakers or equivalent.

Circuit Breakers:

Protective Features

Motor Protection:

t overload protection - 150% for 60 sec, 200% for

3 sec (Provides Class 10 protection) Overcurrent: 200% hardware limit, 300% instantaneous fault Over Volta ge: • 100-120 V AC Input – Trip occurs at 405 V DC bus

voltage (equivalent to 150 V AC incoming line

• 200-240 V AC Input – Trip occurs at 405 V DC bus voltage (equivalent to 290 V AC incoming line)

• 380-460 V AC Input – Trip occurs at 810 V DC bus voltage (equivalent to 575 V AC incoming line)

A-2 MD60 AC Drive User Manual

Under Voltage: • 100-120 V AC Input – Trip occurs at 210 V DC bus

voltage (equivalent to 75 V AC incoming line)

• 200-240 V AC Input – Trip occurs at 210 V DC bus voltage (equivalent to 150 V AC incoming line

• 380-480 V AC Input – Trip occurs at 390 V DC bus voltage (equivalent to 275 V AC incoming line)

Control Ride-

Minimum ride-through is 0.5 sec - typical value 2 sec

Through: Faultless Power

100 milliseconds

Ride-Through:

Dynamic Braking

Internal brake IGBT included with all ratings.

Approvals

UL508C

CSA 22.2

EMC Directive 89/336 LV: EN 50178, EN 60204 EMC: EN 61800-3, EN 50081-1, EN 50082-2

Technical Specifications A-3

A-4 MD60 AC Drive User Manual

APPENDIX B

Record of

User Settings

B.1 Basic Parameter Group

Default

No. Parameter Name

P031 Motor NP Volts Varies 9-2 P032 Motor NP Hertz 60 Hz 9-2 P033 Motor OL Current Varies 9-2 P034 Minimum Frequency 0 Hz 9-2 P035 Maximum Frequency 60 Hz 9-2 P036 Start Source 0 = Keypad 9-3 P037 Stop Mode 1 = Coast,

P038 Speed Reference 0 = Drive

P039 Accel Time 1 5.0 sec 9-7 P040 Decel Time 1 5.0 sec 9-7 P041 Reset to Defaults 0 = Idle State 9-7

Value

Clear Fault

Potentiome ter

Page

No. User Setting

9-5

9-6

Record of User Settings B-1

B.2 Advanced Parameter Group

Default

No. Parameter Name

A051 Digital In1 Select 4 = Preset

A052 Digital In2 Select 4 = Preset

A055 Relay Output Select 0 = Ready (Not

A056 Relay Output Level 0.0 9-11 A067 Accel Time 2 10.0 sec 9-11 A068 Decel Time 2 10.0 sec 9-12 A069 Internal Frequency 0.0 Hz 9-12 A070 Preset Frequency 0 0.0 Hz 9-13 A071 Preset Frequency 1 0.0 Hz 9-13 A072 Preset Frequency 2 0.0 Hz 9-13 A073 Preset Frequency 3 0.0 Hz 9-13 A078 Jog Frequency 10.0 Hz 9-13 A079 Jog Accel/Decel 10.0 sec 9-13 A080 DC Brake Time 0.0 sec 9-14 A081 DC Brake Level Amps x 0.5 9-14 A082 DB Resistor Select 0 = Disabled 9-15 A083 S Curve% 0% (Disabled) 9-15 A084 Start Boost 8 = 5.0 9-16 A088 Maximum Voltage Rated Volts 9-17 A089 Current Limit Amps x 1.8 9-17 A090 Motor OL Select 0 = No Derate 9-17 A091 PWM Frequency 4.0 kHz 9-18 A092 Auto Restart Tries 0 9-18 A093 Auto Restart Delay 1.0 sec 9-19 A094 Start At Power Up 0 = Disabled 9-19 A095 Reverse Disable 0 = Reverse

A096 Flying Start Enable 0 = Disabled 9-20 A097 Compensation 1 = Electrical 9-20 A098 SW Current Trip 0.0 (Disabled) 9-21 A099 Process Factor

(Display Scaling)

Value

Frequencies

Faulted)

Enabled

30.0 9-21

Page

No. User Setting

9-8

9-9

9-19

B-2 MD60 AC Drive User Manual

No. Parameter Name

Default

Value

Page

No. User Setting

A100 Fault Clear 0 = Ready 9-21 A101 Program Lock 0 = Unlocked 9-21 A102 Testpoint Select 0000 9-22 A103 Comm Data Rate 4 = 19.2 K 9-22 A104 Comm Node Address 1 9-22 A105 Comm Loss Action 0 = Fault 9-22 A106 Comm Loss Time 5.0 9-23 A107 Comm Format 0 = RTU 8-N-1 9-23 A110 0 - 10 V Analog Input

0.0% 9-24

Low

A111 0 - 10 V Analog Input

100.0% 9-24

High

A112 4 - 20 mA Analog Input

0.0% 9-25

Low

A113 4 - 20 mA Analog Input

100.0% 9-25

High

A114 Slip Compensation 2.0 Hz 9-25 A115 Process Time Lo 0.00 9-26 A116 Process Time Hi 0.00 9-26

Record of User Settings B-3

B-4 MD60 AC Drive User Manual

Rockwell Automation MD60 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual