i-MO HD2-3.7A-43 User manual

INSTRUCTION MANUAL
HD2
AC Variable Speed Inverter Drives
IMO Precision Controls Ltd. www.imopc.com

HD2 Series Inverter Preface
i
Preface
Thank you for choosing HD2 series inverter.
If not otherwise specified in this manual, the inverter always indicates HD2 series inverter, which is a
high-performance and multi-function inverter aiming to integrate the capability to drive both
synchronous motors and asynchronous motors, and support torque control, speed control, and
position control. The inverter is armed with advanced vector control technology and the latest digital
processor dedicated to motor control, thus enhancing product reliability and adaptability to the
environment. The inverter adopts customized and industrialized design to realize excellent control
performance through optimized functions and flexible applications.
To meet diversified customer demands, the inverter provides abundant expansion cards including
programmable card, PG card, communication card and I/O card to achieve various functions as
needed.
The programmable card adopts the mainstream development environment for customers to carry out
secondary development easily, fulfilling varied customized needs and reducing customer cost.
The PG card supports a variety of encoders like incremental encoders and resolver-type encoders, in
addition, it also supports pulse reference and frequency-division output. The PG card adopts digital
filter technology to improve EMC performance and to realize stable transmission of the encoder
signal over a long distance. It is equipped with encoder offline detection function to contain the impact
of system faults.
The inverter supports multiple types of popular communication modes to realize complicated system
solutions. It can be connected to the internet with the optional wireless communication card, by which
you can monitor the inverter state anywhere any time through mobile APP.
The inverter uses high power density design. Some power ranges carry built-in DC reactors and
braking units to save installation space. Through overall EMC design, it can satisfy the low noise and
low electromagnetic interference requirements to cope with challenging grid, temperature, humidity,
and dust conditions, thus greatly improving product reliability.
This operation manual presents installation wiring, parameter setup, fault diagnosis and trouble
shooting, and precautions related to daily maintenance. Read through this manual carefully before
installation to ensure the inverter is installed and operated in a proper manner to give full play to its
excellent performance and powerful functions.
We reserve the right to update the manual information without prior notice and have the
final interpretation for the manual content.

HD2 Series Inverter Contents
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Contents
Preface.............................................................................................................................................i
Contents.......................................................................................................................................... ii
1 Safety Precautions........................................................................................................................1
1.1 What this chapter contains ...............................................................................................1
1.2 Safety definition................................................................................................................1
1.3 Warning symbols..............................................................................................................1
1.4 Safety guidelines..............................................................................................................2
1.4.1 Delivery and installation.......................................................................................2
1.4.2 Commissioning and running.................................................................................3
1.4.3 Maintenance and component replacement...........................................................4
1.4.4 What to do after scrapping...................................................................................4
2 Quick Startup................................................................................................................................5
2.1 What this chapter contains ...............................................................................................5
2.2 Unpack inspection............................................................................................................5
2.3 Application confirmation....................................................................................................5
2.4 Environment confirmation.................................................................................................5
2.5 Installation confirmation....................................................................................................6
2.6 Basic commissioning........................................................................................................6
2.7 Safety standard related data.............................................................................................7
3 Product Overview..........................................................................................................................8
3.1 What this chapter contains ...............................................................................................8
3.2 Basic principle..................................................................................................................8
3.3 Product specifications.......................................................................................................9
3.4 Product nameplate.........................................................................................................11
3.5 Type designation key......................................................................................................12
3.6 Ratings of a single inverter.............................................................................................12
3.7 Parallel inverter models..................................................................................................13
3.8 Ratings of parallel products............................................................................................13
3.9 Structure diagram...........................................................................................................13
4 Installation Guidelines.................................................................................................................15
4.1 What this chapter contains .............................................................................................15
4.2 Mechanical installation ...................................................................................................15
4.2.1 Installation environment.....................................................................................15
4.2.2 Installation direction...........................................................................................16
4.2.3 Installation mode ...............................................................................................17
4.2.4 Single-unit installation........................................................................................18
4.2.5 Multiple-unit installation......................................................................................18
4.2.6 Vertical installation.............................................................................................19
4.2.7 Tilted installation................................................................................................20
4.3 Standard wiring of main circuit........................................................................................21

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4.3.1 Wiring diagram of main circuit for a single inverter .............................................21
4.3.2 Wiring diagram of main circuit for parallel inverters ............................................22
4.3.3 Main circuit terminal diagram .............................................................................22
4.3.4 Wiring procedure of the main circuit terminals....................................................25
4.4 Standard wiring of control circuit.....................................................................................26
4.4.1 Wiring diagram of basic control circuit................................................................26
4.4.2 Wiring diagram of control circuit for parallel inverters..........................................28
4.4.3 Input/output signal connection diagram..............................................................29
4.5 Wiring protection............................................................................................................30
4.5.1 Protect the inverter and input power cable in short-circuit...................................30
4.5.2 Protect the motor and motor cable in short circuit...............................................30
4.5.3 Protect motor and prevent thermal overload.......................................................30
4.5.4 Bypass connection.............................................................................................31
5 Basic Operation Guidelines.........................................................................................................32
5.1 What this chapter contains .............................................................................................32
5.2 Keypad introduction........................................................................................................32
5.3 Keypad display...............................................................................................................35
5.3.1 Displaying stopped-state parameters .................................................................35
5.3.2 Displaying running-state parameters..................................................................36
5.3.3 Displaying fault information................................................................................37
5.4 Operating the inverter through the keypad......................................................................37
5.4.1 Enter/exit menu .................................................................................................37
5.4.2 Editing a parameter list ......................................................................................42
5.4.3 Adding parameters to the parameter list displayed in stopped/running state .......43
5.4.4 Adding parameters to the user defined parameter list.........................................44
5.4.5 Editing user defined parameters ........................................................................45
5.4.6 Editing parameters in parameter groups ............................................................45
5.4.7 Monitoring states ...............................................................................................46
5.4.8 Autotuning motor parameters.............................................................................46
5.4.9 Backing up parameters......................................................................................47
5.4.10 System settings ...............................................................................................47
5.4.11 Power-on setup wizard.....................................................................................47
5.5 Basic operations.............................................................................................................48
5.5.1 What this section contains .................................................................................48
5.5.2 Common commissioning procedures .................................................................49
5.5.3 Vector control ....................................................................................................52
5.5.4 SVPWM control mode........................................................................................57
5.5.5 Torque control....................................................................................................66
5.5.6 Motor parameter................................................................................................71
5.5.7 Start/stop control ...............................................................................................76
5.5.8 Frequency setup................................................................................................81

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5.5.9 Analog input.......................................................................................................85
5.5.10 Analog output...................................................................................................88
5.5.11 Digital input......................................................................................................92
5.5.12 Digital output .................................................................................................102
5.5.13 Simple PLC ...................................................................................................107
5.5.14 Multi-step speed running................................................................................109
5.5.15 PID control......................................................................................................111
5.5.16 Run at wobbling frequency............................................................................. 116
5.5.17 Local encoder input ....................................................................................... 118
5.5.18 Commissioning procedures for closed-loop control, position control and spindle
positioning................................................................................................................ 118
5.5.19 Fault handling................................................................................................124
5.5.20 Tension control solutions................................................................................129
6 Function Parameter List............................................................................................................134
6.1 What this chapter contains ...........................................................................................134
6.2 Function parameter list.................................................................................................134
P00––Basic functions...............................................................................................135
P01––Start/stop control ............................................................................................139
P02––Parameters of motor 1....................................................................................145
P03––Vector control of motor 1 ................................................................................149
P04––V/F control......................................................................................................156
P05––Input terminals................................................................................................164
P06––Output terminals.............................................................................................172
P07––HMI................................................................................................................177
P08––Enhanced functions........................................................................................183
P09––PID control .....................................................................................................191
P10––Simple PLC and multi-step speed control .......................................................196
P11––Protection parameters ....................................................................................199
P12––Parameters of motor 2....................................................................................206
P13––Control parameters of synchronous motor ......................................................209
P14––Serial communication function........................................................................ 211
P15––Functions of communication expansion card 1................................................216
P16––Functions of communication expansion card 2................................................220
P17––Status viewing................................................................................................227
P18––Closed-loop control state check......................................................................232
P19––Expansion card state check............................................................................234
P20––Encoder of motor 1.........................................................................................236
P21––Position control...............................................................................................240
P22––Spindle positioning .........................................................................................246
P23––Vector control of motor 2 ................................................................................249
P24––Encoder of motor 2.........................................................................................251

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P25––Extension I/O card input functions ..................................................................254
P26––Output functions of expansion I/O card ...........................................................258
P27––Programmable expansion card functions ........................................................261
P28––Master/slave control functions ........................................................................264
P90––Tension control in speed mode .......................................................................267
P91––Tension control in torque mode.......................................................................271
P92––Customized tension control functions..............................................................274
P93––Tension control status viewing ........................................................................276
7 Troubleshooting........................................................................................................................279
7.1 What this chapter contains ...........................................................................................279
7.2 Indications of alarms and faults ....................................................................................279
7.3 Fault reset....................................................................................................................279
7.4 Fault history .................................................................................................................279
7.5 Inverter faults and solutions..........................................................................................279
7.5.1 Details of faults and solutions...........................................................................279
A fault occurred on the customized position..................................................................................287
Perform troubleshooting based on actual customized faults. ........................................................287
Device or ambient temperature is too high. ..................................................................................287
Lower the device or ambient temperature.....................................................................................287
Device or ambient temperature is too high. ..................................................................................287
Lower the device or ambient temperature.....................................................................................287
There is no data transmission between the communication card and the host controller (or PLC). 287
Check whether the communication card wiring is loose or dropped. .............................................287
The upgrade bootloader is missing...............................................................................................287
Contact us. ..................................................................................................................................287
AI1 wiring is disconnected............................................................................................................287
Check the wiring or replace the cables.........................................................................................287
AI2 wiring is disconnected............................................................................................................288
Check the wiring or replace the cables.........................................................................................288
AI4 wiring is disconnected............................................................................................................288
Check the wiring or replace the cables.........................................................................................288
7.5.2 Other state ......................................................................................................288
7.6 Analysis on common faults...........................................................................................288
7.6.1 Motor fails to work ...........................................................................................288
7.6.2 Motor vibrates..................................................................................................289
7.6.3 Overvoltage.....................................................................................................290
7.6.4 Undervoltage...................................................................................................290
7.6.5 Unusual heating of motor.................................................................................291
7.6.6 Inverter overheating.........................................................................................292
7.6.7 Motor stalls during ACC ...................................................................................293
7.6.8 Overcurrent .....................................................................................................294

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7.7 Countermeasures on common interference ..................................................................295
7.7.1 Interference on meter switches and sensors ....................................................295
7.7.2 Interference on communication........................................................................296
7.7.3 Failure to stop and indicator shimmering due to motor cable coupling ..............297
7.7.4 Leakage current and interference on RCD .......................................................297
7.7.5 Live device chassis..........................................................................................298
8 Maintenance and Hardware Fault Diagnosis .............................................................................299
8.1 What this chapter contains ...........................................................................................299
8.2 Periodical inspection ....................................................................................................299
8.3 Cooling fan...................................................................................................................301
8.4 Capacitor .....................................................................................................................302
8.4.1 Capacitor reforming .........................................................................................302
8.4.2 Electrolytic capacitor replacement....................................................................303
8.5 Power cable.................................................................................................................304
9 Communication.........................................................................................................................305
9.1 What this chapter contains ...........................................................................................305
9.2 Modbus protocol introduction........................................................................................305
9.3 Application of Modbus ..................................................................................................305
9.3.1 RS485.............................................................................................................305
9.3.2 RTU mode.......................................................................................................308
9.4 RTU command code and communication data.............................................................. 311
9.4.1 Command code 03H, reading N words (continuously up to 16 words) .............. 311
9.4.2 Command code 06H, writing a word.................................................................313
9.4.3 Command code 08H, diagnosis .......................................................................313
9.4.4 Command code 10H, continuous writing ..........................................................314
9.4.5 Data address definition ....................................................................................315
9.4.6 Fieldbus scale .................................................................................................319
9.4.7 Error message response..................................................................................320
9.4.8 Read/Write operation example.........................................................................322
9.5 Common communication faults.....................................................................................326
Appendix A Expansion Cards .......................................................................................................328
A.1 Model definition............................................................................................................328
A.2 Dimensions and installation..........................................................................................332
A.3 Wiring..........................................................................................................................334
A.4 IO expansion card (HD2-E-IO) .....................................................................................335
A.5 IO expansion card 2 (HD2-E-IO2) ................................................................................337
A.6 Programmable expansion card (HD2-E-PLC)...............................................................339
A.7 Communication cards ..................................................................................................342
A.7.1 Bluetooth communication card (HD2-E-BTP) and WIFI communication card
(HD2-E-WFP)...........................................................................................................342
A.7.2 PROFIBUS-DP communication card (HD2-E-PDP)..........................................344

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A.7.3 Ethernet communication card (HD2-E-ENET)..................................................345
A.7.4 CANopen communication card (HD2-E-COP) and CAN master/slave control
communication card (HD2-E-CAN) ...........................................................................346
A.7.5 PROFINET communication card (HD2-E-PRF)................................................348
A.7.6 Ethernet/IP communication card (HD2-E-EIP) and Modbus TCP communication
card (HD2-E-MTCP).................................................................................................350
A.8 PG expansion card function description........................................................................352
A.8.1 Sin/Cos PG card (HD2-E-PGISC)....................................................................352
A.8.2 UVW incremental PG card (HD2-E-PGI)..........................................................355
A.8.3 Resolver PG card (HD2-E-PGR)......................................................................357
A.8.4 Multifunction incremental PG card (HD2-E-PGIM) ...........................................359
A.8.5 24V incremental PG card (HD2-E-PGIM24).....................................................363
Appendix B Technical Data ..........................................................................................................366
B.1 What this chapter contains...........................................................................................366
B.2 Derated application......................................................................................................366
B.2.1 Capacity..........................................................................................................366
B.2.2 Derating ..........................................................................................................366
B.3 Grid specifications........................................................................................................367
B.4 Motor connection data..................................................................................................367
B.4.1 EMC compatibility and motor cable length .......................................................367
B.5 Application standards...................................................................................................368
B.5.1 CE marking .....................................................................................................368
B.5.2 EMC compliance declaration ...........................................................................368
B.6 EMC regulations..........................................................................................................368
B.6.1 inverter category C2........................................................................................369
B.6.2 inverter category C3 ........................................................................................369
Appendix C Dimension Drawings.................................................................................................370
C.1 What this chapter contains...........................................................................................370
C.2 Keypad structure .........................................................................................................370
C.2.1 Structure diagram ...........................................................................................370
C.2.2 Keypad installation bracket..............................................................................370
C.3 Inverter structure .........................................................................................................371
C.4 Dimensions ofAC 3PH 380V (-15%)–440V (+10%)......................................................371
C.4.1 Wall mounting dimensions...............................................................................371
C.4.2 Flange mounting dimensions...........................................................................373
C.4.3 Floor mounting dimensions .............................................................................375
C.6 Dimensions for parallel inverters ..................................................................................376

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C.6.1 Dimensions with the recommended mounting method.....................................376
C.6.2 Dimensions with the close mounting method ...................................................377
Appendix D Optional PeripheralAccessories................................................................................379
D.1 What this chapter contains...........................................................................................379
D.2 Wiring of peripheral accessories ..................................................................................379
D.3 Power supply...............................................................................................................381
D.4 Cables.........................................................................................................................381
D.4.1 Power cables ..................................................................................................381
D.4.2 Control cables.................................................................................................382
D.4.3 Recommended cable sizes .............................................................................382
D.4.4 Cable sizes for parallel inverters......................................................................383
D.4.5 Cable configuration for parallel inverters..........................................................384
D.4.6 Cable arrangement .........................................................................................385
D.4.7 Insulation inspection........................................................................................385
D.5 Breaker and electromagnetic contactor........................................................................386
D.5.1 For a single inverter ........................................................................................386
D.5.2 For parallel inverters .......................................................................................386
D.6 Reactors......................................................................................................................387
D.6.1 For a single inverter ........................................................................................388
D.6.2 For parallel inverters .......................................................................................389
D.7 Filters..........................................................................................................................390
D.7.1 Filter model description ...................................................................................391
D.7.2 Filter model selection ......................................................................................391
D.8 Braking system............................................................................................................392
D.8.1 Braking component selection...........................................................................392
D.8.2 Braking resistor cable selection.......................................................................394
D.8.3 Braking resistor installation..............................................................................394
Appendix E STO Function Description .........................................................................................396
E.1 STO function logic table...............................................................................................396
E.2 STO channel delay description.....................................................................................396
E.3 STO function installation checklist................................................................................397
Appendix F Further Information....................................................................................................398
F.1 Product and service queries .........................................................................................398
F.2 Feedback on IMO inverter manuals..............................................................................398
F.3 Documents on the Internet............................................................................................398

HD2 Series Inverter Safety Precautions
-1-
1 Safety Precautions
1.1 What this chapter contains
Read this manual carefully and follow all safety precautions before moving, installing, operating, and
servicing the inverter. If these safety precautions are ignored, physical injury, death, or equipment
damage may occur.
Electrical equipment should be installed, operated, service and maintained only by competent
personnel. No responsibility is assumed by IMO Precision Controls Ltd for any consequences arising
out of the use of this product.
1.2 Safety definition
Danger: Serious physical injury or even death may occur if related requirements are not followed.
Warning: Physical injury or damage to the equipment may occur if related requirements are not
followed.
Note: Actions taken to ensure proper operation.
Qualified electricians: People working on the device should take part in professional electrical and
safety training, receive the certification and be familiar with all steps and requirements of installing,
commissioning, operating, and maintaining the device to prevent any emergencies.
1.3 Warning symbols
Warnings caution you about conditions which can result in serious injury or death and/or damage to
the equipment, and advice on how to avoid the danger. The following warning symbols are used in
this manual.
Symbols
Name
Instruction
Abbreviation
Danger
Danger
Serious physical injury or even death
may occur if related requirements
are not followed.
Warning
Warning
Physical injury or damage to the
equipment may occur if related
requirements are not followed.
Forbid
Electrostatic
discharge
The PCBA may be damaged if
related requirements are not followed
Hot
Hot sides
The inverter base may become hot.
Do not touch.
Electric
shock
As high voltage still presents in the
bus capacitor after power off, wait for
at least five minutes (or 15 min / 25
min, depending on the warning
symbols on the machine) after power
off to prevent electric shock.