ICON ICON-500 Series User manual

AC Drive User Manual
Model : ICON-500
Providing Solution Worldwide
INVENTION CONTROLS

EDIT：V2.3
TIME：2019-04
Preface
Thank you for purchasing the ICON500 series high performance vector and torque control frequency
inverter
ICON500 series Performance higher level than ICON300A frequency inverterwith advanced functions,
such as high performance vector control of induction motor, user-programmable function and backstage
monitoring software, variable communication and supporting multiple PG cards etc. It is applicable to
textile, papermaking, tension control, wire drawing fans and pumps, machine tools, packaging, food and
all kinds of automatic production equipment.Its excellent performance is equivalent and competitive to
most of international brand AC drives
This manual introduces functional characteristics and usage of ICON500 series inverter, includes
product model selection, parameter settings, running and debugging, maintenance, checking, and so
on. Please be sure to read this manual carefully before operation. For equipment matching
manufacturers, please send this manual to your end user together with your devices, in order to
facilitate the usage.
PRECAUTIONS
To describe the product details, the illustrations in the manual sometimes are under the state of
removing the outer housing or security covering. While using the product, please be sure to
mount the housing or covering as required, and operate in accordance with the contents of
manual.
The illustrations in this manual is only for explanation, may be different from the products you
ordered.
Committed to constantly improving the products and features will continue to upgrade, the
information provided is subject to change without notice.
Please contact with the regional agent or client service center directly of factory if there is any
questions during usage.

Contents
Chapter 1 Safety Information and Precautions.................................................................................. 1
Safety Precautions.................................................................................................................1
Precaution..............................................................................................................................2
Chapter 2 Product Information........................................................................................................... 4
Designation Rules.................................................................................................................. 4
product series instruction........................................................................................................ 4
Technical Specifications ..........................................................................................................5
Chapter 3 Product appearance and Installation Dimension......................................................7
Product appearance and installation.....................................................................................7
Product appearance..................................................................................................... 7
Appearance and Mounting Hole Dimension ................................................................ 7
Removal and installation of cover and inlet plate....................................................... 10
Wiring....................................................................................................................................12
Standard wiring diagram............................................................................................ 12
Main Circuit Terminals.....................................................................................................13
Terminal screws and wiring specifications................................................................. 14
Cautions for Main Circuit Wiring................................................................................ 14
3.2.4Control Circuit Terminal..................................................................................................15
EMCquestion and solution ....................................................................................................21
Chapter 4 Operation and display...................................................................................................... 23
LED Instruction of operation and display............................................................................. 23
Display hierarchy and menu mode......................................................................................24
Digital tube display............................................................................................................... 25
Test run.................................................................................................................................26
Chapter 5 Function Code Table..................................................................................................................27
Chapter6 Fault Diagnosis and Solution............................................................................................ 90
Chapter7 Selection Guide of inverterAccessory ............................................................................. 95
Selection Guide ofbraking component.................................................................................95
PG card type ........................................................................................................................96
IO Extension card.................................................................................................................98
Chapter8 Daily maintenance of frequency inverters...................................................................... 100
Daily maintenance..............................................................................................................100
Daily maintenance.................................................................................................... 100
Regular inspection.................................................................................................... 100
Wearing parts replacement................................................................................................100
Warranty Items....................................................................................................................101
Appendix A Modbus communication protocol.............................................................................. 102

ICON500 high performance vector control frequency inverter user
manual
Chapter 1 Safety information and precautions
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1-
Chapter 1 Safety Information and Precautions
Safety Definitions: In this manual, safety precautions are divided into the following two categories:
indicates that failure to comply with the notice will result in serous injury or even death
indicates that failure to comply with the notice will result in moderate or minor injury andequipment
damage
Read this manual carefully so that you have a thorough understanding. Installation, commissioning or
maintenance may be performed in conjunction with this chapter. will assume no liability or responsibility
for any injury or loss caused by improper operation.
Safety Precautions
Use stage
Security Level
Precautions
Before
Installation
DANGER
packing water, parts missing or damaged parts, please do not install!
Packaging logo and physical name does not match, please do not
install!
WARNING
Handling should be light lift, otherwise there is the danger ofdamage
to equipment!
Do not use damaged drive or missing drive. Risk of injury!
Do not touch the control system components by hand, or there is the
danger of electrostatic damage!
During
Installation
DANGER
Please install the flame retardant objects such as metal, away from
combustibles, or may cause a fire!
WARNING
Do not allow lead wires or screws to fall into the drive, otherwisethe
drive may be damaged!
Install the drive in a place where there is less vibration anddirect
sunlight.
Drive placed in airtight cabinet or confined space, please note the
installation of space to ensure the cooling effect.
Wiring
DANGER
Youmust follow the guidance of this manual and be used by qualified
electrical engineers. Otherwise, unexpected danger may occur!
There must be a circuit breaker between the drive and thepower
supply, otherwise a fire may occur!
Make sure the power supply is in zero-energy state before wiring,
otherwise there is danger of electric shock!
Please follow the standard to the drive properly grounded, otherwise
there is the risk of electric shock!
WARNING
Never connect input power to the drive's output terminals (U, V,W).
Note that the terminal markings, do not take the wrong line!Otherwise
it will cause damage to the drive!
Never connect the braking resistor directly to the DC bus +, - terminals.
Otherwise it will cause a fire!
Refer to the manual's recommendations for the wire diameterused.
Otherwise it may happen accident!
Do not disassemble the connecting cable inside the driver.Otherwise,
the internal of the servo driver may be damaged.
Before
Power-on
DANGER
Make sure the voltage level of the input power is the same as the rated
voltage of the driver. Check if the wiring position of the power input
terminals (R, S, T) and output terminals (U, V,W) is correct; Ofthe
external circuit is short-circuited, the connection is tightened, or cause

Chapter1 Safety information and precaution
ICON500 high performance vector control frequency inverter user
manual
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Use stage
Security Level
Precautions
damage to the drive!
No part of the drive need to withstand voltage test, the product has
been made before the test. Otherwise it may cause accident!
WARNING
The driver must be covered before the cover can be powered,
otherwise it may cause electric shock!
All peripheral accessories must be wired according to the instructions
in this manual, and be properly wired in accordance with this manual.
Otherwise it may cause accident!
After
Power-on
DANGER
Do not open the cover after power on, otherwise there is danger of
electric shock!
If the indicator light does not light after power on, the keyboard does
not display the situation, immediately disconnect the power switch, do
not touch any input and output terminals of the drive, otherwise there is
the risk of electric shock!
WARNING
If parameter identification is required, preclude the possibility ofinjury
when rotating the motor!
Do not arbitrarily change the drive manufacturer parameters, or it may
cause damage to the device!
During
Operation
DANGER
Do not touch the cooling fan, radiator and discharge resistance totest
the temperature, otherwise it may cause burns!
Non-professional technicians Do not detect the signal during
operation, otherwise it may cause personal injury or equipment
damage!
WARNING
Drive operation, should avoid something falling into thedevice,
otherwise it will cause damage to the device!
Do not use the contactor on-off method to control the start and stop the
drive, otherwise it will cause damage to the equipment!
Maintenance
DANGER
Do not live on the equipment repair and maintenance, or there is a risk
of electric shock!
Turn off the input power for 10 minutes before performing maintenance
and repair on the drive, otherwise the residual charge on the capacitor
will cause harm to people!
Do not carry out maintenance and repair on the drive without
personnel who have been professionally trained, otherwisepersonal
injury or equipment damage will occur!
All pluggable plug-ins must be unplugged in the case of powerfailure!
The parameters must be set and checked after replacing thedrive.
WARNING
Before performing maintenance work on the drive, make sure that the
motor is disconnected from the drive to prevent the motor from feeding
back power to the drive due to accidental rotation.
Precaution
Contactor using
If the contactor is installed on the power input side of the inverter, do not make the contactor frequent on-off
operation. The interval between ON and OFF of the contactor should not be less than one hour. Frequent
charging and discharging will reduce the use of capacitors in the inverter life.
If a contactor is installed between the inverter output terminals (U, V, W) and the motor, make sure that the
inverter is turned on and off when there is no output. Otherwise, the inverter may be damaged.
Lightning impulse protection
Although this series of inverters are equipped with lightning over-current protection device, there is a certain
degree of self-protection for inductive lightning, but for lightning frequent place, customers should also install
lightning protection device in the front of the inverter.

ICON500 high performance vector control frequency inverter user
manual
Chapter 1 Safety information and precautions
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3-
Altitude and derating use
In areas above 1000m above sea level, it is necessary to derate the inverter due to poor air quality due to poor
air quality. In this case, please consult our company.
Power input
The inverter power input should not exceed the operating voltage range specified in this manual. If necessary,
use a step-up or step-down device to change the power supply to the specified voltage range.
Do not change the three-phase inverter to two-phase input, otherwise it will cause malfunction or inverter
damage.
Output filtering
When the cable length between the inverter and the motor exceeds 100 meters, it is suggested to use the
output AC reactor to avoid inverter over-current caused by excessive distributed capacitance. Output filter
according to the needs of the field matching.
Inverter output is PWM wave, please do not install the capacitor on the output side to improve the power factor
or lightning varistor, etc., otherwise it may easily lead to inverter instantaneous overcurrent or even damage the
inverter.
About motor heat and noise
Because the inverter output voltage is PWM wave, contains a certain degree of harmonics, so the motor
temperature rise, noise and vibration compared with the same frequency operation will be slightly increased.
Disposal
Electrolytic capacitors on the main circuit and electrolytic capacitors on the printed circuit board may explode
when incinerated, and poisonous gases are generated when plastic parts are burned. Please dispose as
industrial waste.
The scope of application
This product is not designed and manufactured for use on equipment where life is at stake. To use this product
on a mobile, medical, aerospace, nuclear or other special purpose device, please contact our company For more
information.
This product is manufactured under strict quality control and should be equipped with a safety device if it is
used in a device that may cause a serious accident or damage due to inverter failure.

Chapter 2 Product information
ICON500 high performance vector control frequency inverter user
manual
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MODEL: ICON500-2R2GT4
POWER: 2.2kW/4.0kW
INPUT: 3PH AC380~440V 50Hz/60Hz
OUTPUT: 3PH 0~440V 0~600Hz 5.6A/9.4A
S/N:
4:380-480v three phase 2: 200-240v
Chapter 2 Product Information
Designation Rules
Name plate：TYPE
POWER
INPUT
OUTPUT
CODE
2-1 name plate
Model instruction：
ICON500 -2R2 – G T 4 B
Product series instruction
model instruction
Table 2-ICON500 inverter models and technical data
Model
Power
capacity
(KVA)
Input
current
(A)
Output current(A)
Adapta
ble
Motor
(KW)
SIZE
Brake
Unit
Heavy
load
Light
load
Three phase: 380-480V，50/60Hz
ICON500-R75GT4B
1.5
3.4
2.5
4.2
0.75
SIZE A
Inter
nal
ICON500-1R5GT4B
3
5
4.2
5.6
1.5
ICON500-2R2GT4B
4
5.8
5.6
9.4
2.2
ICON500-4R0G/5R5PT4B
5.9
10.5
9.4
13.0
3.7
ICON500-5R5G/7R5PT4B
8.9
14.6
13.0
17.0
5.5
SIZE B
ICON500-7R5G/011PT4B
11
20.5
17.0
23.0
7.5
ICON500-011G/015PT4B
17
26.0
25.0
31.0
11
SIZE C
Inter
nal
ICON500-015G/018PT4B
21
35.0
32.0
37.0
15
ICON500-018G/022PT4B
24
38.5
37.0
45.0
18.5
SIZE D
ICON500-022G/030PT4B
30
46.5
45.0
57.0
22
Product series
Power，2R2 means 2.2kW
Load type:G normal duty
T:three phase
B means breaking units

ICON500 high performance vector control frequency inverter user
manual
Chapter2 production information
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5-
ICON500-030G/037PT4
40
62.0
60.0
75.0
30
SIZE E
optio
n
ICON500-037G/045PT4
50
76.0
75.0
87.0
37
ICON500-045G/055PT4
60
92.0
90.0
110.0
45
SIZE F
ICON500-055G/075PT4
85
113.0
112.0
135.0
55
ICON500-075G/090PT4
104
157.0
152.0
165.0
75
SIZE G
ICON500-090G/110PT4
112
170.0
176.0
210.0
90
Technical Specifications
Table 2-2 ICON500 Technical Specifications
Item
Specifiation
Input
Inuput Voltage
1phase/3phase 220V：200V～240V
3 phase 380V-480V：380V～480V
Allowed Voltage
fluctuation range
-15%～10%
Input frequency
50Hz / 60Hz，fluctuation less than 5%
Output
Output Voltage
3phase：0～input voltage
Overload capacity
General purpose application：60S for 150% of the rated current
Light load application：60S for 120% of the rated current
Control
Control mode
V/f control
Sensorless flux vector control without PG card（SVC）
Sensor speed flux vector control with PG card (VC)
Operating mode
Speed control、Torque control（SVC and VC）
Speed range
1:100 (V/f)
1:200( SVC)
1:1000 (VC)
Speed control
accuracy
±0.5% (V/f)
±0.2% (SVC)
±0.02% (VC)
Speed response
5Hz(V/f)
20Hz(SVC)
50Hz(VC)
frequency range
0.00～600.00Hz(V/f)
0.00～200.00Hz(SVC)
0.00～400.00Hz(VC)
Input frequency
resolution
Digital setting: 0.01 Hz
Analog setting: maximum frequency x 0.1%
Startup torque
150%/0.5Hz(V/f)
180%/0.25Hz(SVC)
200%/0Hz(VC)
Torque control
accuracy
SVC：within 5Hz10%，above 5Hz5%
VC:3.0%
V/f curve
V / f curve type: straight line, multipoint, power function, V / f separation
Torque boost support: Automatic torque boost (factory setting), manual
torque boost
Frequency giving
ramp
Support linear and S curve acceleration and deceleration;
4 groups of acceleration and deceleration time, setting range 0.00s ~
60000s
DC bus voltage
control
Overvoltage stall control: limit the power generation of the motor by
adjusting the output frequency to avoid skipping the voltage fault;

Chapter 2 Product information
ICON500 high performance vector control frequency inverter user
manual
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Undervoltage stall control: control the power consumption of the motor
by adjusting the output frequency to avoid yaw failure
VdcMax Control: Limit the amount of power generated by the motor by
adjusting the output frequency to avoid over-voltage trip;
VdcMin control: Control the power consumption of the motor by
adjusting the output frequency, to avoid jump undervoltage fault
Carrier frequency
1kHz～12kHz(Varies depending on the type)
Startup method
Direct start (can be superimposed DC brake); speed tracking start
Stop method
Deceleration stop (can be superimposed DC braking); free to stop
Maincontrol
function
Jog control, droop control, up to 16-speed operation, dangerous speed
avoidance, swing frequency operation, acceleration and deceleration
time switching, VF separation, over excitation braking, process PID
control, sleep and wake-up function, built-in simple PLC logic, virtual
Input and output terminals, built-in delay unit, built-in comparison unit
and logic unit, parameter backup and recovery, perfect faultrecord,fault
reset, two groups of motor parameters free switching, software swap
output wiring, terminals UP /DOWN
Function
Keypad
LED Digital keyboard and LCD keypad(option)
communication
Standard:
MODBUS communication
Option:Profibus-DP and CAN OPEN
PG card
Incremental Encoder Interface Card (Differential Output and Open
Collector), Rotary transformer Card
Input terminal
Standard:
5 digital input terminals, one of which supports high-speed pulse input
up to 50kHz;
2 analog input terminals, support 0 ~ 10V voltage input or 0 ~ 20mA
current input;
Option card:
4 digital input terminals
2 analog input terminals.support-10V-+10V voltage input
Output terminal
standard:
1 digital output terminal;
1 high-speed pulse output terminal (open collector type), support 0 ~
50kHz square wave signal output;
1 relay output terminal(second relay is an option )
2 analog output terminals, support 0 ~ 20mA current output or 0 ~10V
voltage output;
Option card: 4 digital output terminals
Protection
Refer to Chapter 6 "Troubleshooting and Countermeasures" for the protection function
Environment
Installation
location
Indoor, no direct sunlight, dust, corrosive gas, combustible gas, oil
smoke, vapor, drip or salt.
Altitude
0-3000m.inverter will be derated if altitude higher than1000m and
rated output current will reduce by 1% if altitude increase by 100m
Ambient
temperature
-10°C~ +40°C,maximum 50°C (derated if the ambient temperature is
between 40°C and 50°C)Rated output current decrease by 1.5% if
temperature increase by 1°C
Humidity
Less than 95%RH, without condensing
Vibration
Less than 5.9 m/s2(0.6 g)
Storage
temperature
-20°C ~ +60°C
Others
Installation
Wall-mounted, floor-controlled cabinet, transmural
Protection level
IP20
cooling method
Forced air cooling

ICON500 high performance vector control frequency inverter user
manual
Chapter3 Product appearance and wiring
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7-
Fan cover
fan
Keypad
Front cover
cover
Back cover
Name plate
Line board
Control terminal
Extension card port
Main circuit terminal
Chapter 3 Product appearance and Installation Dimension
Product appearance and installation
Product appearance
3-1：ICON500 series appearance
Appearance and Mounting Hole Dimension
Keypay and keypad support size
The dimensions of the ICON500 series keypad are shown in Figure 3-1. When installing the keypad on the outside
of the control cabinet, use the two screws on the back of the keypad to fix it (right side of Figure 3-1).