Inovance MD500 Series User manual

MD500 User Manual Preface
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Preface
Thank you for purchasing the MD500 seriesAC drive developed and manufactured by Inovance.
The MD500 is a general-purpose high-performance current vector AC drive for the purpose of control of three-phase AC
asynchronous motor on speed and torque. With advanced vector control technology, it has high torque output at low speed, good
dynamic feature and strong overload capacity. It increases the user programmable function, background monitoring software
and communication bus function, and supports multi-kind PG cards. It is used to drive various automation production equipment
involving textile, paper-making, wiredrawing, machine tool, packing, food, fan and pump.
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Introduction
Advantages
1. Small size and high power density
2. Wide voltage range design
Rated voltage input: 380 to 480 V, wide voltage range: 323 to 528 V
3. Built-in DC reactor
The MD500AC drives of 30 kW and above have built-in DC reactor.
4. Built-in braking unit and related protective function
The power class of the MD500AC drives with built-in braking unit extends to 75 kW. The protective functions including braking
resistor short-circuit, braking circuit overcurrent, brake pipe shoot-througn.
5. Long serving life design
The bus capacitor has high disposition and long servicing life.
6. Cooling fan drive circuit protection
When short-circuit occurs on the cooling fan due to motor rotor-lock or damage, the cooling fan drive circuit provides
protection.
7. Complete protective functions
The whole series of MD500 AC drives have the protections on short-circuit to ground and pre-charge relay (contactor) close
fault.
8. Complete EMC solution
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Product Checking
Upon unpacking, check:
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of conformity, user manual and warranty card.
ƕWhether the AC drive is damaged during transportation. If you find any omission or damage, contact Inovance or your
supplier immediately.
First-time Use
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or performance, contact the technical support personnel of Inovance to ensure correct use.
CE Mark
The CE mark on the MD500 declares that theAC drive complies with the European low voltage directive (LVD) and EMC directive.
The MD500 seriesAC drive complies with the international standards listed in the following table.
Directive Directive Code Standard
EMC directive (& EN 61800-3
EN 55011
EN 61000-6-2
LVD directive (&
((&
EN 61800-5-1
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use by following the instructions in chapter 7.
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Preface MD500 User Manual
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MD500 User Manual Preface
- 5 -
Contents
Preface....................................................................................................................1
Introduction..............................................................................................................2
Safety Information and Precautions ......................................................................10
Safety Information .......................................................................................................................11
General Precautions....................................................................................................................14
1. Product Information .........................................................................................21
3URGXFW7\SH,GHQWL¿FDWLRQ ...................................................................................................21
1.2 Components of the MD500...................................................................................................22
2. Mechanical Installation ....................................................................................26
2.1 Installation Environment.......................................................................................................26
2.2 Mounting Orientation and Clearance....................................................................................27
2.3 Physical Appearance and Mounting Dimensions .................................................................29
2.4 Installation Method and Proces............................................................................................31
2.5 Removing and Installing the Front Cover.............................................................................36
3. Electrical Installation ........................................................................................40
3.1 Typical System Connection..................................................................................................40
3.2 Main Circuit Wiring ...............................................................................................................41
3.3 Control Circuit Wiring............................................................................................................50
3.4 Wiring Checklist .................................................................................................................56
4. Operations .......................................................................................................58
4.1 Introduction to the Operating Panel.............................................................................. 58
4.2 Operating Panel Menu Structure..........................................................................................62
4.3 Overall Arrangement of Function Parameters......................................................................65
4.4 Function Parameter Operations ...........................................................................................66
5. Quick Setup......................................................................................................70
5.1 Get Familiar With Operation Panel.......................................................................................70
5.2 Setup Flowchart....................................................................................................................71
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6. Parameter Table...............................................................................................84
6.1 Introduction...........................................................................................................................84
6.2 Standard Parameters ............................................................................................................85
6.3 Monitoring Function Codes..................................................................................................103
7 Description of Parameters.............................................................................106
7.1 Start/Stop Command Source .............................................................................................106
7.2 Frequency Reference Settings...........................................................................................114
7.3 Start/Stop the AC Drive ......................................................................................................139
7.4 Motor Auto-tuning...............................................................................................................145
7.5 Control Performance ..........................................................................................................149
7.6 Protections..........................................................................................................................161
7.7 Monitoring...........................................................................................................................168
7.8 Process...............................................................................................................................175
7.9 Input and Output Terminals ................................................................................................191
7.10 Communication.................................................................................................................202
7.11 Auxiliary Function..............................................................................................................209
8 Interfaces and Communication......................................................................220
8.1 About the Use of MD500 Terminals....................................................................................220
8.2 Serial Communication ........................................................................................................223
8.3 About Multifunctional Extension Interfaces.........................................................................224
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8.5 Modbus Communication Protocol.......................................................................................228
9 Peripherals and Options................................................................................240
9.1 Connecting Peripheral Devices..........................................................................................241
9.2 Options ..............................................................................................................................247
6SHFL¿FDWLRQV ...............................................................................................274
7HFKQLFDO6SHFL¿FDWLRQV ...................................................................................................274
10.2 De-rating...........................................................................................................................278
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11 Maintenance and Inspection........................................................................280
11.1 Daily Inspection .................................................................................................................280
11.2 Periodic Inspection ............................................................................................................281
11.3 Replacement of Vulnerable Components..........................................................................283
11.4 Storage..............................................................................................................................286
11.5 Warranty Agreement.........................................................................................................286
12 Troubleshooting...........................................................................................288
12.1 Safety Information .......................................................................................288
12.2 Troubleshooting During Trial Run......................................................................................289
12.3 Fault Display......................................................................................................................291
12.4 Resetting Fault ...............................................................................................................291
12.5 Faults and Diagnostics......................................................................................................292
12.6 Symptoms and Diagnostics..............................................................................................299
13 EMC.............................................................................................................302
13.1 CE Mark...........................................................................................................................302
13.2 CE Low Voltage Directive Compliance............................................................................302
13.3 EMC Guidelines Compliance.............................................................................................304
'H¿QLWLRQRI7HUPV............................................................................................................304
13.5 Selection of Peripheral EMC Devices..............................................................................305
13.6 Breaker & Fuse Selection................................................................................................317
13.7 Shielded Cable................................................................................................................318
13.8 Solutions to Current Leakage............................................................................................319
Warranty Agreement............................................................................................321
Product Warranty Card.......................................................................................322
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i
Safety Information and Precautions
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Safety Information and Precautions MD500 User Manual
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Safety Information and Precautions
Before the Use
Thank you for purchasing the MD500 series AC drive. This manual introduces how to use the drive correctly. Before using the
drive (installation, wiring, operation, maintenance and inspection), read this manual carefully. In addition, use the drive only after
you get to understand the safety information and precautions in this chapter.
About This Manual
The manual related to the MD500 seriesAC drive is listed in the following table.
MD500 AC Drive Manual Description
MD500 Series High-performance Vector Control AC Drive User Manual
The manual is packed together with the drive in the carton.
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This manual is designed to ensure correct use of the drive, including selection,
parameter setting, commissioning, maintenance & inspection. Before using
the drive, read this manual carefully to have a thorough understanding of the
product. Keep the manual well and forward it with the product to end users.
ƕThe drawings in the manual are sometimes shown without covers or protective
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ƕThe drawings in the manual are shown for description only
and may not match the product you purchased.
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increase the accuracy and convenience of the manual.
ƕContact our agents or customer service center if you have any problem during the use.
This manual includes some very important safety warnings and notices. There are three types of safety notice, and you must
comply with the three types of notice.
DANGER
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WARNING
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CAUTION
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Read the following safety information and instructions carefully so that you understand how to install, commission, operate and
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operation of the equipment described in the manual.
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MD500 User Manual Safety Information and Precautions
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Safety Information
General
DANGER
To Prevent Electric Shock
ƕNever wire the AC drive while the power is on. Cut off all power supplies and wait for at least ten minutes
before any checking work so that the residual voltage on capacitors can discharge safely.
ƕAlways ensure that the AC drive is tied to ground well because the contact current of the drive is larger than 3.5 mA.
WARNING
To Prevent Sudden Movement
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that the cover of the AC drive is secure and the motor is allowed to restart before applying power to the drive.
To Prevent Electric Shock
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ƕNever remove the cover or touch the PCB of the drive.
To Prevent Fire
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CAUTION
To Prevent Crush
ƕNever transporting the drive by carrying the front cover. Failure to comply may
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ƕAlways handle the drive with care.
ƕDo not use the drive if there are damaged or missing parts.
To Prevent Damage to the Equipment
ƕFollow the proper electrostatic discharge (ESD) procedures when operating the AC
drive. Failure to comply will damage the interna circuit of the drive.
ƕDo not perform a voltage resistance test on any part of the AC drive. The factory performs tests
of this type during manufacture and damage might occur if you repeat these tests.
ƕDo not power on or operate the drive that has been damaged or has any missing part. Failure to comply may cause further damage.
ƕPerform branch circuit and short circuit protection according to local code. Failure to comply may damage the drive. The drive
is applicable to the circuit capable of 100 kA below short-circuit current and and 480 VAC maximum voltage (400 V class).
To Reduce Interference
ƕNever install equipments such as transformer that generate electromagnetic wave or interference
surrounding the drive. Failure to comply may result in unexpected action of the drive. If it is
necessay to install such equipment, install a shield plate between it and the drive.
To Prevent Malfunction
ƕNever share grounding cable with welding machines or electrical equipments that require large
current. Failure to comply may result in the drive or equipment malfunction.
ƕWhen using multiple drives, ground them properly according to the instructions in this
manual. Improper grounding may result in the drive or equipment malfunction.
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Safety Information and Precautions MD500 User Manual
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Before Installation
DANGER
ƕNever install the equipment if the equipment shows signs of water damage or damage during transit, or if parts are missing.
ƕNever install the the equipment if the packing list does not conform to the product you receive.
During Installation
DANGER
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WARNING
ƕNever connect power cables to the output terminals (U, V, W) of theAC drive. Identify the marks of
the cable terminals carefully, and make sure you complete all connections correctly.
ƕNever connect the regen resistor between the DC bus terminals (+) and (–).
ƕUse a shielded cable for connections to the encoder, and make sure you connect the shielding layer to an effective ground.
Making Electrical Connections
DANGER
ƕConnect the output terminals (U, V, W) of theAC drive to the input terminals (U, V, W) of the motor. Make sure to keep
their phase sequence consistent. Inconsistent phase sequence will result in reverse rotation of the motor.
ƕNever connect power cables to the output terminals of the AC drive. Failure to
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After Power-on
DANGER
ƕNever open or remove the protective cover of the AC drive when the equipment is powered on.
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WARNING
ƕNever touch the rotating part of the motor during motor auto-tuning or while the motor is running.
ƕNever change the factory settings of the MD500 AC drive.
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MD500 User Manual Safety Information and Precautions
- 13 -
During Operation
DANGER
ƕDo not touch the fan or the discharging resistor, which becomes hot.
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WARNING
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ƕFollow the correct procedures described in this user manual to start and to stop the MD500 AC
drive. Do not start or stop the AC drive by using the power contactor or circuit breaker.
During Maintenance
DANGER
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ƕNever repair or main the drive while the power is on. Follow the repair and maintenance instructions in this user manual.
ƕWait for a period of 10 minutes after the AC drive is powered off before allowing any repairs or maintenance work
to start, so that hot parts can cool down and to allow the residual voltage on capacitors to discharge safely.
ƕDisconnect the AC drive from the power supply before starting any repair or maintenance operations.
ƕPerform parameter setting and check after the drive is replaced.
WARNING
ƕThe rotating motor feeds power back to the AC drive system. Because of this, theAC drive will
still be charged even if the motor stops and the power is disconnected. Therefore, disconnect
the motor from the AC drive before starting any maintenance on theAC drive.
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Safety Information and Precautions MD500 User Manual
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General Precautions
1. Requirements of a residual current device (RCD)
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Thus install a type-B RCD at primary side of the power supply. When selecting the RCD, you should consider the transient and
steady-state leakage current to ground that may be generated at startup and during running of the AC drive. You can select a
specialized RCD with the function of suppressing high harmonics or a general-purpose RCD of 300 mA (
n
I'
is two to four
times of protective conductor current).
2. Motor insulation test
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ƕWhen the motor is reused after being stored for a long time
ƕDuring regular maintenance checks.
This precaution detects poor insulation of the motor windings so that early actions can be taken to prevent damage to
the AC drive. The motor must be disconnected from the AC drive during the insulation test. A 500 volt insulation tester is
recommended for this test, and the insulation resistance must not be less than 5 M.
Figure 1 Connections required for a motor insulation test
U V W Motor input terminals
Insulation tester
Motor ground
3. Thermal protection of the motor
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operation panel of the AC drive or install a thermal relay in the motor circuit for protection. It is especially important to take
this precaution if theAC drive has a higher power rating than the motor.
4. Running at frequency higher than 50 Hz
The MD500 AC drive can output frequency in the range 0 to 500 Hz. If it is necessary to operate the MD500 AC drive at
frequency higher than 50 Hz, consider the capacity of the machine.
5. Vibration of the mechanical device
The AC drive might experience mechanical resonance at some output frequencies. It is possible to avoid this by selecting the
MXPSIUHTXHQF\
6. Motor heat and noise
The output from the MD380 AC Drive is a pulse width modulation (PWM) waveform, which contains harmonic frequencies.
Because of this, the motor temperature, noise and vibration increase slightly when the AC drive operates at the line frequency
(50 Hz).
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MD500 User Manual Safety Information and Precautions
- 15 -
7. Voltage-sensitive device or capacitor on the output side of the AC drive
Do not install a capacitor for improving power factor, or a voltage sensitive resistor for lightning protection, on the output side
of the AC drive. This is because the output is a PWM waveform and the AC drive might suffer transient overcurrent or become
damaged.
Figure 2 Disallowed connections to theAC Drive output
Capacitor or
voltage-sensitive resistor
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If there is a contactor installed between the input side of the AC drive and the power supply, DO NOT use it to start or to stop
the AC drive. However, if there is a real and urgent need to use the contactor to start or to stop the AC drive, make sure the
time interval between switching is at least one hour. If the interval between switching is shorter than one hour, this will reduce
the service life of the capacitor inside theAC drive.
If there is a contactor installed between the output side of the AC drive and the motor, do not switch off this contactor when
the AC drive is operating. Damage might occur to components inside the AC drive if you switch off the output contactor when
theAC drive is operating.
Figure 3 Input and output contactors
R
S
T
U
V
W
AC power
input
Input
contactor Output
contactor
Do not start or stop the AC drive by switching
the input contactor. If you must operate the AC
drive by using the input contactor, wait at least
one hour between switching operations.
Switch the output contactor
on or off ONLY when there is
no output from the AC drive.
 When the external voltage exceeds the rated voltage range
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its rated voltage range, components inside the AC drive might be damaged. If necessary, use an appropriate voltage step-up
or step-down device to match the supply voltage to the rated voltage range for theAC drive.
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Safety Information and Precautions MD500 User Manual
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10. Prohibition of three-phase input changed into two-phase input
Do not change a three-phase input of theAC drive into a two-phase input.
11. Surge suppressor
The AC drive has a built-in voltage-dependent resistor (VDR) for suppressing the surge voltage generated when the inductive
loads around the AC drive (for example the electromagnetic contactor, electromagnetic relay, solenoid valve, electromagnetic
coil and electromagnetic brake) are switched on or off.
If the inductive loads generate a very high surge voltage, use a surge suppressor for the inductive load and possibly also use
a diode.
Note
Do not connect the surge suppressor to the output side of the AC Drive.
12. Some special usages
If your installation requires special cabling that this user manual does not describe, for example to support a common DC bus,
contact Inovance for technical support and advice.
13. Disposal
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do, the electrolytic capacitors might explode, and the plastic components will create poisonous gases. Treat any parts for
disposal as ordinary industrial waste.
14. Adaptable motor
ƕThe standard adaptable motor is an adaptable four-pole squirrelcage asynchronous induction motor. For other types of
motor, select the correct AC drive according to the rated motor current.
ƕThe cooling fan and rotor shaft of non-variable-frequency motors are coaxial, which results in reduced cooling effect
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applications where the motor overheats easily.
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necessary to perform motor auto-tuning or to modify the default values based on actual conditions. Otherwise, the
running result and protection performance will be adversely affected.
ƕThe AC drive might cause an alarm or might be damaged when a short-circuit exists on cables or inside the motor.
Therefore, perform insulation short-circuit test when the motor and cables are newly installed or during routine
maintenance. During the test, disconnect the drive from the tested parts.
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MD500 User Manual Safety Information and Precautions
- 17 -
Drive Label Warnings
TheAC drive labels the warning information in the following position.
Please obey the warning information during the use.
Directive Code Standard
Read the user manual of the MD500 AC drive carefully before installation
or operation. Failure to comply will result in electric shock.
Never remove the protective covers while the power is on or within10 minutes
after the power is turned off. Wait for a period of 10 minutes after the AC drive is
powered off before starting any repair, maintenance or wiring work .
Restrictions
ƕThe MD500 AC drive is not designed or manufactured for use in devices or systems that may directly affect or threaten human
livesor health.
ƕCustomers who intend to arrange the AC drive for special use such as device or system relating to manned transportation
vehicles, health care, space aviation, nuclear energy, electric power, or in underwater applications must contact the agent or
sales representatives of Inovance..
ƕThe AC drive has been manufactured under strict quality control. However, if this product is to be installed in any location
where the fault of this product may result in a severe accident or loss, install safety devices.
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Safety Information and Precautions MD500 User Manual
- 18 - efesotomasyon.com

1
Product Information
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