iRZ 500 Series User manual

IRZ 500
VARIABLE SPEED DRIVE
«QUICK START»
INSTALLATION MANUAL
2019

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Contents
1 GENERAL PROVISIONS FOR WORK WITH THE PRODUCT....................................................................3
1.1 Safety measures ..........................................................................................................................3
1.2 Installation of VSD .......................................................................................................................3
1.3 Technical characteristics..............................................................................................................3
1.4 Description of VSD design ...........................................................................................................5
1.5 VSD operation at environment temperature variations .............................................................6
2. INTENDED USE....................................................................................................................................7
2.1 Operations with the drive controller...........................................................................................7
3 PROCEDURE OF DRIVE OPERATION ..................................................................................................13
3.1 Preparation of the drive ............................................................................................................13
3.2 Emergency actions.....................................................................................................................15
ANNEX А- IRZ-500 MENU STRUCTURE................................................................................................17
ANNEX B - RECOMMENDED IRZ-500 DRIVE CONNECTION DIAGRAM ................................................18

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1 GENERAL PROVISIONS FOR WORK WITH THE PRODUCT
1.1 Safety measures
1.1.1 All dismounting, installation, start and adjustment works shall be performed according to the
applicable “Safety Standards for Users of Electrical Installations” and “Maintenance Rules for
Users of Electrical Installations” and applicable departmental regulations.
1.1.2 Grounding and safety measures shall be performed according to requirements of applicable
“Rules for Electrical Equipment Installation”.
1.1.3 When installed in the place, the drive shall be grounded by a steel grounding conductor with
cross section not less than 75 mm2. The grounding conductor shall be connected to the drive’s
terminal for external protective conductor; the connection shall be a bolted or welded joint. The
joint shall be protected against corrosion.
ATTENTION! WHEN INSTALLING THE DRIVE, CHECK THAT THE 480V, 50
Hz 3-PHASE SUPPLY LINE AND LOAD LINE ARE CORRECTLY CONNECTED
TO THE DRIVE INPUT AND OUTPUT TERMINALS.
1.1.4 Before starting the drive, check and if necessary tighten the fastening of components,
conductors and contact connections of the main circuit.
ATTENTION! WHEN THE Q1 SWITCH IS IN OFF STATE, VOLTAGE REMAINS
ACROSS THE ХТ1, ХТ2, AND ХТ3 TERMINALS, AS WELL AS ACROSS
TERMINALS OF THE Q1, SF1, AND SF2 SWITCHES, RU1…RU3 OUTPUTS AND
ELECTRICAL ENERGY METER (WHEN INCLUDED)
1.1.4 Before to perform any works inside the drive:
-shut down power, and disconnect and ground the external leading-in cables.
-put up warning posters
1.2 Installation of VSD
1.2.1 The environment shall be inexplosive, free from current-conducting dust and have type II
atmosphere as per GOST 15150.
1.2.2 The unit shall be positioned vertically; the slant from the vertical shall not exceed 5 degrees.
1.2.3 It is not allowed to install the drive under an overhead power transmission line.
1.2.4 The drive must not be operated without proper grounding.
1.2.5 The drive shall be installed on a foundation or pedestal that prevents from flooding or snowdrift.
The drive shall be fixed to the foundation or pedestal with bolts using holes in the mounting frame.
1.2.6 Before the start of operation, be sure to familiarize yourself with the operating manual for the
IRZ-500 drive.
1.3 Technical characteristics
1.3.1 Characteristics of the various versions of the drive are given in table 1.1.

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Table 1.1
Name
Main circuit
rated current, А
Total output power
(at rated input
voltage of 480 V and
frequency of 50/60
Hz), kV·А
Recommended rated
power of the
connected motor (at
rated input voltage of
480 V and frequency
of 50/60 Hz), kW
Motor type
IRZ-510-хх-100
100
80
35
Induction
IRZ-510-хх-160
160
120
60
IRZ-511-хх-250
250
190
90
IRZ-512-хх-400
400
300
150
IRZ-513-хх-630
630
480
210
IRZ-514-хх-800
800
600
270
IRZ-515-хх-1000
1000
800
360
IRZ-516-хх-1200
1200
900
480
IRZ-517-хх-1400
1400
1100
540
IRZ -518-хх-1600
1600
1200
600
IRZ -540-хх-100
100
80
35
Induction or permanent
magnet
IRZ -540-хх-160
160
120
60
IRZ -541-хх-250
250
190
90
IRZ -542-хх-400
400
300
150
IRZ -543-хх-630
630
480
210
IRZ -544-хх-800
800
600
270
IRZ -545-хх-1000
1000
800
360
IRZ -551-хх-160
160
120
60
Permanent magnet
IRZ -551-хх-250
250
190
90
IRZ -552-хх-400
400
300
150
IRZ -553-хх-630
630
480
210
IRZ -554-хх-800
800
600
270
IRZ -555-хх-1000
1000
800
360

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1.4 Description of VSD design
1.4.1 The drive constitutes a metallic cabinet that can be accessed on two sides.
Functionally the drive consists of a power section and control system.
1.4.2 The connection of the drive to the power supply network and to the load is made inside the main
circuit I/O compartments located on the rear side of the cabinet.
1.4.3 On the rear side of the cabinet, there are also compartments for connection to a telemechanics
system and to the step-up transformer Y-point, and a compartment of the frequency inverter.
1.4.4 The operator’s panel is located inside a separate lockable compartment on the front side of the
cabinet.
1.4.5 Design and operation of the control system
1.4.5.1 The control system consists of control units and IRZ-500 drive controller (hereinafter referred to
as “controller”).
1.4.5.2 The operator’s panel includes the following controls and indicators:
- Incoming power circuit breaker;
- controller with a USB connector for connection of USB-flash devices;
- three-position switch of operation modes (see table 1.2);
- “~220 V, 50 Hz” receptacle for geophysical instruments;
- circuit breakers: Light, Receptacle, Controller, Heating, Venting, DHS (see figure 1.1);
- electrical energy meter (optional)
Figure 1.1 –Plate of automatic circuit breakers on the operator’s panel
Table 1.2
Position of
operation mode
switch
VSD operation
mode
Motor start/
shut-down via
START/STOP
buttons
Motor remote
start via RS485
interface
Motor auto-
restart
AUTO
Automatic control
mode
+
+
+ *
MANUAL
Manual control
mode
+
+ **
-
NO
Motor start blocking
mode
-
-
-
* - when there is no auto-restart blocking
** - when the relevant setting in the “Additional settings” menu is selected

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1.4.5.3 The plate (fig. 1.1) on the operator’s panel of the IRZ-500 drive is for understanding the purpose
of the automatic circuit breakers:
“220V, 10A” receptacle
To switch on the drive controller
To switch on the drive lighting circuit
To switch on the heating circuit
To switch on the fan circuit
To switch on the downhole sensor system power
circuit
1.5 VSD operation at environment temperature variations
1.5.1 A temperature control system is used to ensure operability of the drive within the given operating
temperatures range. This system ensures operating temperature inside the drive cabinet. Depending
on the heatsink temperature, the drive can be in several states in accordance with table 1.3.
Table 1.3
Drive temperature
Drive condition
below minus 20 °С
Heating of the drive and controller is turned on, the inverter and
controller are deactivated. Start is impossible.
from minus 20 °С to
minus 5 °С
Heating of the drive and controller is turned on. The controller and
inverter are activated. Start is possible.
from minus 5 °С to 45 °С
Heating and ventilation of the drive are turned off.
above 45 °С
Instrument compartment ventilation is turned on.
above 50 °С
Turning on the ventilation of the inverter compartment and sine filter
compartment
above 80 °С
Drive shutdown due to inverter overheating
above 150 °С (in sine
filter compartment)
Drive shutdown due to sine filter overheating

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2. INTENDED USE
2.1 Operations with the drive controller
Description of the main menu is given in Table 2.1.
Table 2.1
Menu item
Menu description
MAIN REAL-TIME PARAMETERS
Real-time condition of the drive, inverter and DHS
INPUT VOLTAGE PARAMETERS
View and edit of input voltage settings
MOTOR CONTROL POINTS AND
PROTECTION FUNCTIONS
View and edit of drive protection main settings and
parameters
DHS CONTROL POINTS AND
PROTECTION FUNCTIONS
View and edit of DHS settings and motor protections
INVERTER SETTINGS
View and edit of inverter operation settings (frequency,
acceleration and deceleration rates, motor start mode)
TECHNOLOGICAL SETTINGS
Settings for automatic intermittent mode of motor
operation, as well as the characteristics of additional
modes of drive operation
SETTINGS OF ADDITIONAL ANALOG
INPUTS
Settings to measure the input signal from each of the two
analog inputs
SETTINGS OF ADDITIONAL DIGITAL
INPUTS
Settings for operation with additional digital inputs of the
drive
NOTEBOOK
Characteristics of the field, pad, and well.
Technical parameters of the motor, ESP, step-up
transformer, drive and controller.
Statistics of operation, number of motor starts and
shutdowns
POWER ENERGY
Indications of active, reactive and total electrical energy
consumed by the motor and drive
ADDITIONAL SETTINGS
Adjusting parameters of information exchange of the drive
in the network and parameters of record in the history of
operation.
Clearing the event archive of the drive
Parameters for calculating step-up transformer secondary
voltage
PASSWORD SETTING
View and change of security profiles, passwords change
DATE AND TIME
Setting the current date and time
EVENT ARCHIVE
History of motor operation
DIAGNOSTICS
Condition of various modules
SERVICE MENU
Setup and reprogramming of individual drive modules

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2.1.2 "▲" and "▼" buttons are used to navigate between menu items and drive parameters, and to
adjust control points values ("▲" –increase, "▼" - decrease).
2.1.3 "ENTER" button is intended to select certain menu item and to approve correctness of the value
entered.
2.1.4 “ESC” button is intended to exit current menu item and cancel new control point value
2.1.5 It is also possible to access the PASSWORD SETTING menu from any section of the drive menu by
pressing the F3 button.
2.1.6 It is possible to view real-time parameters of the drive from any menu section by pressing F2.
2.1.7 F1 button is used to return to the previous menu item from the real-time parameters window.
2.1.8 As indicated in Table 2.2, the controller of the drive can be operated and configured on four access
levels.
2.1.9 The real-time parameters page displays the real-time status of the drive, inverter, and downhole
unit (DHS). Designations of possible states and their descriptions are given in Tables 2.3 - 2.6.

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Table 2.2 –List of security profiles with allowed actions
Allowed actions
Access level
OPERATOR
ELECTRICIAN
WORKS
FOREMAN
ADMINISTRA
TOR
Profile access password
No password
159
410
*
Control points (settings) review**
+
+
+
+
Control points change**
-
+
+
+
SERVICE MENU contents review
-
-
+
+
Full access to SERVICE MENU
-
-
-
+
Reset of history and statistics
counters
-
-
+
+
Change of password for the
ELECTRICIAN profile
-
+
+
+
Change of password for the
WORKS FOREMAN profile
-
-
+
+
Change of password for the
ASMINISTRATOR profile
-
-
-
+
* -only servicing specialists have password to the profile access
** - except for the SERVICE MENU section
Table 2.3 –Real-time parameters of the downhole sensor system
Message on the drive’s
display
Description
Message on the drive’s
display
Description
DHS status
Codes of downhole
sensor actual status
No. of instrument
counted from the
wellhead, 1-6
No. of the instrument
ESP intake pressure
ESP intake pressure
Ser. No.
Serial number
Motor oil temperature
Motor oil temperature
Type
Instrument type
Motor winding
temperature
Motor winding
temperature
Pin
Intake pressure
ESP intake temperature
Fluid temperature at the
ESP intake
Tin
Intake temperature
Vibration - X/Y/Z
Vibration along X/Y/Z
axis
Flowrate1
Flow rate
Frame
Counter of downhole
sensor system
responses
Flowrate2
Flow rate
Frame type
Frame type
Humidity
Humidity value

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Table 2.4 –Drive and frequency inverter actual status codes
Message on the drive’s
display
Status description
RUNNING
The motor has been started and is now operating; the rotor catch mode may
be active
PUSH
The motor is running, the PUSH mode is active
ROCKING
The motor is running, the ROCKING mode is active
SYNCHRONIZATION
The motor is running, the frequency synchronization mode is active
PID
The motor is running, the PID-regulation mode is active
JOGGLE
The motor is running, the JOGGLE deposits removal mode is active
F SMOOTH CHANGE
The motor is running, the mode of frequency change by software is active
Un SEARCH
The motor is running, the voltage optimization mode is active
I LIMIT
The motor is running, the current limiting mode is active
T LIMIT
The motor is running, the temperature limiting mode is active
STOP
The motor has been stopped
WAIT
The motor has been stopped and time is being counted till the start (at
operation with the timer in automatic mode or when time till automatic
restart after tripping is counted) or time is counted to the start after power
supply
START IS BLOCKED
The motor has been stopped, start is blocked either according to a setting or
after a remote stop command
MANY AUTORESTARTS
BLOCKING
The motor has been stopped, start is blocked due to achieving the limit
number of automatic restarts
Table 2.5 –List of messages on causes of drive starts and stops
Status designation
Event type
STOP
The motor has been stopped
Rinsul STOP
The motor has been stopped due to decrease of insulation
resistance below the control point or failure of the Rinsul control
circuit
Uab<NORM
The motor has been stopped due to decrease of Uab below the
normal value set by the control point
Ubc<NORM
The motor has been stopped due to decrease of Ubc below the
normal value set by the control point
Uca< NORM
The motor has been stopped due to decrease of Uca below the
normal value set by the control point
Uab>NORM
The motor has been stopped due to increase of Uab above the
normal value set by the control point
Ubc> NORM
The motor has been stopped due to increase of Ubc above the
normal value set by the control point
Uca> NORM
The motor has been stopped due to increase of Uca above the
normal value set by the control point