Rockwell Automation MD60 User manual

Instruction Manual
MD60 AC Drive
User Manual
Version 3.0
D2-3499-3

©2003 Rockwell Automation. All rights reserved.
The information in this manual is subject to change without notice.
Throughout this manual, the following notes are used to alert you to safety
considerations:
Important: Identifies information that is critical for successful application and
understanding of the product.
!
ATTENTION:Identifies information about practices or
circumstances that can lead to personal injury or death,
property damage, or economic loss.
MD60, VS Utilities, and Reliance are trademarks of Rockwell Automation.
!
ATTENTION: Only qualified personnel familiar with the
construction and operation of this equipment and the hazards
involved shouldinstall,adjust,operate,orservicethisequipment.
Read and understand this document in its entirety before
proceeding. Failure to observe this precaution could result in
severe bodily injury or loss of life.
ATTENTION: Thedrivecontainshighvoltagecapacitorsthattake
time to discharge after removal of mains supply. Before working
on the drive, ensure isolation ofmains supply from line inputs [R,
S, T (L1, L2, L3)]. Wait three (3) minutes for capacitors to
dischargeto safevoltage levels.DarkeneddisplayLEDs isnot an
indication that capacitors have discharged to safe voltage levels.
Failure to observe this precaution could result in severe bodily
injury or loss of life.
ATTENTION: Thedrivecanoperateatandmaintainzerospeed.
The user is responsible for assuring safe conditions for operating
personnel by providing suitable guards, audible or visual alarms,
or other devices to indicate that the drive is operating, or may
operate, at or near zero speed. Failure to observe this precaution
could result in severe bodily injury or loss of life.
ATTENTION: The drive contains ESD- (Electrostatic Discharge)
sensitive parts and assemblies. Static control precautions are
required when installing, testing, servicing, or repairing the drive.
Erratic machine operation and damage to, or destruction of,
equipment can result if this procedure is not followed. Failure to
observe this precaution can result in bodily injury.
ATTENTION: The user must provide an external, hardwired
emergency stop circuit outside of the drive circuitry. This circuitry
must disable the system in case of improper operation.
Uncontrolledmachineoperationmayresultifthisprocedureisnot
followed. Failure to observe this precaution could result in bodily
injury.
ATTENTION: The user is responsible for conforming with all
applicable local and national codes. Failure to observe this
precaution could result in damage to, or destruction of, the
equipment.
ATTENTION: An incorrectly applied or installed drive can result
in component damage or reduction in product life. Wiring or
application errors, such as undersizing the motor, incorrect or
inadequate AC supply, or excessive ambient temperatures may
result in malfunction of the system.

Contents I
CONTENTS
Chapter 1 Introduction
1.1 Getting Assistance from Reliance Electric..................... 1-1
Chapter 2 About the MD60 Drive
2.1 Identifying the Drive by Model Number.......................... 2-1
2.2 MD60 Drive Ratings, Model Numbers, and Frame
Sizes ............................................................................. 2-2
2.3 Kits................................................................................. 2-3
2.4 Storage Guidelines........................................................ 2-4
Chapter 3 Mounting the Drive
3.1 General Requirements for the Installation Site.............. 3-1
3.1.1 Operating Conditions........................................... 3-2
3.1.2 Recommended Mounting Clearances................. 3-2
3.1.3 Mounting Dimensions for the MD60 Drive........... 3-3
3.2 Mounting the Drive......................................................... 3-4
3.2.1 Protecting the Drive from Debris ......................... 3-4
Chapter 4 Grounding the Drive
4.1 RFI Filter Grounding...................................................... 4-2
Chapter 5 Installing Power Wiring
5.1 Opening the Cover......................................................... 5-1
5.2 Verifying Drive AC Input Ratings Match Available
Power........................................................................... 5-2
5.2.1 Ungrounded Distribution Systems....................... 5-2
5.2.2 Input Power Conditioning .................................... 5-4
5.3 Power Wiring Specifications.......................................... 5-5
5.4 Power Terminal Block Connections............................... 5-5
5.5 Fuses and Circuit Breakers ........................................... 5-6
5.6 Motor Cable Types Acceptable for 200-600 Volt
Installations ................................................................... 5-8
5.7 Reflected Wave Protection............................................ 5-9
5.8 Output Disconnect....................................................... 5-10
Chapter 6 Installing Control Wiring
6.1 Stop Circuit Requirements............................................. 6-1
6.1.1 Compliance with Machinery Safety Standard EN
60204-1:1992...................................................... 6-2
6.2 Motor Start/Stop Precautions......................................... 6-2
6.3 I/O Wiring Recommendations........................................ 6-3
6.3.1 Maximum Cable Length Recommendations........ 6-3
6.4 Wiring the Control Terminal Block................................. 6-4
6.4.1 I/O Wiring Examples............................................ 6-5

II MD60 AC Drive User Manual
6.4.2 Typical Multiple Drive Connection Examples....... 6-7
6.5 Start and Speed Reference Control...............................6-8
6.6 Accel/Decel Selection....................................................6-9
Chapter 7 Completing the Installation
7.1 Checking the Installation Before Applying Power to the
Drive .............................................................................. 7-1
7.2 Powering Up After Installation is Complete....................7-2
Chapter 8 Using the Integral Keypad to Program and Control the Drive
8.1 Keypad Components .....................................................8-1
8.1.1 Display Description..............................................8-2
8.1.2 LED Descriptions.................................................8-2
8.1.3 Key Descriptions..................................................8-3
8.2 About Parameters..........................................................8-4
8.3 How Parameters are Organized ....................................8-4
8.4 Viewing and Adjusting Basic (P) and Advanced (A)
Parameters....................................................................8-5
8.5 Viewing the Display (d) Parameters...............................8-6
Chapter 9 Parameter Descriptions
9.1 Basic Program Group Parameters.................................9-2
9.2 Advanced Group Parameters ........................................9-8
9.3 Display Group Parameters...........................................9-27
Chapter 10 Troubleshooting the Drive
10.1Fault Codes..................................................................10-1
10.1.1Manually Clearing Faults...................................10-2
10.1.2Automatically Clearing Faults (Auto Restart
Feature)............................................................10-2
10.2Troubleshooting Tables ................................................10-6
10.2.1Problem: Drive Does Not Start From Terminal Block
Start or Run Inputs ............................................10-6
10.2.2Problem: Drive Does Not Start From Integral
Keypad.............................................................10-7
10.2.3Problem: Drive Does Not Respond to Changes in
Speed Command ..............................................10-7
10.2.4Problem: Motor and/or Drive Will Not Accelerate to
Commanded Speed ..........................................10-8
10.2.5Problem: Motor Operation is Unstable...............10-8
10.2.6Problem: Drive Will Not Reverse Motor
Direction...........................................................10-9
Appendix A Technical Specifications................................................... A-1
Appendix B Record of User Settings ................................................... B-1
Appendix C Parameters Cross-Referenced by Name ......................... C-1

Contents III
Appendix D CE Conformance Requirements .......................................D-1
Appendix E Accessories.......................................................................E-1
Appendix F RS485 (MDI) Protocol........................................................F-1
Appendix G RJ45 Splitter Cable..........................................................G-1
Index ...................................................................................... Index-1

IV MD60 AC Drive User Manual

Contents V
List of Figures
Figure 2.1 – Identifying the Drive by Model Number..................................2-1
Figure 3.1 – Minimum Mounting Clearances.............................................3-2
Figure 3.2 – Drive Dimensions - Front View..............................................3-3
Figure 3.3 – Drive Dimensions - Bottom View...........................................3-3
Figure 4.1 – Typical Grounding..................................................................4-1
Figure 5.1 – Opening the Cover.................................................................5-1
Figure 5.2 – Removing the Finger Guard..................................................5-2
Figure 5.3 – Jumper Location (A Frame Shown).......................................5-3
Figure 5.4 – Phase-to-Ground MOV Removal...........................................5-3
Figure 5.5 – Power Terminal Block Connections....................................... 5-5
Figure 6.1 – Wiring the Control Terminal Block.........................................6-4
Figure 6.2 – I/O Wiring Examples..............................................................6-5
Figure 6.3 – Override Priority for the Speed Reference Command........... 6-8
Figure 6.4 – Accel/Decel Selection............................................................6-9
Figure 8.1 – Integral Keypad .....................................................................8-1
Figure 9.1 – Accel Time 1 (P039)..............................................................9-7
Figure 9.2 – Decel Time 1 (P040)..............................................................9-7
Figure 9.3 – Accel Time 2 (A067)............................................................9-11
Figure 9.4 – Decel Time 2 (A068)............................................................9-12
Figure 9.5 – DC Brake Level (A081)........................................................9-14
Figure 9.6 – S Curve% (A083) Examples................................................9-15
Figure 9.7 – Start Boost (A084)...............................................................9-16
Figure 9.8 – Motor OL Select (A090).......................................................9-17
Figure 9.9 – Derating Guidelines Based on PWM Frequency (A091)
Selection...........................................................................9-18
Figure 9.10 – Drive Status (d006) Bit Definitions.....................................9-28
Figure 9.11 – Control Source (d012) Bit Definitions ................................9-29
Figure 9.12 – Control Input Status (d013) Bit Definitions.........................9-30
Figure 9.13 – Digital Input Status (d014) Bit Definitions..........................9-30
Figure 9.14 – Comm Status (d015) Bit Definitions...................................9-31

VI MD60 AC Drive User Manual

Contents VII
List of Tables
Table 2.1 – Drive Ratings, Model Numbers, and Frame Sizes..................2-2
Table 2.2 – Standard Kits..........................................................................2-3
Table 3.1 – Ambient Operating Temperatures and Mounting Clearances.3-2
Table 3.2 – Mounting Specifications..........................................................3-4
Table 5.1 – Corrective Actions for Input Power Conditions.......................5-4
Table 5.2 – Power Wiring Specifications ...................................................5-5
Table 5.3 – Power Terminal Block Specifications......................................5-5
Table 5.4 – Drive, Fuse, and Circuit Breaker Ratings................................5-7
Table 5.5 – Shielded Motor Cable Types Acceptable for 200-600 Volt
Installations..........................................................................5-8
Table 5.6 – Maximum Cable Length Recommendation.............................5-9
Table 6.1 – Recommended Control and Signal Wire.................................6-3
Table 6.2 – I/O Terminal Block Specifications...........................................6-3
Table 6.3 – Typical Multiple Drive Connection Examples..........................6-7
Table 8.1 – LED Descriptions....................................................................8-2
Table 8.2 – Key Descriptions.....................................................................8-3
Table 8.3 – Viewing and Adjusting Basic (P) and Advanced (A)
Parameters ..........................................................................8-5
Table 8.4 – Viewing the Display (d) Parameters........................................8-6
Table 9.1 – Trip Points for Digital Output Relay.......................................9-11
Table 9.2 – Selecting the Reference Source Using Presets....................9-13
Table 10.1 – Fault Descriptions and Corrective Actions..........................10-3
Table 10.2 – Problem: Drive Does Not Start From Terminal Block Start
or Run Inputs ...................................................................10-6
Table 10.3 – Problem: Drive Does Not Start From Integral Keypad........10-7
Table 10.4 – Problem: Drive Does Not Respond to Changes in Speed
Command .........................................................................10-7
Table 10.5 – Problem: Motor and/or Drive Will Not Accelerate to
Commanded Speed..........................................................10-8
Table 10.6 – Problem: Motor Operation is Unstable................................10-8
Table 10.7 – Problem: Drive Will Not Reverse Motor Direction...............10-9

VIII MD60 AC Drive User Manual