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

Introduction 1-1
CHAPTER 1
Introduction
This manual is intended for qualified electrical personnel familiar
with installing, programming, and maintaining AC drives.
This manual contains information on:
•Installing and wiring the MD60 drive
•Programming the drive
•Troubleshooting the drive
The latest version of this manual is available from
http://www.theautomationbookstore.com or
http://www.reliance.com/docs_onl/online_stdrv.htm.
1.1 Getting Assistance from Reliance
Electric
If you have any questions or problems with the products described
in this instruction manual, contact your local Reliance Electric sales
office.
For technical assistance, call 1-800-726-8112. Before calling,
please review the troubleshooting section of this manual and check
the Reliance Standard Drives website for additional information.
When you call this number, you will be asked for the drive model
number or catalog number and this instruction manual number.

1-2 MD60 AC Drive User Manual

About the MD60 Drive 2-1
CHAPTER 2
About the MD60 Drive
This chapter provides information about the MD60 AC drive,
including:
•How to identify the drive
•Descriptions of NEMA ratings
2.1 Identifying the Drive by Model
Number
Each drive can be identified by its model number, as shown in
figure 2.1. The model number is on the shipping label and the drive
nameplate. The model number includes the drive and any options.
Drive model numbers are provided in table 2.1.
Figure 2.1 – Identifying the Drive by Model Number
Reserved
6MD V N - 1P5 1 1 1
6MD = MD60 Drive
@115V / 230 VAC
1P5 = 1.5 A, 0.25 HP
2P3 = 2.3 A, 0.5 HP
4P5 = 4.5 A, 1 HP
6P0 = 6.0 A, 1.5 HP
8P0 = 8 A, 2 HP
012 = 12 A, 3 HP
017 = 17.5 A, 5 HP
@460 VAC
1P4 = 1.4 A, 0.5 HP
2P3 = 2.3 A, 1 HP
4P0 = 4 A, 2 HP
6P0 = 6 A, 3 HP
8P7 = 8.7 A, 5 HP
A = 1-Phase, 240 VAC
V = 1-Phase, 120 VAC
B = 3-Phase, 240 VAC
D = 3-Phase, 460VAC
N = IP20 (Open)
0 = Not Filtered
1 = Internal Filter
Reserved

2-2 MD60 AC Drive User Manual
2.2 MD60 Drive Ratings, Model Numbers,
and Frame Sizes
Similar MD60 drive sizes are grouped into frame sizes to simplify
re-ordering and dimensioning. Refer to figure 3.2 for the dimensions
of each frame size.
Table 2.1 provides MD60 drive ratings, model numbers, and frame
sizes.
Table 2.1 – Drive Ratings, Model Numbers, and Frame Sizes
Drive Ratings
Model Number Frame SizeInput Voltage kW HP Output Current
115V, 50/60 Hz
1-Phase 0.2 0.25 1.5A 6MDVN-1P5101 A
0.37 0.5 2.3A 6MDVN-2P3101 A
0.75 1.0 4.5A 6MDVN-4P5101 B
1.1 1.5 6.0A 6MDVN-6P0101 B
230V, 50/60 Hz
1-Phase
With Integral
EMC Filter
0.2 0.25 1.5A 6MDAN-1P5111 A
0.37 0.5 2.3A 6MDAN-2P3111 A
0.75 1.0 4.5A 6MDAN-4P5111 A
1.5 2.0 8.0A 6MDAN-8P0111 B
230V, 50/60 Hz
1-Phase
No Filter
0.2 0.25 1.5A 6MDAN-1P5101 A
0.37 0.5 2.3A 6MDAN-2P3101 A
0.75 1.0 4.5A 6MDAN-4P5101 A
1.5 2.0 8.0A 6MDAN-8P0101 B
230V, 50/60 Hz
3-Phase 0.2 0.25 1.5A 6MDBN-1P5101 A
0.37 0.5 2.3A 6MDBN-2P3101 A
0.75 1.0 4.5A 6MDBN-4P5101 A
1.5 2.0 8.0A 6MDBN-8P0101 A
2.2 3.0 12.0A 6MDBN-012101 B
3.7 5.0 17.5 6MDBN-017101 B
460V, 50/60 Hz
3-Phase 0.37 0.5 1.4A 6MDDN-1P4101 A
0.75 1.0 2.3A 6MDDN-2P3101 A
1.5 2.0 4.0A 6MDDN-4P0101 A
2.2 3.0 6.0A 6MDDN-6P0101 B
3.7 5.0 8.7A 6MDDN-8P7101 B

About the MD60 Drive 2-3
2.3 Kits
Table 2.2 lists kits for the MD60 drive. Contact Reliance Electric for
more information about these kits.
Table 2.2 – Standard Kits
Kit Description Model Number
MD60 Serial Converter and cables MDCOMM-232
VS Utilities Software CD RECOMM-VSUTIL
MD60 Serial Converter (includes VS
Utilities Software) MDCOMM-VSU232
NEMA 1/IP30 Kit (contains conduit box and
converter cover) 6MD-NM1A 6MD-NM1B
Remote LCD OIM Nema 4x/12 (includes
2.9 meter cable) MD4ALCD 1
1See Appendix E for more information.
Remote Handheld OIM (Copy Cat Keypad;
includes 1.0 meter cable) MD1CC1
Bezel Kit (panel mount for Remote
Handheld OIM) MDBZL-N1
OIM Cable (1.0 meter OIM-to-RJ45 cable) MDCBL-CC1
OIM Cable (2.9 meter OIM-to-RJ45 cable) MDCBL-CC3
RJ45 Cable (2.0 meter RJ45-to-RJ45
cable, male-to-male connectors) MDCBL-RJ45
Serial Cable (2.0 meter serial cable with a
locking low profile connector to connect to
the serial converter and a 9-pin sub-
miniature D female connector to connect to
a computer)
RECBL-SFC
RJ45 Splitter Cables See Appendix G
Terminating Resistors (RJ45 120 Ohm
resistors; 2 pieces) AK-UO-RJ45-TRI
Terminal Block (RJ45 two-position terminal
block; 5 pieces) AK-UO-TB2P
Communications Option Kits See Appendix E
Dynamic Brake Resistors AK-R2-xxx1
EMI Filters 6MDF-xxx1

2-4 MD60 AC Drive User Manual
2.4 Storage Guidelines
If you need to store the drive, follow these recommendations to
prolong drive life and performance:
•Store the drive within an ambient temperature range of -40° to
+85° C.
•Store the drive within a relative humidity range of 0% to 95%,
non-condensing.
•Do not expose the drive to a corrosive atmosphere.

Mounting the Drive 3-1
CHAPTER 3
Mounting the Drive
This chapter provides information that must be considered when
planning an MD60 drive installation and provides drive mounting
information and installation site requirements.
3.1 General Requirements for the
Installation Site
It is important to properly plan before installing an MD60 drive to
ensure that the drive’s environment and operating conditions are
satisfactory.
The area behind the drive must be kept clear of all control and
power wiring. Power connections may create electromagnetic fields
that may interfere with control wiring or components when run in
close proximity to the drive.
Read the recommendations in the following sections before
continuing with the drive installation.
!
ATTENTION: Only qualified electrical personnel familiar with
the construction and operation of this equipment and the
hazardsinvolvedshouldinstall,adjust,operate,orservicethis
equipment. Read and understand this manual and other
applicablemanualsintheirentiretybeforeproceeding.Failure
to observe this precaution could result in severe bodily injury
or loss of life.
ATTENTION: Use of power correction capacitors on the
output of the drive can result in erratic operation of the motor,
nuisance tripping, and/or permanent damage to the drive.
Remove power correction capacitors before proceeding.
Failure to observe this precaution could result in damage to,
or destruction of, the equipment.
ATTENTION: The user is responsible for conforming with all
applicable local, national, and international codes. Failure to
observe this precaution could result in damage to, or
destruction of, the equipment.

3-2 MD60 AC Drive User Manual
3.1.1 Operating Conditions
Before deciding on an installation site, consider the following
guidelines:
•Protect the cooling fan by avoiding dust or metallic particles.
•Do not expose the drive to a corrosive atmosphere.
•Protect the drive from moisture and direct sunlight.
•Verify that the drive location will meet the environmental
conditions specified in table 3.1.
3.1.2 Recommended Mounting Clearances
Refer to figure 3.1 for the minimum mounting clearances. Refer to
section 3.1.3 for drive mounting dimensions.
Table 3.1 – Ambient Operating Temperatures and Mounting Clearances
Ambient
Temperature Enclosure
Rating Minimum Mounting ClearancesMinimum Maximum
-10°C
(14°F) 40°C (104°F) IP 20/Open Type Use Mounting Option A (figure 3.1)
IP 30/NEMA 1/
UL Type 11Use Mounting Option B
(figure 3.1)
50°C
(122°F) IP 20/Open Type Use Mounting Option B (figure 3.1)
1Rating requires installation of the MD60 NEMA 1/IP30 Kit.
Figure 3.1 – Minimum Mounting Clearances
25 mm
(1.0 in)
120 mm
(4.7 in)
120 mm
(4.7 in)
120 mm
(4.7 in)
120 mm
(4.7 in)
Mounting Option A
No clearance required
between drives
Mounting Option B
See figure 3.2 for drive dimensions.

Mounting the Drive 3-3
3.1.3 Mounting Dimensions for the MD60 Drive
Overall dimensions and weights are illustrated in figures 3.2 and 3.3
as an aid to calculating the total area required by the MD60 drive.
Dimensions are in millimeters and (inches). Weights are in
kilograms and (pounds). See table 2.1 for drive ratings by frame.
Frame A B1CDE
2FG
Shipping
Weight
A 80 (3.15) 185 (7.28) 136 (5.35) 67 (2.64) 152 (5.98) 59.3 (2.33) 140 (5.51) 1.4 (3.1)
B 100 (3.94) 213 (8.39) 136 (5.35) 87 (3.43) 180 (7.09) 87.4 (3.44) 168 (6.61) 2.2 (4.9)
Figure 3.2 – Drive Dimensions - Front View
1Height dimension includes NEMA 1/IP30 Kit; see figure 3.3.
2Height dimension without NEMA 1/IP30 Kit.
A
GE
DC
B
F
5.5 (0.22)
Front Side
NEMA 1/IP30
Kit
Figure 3.3 – Drive Dimensions - Bottom View
59.2
(2.33)
40.0
(1.57)
20.7
(0.81)
75.3
(2.96)
34.0
(1.34)
74.3
(2.93)
35.6
(1.40)
64.1
(2.52)
79.1
(3.11)
40.6
(1.60)
25.6
(1.01)
∅ 22.2
(0.88) ∅ 22.2 (0.88)
Frame A Frame B

3-4 MD60 AC Drive User Manual
3.2 Mounting the Drive
Mount the drive upright on a flat, vertical, and level surface.
•Install on 35 mm DIN rail
or
•Install with screws (see table 3.2).
3.2.1 Protecting the Drive from Debris
A plastic top panel is included with the drive. Install the panel to
prevent debris from falling through the vents of the drive housing
during installation. Remove the panel for IP 20/Open Type
applications.
Table 3.2 – Mounting Specifications
Minimum Panel
Thickness Screw Size Mounting Torque
1.9 mm (0.0747 in) M4 (#8-32) 1.56-1.96 N-m (14-17 in-lb)