Rockwell Automation Reliance Electric MD65 User manual

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Instruction Manual
MD65 AC Drive
User Manual
Version 2.0
D2-3519-2

©2004 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.
The thick black bar shown on the outside margin of this page is used throughout this
manual to signify new or revised text or figures.
!ATTENTION:Identifies information about practices or
circumstances that can lead to personal injury or death,
property damage, or economic loss.
MD65, 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,or service this equipment.
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 of mains supply from line inputs [R,
S, T (L1, L2, L3)]. Wait three (3) minutes for capacitors to
discharge to safe voltage levels. Darkened display LEDs is not 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: The drive can operate at and maintain zero speed.
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 precaution 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.
Uncontrolled machine operation may result if this precaution is
not 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.
Trademarks not belonging to Rockwell Automation are property of their respective
companies.

Contents I
CONTENTS
Chapter 1 Introduction
1.1 Getting Assistance from Reliance Electric..................... 1-1
Chapter 2 About the MD65 Drive
2.1 Identifying the Drive by Model Number.......................... 2-1
2.2 MD65 Drive Ratings, Model Numbers, and
Frame Sizes.................................................................. 2-2
2.3 Kits and Accessories ..................................................... 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 Minimum Mounting Clearances........................... 3-2
3.1.3 Mounting Dimensions for the MD65 Drive........... 3-3
3.2 Mounting the Drive......................................................... 3-6
3.2.1 Protecting the Drive from Debris ......................... 3-6
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.......................................... 5-4
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.......................................... 5-10
5.8 Output Disconnect....................................................... 5-10
Chapter 6 Installing Control Wiring
6.1 Stop Circuit Requirements............................................. 6-1
6.2 Motor Start/Stop Precautions......................................... 6-2
6.3 I/O Wiring Recommendations........................................ 6-3
6.3.1 Maximum Control Wire Length
Recommendations............................................. 6-3
6.4 Wiring the Control Terminal Block................................. 6-4
6.4.1 I/O Wiring Examples............................................ 6-6

II MD60 AC Drive User Manual
6.4.2 Typical Multiple Drive Connection Examples.......6-9
6.5 Start and Speed Reference Control.............................6-10
6.6 Accel/Decel Selection..................................................6-11
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 Programand 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...........................................9-46
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 ................................................10-7
10.2.1Problem: Drive Does Not Start From
Terminal Block Start or Run Inputs...................10-7
10.2.2Problem: Drive Does Not Start From
Integral Keypad................................................10-8
10.2.3Problem: Drive Does Not Respond to
Changes in Speed Command..........................10-8
10.2.4Problem: Motor Does Not Start..........................10-9
10.2.5Problem: Motor and/or Drive Will Not
Accelerate to Commanded Speed .................10-10
10.2.6Problem: Motor Operation is Unstable.............10-10
10.2.7Problem: Drive Will Not Reverse Motor
Direction.........................................................10-11
10.2.8Problem: Drive Does Not Power Up................10-11
Appendix ATechnical Specifications...................................................... A-1

Contents III
Appendix BRecord of User Settings.......................................................B-1
Appendix CParameters Cross-Referenced by Name.............................C-1
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
Appendix HStepLogicTM, Basic Logic and Time/Counter Functions......H-1
Appendix I PID Setup..............................................................................I-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 and Weights............................................... 3-3
Figure 3.3 – Drive Dimensions - NEMA 1/IP30 Kit Without
Communication Option ......................................................... 3-4
Figure 3.4 – Drive Dimensions - NEMA 1/IP30 Kit With
Communication Option ......................................................... 3-5
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 – Removing the Jumper............................................................. 5-3
Figure 5.4 – Phase-to-Ground MOV Removal............................................ 5-3
Figure 5.5 – Power Terminal Block Connections........................................ 5-5
Figure 6.1 – Control Terminal Block ........................................................... 6-4
Figure 6.2 – Override Priority for the Speed Reference Command.......... 6-10
Figure 6.3 – Accel/Decel Selection........................................................... 6-11
Figure 8.1 – Integral Keypad ...................................................................... 8-1
Figure 9.1 – Accel Time 1 (P039)............................................................... 9-6
Figure 9.2 – Decel Time 1 (P040)............................................................... 9-7
Figure 9.3 – Accel Time 2 (A067)............................................................. 9-18
Figure 9.4 – Decel Time 2 (A068)............................................................. 9-19
Figure 9.5 – DC Brake Level (A081)......................................................... 9-21
Figure 9.6 – S Curve % (A083) Example..................................................9-22
Figure 9.7 – Boost Select (A084).............................................................. 9-23
Figure 9.8 – Start Boost (A085)................................................................ 9-24
Figure 9.9 – Motor OL Select (A090)........................................................ 9-25
Figure 9.10 – Derating Guidelines Based on PWM Frequency
(A091) Selection .............................................................. 9-26
Figure 9.11 – Anlg In 0-10V Lo (A110)..................................................... 9-32
Figure 9.12 – Skip Freq Band (A120)....................................................... 9-35
Figure 9.13 – Digit Settings....................................................................... 9-43
Figure 9.14 – EM BRK Off Delay.............................................................. 9-44
Figure 9.15 – Drive Status (d006) Bit Definitions...................................... 9-47
Figure 9.16 – Control Source (d012) Bit Definitions .................................9-48
Figure 9.17 – Contrl In Status (d013) Bit Definitions.................................9-49
Figure 9.18 – Dig In Status (d014) Bit Definitions..................................... 9-49
Figure 9.19 – Comm Status (d015) Bit Definitions.................................... 9-50

VI MD65 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 and Accessories................................................2-3
Table 3.1 – Ambient Operating Temperatures and Mounting
Clearances.............................................................................3-2
Table 3.2 – Mounting Specifications...........................................................3-6
Table 5.1 – Corrective Actions for Input Power Conditions ........................5-4
Table 5.2 – Power Wiring Specifications....................................................5-4
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.....................................................................5-9
Table 5.6 – Maximum Cable Length Recommendation............................5-10
Table 6.1 – Recommended Control and Signal Wire..................................6-3
Table 6.2 – I/O Terminal Block Specifications............................................6-3
Table 6.3 – Control Terminal Definitions and Related Parameters.............6-5
Table 6.4 – Typical Multiple Drive Connection Examples...........................6-9
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........................................9-13
Table 9.2 – On/Off Points for the Opto Outputs........................................9-16
Table 9.3 – A064 Options.........................................................................9-17
Table 9.4 – Analog Output Signal Mode Selections .................................9-17
Table 9.5 – Selecting the Reference Source Using Presets.....................9-20
Table 9.6 – Related Parameters for Stp Logic Parameters
(A140-A147) ........................................................................9-41
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.............................................................10-7
Table 10.3 – Problem: Drive Does Not Start From Integral Keypad.........10-8
Table 10.4 – Problem: Drive Does Not Respond to Changes in
Speed Command...............................................................10-8
Table 10.5 – Problem: Motor and/or Drive Will Not Accelerate to
Commanded Speed.........................................................10-10
Table 10.6 – Problem: Motor Operation is Unstable...............................10-10
Table 10.7 – Problem: Drive Will Not Reverse Motor Direction..............10-11