TECO-Westinghouse A510 User manual

INSTRUCTION MANUAL
DOCUMENT - TECO-A510IM
Ver 01: 2016.11
460V Class 3~
575/690V Class 3~
230V Class 3~
230V Class 1/3~ 0.75 - 2.2kW
1 - 3 HP
3.7 - 110 kW
5 - 150 HP
0.75 - 315 kW
1 - 425 HP
0.75 - 200 kW
1 - 270 HP
Read all operating instructions before installing,
connecting (wiring), operating, servicing, or inspecting
the inverter.
Ensure that this manual is made available to the end user of
the inverter.
Store this manual in a safe, convenient location.
T
The manual is subject to change without prior notice.
A510
INVERTER

**** STATEMENT ****
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Table of Contents
Preface........................................................................................................................................................... 0-1
1 Safety Precautions .................................................................................................................................... 1-1
1.1 Before Supplying Power to the Inverter.................................................................................................... 1-1
1.2 Wiring........................................................................................................................................................ 1-2
1.3 Before Operation ...................................................................................................................................... 1-3
1.4 Parameters Setting................................................................................................................................... 1-3
1.5 Operation.................................................................................................................................................. 1-4
1.6 Maintenance, Inspection and Replacement ............................................................................................. 1-5
1.7 Disposal of the Inverter............................................................................................................................. 1-5
2 Model Description...................................................................................................................................... 2-1
2.1 Nameplate Data........................................................................................................................................ 2-1
2.2 Inverter Models –Motor Power Rating..................................................................................................... 2-2
3 Environment and Installation ................................................................................................................... 3-1
3.1 Environment.............................................................................................................................................. 3-1
3.2 Installation................................................................................................................................................. 3-2
3.3 External View............................................................................................................................................ 3-3
3.4 Warning Labels......................................................................................................................................... 3-5
3.5 Removing the Front Cover and Keypad................................................................................................... 3-6
3.5.1 Standard type.................................................................................................................................. 3-6
3.5.2 Built-in filter type (460V 1 ~60HP).................................................................................................3-12
3.6 Wire Gauges and Tightening Torque .....................................................................................................3-13
3.7 Wiring Peripheral Power Devices...........................................................................................................3-14
3.8 General Wiring Diagram.........................................................................................................................3-16
3.9 User Terminals ....................................................................................................................................... 3-17
3.10 Power Terminals................................................................................................................................... 3-21
3.11 Input / Output Section Block Diagram .................................................................................................. 3-26
3.11.1 Cooling Fan Supply Voltage Selection (400V class).................................................................3-30

3.12 Inverter Wiring ......................................................................................................................................3-32
3.13 Input Power and Motor Cable Length................................................................................................... 3-33
3.14 Cable Length vs, Carrier Frequency..................................................................................................... 3-33
3.15 Installing an AC Line Reactor...............................................................................................................3-33
3.16 Power Input Wire Size, NFB and MCB Part Numbers .........................................................................3-34
3.17 Control Circuit Wiring............................................................................................................................3-37
3.18 Inverter Specifications .......................................................................................................................... 3-39
3.19 General Specifications..........................................................................................................................3-44
3.20 Inverter Derating Based on Carrier Frequency ....................................................................................3-46
3.21 Inverter Derating Based on Temperature.............................................................................................3-49
3.22 Inverter Dimensions..............................................................................................................................3-50
3.23 Dimensions for Models with Built-in Filter............................................................................................. 3-59
4. Keypad and Programming Functions..................................................................................................... 4-1
4.1 LCD Keypad ............................................................................................................................................. 4-1
4.1.1 Keypad Display and Keys............................................................................................................... 4-1
4.1.2 Keypad Menu Structure .................................................................................................................. 4-3
4.2 LED Keypad.............................................................................................................................................. 4-8
4.2.1 Keypad Display and Keys............................................................................................................... 4-8
4.3 Parameters .............................................................................................................................................4-10
4.4 Description of Parameters......................................................................................................................4-76
5. Check Motor Rotation and Direction .......................................................................................................5-1
6. Speed Reference Command Configuration............................................................................................6-1
6.1 Reference from the Keypad.......................................................................................................................6-1
6.2 Reference from an Analog Signal (0-10V / 4-20mA) / Speed Pot.............................................................6-2
6.3 Reference from Serial Communication RS485 .........................................................................................6-5
6.4 Reference from Pulse Input.......................................................................................................................6-7
6.5 Reference from two Analog Inputs ............................................................................................................6-8
6.6 Change Frequency Unit from Hz to rpm....................................................................................................6-9

7. Operation Method Configuration (Run / Stop)........................................................................................7-1
7.1 Run / Stop from the Keypad ......................................................................................................................7-1
7.2 Run / Stop from External Switch / Contact or Pushbutton ........................................................................7-3
7.3 Run / Stop from Serial Communication RS485.........................................................................................7-4
8. Motor and Application Specific Settings.................................................................................................8-1
8.1 Set Motor Nameplate Data........................................................................................................................8-1
8.2 Acceleration and Deceleration Time..........................................................................................................8-2
8.3 Torque Compensation Gain ......................................................................................................................8-3
8.4 Automatic Energy Savings Functions........................................................................................................8-4
8.5 Emergency Stop........................................................................................................................................8-6
8.6 Forward and Reverse Jog .........................................................................................................................8-7
8.7 Direct / Unattended Startup.......................................................................................................................8-8
8.8 Analog Output Setup .................................................................................................................................8-9
9. Using PID Control for Constant Flow / Pressure Applications.............................................................9-1
9.1 What is PID Control...................................................................................................................................9-1
9.2 Connect Transducer Feedback Signal ....................................................................................................9-3
9.3 Engineering Units ......................................................................................................................................9-5
9.4 Sleep / Wakeup Function ..........................................................................................................................9-6
10. Troubleshooting and Fault Diagnostics............................................................................................. 10-1
10.1 General.................................................................................................................................................10-1
10.2 Fault Detection Function....................................................................................................................... 10-1
10.3 Warning / Self-diagnosis Detection Function ....................................................................................... 10-7
10.4 Auto-tuning Error ................................................................................................................................ 10-16
10.5 PM Motor Auto-tuning Error................................................................................................................ 10-17

11. Inverter Peripheral Devices and Option............................................................................................. 11-1
11.1 Braking Resistors and Braking Units....................................................................................................11-1
11.2 AC Line Reactors.................................................................................................................................. 11-4
11.3 Input Noise Filters.................................................................................................................................11-4
11.4 Input Current and Fuse Specifications ................................................................................................. 11-4
11.5 PG Speed Feedback Card ................................................................................................................... 11-7
11.6 Other Options .....................................................................................................................................11-11
Appendix A: Communication Networks......................................................................................................A1
A1.1 RS485 Network (Modbus)....................................................................................................................A1-1
A1.2 Profibus DB Network............................................................................................................................A1-1
Appendix B: UL Instructions........................................................................................................................B1

1-1
1. Safety Precautions
1.1Before Supplying Power to the Inverter
Warning
The main circuit must be correctly wired. For single phase supply use input terminals (R/L1, T/L3) and for
three phase supply use input terminals (R/L1, S/L2, T/L3). Terminals U/T1, V/T2, W/T3 must only be
used to connect the motor. Connecting the input supply to any of the U/T1, V/T2 or W/T3 terminals will
cause damage to the inverter.
Caution
To avoid the front cover from disengaging or other physical damage, do not carry the inverter by
its cover. Support the unit by its heat sink when transporting. Improper handling can damage the
inverter or injure personnel, and should be avoided.
To avoid the risk of fire, do not install the inverter on or near flammable objects. Install on
nonflammable objects such as metal surfaces.
If several inverters are placed inside the same control panel, provide adequate ventilation to
maintain the temperature below 40°C/104°F (50°C/122°F) without a dust cover to avoid
overheating or fire.
When removing or installing the digital operator, turn off the power first, and then follow the
instructions in this manual to avoid operator error or loss of display caused by faulty connections.
Warning
This product is sold subject to IEC 61800-3. In a domestic environment this product may cause radio
interference in which case the user may need to apply corrective measures.

1-2
1.2Wiring
Warning
Always turn OFF the power supply before attempting inverter installation and wiring of the user
terminals.
Wiring must be performed by a qualified personnel / certified electrician.
Make sure the inverter is properly grounded. (230V Class: Grounding impedance shall be less
than 100Ω. 460V Class: Grounding impedance shall be less than 10Ω.)
Please check and test emergency stop circuits after wiring. (Installer is responsible for the correct
wiring.)
Never touch any of the input or output power lines directly or allow any input of output power lines to
come in contact with the inverter case.
Do not perform a dielectric voltage withstand test (megger) on the inverter this will result in inverter
damage to the semiconductor components.
Caution
The line voltage applied must comply with the inverter’s specified input voltage. (See product
nameplate section 2.1)
Connect braking resistor and braking unit to the designated terminals. (See section 3.10)
Do not connect a braking resistor directly to the DC terminals P(+) and N(-), otherwise fire may result.
Use wire gauge recommendations and torque specifications. (See Wire Gauge and Torque
Specification section 3.6)
Never connect input power to the inverter output terminals U/T1, V/T2, W/T3.
Do not connect a contactor or switch in series with the inverter and the motor.
Do not connect a power factor correction capacitor or surge suppressor to the inverter output.
Ensure the interference generated by the inverter and motor does not affect peripheral devices.

1-3
1.3Before Operation
Warning
Make sure the inverter capacity matches the parameters 13-00.
Reduce the carrier frequency (parameter 11-01) If the cable from the inverter to the motor is
greater than 80 ft (25m). A high-frequency current can be generated by stray capacitance
between the cables and result in an overcurrent trip of the inverter, an increase in leakage
current, or an inaccurate current readout.
Be sure to install all covers before turning on power. Do not remove any of the covers while power to
the inverter is on, otherwise electric shock may occur.
Do not operate switches with wet hands, otherwise electric shock may result.
Do not touch inverter terminals when energized even if inverter has stopped, otherwise electric shock
may result.
1.4Parameter Setting
Caution
Do not connect a load to the motor while performing a rotational auto-tune.
Make sure the motor can freely run and there is sufficient space around the motor when
performing a rotational auto-tune.

1-4
1.5Operation
Warning
Be sure to install all covers before turning on power. Do not remove any of the covers while power to
the inverter is on, otherwise electric shock may occur.
Do not connect or disconnect the motor during operation. This will cause the inverter to trip and
may cause damage to the inverter.
Operations may start suddenly if an alarm or fault is reset with a run command active. Confirm that no
run command is active upon resetting the alarm or fault, otherwise accidents may occur.
Do not operate switches with wet hands, otherwise electric shock may result.
It provides an independent external hardware emergency switch, which emergently shuts down the
inverter output in the case of danger.
If automatic restart after power recovery (parameter 07-00) is enabled, the inverter will start
automatically after power is restored.
Make sure it is safe to operate the inverter and motor before performing a rotational auto-tune.
Do not touch inverter terminals when energized even if inverter has stopped, otherwise electric shock
may result.
Do not check signals on circuit boards while the inverter is running.
After the power is turned off, the cooling fan may continue to run for some time.
Caution
Do not touch heat-generating components such as heat sinks and braking resistors.
Carefully check the performance of motor or machine before operating at high speed, otherwise
Injury may result.
Note the parameter settings related to the braking unit when applicable.
Do not use the inverter braking function for mechanical holding, otherwise injury may result.
Do not check signals on circuit boards while the inverter is running.

1-5
1.6Maintenance, Inspection and Replacement
Warning
Wait a minimum of five minutes after power has been turned OFF before starting an inspection. Also
confirm that the charge light is OFF and that the DC bus voltage has dropped below 25Vdc.
Never touch high voltage terminals in the inverter.
Make sure power to the inverter is disconnected before disassembling the inverter.
Only authorized personnel should perform maintenance, inspection, and replacement operations.
(Take off metal jewelry such as watches and rings and use insulated tools.)
Caution
The Inverter can be used in an environment with a temperature range from 14° -104°F (-10 ~
40°C) and relative humidity of 95% non-condensing.
The inverter must be operated in a dust, gas, mist and moisture free environment.
1.7Disposal of the Inverter
Caution
Please dispose of this unit with care as an industrial waste and according to your required local
regulations.
The capacitors of inverter main circuit and printed circuit board are considered as hazardous
waste and must not be burned.
The Plastic enclosure and parts of the inverter such as the top cover board will release harmful
gases if burned.

2-1
2. Model Description
2.1Nameplate Data
It is essential to verify the A510 inverter nameplate and make sure that the A510 inverter has the correct rating so
it can be used in your application with the proper sized AC motor.
Unpack the A510 inverter and check the following:
(1) The A510 inverter and start-up and installation manual are contained in the package.
(2) The A510 inverter has not been damaged during transportation there should be no dents or parts missing.
(3) The A510 inverter is the type you ordered. You can check the type and specifications on the main nameplate.
(4) Check that the input voltage range meets the input power requirements.
(5) Ensure that the motor HP matches the motor rating of the inverter.
HD: Heavy Duty (Constant Torque); ND: Normal Duty (Variable Torque) (1HP = 0.746 kW)
Product Name and Motor Rating
Input Power Specifications
Output Power Specifications
Series No
UL and CE Marks
Model Identification
A510 Inverter Series
A510 - 4 010 - C 3 - U
2:
4:
5:
6:
230V
460V
575V
690V
Voltage Rating
001:
002:
150:
175:
215:
375:
425:
1 HP
2 HP
150 HP
175 HP
215 HP
375 HP
425 HP
Motor Rating
H:
C:
LED Operator
LCD Operator
Operator Type
Blank:
3:
1Ph or 3Ph
3Ph
Input
Blank:
F:
No RFI
RFI Filer
Noise Filter

2-2
2.2 Inverter Models –Motor Power Rating (HD –Heavy Duty)
230V Class
Voltage
A510 Model
Applied
Motor
(HP)
Applied
Motor
(KW)
Filter
with
without
1ph/3ph,
200~240V
+10%/-15%
50/60Hz
A510-2001-C-U
1
0.75
◎
A510-2002-C-U
2
1.5
◎
A510-2003-C-U
3
2.2
◎
3ph, 200~240V
+10%/-15%
50/60Hz
A510-2005-C3-U
5
3.7
◎
A510-2008-C3-U
7.5
5.5
◎
A510-2010-C3-U
10
7.5
◎
A510-2015-C3-U
15
11
◎
A510-2020-C3-U
20
15
◎
A510-2025-C3-U
25
18.5
◎
A510-2030-C3-U
30
22
◎
A510-2040-C3-U
40
30
◎
A510-2050-C3-U
50
37
◎
A510-2060-C3-U
60
45
◎
A510-2075-C3-U
75
55
◎
A510-2100-C3-U
100
75
◎
A510-2125-C3-U
125
94
◎
A510-2150-C3-U
150
112
◎
Shaded Section: Models currently under Development
Short Circuit Rating: 230V Class: 5kA

2-3
460V Class
Voltage
A510 Model
Applied
Motor
(HP)
Applied
Motor
(KW)
Filter
with
without
3ph, 380~480V
+10%/-15%
50/60Hz
A510-4001-C3-U
1
0.75
◎
A510-4001-C3F-U
1
0.75
◎
A510-4002-C3-U
2
1.5
◎
A510-4002-C3F-U
2
1.5
◎
A510-4003-C3-U
3
2.2
◎
A510-4003-C3F-U
3
2.2
◎
A510-4005-C3-U
5
3.7
◎
A510-4005-C3F-U
5
3.7
◎
A510-4008-C3-U
7.5
5.5
◎
A510-4008-C3F-U
7.5
5.5
◎
A510-4010-C3-U
10
7.5
◎
A510-4010-C3F-U
10
7.5
◎
A510-4015-C3-U
15
11
◎
A510-4015-C3F-U
15
11
◎
A510-4020-C3-U
20
15
◎
A510-4020-C3F-U
20
15
◎
A510-4025-C3-U
25
18.5
◎
A510-4025-C3F-U
25
18.5
◎
A510-4030-C3-U
30
22
◎
A510-4030-C3F-U
30
22
◎
A510-4040-C3-U
40
30
◎
A510-4040-C3F-U
40
30
◎
A510-4050-C3-U
50
37
◎
A510-4050-C3F-U
50
37
◎
A510-4060-C3-U
60
45
◎
A510-4060-C3F-U
60
45
◎
A510-4075-C3-U
75
55
◎
A510-4100-C3-U
100
75
◎
A510-4125-C3-U
125
94
◎
A510-4150-C3-U
150
112
◎
A510-4175-C3-U
175
130
◎
A510-4215-C3-U
215
160
◎
A510-4250-C3-U
250
185
◎
A510-4300-C3-U
300
220
◎
A510-4375-C3-U
375
280
◎
A510-4425-C3-U
425
315
◎
Short Circuit Rating: 460V Class: 5kA

2-4
575/690V Class
Voltage
A510 Model
Applied
Motor
(HP)
Applied
Motor
(KW)
Filter
with
without
3ph, 575V
+10%/-15%
50/60Hz
A510-5001-C3-U
1
0.75
◎
A510-5002-C3-U
2
1.5
◎
A510-5003-C3-U
3
2.2
◎
A510-5005-C3-U
5
3.7
◎
A510-5008-C3-U
7.5
5.5
◎
A510-5010-C3-U
10
7.5
◎
3ph, 575~690V
+10%/-15%
50/60Hz
A510-6015-C3-U
15
11
◎
A510-6020-C3-U
20
15
◎
A510-6025-C3-U
25
18.5
◎
A510-6030-C3-U
30
22
◎
A510-6040-C3-U
40
30
◎
A510-6050-C3-U
50
37
◎
A510-6060-C3-U
60
45
◎
A510-6075-C3-U
75
55
◎
A510-6100-C3-U
100
75
◎
A510-6125-C3-U
125
94
◎
A510-6150-C3-U
150
112
◎
A510-6175-C3-U
175
130
◎
A510-6215-C3-U
215
160
◎
A510-6250-C3-U
250
185
◎
A510-6270-C3-U
270
200
◎
Short Circuit Rating: 575/690V Class: 5kA

3-1
3. Environment and Installation
3.1 Environment
The environment will directly affect the proper operation and the life span of the inverter. To ensure that the
inverter will give maximum service life, please comply with the following environmental conditions:
Protection
Protection Class
IP20/NEMA 1 or IP00
Operating
Temperature
Ambient Temperature: (-10°C - +40°C (14 -104 °F)
Without Cover: -10°C - +50°C (14-122 °F); derate inverter by 2% for 1°C rise.
Maximum operating temperature is 60°C (140°F)
If several inverters are placed in the same control panel, provide a heat
removal means to maintain ambient temperatures below 40°C
Storage
Temperature
-20°C - +70°C (-4 -158 °F)
Humidity:
95% non-condensing
Relative humidity 5% to 95%, free of moisture.
(Follow IEC60068-2-78 standard)
Altitude:
< 1000m (3,281 ft.), maximum altitude is 3000m (9843 ft.)
Installation Site:
Avoid exposure to rain or moisture.
Avoid direct sunlight.
Avoid oil mist and salinity.
Avoid corrosive liquid and gas.
Avoid dust, lint fibers, and small metal filings.
Keep away from radioactive and flammable materials.
Avoid electromagnetic interference (soldering machines, power machines).
Avoid vibration (stamping, punching machines etc.).
Add a vibration-proof pad if the situation cannot be avoided.
Shock
Maximum acceleration: 1.2G (12m/s²), from 49.84 to 150 Hz
Displacement amplitude : 0.3mm (peak value), from 10 to 49.84 Hz
(Follow IEC60068-2-6 standard)

3-2
3.2 Installation
When installing the inverter, ensure that inverter is installed in upright position (vertical direction) and there is
adequate space around the unit to allow normal heat dissipation as per the following Fig. 3.2.1
5.9in.
150mm
X
5.9in.
150mm
Air Flow
Ambient
temperature
-10 to +40°C
5.9in.
150mm
X
5.9in.
150mm
Fig 3.2.1: A510 Installation space
X = 1.18” (30mm) for inverter ratings up to 25HP
X = 1.96” (50mm) for inverter ratings 30HP or higher
Important Note: The inverter heatsink temperature can reach up to 194°F / 90°C during operation; make sure
to use insulation material rated for this temperature.

3-3
3.3 External View
(a) 230V 1 ~ 5 HP / 460V 1 ~ 7.5 HP / 575V 1 ~ 3HP
(Wall-mounted type, IEC IP20) (Wall-mounted type, IEC IP20, NEMA1)
(b) 230V 7.5 ~ 25 HP / 460V 10 ~ 30 HP / 575V 5 ~ 10HP / 690V 15 ~ 40 HP
(Wall-mounted type, IEC IP20) (Wall-mounted type, IEC IP20, NEMA1)

3-4
(c) 230V 30 ~ 40 HP / 460V 40 ~ 60 HP / 690V 50 ~ 75 HP
(Wall-mounted type, IEC IP20, NEMA1)
(d) 230V 50 ~ 100 HP / 460V 75 ~ 215 HP / 690V 100 ~ 270 HP
(Wall-mounted type, IEC IP00) (Wall-mounted type, IEC IP20, NEMA1)

3-5
(e) 230V 125 ~ 150 HP / 460V 250 ~ 425 HP
(Wall-mounted type, IEC IP00) (Wall-mounted type, IEC IP20, NEMA1)
3.4 Warning Labels
Important: Warning information located on the front cover must be read upon installation of the inverter.
(a) 230V: 1-7.5HP / 460V: 1-7.5HP /575V 1~ 3 HP
(b) 230V: 10HP / 460V: 10-20HP /575V 5~10HP
(c) 230V: 15-150HP / 460V: 20(F)-425HP/690V 15~270HP

3-6
3.5 Removing the Front Cover and Keypad
Caution
Before making any wiring connections to the inverter the front cover needs to be removed.
It is not required to remove the digital operator before making any wiring connections.
Models 230V, 1 –25 HP, 460V, 1 –30 HP and 575/690V 1 –40 HP have a plastic cover.
Loosen the screws and remove the cover to gain access to the terminals and make wiring
connections. Place the plastic cover back and fasten screws when wiring connections have been
made.
Models 230V, 1 - 25HP, 460V, 1 - 30HP and 690V 50 –270 HP have a metal cover. Loosen the
screws and remove the cover to gain access to the terminals and make wiring connections.
Place the metal cover back and fasten screws when wiring connections have been made.
3.5.1 Standard Type
(a) 230V: 1 ~ 7.5 HP / 460V: 1 ~ 7.5 HP / 575V: 1 ~ 3 HP
Step 1: Unscrew Step 2: Remove cover