TECO A510 Installation and operating manual

I
****STATEMENT****
Si Desea descargar el manual en espanol a este Link: www.tecowestinghouse.com
Table of Contents
Preface ........................................................................................................................................................... 0-1
Chapter 1 Safety Precautions...................................................................................................................... 1-1
1.1 Before Supplying Power to the Inverter.................................................................................................... 1-1
1.2 Wiring........................................................................................................................................................ 1-2
1.3 Before Operation ...................................................................................................................................... 1-2
1.4 Parameters Setting ................................................................................................................................... 1-2
1.5 Operation .................................................................................................................................................. 1-2
1.6 Maintenance, Inspection and Replacement ............................................................................................. 1-3
1.7 Disposal of the Inverter............................................................................................................................. 1-3
Chapter 2 Model Description ....................................................................................................................... 2-1
2.1 Nameplate Data........................................................................................................................................ 2-1
2.2 Inverter Models – Motor Power Rating (HD-Heavy Duty) ........................................................................ 2-2
Chapter 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 (400V 1 ~60HP)................................................................................................. 3-12
3.6 Wire Gauges and Tightening Torque ..................................................................................................... 3-13
3.7 Wiring Peripheral Power Devices ........................................................................................................... 3-15
3.8 General Wiring Diagram ......................................................................................................................... 3-16
3.9 User Terminals ....................................................................................................................................... 3-18
3.10 Power Terminals................................................................................................................................... 3-23
3.11 Input / Output Power Section Block Diagram ....................................................................................... 3-31

II
3.11.1 Cooling Fan Supply Voltage Selection (400V class).................................................................. 3-34
3.12 Inverter Wiring ...................................................................................................................................... 3-36
3.13 Input Power and Motor Cable Length................................................................................................... 3-37
3.14 Cable Length vs, Carrier Frequency..................................................................................................... 3-37
3.15 Installing an AC Line Reactor ............................................................................................................... 3-37
3.16 Power Input Wire Size, NFB and MCB Part Numbers ......................................................................... 3-38
3.17 Control Circuit Wiring............................................................................................................................ 3-40
3.18 Inverter Specifications .......................................................................................................................... 3-42
3.19 Inverter Derating Based on Carrier Frequency .................................................................................... 3-49
3.20 Inverter Derating Based on Temperature............................................................................................. 3-52
Capacitor Guide After Long Storage ..................................................................................................... 3-34
3.21 Inverter Dimensions.............................................................................................................................. 3-54
Chapter 4 Keypad and Programming Functions ....................................................................................... 4-1
4.1 LCD Keypad (Standard) ........................................................................................................................... 4-1
4.1.1 Keypad Display and Keys ............................................................................................................... 4-1
4.1.2 Keypad Menu Structure .................................................................................................................. 4-3
4.2 LCD Keypad ............................................................................................................................................. 4-8
4.3 Parameters ............................................................................................................................................. 4-10
4.4 Description Common of Parameters .................................................................................................. 4-82
Chapter 5 Check Motor Rotation and Direction .........................................................................................5-1
Chapter 6 Speed Reference Command Configuration ..............................................................................6-1
6.1 Reference from the Keypad.......................................................................................................................6-1
6.2 Reference from External Analog Signal (0-10V / 4-20mA)........................................................................6-2
6.3 Reference from Serial Communication RS485 .........................................................................................6-4
6.4 Reference from Pulse Input.......................................................................................................................6-6
6.5 Reference from two Analog Inputs ............................................................................................................6-7
6.6 Change Frequency Unit from Hz to rpm....................................................................................................6-7
Chapter 7 Operation Method Configuration (Run / Stop) ..........................................................................7-1
7.1 Run / Stop from the LED/ LCD Keypad.....................................................................................................7-1

III
7.2 Run / Stop from External Switch / Contact or Pushbutton ........................................................................7-2
7.3 Run / Stop from Serial Communication RS485 .........................................................................................7-4
Chapter 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 Emergency Stop ........................................................................................................................................8-3
8.6 Forward and Reverse Jog .........................................................................................................................8-4
Chapter 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 ......................................................................................................................................9-4
9.4 Sleep / Wakeup Function ..........................................................................................................................9-5
Chapter 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 ................................................................................................................................ 10-17
10.5 PM Motor Auto-tuning Error................................................................................................................ 10-18
10.6 General troubleshooting ..................................................................................................................... 10-19
10.7 Troubleshooting of the Inverter........................................................................................................... 10-20
10.7.1 Quick troubleshooting of the Inverter ........................................................................................ 10-20
10.7.2 Troubleshooting for OC, OL error displays ............................................................................... 10-22
10.7.3 Troubleshooting for OV, LV error.............................................................................................. 10-23
10.7.4 The motor can not run............................................................................................................... 10-24
10.7.5 Motor Overheating .................................................................................................................... 10-25
10.7.6 Motor runs unbalanced ............................................................................................................. 10-26
10.8 Routine and periodic inspection ......................................................................................................... 10-27
10.9 Maintenance ....................................................................................................................................... 10-28
Chapter 11 Inverter Peripheral Devices and Options ............................................................................. 11-1

IV
11.1 Braking Resistors and Braking Units .................................................................................................... 11-1
11.2 AC Line Reactors.................................................................................................................................. 11-6
11.3 Input Noise Filters................................................................................................................................. 11-6
11.4 Input Current and Fuse Specifications ................................................................................................. 11-7
11.5 PG Speed Feedback Card ................................................................................................................. 11-10
11.6 Other Options ..................................................................................................................................... 11-16
11.7 NEMA1 Kit ......................................................................................................................................... 11-18
Appendix A: Communication Networks ...................................................................................................A1-1
A1.1 RS485-- Network (Modbus) .................................................................................................................A1-1
Appendix B: UL Instructions .......................................................................................................................B-1
The complete A510 Instruction can be found at www.tecowestinghouse.com

0-1
Preface
The A510 product is an inverter designed to control a three-phase induction motor. Please
read this manual carefully to ensure correct operation, safety and to become familiar with the
inverter functions.
The A510 inverter is an electrical / electronic product and must be installed and handled by
qualified service personnel.
Improper handling may result in incorrect operation, shorter life cycle, or failure of this product
as well as the motor.
All A510 documentation is subject to change without notice. Be sure to obtain the latest
editions for use or visit our website at www.tecowestinghouse.com
Available Documentation:
1. A510 Start-up and Installation Manual
2. A510 Instruction Manual
Ensure you have sound knowledge of the device and familiarize yourself with all safety
information and precautions before proceeding to operate the inverter.
Ensure you have sound knowledge of the inverter and familiarize yourself with all safety
information and precautions before proceeding to operate the inverter.
Please pay close attention to the safety precautions indicated by the warning and
caution symbol.
Warning Failure to ignore the information indicated by the warning symbol may
result in death or serious injury.
Caution Failure to ignore the information indicated by the caution symbol may
result in minor or moderate injury and/or substantial property damage.

1-1
Chapter 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 our instruction 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.
•Motor over temperature protection is provided.
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. (220V Class: Grounding impedance shall be less
than 100Ω. 460V Class: Grounding impedance shall be less than 10Ω.)
•Make sure the inverter is properly grounded. It is required to disconnect the ground wire in the
control board to avoid the sudden surge causing damage on electronic parts if it is improperly
grounded.
•RCD is required to be in compliance with the protection norm of B-type leakage current.
•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.

1-2
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 power terminals
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 guage 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.
1.3Before 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.
1.4Parameters 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.
1.5Operation
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.

1-3
•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.
1.6Maintenance, 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 ( 140) °F
(-10~+40(60)°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.
Equipment containing electrical components may not be disposed of together with domestic
waste. It must be separately collected with electrical and electronic waste according to local
and currently valid legislation.

2-1
Chapter 2 Model Description
2.1 Nameplate 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)
Model Identification
A510 - 4 010 - C 3 - U E
Voltage Rating
2: 230V Class
4: 460V Class
5: 575V Class
6: 690V Class
Motor Rating
001: 1HP
002: 2HP
…
150: 150HP
215: 200HP
…
375: 350HP
425: 400HP
Input
Blank: 1Ph or 3Ph
3: 3Ph
Operator Type
H: Standard Type (LED Keypad)
C: Standard Type (LCD Keypad)
E: Enhanced Type (LED Keypad)
C: Enhanced Type (LCD Keypad)
Enhanced
Type

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-UE 1 0.75
◎
A510-2002-C-UE 2 1.5
◎
A510-2003-C-UE 3 2.2
◎
3ph, 200~240V
+10%/-15%
50/60Hz
A510-2005-C3-UE
5 3.7
◎
A510-2008-C3-UE
7.5 5.5
◎
A510-2010-C3-UE
10 7.5
◎
A510-2015-C3-UE
15 11
◎
A510-2020-C3-UE
20 15
◎
A510-2025-C3-UE
25 18.5
◎
A510-2030-C3-UE
30 22
◎
A510-2040-C3-UE
40 30
◎
A510-2050-C3-UE
50 37
◎
A510-2060-C3-UE
60 45
◎
A510-2075-C3-UE
75 55
◎
A510-2100-C3-UE
100 75
◎
A510-2125-C3-UE
125 94
◎
A510-2150-C3-UE
150 112
◎
Short Circuit Rating: 230V Class: 100kA

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-UE
1 0.75
◎
A510-4002-C3-UE
2 1.5
◎
A510-4003-C3-UE
3 2.2
◎
A510-4005-C3-UE
5 3.7
◎
A510-4008-C3-UE
7.5 5.5
◎
A510-4010-C3-UE
10 7.5
◎
A510-4015-C3-UE
15 11
◎
A510-4020-C3-UE
20 15
◎
A510-4025-C3-UE
25 18.5
◎
A510-4030-C3-UE
30 22
◎
A510-4040-C3-UE
40 30
◎
A510-4050-C3-UE
50 37
◎
A510-4060-C3-UE
60 45
◎
A510-4075-C3-UE
75 55
◎
A510-4100-C3-UE
100 75
◎
A510-4125-C3-UE
125 94
◎
A510-4150-C3-UE
150 112
◎
A510-4215-C3-UE
200 160
◎
A510-4270-C3-UE
250 200
◎
A510-4300-C3-UE
300 220
◎
A510-4375-C3-UE
350 280
◎
A510-4425-C3-UE
400 315
◎
Short Circuit Rating: 460V Class: 100kA

2-4
575/690V Class
Voltage A510 Model
Applied
Motor
(HP)
Applied
Motor
(KW)
Filter
with without
3ph, 500~600V
+10%/-15%
50/60Hz
A510-5001-C3-UE 1 0.75
◎
A510-5002-C3-UE 2 1.5
◎
A510-5003-C3-UE 3 2.2
◎
A510-5005-C3-UE 5 3.7
◎
A510-5008-C3-UE 7.5 5.5
◎
A510-5010-C3-UE 10 7.5
◎
3ph, 575~690V
+10%/-15%
50/60Hz
A510-6015-C3-UE 15 11
◎
A510-6020-C3-UE 20 15
◎
A510-6025-C3-UE 25 18.5
◎
A510-6030-C3-UE 30 22
◎
A510-6040-C3-UE 40 30
◎
A510-6050-C3-UE 50 37
◎
A510-6060-C3-UE 60 45
◎
A510-6075-C3-UE 75 55
◎
A510-6100-C3-UE 100 75
◎
A510-6125-C3-UE 125 94
◎
A510-6150-C3-UE 150 112
◎
A510-6175-C3-UE 175 130
◎
A510-6215-C3-UE 215 160
◎
A510-6250-C3-UE 250 185
◎
A510-6270-C3-UE 270 200
◎
Short Circuit Rating: 575/690V Class: 100kA

3-1
Chapter 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/IP21/NEMA 1 or IP00
Operating
Temperature
IP20/IP21: -10°C - +40°C (14 -104 °F)
IP00 or without cover: -10°C - +50°C (14-122 °F)
Enhanced type frame 5 is 50°C without de-rating.
The maximum operating temperature is 60°C, but it is required to derate 2% of
current at each additional 1°C.
If several inverters are placed in the same control panel,
provide a heat removal
means to maintain ambient temperatures
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
Altitude: Below 1000 m (3281 ft.)
It is required to derate 1% of current at each additional 100 m.
The maximum altitude is 3000 m.
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: 1.0G (9.8m/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
Fig 3.2.1: A510s 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) 200V 1 ~ 7.5 HP / 400V 1 ~ 7.5 HP / 575V 1~ 3 HP
Mounting Hole
Rings (4 rings)
Nameplate
and Barcode
Terminal Cover
Digital Operator
Front Cover
Fan Cover
Anti-dust Cover
(Wall-mounted type, IEC IP20) (Wall-mounted type, IEC IP20, NEMA1)
(b) 200V 10 ~ 25 HP / 400V 10 ~ 30 HP / 575V 5~10HP / 690V 15~40HP
(Wall-mounted type, IEC IP20) (Wall-mounted type, IEC IP20, NEMA1)

3-4
(c) 200V 30 ~ 40 HP / 400V 40 ~ 75 HP / 690V 50~75HP
Mounting Hole
Rings (4 rings)
Nameplate
and Barcode
Terminal Cover
Digital Operator
Front Cover
(Wall-mounted type, IEC IP20, NEMA1)
(d) 200V 50 ~ 100 HP / 400V 100 ~ 215 HP / 690V 100~270HP
Mounting Hole
Rings (4 rings)
Nameplate
and Barcode
Terminal Cover
Digital Operator
Front Cover
Mounting Hole
Rings (4 rings)
Nameplate
and Barcode
Terminal Cover
Digital Operator
Front Cover
Anti-dust Cover
Wiring Box
(Wall-mounted type, IEC IP00) (Wall-mounted type, IEC IP20, NEMA1)

3-5
(e) 200V 125 ~ 150 HP / 400V 270 ~ 425 HP
Mounting Hole
Rings (4 rings)
Nameplate
and Barcode
Terminal Cover
Digital Operator
Front Cover
Mounting Hole
Rings (4 rings)
Nameplate
and Barcode
Terminal Cover
Digital Operator
Front Cover
Anti-dust Cover
Wiring Box
(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) 200V: 1-7.5HP / 400V: 1-7.5HP /575V 1~ 3 HP
(b) 200V: 10HP / 400V: 10-20HP /575V 5~10HP
(c) 200V: 15-150HP / 400V: 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 200V, 1 – 25 HP and 400V, 1 – 30 HP and 575V/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 200V, 30 - 150HP and 400V, 40 - 425HP and 690V 50 - 270HP 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 Without Built-in filter type (Standard Type)
(a) 200V: 1 ~ 7.5 HP / 400V: 1 ~ 7.5 HP /575V: 1~3HP
Step 1: Unscrew Step 2: Remove cover

3-7
Step 3: Make wire connections and place cover back Step 4: Fasten screw
(b) 200V: 10 ~ 25 HP / 400V: 10 ~ 30 HP /575V: 5~10HP/690V 15~40HP
Step 1: Unscrew cover Step 2: Remove cover