WEG MW500 series User manual

Frequency Inverter
Convertidor de Frecuencia
Inversor de Frequência
MW500
Motors | Automation | Energy | Transmission & Distribution | Coatings
User's Manual
Manual del Usuario
Manual do Usuário

User’s Manual
Series: MW500
Language: English
Document Nº: 10002218015 / 04
Publishing Date: 05/2017

Summary of Reviews
English
The information below describes the reviews in this manual.
Version Review Description
-R00 First edition
-R01 General review and inclusion of frame size A
-R02 General review
-R03 General review
-R04 General review and inclusion of frame size C
NOTE!
The inverters MW500 have the default parameters set as described below:
50 Hz for models with internal filter (check the smart code E.g.:
MW500B06P5T4).
ATTENTION!
Check the frequency of the power supply.
In case the power supply frequency is different from the default frequency
(check P0403), it is necessary to set:
P0204 = 5 for 60 Hz.
P0204 = 6 for 50 Hz.
It is only necessary to set these parameters once.
Refer to the programming manual of the MW500 for further details about the
setting of parameter P0204.

Contents
English
1 SAFETY INSTRUCTIONS....................................................................1
1.1 SAFETY WARNINGS IN THIS MANUAL...................................................1
1.2 SAFETY WARNINGS IN THE PRODUCT .................................................1
1.3 PRELIMINARY RECOMMENDATIONS....................................................2
2 GENERAL INFORMATION ..................................................................3
2.1 ABOUT THE MANUAL ..............................................................................3
2.2 ABOUT THE MW500..................................................................................3
2.3 NOMENCLATURE .....................................................................................5
2.4 IDENTIFICATION LABELS........................................................................6
2.5 RECEIVING AND STORAGE.....................................................................6
3 INSTALLATION AND CONNECTION..................................................8
3.1 MECHANICAL INSTALLATION.................................................................8
3.1.1 Environmental Conditions ..............................................................8
3.1.2 Positioning and Mounting...............................................................8
3.1.3 Motor and Adaptation Kit Selection..............................................9
3.2 ELECTRICAL INSTALLATION ..................................................................9
3.2.1 Identification of the Power Terminals and Grounding Points ...9
3.2.2 Power and Grounding Wiring, Circuit Breakers and Fuses.....10
3.2.3 Power Connections.......................................................................11
3.2.3.1 Input Connections.............................................................11
3.2.3.2 IT Networks .......................................................................12
3.2.3.3 Dynamic Braking...............................................................12
3.2.3.4 Output Connections .........................................................13
3.2.4 Grounding Connections ...............................................................14
3.2.5 Control Board ................................................................................15
3.2.6 Control Connections.....................................................................15
3.2.7 Cable Separation Distance..........................................................17
3.3 INSTALLATIONS ACCORDING TO EUROPEAN DIRECTIVE OF
ELECTROMAGNETIC COMPATIBILITY .....................................................17
3.3.1 Conformal Installation ................................................................17
3.3.2 Emission and Immunity Levels....................................................18
4 KEYPAD (HMIR) AND BASIC PROGRAMMING .............................19
4.1 USE OF THE HMIR TO OPERATE THE INVERTER...............................19
4.2 INDICATIONS ON THE HMIR DISPLAY.................................................20
4.3 OPERATING MODES OF THE HMIR .....................................................21
5 POWERING UP AND START-UP ......................................................23
5.1 PREPARATION AND POWERING UP.....................................................23
5.2 CONSIDERATIONS FOR INTEGRATED MOUNTING IN
VENTILATED MOTORS ..............................................................................24
5.3 START-UP ................................................................................................25
5.3.1 Start-up (using Superdrive and default circuit
configuration)..........................................................................................25
5.3.2 STARTUP Menu (Using Remote Keypad (HMIR)) .....................25
5.3.2.1 V/f Control Type (P0202 = 0) ............................................26
5.3.2.2 VVW Control Type (P0202 = 5)......................................27
5.3.3 Menu BASIC - Basic Application.................................................29

Contents
English
6 TROUBLESHOOTING AND MAINTENANCE...................................30
6.1 FAULT AND ALARMS ..............................................................................30
6.2 SOLUTIONS FOR THE MOST FREQUENT PROBLEMS ......................30
6.3 DATA TO CONTACT THE TECHNICAL ASSISTANCE ..........................30
6.4 PREVENTIVE MAINTENANCE................................................................31
6.5 CLEANING INSTRUCTIONS ..................................................................32
7 OPTIONAL KITS AND ACCESSORIES ..........................................33
7.1 OPTIONAL KITS ......................................................................................33
7.1.1 RFI Filter ..........................................................................................33
7.1.2 Disconnecting Switch .................................................................33
7.2 ACCESSORIES.........................................................................................33
8 TECHNICAL SPECIFICATIONS .......................................................35
8.1 POWER DATA ..........................................................................................35
8.2 ELECTRONICS/GENERAL DATA...........................................................36
8.2.1 Codes and Standards ...................................................................37

MW500 | 1
Safety Instructions
English
1 SAFETY INSTRUCTIONS
This manual contains the information necessary for the correct use of the frequency inverter
MW500.
It was developed to be operated by people with proper technical training and qualification to
handle this kind of equipment. Those people must follow the safety instructions defined by the
local standards. The noncompliance with the safety instructions may cause risk of death and/or
damages to the equipment.
1.1 SAFETY WARNINGS IN THIS MANUAL
DANGER!
The procedures recommended in this warning aim at protecting the user against
death, serious injuries and/or considerable material damages.
ATTENTION!
The procedures recommended in this warning aim at preventing material
damages.
NOTE!
The information mentioned in this warning is important for the proper
understanding and good operation of the product.
1.2 SAFETY WARNINGS IN THE PRODUCT
High voltages present.
Components sensitive to electrostatic discharges. Do not touch them.
The connection to the protection grounding is required (PE).
Connection of the shield to the grounding.
High temperature warning.

2 | MW500
Safety Instructions
English
1.3 PRELIMINARY RECOMMENDATIONS
DANGER!
Always disconnect the general power supply before changing any electric
component associated to the inverter. Many components may remain loaded
with high voltages and/or moving (fans), even after the AC power supply is
disconnected or turned off. Wait for at least ten minutes in order to guarantee
the full discharge of the capacitors. Always connect the grounding point of the
inverter to the protection grounding.
NOTE!
The MW500 inverter may interfere in other electronic equipment. To
minimize these effects, carefully follow the recommendations of Chapter 3
INSTALLATION AND CONNECTION on page 8.
Read the entire manual before installing or operating this inverter.
Do not execute any applied withstand voltage test on the inverter!
If necessary, contact WEG.
ATTENTION!
The electronic boards have components sensitive to electrostatic discharges.
Do not touch the components or connectors directly. If necessary, first touch
the grounding point of the inverter, which must be connected to the protection
ground or use a proper grounding strap.
ATTENTION!
Do not touch the frame of the inverter directly. The inverter may be very hot
during and after the operation.
ATTENTION!
When in operation, electric energy systems – such as transformers, converters,
motors and cables – generate electromagnetic fields (EMF), posing a risk to
people with pacemakers or implants who stay in close proximity to them.
Therefore, those people must stay at least 2 meters away from such equipment.

General Information
MW500 | 3
English
2 GENERAL INFORMATION
2.1 ABOUT THE MANUAL
This manual contains information for the proper installation and operation of the inverter, as well
as start-up procedures, main technical features and how to identify the most usual problems
of the different models of the MW500 series of inverters.
ATTENTION!
The operation of this equipment requires installation instructions and detailed
operation provided in the user's manual, programming manual and manuals/
guides for kits and accessories. The user's manual and the parameters quick
reference are supplied in a hard copy together with the inverter. The user guides
are also provided in a hard copy along with the kit/accessories. The other manuals
are available at www.weg.net. A printed copy of the files available on WEG’s
website can be requested at your local WEG dealer.
NOTE!
It is not the intention of this manual to present all the possibilities for the
application of the MW500, as well as WEG cannot take any liability for the use
of the MW500 which is not based on this manual.
2.2 ABOUT THE MW500
The MW500 is a high-performance, decentralized inverter with IP66 degree of protection dust
an water. The MW500 allows speed and torque control of three-phase induction motors. This
product features vector (VVW) and scalar (V/f) control - both programmable according to your
application.
In the vector control mode (VV W), the operation is optimized for the motor in use, providing a
better performance in terms of speed regulation.
The scalar mode (V/f) is recommended for simpler applications, such as the activation of most
pumps and fans. The V/f mode is used when more than one motor is activated by a inverter
simultaneously (multimotor applications).
The MW500 can be mounted coupled to the motor or on the wall, depending on the application
requirements.
The MW500 inverter also provides PLC functions (Programmable Logic Controller) by means
of the SoftPLC (integrated) feature. For further details regarding the programming of those
functions on the MW500, refer to the SoftPLC user's manual of the MW500.
The main components of the MW500 are shown in the block diagram of Figure 2.1 on page 4.

General Information
4 | MW500
English
Analog input
(AI1) (*)
Digital input
(DI1 to DI4) (*)
Supplies for electronics and interfaces
between power and control
RS-485
PC
Power
Rectifier
Disconnecting
switch
Power
supply Motor
Dedicate
knob for
reference
U/T1
V/T2
W/T3
DC+ DC-
BR
IGBT
module
R/L1
S/L2
T/L3


= bus connection DC
= connection for brake resistor


Pre-
charge
Software WLP
SUPERDRIVE (*)
MODBUS
DC Link capacitors bank
Braking IGBT
CPU
32 bits
"RISC"
EEPROM
(memory)
User’s
plug-in
card
Interface
(RS232,
RS-485 or
USB)
Analog output
(AO1) (*)
Power supply 24 V
Power supply 10 V
Digital output
DO1 (RL1)
Digital output
DO2 (TR) (*)
Current feedback
PE
Memory card (MCard)
Accessory
Control
XC10
Control
Plug-in module
MW500 keypad
(remote) (**)
RFI
filter
(*) The number of analog/digital inputs/outputs, as well as other resources, may vary according to the model plug-in module used. Table 7.1 on page
34 provides a list of the available modules plug-ins. For further information, refer to the guide supplied with the accessory.
(**) Not provided with the product.
Figure 2.1: Block diagram of the MW500
Part of the figures and tables are available in the appendixes, which are divided in to APPENDIX
A - PARTS on page 122 for parts, APPENDIX B - TECHNICAL SPECIFICATIONS on page
127 for technical specifications and APPENDIX D - MOUNTING INSTRUCTIONS on page
137 for mounting instructions.

General Information
MW500 | 5
English
2.3 NOMENCLATURE
Table 2 .1: Nomenclature of the MW500 inverters
Product and
Series
Identification of the Model
Brake
Degree of
Protection
Conducted
Emission Level
Disconnecting
Switch
Connection
Box
Hardware
Version
Special
Software
Version
Frame Rated
Current
N° of
Phases
Rated
Voltage
Eg.: MW500 B06P5 T 4 DB 66 C2 DS A56 --- --
Available options
MW500
See Table 2.2 on page 5 A56 = motor
connection
box size
56 x 56 mm;
this applies
only to the
frame sizes A
and B
Blank =
standard
DB = with dynamic braking
Sx = special
software
A70 = motor
connection
box size
70 x 70 mm;
this applies
only to the
frame sizes A
and B
Blank = standard
plug-in module
Blank =
motor
connection
box size
70 x 70 mm
and 110 x
110 mm; this
applies only
to the frame
size C
H00 = without
plug-in
66 = IP66/Nema4X (degree of protection) DS = with disconnecting switch
Blank = without disconnecting switch
Blank = It does not meet the standards leves for
conducted emission
C2 = with internal RFI filter
Table 2.2: Available options for each field of the nomenclature according to the rated current and voltage of the inverter
Frame
Rated Output
Current N° of Phases Rated Voltage
Available Options for the Remaining Identification Codes of
the Inverters
Brake
Degree of
Protection
Conducted
Emission Level
Disconnecting
Switch
Connection
Box
A
04P3 = 4.3 A S = single-
phase power
supply
2 = 200...240 V
DB 66 Blank or C2 Blank or DS A56 or A70
06P0 = 6.0 A
02P6 = 2.6 A T = three-
phase power
supply
4 = 380…480 V
04P3 = 4.3 A
B06P5 = 6.5 A T = three- phase power
supply
4 = 380...480 V
10P0 = 10.0 A
C14P0 T = three- phase power
supply
4 = 380...480 V
16P0

General Information
6 | MW500
English
2.4 IDENTIFICATION LABELS
There are two identification labels: one complete nameplate, located on the side of the inverter
and other simplified label inside the inverter shown in Figure 2.2 on page 6. The simplified
label over the plug-in module allows the identification of the most important characteristics of
the inverter. For further details about the position of the labels, see Figure A.2 on page 123
and Figure A.3 on page 124 of APPENDIX A - PARTS on page 122.
Manufacturing date
Serial number
Rated output data
(voltage, current and
frequency)
Rated input data (voltage,
current and frequency)
MW500 model
WEG part number
(a) Side label of the MW500
MW500 model
WEG part number
Serial number Manufacturing date
(b) Simplified internal label (over the plug-in module)
Figure 2.2: (a) and (b) Description of the identification labels series MW500
2.5 RECEIVING AND STORAGE
The MW500 is supplied packed in a cardboard box. On this package, there is an identification
label which is the same as the one attached to the side of the inverter.
Check if:
The identification of the MW500 matches the model purchased.
Any damages occurred during transportation.
Report any damage immediately to the carrier.

General Information
MW500 | 7
English
If the MW500 will not be installed soon, store it in a clean and dry location (temperature between
-25 °C and 60 °C (-13 °F and 140 °F)), with a cover to protect it against dust accumulation and
in consequence maintain the dissipation capacity of the inverter.
ATTENTION!
When the inverter is stored for a long period, it is necessary to perform the
capacitor reforming. Refer to the procedure recommended in Section 6.4
PREVENTIVE MAINTENANCE on page 31 of this manual.

Installation and Connection
8 | MW500
English
3 INSTALLATION AND CONNECTION
3.1 MECHANICAL INSTALLATION
3.1.1 Environmental Conditions
Avoid:
Direct exposure to sunlight.
Inflammable, corrosive liquids or gases.
Metallic particles or oil mist.
Environmental conditions permitted for the operation of the inverter:
Ambient temperature surrounding the inverter: from 0 ºC (32 °F) until:
40 ºC (104 °F) - Nema4x/IP66 (mounted on the wall).
50 ºC (122 °F) - Nema4x/IP66 (mounted integrated on the motor).
For temperatures surrounding the inverter higher than the specifications above, it is necessary
to apply a derating on the current of 2 % for each Celsius degree ( or 1.11 % each °F), limited
to an increase of 10 ºC (50 °F).
Air relative humidity: 5 % to 90 % non-condensing.
Maximum altitude: up to 1000 m (3.300 ft) - standard conditions (no derating required of
current).
From 1000 m to 4000 m (3.300 ft to 13.200 ft) current derating of 1 % each 100 m (or 0.3 %
each 100 ft) above 1000 m (3.300 ft) altitude.
From 2000 m to 4000 m (6.600 ft to 13.200 ft) maximum voltage reduction (480 V for 380…480 V
models) of 1.1 % for each 100 m (330 ft) above 2000 m (6.600 ft) altitude.
Pollution degree: 2 (according to EN50178 and UL508C), with non-conductive pollution.
Condensation must not originate conduction through the accumulated residues.
3.1.2 Positioning and Mounting
The external dimensions, the net weight (mass) of the inverter and the suggested torque values
are presented in Figure B.1 on page 131 of APPENDIX B - TECHNICAL SPECIFICATIONS
on page 127.
Integrate the motor
For assembling of the inverter coupled to the motor follow the step by step in Figure D.1 on
page 137 of APPENDIX D - MOUNTING INSTRUCTIONS on page 137.
Wall mounted
For assembling of the inverter in the wall follow the step by step in Figure D.2 on page 138 of
APPENDIX D - MOUNTING INSTRUCTIONS on page 137.

Installation and Connection
MW500 | 9
English
ATTENTION!
Provide independent conduits for the physical separation of signal, control, and
power cables (refer to Section 3.2 ELECTRICAL INSTALLATION on page 9).
3.1.3 Motor and Adaptation Kit Selection
To select the compatible motor frame:
See Table C.1 on page 134 of APPENDIX C - MOTOR FRAME AND ADAPTATION KITS on
page 134.
To select adaptation kits:
See Table C.2 on page 135 of APPENDIX C - MOTOR FRAME AND ADAPTATION KITS on
page 134.
NOTE!
In order to install the MW500 on the motor, it is recommended to use the
terminals supplied with the inverter. (See Table C.1 on page 134)
ATTENTION!
In case the MW500 Frame A is installed on a WEG motor W22 frame 112,
182/T4 and 213/5T the terminals supplied with the motor cannot be used.
If the MW500 is installed on a motor that is not of the WEG W22 line, the use
of the terminals must be checked.
Always check the tightening torque of the motor terminal connections
(Example: 2 Nm).
3.2 ELECTRICAL INSTALLATION
DANGER!
The following information is merely a guide for proper installation. Comply
with the applicable local regulations for electrical installations.
Make sure the power supply is disconnected before starting the installation.
The MW500 must not be used as an emergency stop device. Provide other
devices for that purpose.
3.2.1 Identification of the Power Terminals and Grounding Points
The location of the power, grounding and control connections are shown in Figure A.2 on
page 123.

Installation and Connection
10 | MW500
English
Description of the power terminals:
Terminal X1 (L1/L, L2/N and L3 (R, S, T, )): AC power supply.
Terminal X2 (U/T1, V/T2, W/T3, ): connection for the motor.
Terminal X3 (DC-, BR, DC+, ): DC bus and brake connection. DC- is the negative pole of
the voltage of the DC bus, BR is the connection of the brake resistor and DC+ is the positive
pole of the voltage of the DC bus.
3.2.2 Power and Grounding Wiring, Circuit Breakers and Fuses
ATTENTION!
Use proper cable lugs for the power and grounding connection cables.
Refer to Table B.1 on page 127 for recommended wiring, circuit breakers
and fuses.
Keep sensitive equipment and wiring at a minimum distance of 0.25 m from
the inverter and from the cables connecting the inverter to the motor.
It is not recommended the use of mini circuit breakers (MDU), because of
the actuation level of the magnet.
NOTE!
The wire gauges listed in Table B.1 on page 127 are approximate values.
Installation conditions and the maximum permitted voltage drop must be
considered for the proper wiring sizing.

Installation and Connection
MW500 | 11
English
3.2.3 Power Connections
Shield
WEG industrial motor
U/T1
U/T1
V/T2
V/T2
W/T3
W/T3
R/L1 S/L2 T/L3
R/L1
S/L2
T/L3
Fuses
Input power supply
1. M8 connector input for
HMIR.
2. Dedicated potentiometer for
speed reference.
Figure 3.1: Power and grounding connection
3.2.3.1 Input Connections
ATTENTION!
The power supply that feeds the inverter must have a grounded neutral. In case
of IT networks, follow the instructions described in Item 3.2.3.2 IT Networks
on page 12.
NOTE!
The input power supply voltage must be compatible with the inverter rated
voltage.
Capacitors for power factor correction are not needed at the inverter input (L1/L,
L2/N, L3 or R, S, T) and must not be installed at the output (U/T1, V/T2, W/T3).

Installation and Connection
12 | MW500
English
Power supply capacity
The MW500 is suitable for use in a circuit capable of delivering not more than 30.000 Arms
symmetrically (200 V - 480 V).
In case the MW500 is installed in power supplies with current capacity over 30.000 Arms, it
is necessary to use proper protection circuits for those power supplies, such as fuses or
circuit breakers.
3.2.3.2 IT Networks
ATTENTION!
When inverters with internal RFI filter is used in IT networks (neutral conductor
not grounded or grounded through a high ohmic value resistor), remove
grounding screw XE1, since those kinds of network cause damage to the filter
capacitors of the inverter.
3.2.3.3 Dynamic Braking
Refer to Table B.1 on page 127 for the following specifications of the dynamic braking: maximum
current, recommended resistance, effective current (*) and cable gauge.
Input power
supply
Thermostat
Brake
resistor
Thermal
relay
R
S
T
Control power
supply
Contactor
BR DC+
R
S
T
Figure 3.2: Installation of brake resistor

Installation and Connection
MW500 | 13
English
(*) The effective braking current can be calculated as follows:
Ieffective = Imax . tbr (min)
√ 5
Where: tbr corresponds to the sum of the braking actuation times during the most severe cycle
of five minutes.
The power of the brake resistor must be calculated considering the deceleration time, the inertia
of the load and of the resistive torque.
Procedure to use the dynamic braking:
Connect the brake resistor between the power terminals DC+ and BR (X3).
Use a twisted cable for the connection. Separate these cables from the signal and control
wiring.
Dimension the cables according to the application, observing the maximum and effective
currents.
The resistor braking should not be mounted next to the inverter.
DANGER!
The internal braking circuit and the resistor may be damaged if the latter is not
properly dimensioned and/or if the voltage of the input power supply exceeds
the maximum permitted value. In order to avoid the destruction of the resistor or
risk of fire, the only guaranteed method is the inclusion of a thermal relay in series
with the resistor and/or a thermostat in contact with its housing, connected so
as to disconnect the input power supply of the inverter in case of overload, as
shown in Figure 3.2 on page 12.
Set P0151 to the maximum value when using dynamic braking.
The voltage level on the DC bus for activation of the dynamic braking is defined by parameter
P0153 (Level of the Dynamic Braking).
Refer to the MW500 programming manual.
3.2.3.4 Output Connections
ATTENTION!
The inverter has an electronic motor overload protection that must be adjusted
according to the driven motor. When several motors are connected to the
same inverter, install individual overload relays for each motor.
The motor overload protection available in the MW500 is in accordance with
the UL508C standard. Note the following information:
1. Trip current equal to 1.2 times the motor rated current (P0401).
2. When parameters P0156, P0157 and P0158 (Overload current at 100 %, 50 %
and 5 % of the rated speed, respectively) are manually set, the maximum
value to meet condition 1 is 1.1 x P0401.

Installation and Connection
14 | MW500
English
ATTENTION!
If a disconnect switch additional or a contactor is installed at the power supply
between the inverter and the motor, never operate it with the motor spinning
or with voltage at the inverter output.
The characteristics of the cable used to connect the motor to the inverter, as well as its
interconnection and routing, are extremely important to avoid electromagnetic interference in
other equipment and not to affect the life cycle of windings and bearings of the controlled motors.
Keep motor cables away from other cables (signal cables, sensor cables, control cables, etc.),
according to Item 3.2.7 Cable Separation Distance on page 17.
Connect a fourth cable between the motor ground and the inverter ground.
When using shielded cables to install the motor:
Follow the safety recommendations of IEC60034-25.
Use the low impedance connection for high frequencies to connect the cable shield to the
grounding. Use parts supplied with the inverter.
Figure 3.3: Details of the connection of the motor cable
3.2.4 Grounding Connections
DANGER!
The inverter must be connected to a protection grounding (PE).
Use grounding wiring with a gauge at least equal to that indicated in Table
B.1 on page 127.
The maximum tightening torque of the grounding connections is of 1.7 N.m
(15 lbf.in).
Connect the grounding points of the inverter to a specific grounding rod, or
specific grounding point or to the general grounding point (resistance ≤ 10 Ω).
Do not share the grounding wiring with other equipment that operate with
high currents (e.g. high power motors, soldering machines, etc.).