WEG MW500 series User manual

Frequency Inverter
MW500
Motors | Automation | Energy | Transmission & Distribution | Coatings
User's Manual

User’s Manual
Series: MW500
Language: English
Document Nº: 10002218015 / 00
Publishing Date: 05/2013

Summary of Reviews
The information below describes the reviews made in this manual.
Review Description Chapter
1First edition -
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.

Index
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......................................................................7
3 INSTALLATION AND CONNECTION...................................................8
3.1 MECHANICAL INSTALLATION..................................................................8
3.1.1 Environmental Conditions ...............................................................8
3.1.2 Positioning and Mounting................................................................8
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........9
3.2.3 Power Connections........................................................................10
3.2.3.1 Input Connections.............................................................10
3.2.3.2 IT Networks........................................................................ 11
3.2.3.3 Dynamic Braking............................................................... 11
3.2.3.4 Output Connections .........................................................13
3.2.4 Grounding Connections ................................................................ 14
3.2.5 Control Board ................................................................................. 14
3.2.6 Control Connections...................................................................... 14
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 DRIVE .......................................19
4.2 INDICATIONS ON THE HMIR DISPLAY..................................................20
4.3 OPERATING MODES OF THE HMIR ......................................................21

Index
5 POWERING UP AND START-UP .......................................................25
5.1 PREPARATION AND POWERING UP......................................................25
5.2 CONSIDERATIONS FOR INTEGRATED MOUNTING IN VENTILATED
MOTORS .......................................................................................................26
5.3 START-UP .................................................................................................27
5.3.1 Start-up (using Superdrive and default circuit configuration) .27
5.3.2 STARTUP Menu (Using Remote Keypad (HMIR)) ......................28
5.3.2.1 V/f Control Type (P0202 = 0) ............................................28
5.3.2.2 V V W Control Type (P0202 = 5) ........................................29
5.3.3 Menu BASIC – Basic Application .................................................31
6 TROUBLESHOOTING AND MAINTENANCE....................................32
6.1 FAULT AND ALARMS ...............................................................................32
6.2 SOLUTIONS FOR THE MOST FREQUENT PROBLEMS .......................32
6.3 DATA TO CONTACT THE TECHNICAL ASSISTANCE ...........................33
6.4 PREVENTIVE MAINTENANCE.................................................................33
6.5 CLEANING INSTRUCTIONS ...................................................................34
7 OPTIONAL KITS AND ACCESSORIES ...........................................35
7.1 OPTIONAL KITS .......................................................................................35
7.1.1 RFI Filter ...........................................................................................35
7.1.2 Disconnecting Switch ..................................................................35
7.2 ACCESSORIES..........................................................................................35
8 TECHNICAL SPECIFICATIONS ........................................................37
8.1 POWER DATA ...........................................................................................37
8.2 ELECTRONICS/GENERAL DATA ............................................................37
8.2.1 Codes and Standards ....................................................................38
APPENDIX A – PARTS...........................................................................40
APPENDIX B – TECHNICAL SPECIFICATIONS ..................................43
APPENDIX C – MOUNTING INSTRUCTIONS......................................46

MW500 | 1
Safety Instructions
- English -
1 SAFETY INSTRUCTIONS
This manual contains the information necessary for the correct use of the MW500 drive.
It was developed to be operated by people with proper technical training or 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 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.
Connection of the shield to the grounding.
Connection to the protection grounding is required.
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 drive. Many components may remain
charged 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 drive to the protection grounding.
NOTES!
The MW500 drive may interfere in other electronic equipment. Observe
the recommendations of chapter 3 - Installation and Connection in
order to minimize these effects.
Read the entire manual before installing or operating this drive.
Do not execute any applied withstand voltage test on the drive!
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 drive, which must be connected to the
protection ground or use a proper grounding strap.
ATTENTION!
Do not touch the enclouser of the drive directly. The drive may be very
hot during and after the operation.

MW500 | 3
General Information
- English -
2 GENERAL INFORMATION
2.1 ABOUT THE MANUAL
This manual contains information for the proper installation and operation of the drive,
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 drives.
ATTENTION!
The operation of this equipment requires detailed installation and operation
instructions provided in the user’s manual, programming manual and
communication manuals. The user’s manual and the quick reference of the
parameters are supplied at the purchase of the drive, while the guides
are supplied with their respective accessories. Other manuals are only
supplied in CD-ROM, which comes with the drive, or can be downloaded
in WEG’s website - www.weg.net. This CD must be always kept with this
equipment. A printed copy of the files available in the CD 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 motordrive with IP66 degree of
protection which 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 (VVW), 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 drive simultaneously (multimotor applications).
The MW500 can be mounted on the motor or on the wall, depending on the application
requirements.
The MW500 drive 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.

4 | MW500
General Information
- English -
The main components of the MW500 are shown in the block diagram of figure 2.1.
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
Inverter with
IGBT´s
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,
RS485
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 plug-in module used.
Table 7.1 provides a list of the available plug-ins. For further information, refer to the guide supplied with the accessory or the
CD-ROM.
(**) 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 into
Appendix A for parts, Appendix B for technical specifications and Appendix C for
mounting instructions.

MW500 | 5
General Information
- English -
2.3 NOMENCLATURE
Table 2.1: Nomenclature of the MW500 drives
Product
and
Series
Identification of the Model
Brake Degree of
Protection
Conducted
Emission
Level
Disconnecting
Switch
Hardware
Version
Special Software
Version
Frame Rated
Current
N° of
Phases
Rated
Voltage
Ex.: MW500 B06P5 T 4 DB 66 C2 DS --- --
Available options
MW500
See table 2.2.Blank = standard
DB = with dynamic braking
Sx = special software
Blank = standard plug-in module
H00 = without plug-in
66 = IP66 (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 drive
Frame Rated Output
Current N° of Phases Rated Voltage
Available Options for the Remaining Identification Codes
of the Drives
Brake Degree of
Protection
Conducted
Emission Level
Disconnecting
Switch
B
06P5 = 6.5 A T = three-phase
power supply 4 = 380...480 V DB IP66 or NEMA 4X Blank or C2 DS
10P0 = 10.0 A

6 | MW500
General Information
- English -
2.4 IDENTIFICATION LABELS
There are two identification labels: one complete name plate, located on the side of the
drive and a simplified label inside the drive shown in figure 2.2. The simplified label over
the plug-in module allows the identification of the most important characteristics of the
drive, even in drives mounted side-by-side. For further details about the position of the
labels, see figure A.2 and A.3 of Appendix A.
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 (Inside the drive)
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 on the MW500

MW500 | 7
General Information
- English -
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 drive.
Check if:
The identification of the MW500 matches the model purchased.
Any damages occurred during transportation.
Report any damage immediately to the carrier.
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 drive.
ATTENTION!
When the drive 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 of this manual.

8 | MW500
Installation and Connection
- English -
3 INSTALLATION AND CONNECTION
3.1 MECHANICAL INSTALLATION
3.1.1 Environmental Conditions
Avoid:
Direct exposure to sunlight.
Inflammable or corrosive liquids or gases.
Dust, metallic particles or oil mist.
Environmental conditions permitted for the operation of the drive:
Temperature surrounding the inverter: from 0 ºC (32 °F) to the rated temperature
specified as follows:
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).
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 drive and the suggested torque
values are presented in figure B.1 of Appendix B.
Integrate the motor
For assembling of the drive onto the motor follow the step by step guide in figure C.1
of Appendix C.
Wall mounted
For assembling of the drive in the wall follow the step by step guide in figure C.2 of
Appendix C.
ATTENTION!
Provide independent conduits for the physical separation of signal, control,
and power cables (refer to section 3.2 - Electrical Installation).

MW500 | 9
Installation and Connection
- English -
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.
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 for recommended wiring, circuit breakers and fuses.
Keep sensitive equipment and wiring at a minimum distance of 0.25 m
from the drive and from the cables connecting the drive 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 are approximate values. Installation
conditions and the maximum permitted voltage drop must be considered
for the proper wiring sizing.

10 | MW500
Installation and Connection
- 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
Fig ure 3.1: Power and grounding connection
3.2.3.1 Input Connections
ATTENTION!
The power supply that feeds the drive must have a grounded neutral.
In case of IT networks, follow the instructions described in item
3.2.3.2 - IT Networks.
NOTE!
The input power supply voltage must be compatible with the drive
rated voltage.
Capacitors for power factor correction are not needed at the drive
input (L1/L, L2/N, L3 or R, S, T) and must not be installed at the output
(U/T1, V/T2, W/T3).

MW500 | 11
Installation and Connection
- English -
Power supply capacity
The MW500 is suitable for use in a circuit capable of delivering not more than 30.000 Arms
symmetrically (380 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 drives 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 drive.
3.2.3.3 Dynamic Braking
Refer to table B.1 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
(*) The effective braking current can be calculated as follows:

12 | MW500
Installation and Connection
- English -
Ieficaz = 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.
If the brake resistor is mounted within the cabinet of the drive, consider its energy
when dimensioning the ventilation of the cabinet.
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
drive in case of overload, as shown in figure 3.2.
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.

MW500 | 13
Installation and Connection
- English -
3.2.3.4 Output Connections
ATTENTION!
The drive has an electronic motor overload protection that must be
adjusted according to the driven motor. When several motors are
connected to the same drive, 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.
ATTENTION!
If a disconnect switch or a contactor is installed at the power supply
between the drive and the motor, never operate it with the motor spinning
or with voltage at the drive output.
The characteristics of the cable used to connect the motor to the drive, 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.
Connect a fourth cable between the motor ground and the drive 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 drive.

14 | MW500
Installation and Connection
- English -
Figure 3.3: Details of the connection of the motor cable
3.2.4 Grounding Connections
DANGER!
The drive must be connected to a protection grounding (PE).
Use grounding wiring with a gauge at least equal to that indicated in
table B.1.
The maximum tightening torque of the grounding connections is of
1.7 N.m (15 lbf.in).
Connect the grounding points of the drive 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.).
3.2.5 Control Board
Plug-in modules are connected to control board. S10 DIP-switch are available in control
board, for more information refer to section 4.3 - Operating Modes of the HMIR.
3.2.6 Control Connections
The control connections (analog input/output, digital input/output and interface RS485)
must be performed according to the specification of the connector of the plug-in module
connected to the MW500. Refer to the guide of the plug-in module in print or in the CD
of the product. The typical functions and connections for the CFW500-IOS standard
plug-in module are shown in figure 3.4. For further details about the specifications of
the connector signals, refer to chapter 8 - Technical Specifications.