Worldwide WorldDrive 4X VFD User manual

WorldDrive 4X VFD – The WD4X: Operation and Instructional Manual
NOTE: This operation and instruction manual is intended for users with basic knowledge of
electricity and electric devices.
WorldWide Electric Corp.
3540 Winton Place
Rochester, NY 14623
Phone: [phone]
Fax: [phone]
www.worldwideelectric.net

ii
Safety Information
Safety Information
Read and follow all safety instructions in this manual precisely to avoid unsafe operating conditions,
property damage, personal injury, or death.
Safety symbols in this manual
Indicates an imminently hazardous situation which, if not avoided, will result in severe injury or death.
Indicates a potentially hazardous situation which, if not avoided, could result in injury or death.
Indicates a potentially hazardous situation that, if not avoided, could result in minor injury or property
damage.
Safety information
•
Do not open the cover of the equipment while it is on or operating. Likewise, do not operate the
inverter while the cover is open. Exposure of high voltage terminals or charging area to the
external environment may result in an electric shock. Do not remove any covers or touch the
internal circuit boards (PCBs) or electrical contacts on the product when the power is on or
during operation. Doing so may result in serious injury, death, or serious property damage.
•Do not open the cover of the equipment even when the power supply to the inverter has been
turned off unless it is necessary for maintenance or regular inspection. Opening the cover may
result in an electric shock even when the power supply is off.
•The equipment may hold charge long after the power supply has been turned off. Use a multi-
meter to make sure that there is no voltage before working on the inverter, motor or motor cable.

iii
Safety Information
•
This equipment must be grounded for safe and proper operation.
•Do not supply power to a faulty inverter. If you find that the inverter is faulty, disconnect the
power supply and have the inverter professionally repaired.
•The inverter becomes hot during operation. Avoid touching the inverter until it has cooled to
avoid burns.
•Do not allow foreign objects, such as screws, metal chips, debris, water, or oil to get inside the
inverter. Allowing foreign objects inside the inverter may cause the inverter to malfunction or
result in a fire.
•Do not operate the inverter with wet hands. Doing so may result in electric shock.
•Check the information about the protection level for the circuits and devices.
The following connection terminals and devices are the ProtectiveClass 0. It means that the circuit
protection level depends on the basic insulation. If there is no basic insulation is failed, it may cause
electric shock accident. When installing or wiring the connection terminals and devices, take the
same protective action as with the power wire.
- Multi-function Input: P1-P7, CM
-Analog Frequency Input:VR,V1, I2,TI
-Safety Function: SA, SB, SC
-Analog Output:AO,TO
- Digital Output: Q1, EG, 24, A1/C1/B1
-Communications: S+/S-/SG
- Fan
•The protection level of this equipment (inverter) is the Protective Class I.

iv
Safety Information
•
Do not modify the interior workings of the inverter. Doing so will void the warranty.
•The inverter is designed for 3-phase motor operation. Do not use the inverter to operate a single
phase motor.
•Do not place heavy objects on top of electric cables. Doing so may damage the cable and
result in an electric shock.
•Do not operate Disconnect Switch when motor is operating.
Note
Maximum allowed prospective short-circuit current at the input power connection is defined in IEC
60439-1 as 100 kA.The following table shows the recommended MCCB for RMS symmetrical amperes.
Remarque
Le courant maximum de court-circuit présumé autorisé au connecteur d’alimentation électrique est
défini dans la norme IEC 60439-1 comme égal à 100 kA. Le tableau suivant indique le MCCB
recommandé selon le courant RMS symétrique en ampères.
WorkingVoltage UTE100(E/N) UTS150(N/H/L) ABS33c ABS53c ABS63c ABS103c
240V(50/60Hz) 50/65 kA 65/100/150 kA 30 kA 35 kA 35 kA 85 kA
480V(50/60Hz) 25/35 kA 35/65/100 kA 7.5 kA 10 kA 10 kA 26 kA

Safety Information
v
Quick Reference Table
The following table contains situations frequently encountered by users while working with
inverters. Refer to the typical and practical situations in the table to quickly and easily locate
answers to your questions.
Situation Reference
I want to run a slightly higher rated motor than the inverter’s rated capacity.
p. 210
I want to configure the inverter to start operating as soon as the power source is
applied.
p. 80
I want to configure the motor’s parameters.
p.142
I want to set up sensorless vector control.
p.145
Something seems to be wrong with the inverter or the motor.
p. 228, p.346
What is auto tuning? p.142
What are the recommended wiring lengths? p. 228, p.346
The motor is too noisy. p. 176
I want to apply PID control on my system. p. 134
What are the factory default settingss for P1–P5 multi-function terminals? p. 26
I want to view all of the parameters I have modified. p. 184
I want to review recent fault trip and warning histories. p. 312
I want to change the inverter’s operation frequency using a potentiometer. p. 52
I want to install a frequency meter using an analog terminal. p. 27
I want to display the supply current to motor. p. 55
I want to operate the inverter using a multi-step speed configuration. p. 73
The motor runs too hot. p. 209
The inverter is too hot. p. 217
The cooling fan does not work. p. 352
I want to change the items that are monitored on the keypad. p. 204

Table of Contens
vi
Table of Contents
1Preparing the Installation .................................................................................. 1
1.1 Product Identification ..........................................................................................1
1.2Part Names...........................................................................................................3
1.3 Installation Considerations ..................................................................................5
1.4 Selecting and Preparing a Site for Installation ...................................................6
1.5 Cable Selection.....................................................................................................9
2Installing the Inverter .......................................................................................11
2.1 Mounting the Inverter........................................................................................ 13
2.2Cable Wiring ....................................................................................................... 17
2.3 Post-Installation Checklist .................................................................................32
2.4 Test Run .............................................................................................................. 33
3Learning to Perform Basic Operations ..............................................................37
3.1 About the Keypad .............................................................................................. 37
3.1.1 About the Display.................................................................................38
3.1.2Operation Keys.....................................................................................39
3.1.3 Control Menu........................................................................................40
3.2 Learning to Use the Keypad ..............................................................................41
3.2.1 Group and Code Selection ...................................................................41
3.2.2 Navigating Directly to Different Codes...............................................42
3.2.3 Setting Parameter Values....................................................................43
3.2.4 Configuring the [ESC] Key ...................................................................45
3.3 Actual Application Examples.............................................................................46
3.3.1 AccelerationTime Configuration.........................................................46
3.3.2 Frequency Reference Configuration ...................................................47
3.3.3 Jog Frequency Configuration...............................................................49
3.3.4 Initializing All Parameters ....................................................................50
3.3.5 Frequency Setting (Keypad) and Operation (via Terminal Input) ......51
3.3.6 Frequency Setting (Potentiometer) and Operation (Terminal Input)52
3.3.7 Frequency Setting (Potentiometer) and Operation (Keypad) ........... 53

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vii
3.4 Monitoring the Operation .................................................................................55
3.4.1 Output Current Monitoring .................................................................55
3.4.2 FaultTrip Monitoring............................................................................56
4Learning Basic Features................................................................................... 58
4.1 Setting Frequency Reference............................................................................61
4.1.1 Keypad as the Source (KeyPad-1 setting)...........................................61
4.1.2 Keypad as the Source (KeyPad-2 setting)...........................................62
4.1.3 V1Terminal as the Source ....................................................................62
4.1.4 Setting a Frequency Reference with InputVoltage (Terminal I2)..... 69
4.1.5 Setting a Frequency withTI Pulse Input............................................. 69
4.1.6 Setting a Frequency Reference via RS-485 Communication............. 71
4.2 Frequency Hold by Analog Input....................................................................... 72
4.3 Changing the Displayed Units (Hz↔Rpm) ....................................................... 72
4.4 Setting Multi-step Frequency............................................................................ 73
4.5 Command Source Configuration ...................................................................... 75
4.5.1 The Keypad as a Command Input Device ........................................... 75
4.5.2 Terminal Block as a Command Input Device (Fwd/Rev Run
Commands)......................................................................................... 75
4.5.3 Terminal Block as a Command Input Device (Run and Rotation
Direction Commands).........................................................................76
4.5.4 RS-485 Communication as a Command Input Device....................... 77
4.6 Local/Remote Mode Switching......................................................................... 77
4.7 Forward or Reverse Run Prevention .................................................................79
4.8 Power-on Run.....................................................................................................80
4.9 Reset and Restart ...............................................................................................80
4.10 Setting Acceleration and DecelerationTimes ..................................................82
4.10.1 Acc/DecTime Based on Maximum Frequency...................................82
4.10.2 Acc/DecTime Based on Operation Frequency ...................................84
4.10.3 Multi-step Acc/Dec Time Configuration..............................................85
4.10.4 Configuring Acc/Dec Time Switch Frequency.....................................86
4.11 Acc/Dec Pattern Configuration .........................................................................87
4.12 Stopping the Acc/Dec Operation ......................................................................91

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viii
4.13 V/F(Voltage/Frequency) Control .......................................................................91
4.13.1 LinearV/F Pattern Operation...............................................................91
4.13.2 Square ReductionV/F pattern Operation ...........................................92
4.13.3 User V/F Pattern Operation..................................................................93
4.14 Torque Boost ......................................................................................................94
4.14.1 ManualTorque Boost ...........................................................................94
4.14.2 AutoTorque Boost-1 ............................................................................95
4.14.3 AutoTorque Boost-2........................................................................... 96
4.15 OutputVoltage Setting..................................................................................... 96
4.16 Start Mode Setting ........................................................................................... 96
4.16.1 Acceleration Start.................................................................................97
4.16.2 Start After DC Braking .........................................................................97
4.17 Stop Mode Setting.............................................................................................98
4.17.1 Deceleration Stop.................................................................................98
4.17.2 Stop After DC Braking..........................................................................98
4.17.3 Free Run Stop ...................................................................................... 99
4.17.4 Power Braking ....................................................................................100
4.18 Frequency Limit ...............................................................................................101
4.18.1 Frequency Limit Using Maximum Frequency and Start Frequency 101
4.18.2 Frequency Limit Using Upper and Lower Limit FrequencyValues .101
4.18.3 Frequency Jump .................................................................................102
4.19 2nd Operation Mode Setting............................................................................ 103
4.20 Multi-function Input Terminal Control ............................................................104
4.21 P2P Setting....................................................................................................... 107
4.22 Multi-keypad Setting .......................................................................................108
4.23 User Sequence Setting ....................................................................................109
4.24 Fire Mode Operation ....................................................................................... 115
5Learning Advanced Features ..........................................................................118
5.1 Operating with Auxiliary References ..............................................................119
5.2 Jog operation.................................................................................................... 123
5.2.1 Jog Operation 1-Forward Jog by Multi-functionTerminal ............... 123

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ix
5.2.2 Jog Operation 2-Fwd/Rev Jog by Multi-function Terminal .............. 125
5.2.3 Jog Operation by Keypad................................................................... 125
5.3 Up-down Operation.........................................................................................126
5.4 3-Wire Operation.............................................................................................. 127
5.5 Safe Operation Mode ......................................................................................128
5.6 Dwell Operation ............................................................................................... 131
5.7 Slip Compensation Operation......................................................................... 132
5.8 PID Control ....................................................................................................... 134
5.8.1 PID Basic Operation ........................................................................... 134
5.8.2 Pre-PID Operation..............................................................................140
5.8.3 PID Operation Sleep Mode ................................................................140
5.8.4 PID Switching (PID Openloop)........................................................... 141
5.9 AutoTuning ......................................................................................................142
5.10 Sensorless Vector Control for Induction Motors ............................................146
5.10.1 SensorlessVector Control Operation Setting for Induction Motors149
5.10.2 SensorlessVector Control Operation Guide for Induction Motors ..152
5.11 SensorlessVector Control for PM (Permanent-Magnet) Synchronous Motors
154
5.11.1 Detecting the Initial Pole Position .....................................................156
5.11.2 SensorlessVector Control Mode Settings for PM Synchronous
Motors................................................................................................ 157
5.11.3 Guidelines for Running a PM Synchronous Motor in Sensorless
Vector Control Mode.........................................................................160
5.12 Kinetic Energy Buffering Operation................................................................163
5.13 Torque Control .................................................................................................166
5.14 Energy Saving Operation.................................................................................169
5.14.1 Manual Energy Saving Operation .....................................................169
5.14.2 Automatic Energy Saving Operation ................................................ 170
5.15 Speed Search Operation.................................................................................. 170
5.16 Auto Restart Settings....................................................................................... 175
5.17 Operational Noise Settings (carrier frequency settings) ............................... 176
5.18 2nd Motor Operation .........................................................................................177

Table of Contents
x
5.19 Supply PowerTransition .................................................................................. 179
5.20 Cooling Fan Control .........................................................................................180
5.21 Input Power Frequency andVoltage Settings ................................................180
5.22 Read, Write, and Save Parameters .................................................................181
5.23 Parameter Initialization ................................................................................... 181
5.24 ParameterView Lock.......................................................................................182
5.25 Parameter Lock................................................................................................183
5.26 Changed Parameter Display ...........................................................................184
5.27 User Group........................................................................................................185
5.28 Easy Start On....................................................................................................186
5.29 Config(CNF) Mode ...........................................................................................188
5.30 Timer Settings..................................................................................................189
5.31 Brake Control....................................................................................................189
5.32 Multi-Function Output On/Off Control...........................................................191
5.33 Press Regeneration Prevention.......................................................................191
5.34 Analog Output..................................................................................................193
5.34.1 Voltage and Current Analog Output..................................................193
5.34.2 Analog Pulse Output ..........................................................................195
5.35 Digital Output...................................................................................................198
5.35.1 Multi-function OutputTerminal and Relay Settings ........................198
5.35.2 FaultTrip Output using Multi-Function OutputTerminal and Relay202
5.35.3 Multi-function OutputTerminal Delay Time Settings ......................202
5.36 Keypad Language Settings .............................................................................204
5.37 Operation State Monitor .................................................................................204
5.38 OperationTime Monitor..................................................................................206
6Learning Protection Features .........................................................................209
6.1 Motor Protection .............................................................................................209
6.1.1 ElectronicThermal Motor Overheating Prevention (ETH) ..............209
6.1.2 Overload Early Warning andTrip.......................................................210
6.1.3 Stall Prevention and Flux Braking .....................................................212
6.2 Inverter and Sequence Protection ..................................................................215

Table of Contents
xi
6.2.1 Open-phase Protection .....................................................................215
6.2.2 ExternalTrip Signal.............................................................................216
6.2.3 Inverter Overload Protection............................................................. 217
6.2.4 Speed Command Loss .......................................................................218
6.2.5 Dynamic Braking (DB) Resistor Configuration .................................220
6.3 Under load FaultTrip and Warning .................................................................221
6.3.1 Fan Fault Detection............................................................................ 223
6.3.2 Lifetime diagnosis of components.................................................... 223
6.3.3 LowVoltage FaultTrip........................................................................225
6.3.4 Output Block by Multi-FunctionTerminal ........................................226
6.3.5 Trip Status Reset.................................................................................226
6.3.6 Inverter Diagnosis State..................................................................... 227
6.3.7 Operation Mode on Option CardTrip................................................ 227
6.3.8 No MotorTrip......................................................................................228
6.3.9 Low voltage trip 2...............................................................................228
6.4 Fault/Warning List............................................................................................228
7RS-485 Communication Features ................................................................... 231
7.1 Communication Standards ............................................................................. 231
7.2 Communication System Configuration.......................................................... 231
7.2.1 Communication Line Connection .....................................................232
7.2.2 Setting Communication Parameters ................................................232
7.2.3 Setting Operation Command and Frequency ..................................234
7.2.4 Command Loss Protective Operation ..............................................235
7.2.5 SettingVirtual Multi-Function Input .................................................235
7.2.6 Saving Parameters Defined by Communication.............................. 237
7.2.7 Total Memory Map for Communication ...........................................238
7.2.8 Parameter Group for Data Transmission ..........................................238
7.3 Communication Protocol ................................................................................239
7.3.1 INV 485 Protocol ................................................................................239
7.3.2Modbus-RTU Protocol .......................................................................245
7.4 Compatible Common Area Parameter.......................................................... 248
7.5 WD4X Expansion Common Area Parameter .................................................252

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xii
7.5.1 Monitoring Area Parameter (Read Only) ..........................................252
7.5.2 Control Area Parameter (Read/ Write) .............................................. 257
7.5.3 Inverter Memory Control Area Parameter (Read and Write)...........259
8Table of Functions...........................................................................................263
8.1 Operation Group ..............................................................................................263
8.2 Drive group (PAR→dr).....................................................................................265
8.3 Basic Function group (PAR→bA) ....................................................................270
8.4 Expanded Function group (PAR→Ad)............................................................276
8.5 Control Function group (PAR→Cn).................................................................282
8.6 InputTerminal Block Function group (PAR→In) ........................................... 289
8.7 Output Terminal Block Function group (PAR→OU) ..................................... 294
8.8 Communication Function group (PAR→CM) ............................................... 299
8.9 Application Function group (PAR→AP) .........................................................304
8.10 Protection Function group (PAR→Pr) ............................................................ 307
8.11 2nd Motor Function group (PAR→M2) .......................................................... 312
8.12 User Sequence group (US) ..............................................................................314
8.13 User Sequence Function group(UF)................................................................318
8.14 Groups for LCD Keypad Only ..........................................................................338
8.14.1 Trip Mode (TRP Last-x) ......................................................................338
8.14.2 Config Mode (CNF).............................................................................338
9Troubleshooting .............................................................................................342
9.1 Trips and Warnings...........................................................................................342
9.1.1 Fault Trips ............................................................................................342
9.1.2 Warning Messages .............................................................................345
9.2 Troubleshooting FaultTrips.............................................................................346
9.3 Troubleshooting Other Faults .........................................................................348
10 Maintenance ..................................................................................................354
10.1 Regular Inspection Lists...................................................................................354
10.1.1 Daily Inspections.................................................................................354
10.1.2 Annual Inspections ............................................................................. 355
10.1.3 Bi-annual Inspections......................................................................... 357

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xiii
10.2 Storage and Disposal....................................................................................... 357
10.2.1 Storage................................................................................................ 357
10.2.2 Disposal...............................................................................................358
11 Technical Specification ...................................................................................360
11.1 Input and Output Specification .......................................................................360
11.2 Product Specification Details ..........................................................................364
11.3 External Dimensions (IP 66Type).................................................................... 367
11.4 Peripheral Devices............................................................................................ 372
11.5 Fuse and Reactor Specifications ..................................................................... 373
11.6 Terminal Screw Specification .......................................................................... 374
11.7 Braking Resistor Specification......................................................................... 376
11.8 Continuous Rated Current Derating ............................................................... 377
11.9 Heat Emmission............................................................................................... 379
Product Warranty..................................................................................................380
Index .....................................................................................................................387

Preparing the Installation
1
1Preparing the Installation
This chapter provides details on product identification, part names, correct installation and cable
specifications.To install the inverter correctly and safely, carefully read and follow the instructions.
1.1 Product Identification
The WD4X Inverter is manufactured in a range of product groups based on drive capacity and
power source specifications. Product name and specifications are detailed on the rating label.The
illustration on the next page shows the location of the rating label. Check the rating plate before
installing the product and make sure that the product meets your requirements. For more detailed
product specifications, refer to 11.1 Input and Output Specification on page 360.
Note
Check the product name, open the packaging, and then confirm that the product is free from defects.
Contact your supplier if you have any issues or questions about your product.

Preparing the Installation
2
Product Rating Label
Rating and Selection Chart

Preparing the Installation
3
1.2 Part Names
The illustration below displays part names. Details may vary between product groups.
Full product
Do not operate Disconnect Switch when motor is operating.
Cooling fan is only supported to 5.5~7.5kW products.

Preparing the Installation
4
Front cover removed

Preparing the Installation
5
1.3 Installation Considerations
Inverters are composed of various precision, electronic devices, and therefore the installation
environment can significantly impact the lifespan and reliability of the product.The table below
details the ideal operation and installation conditions for the inverter.
Items
Description
AmbientTemperature* Heavy Duty: 14–122
°
F (-10– 40℃)
Ambient Humidity
90% relative humidity (no condensation)
StorageTemperature
- 4–149°F (-20–65
℃
)
Environmental Factors
An environment free from corrosive or flammable gases, oil residue or dust
Altitude/Vibration
Lower than 3,280 ft (1,000 m) above sea level/less than 1G (9.8m/sec2)
Air Pressure
70 –106kPa
*The ambient temperature is the temperature measured at a point 2” (5 cm) from the surface of
the inverter.
Do not allow the ambient temperature to exceed the allowable range while operating the inverter.

Preparing the Installation
6
1.4 Selecting and Preparing a Site for Installation
When selecting an installation location consider the following points:
•The inverter must be installed on a wall that can support the inverter’s weight.
•The location must be free from vibration.Vibration can adversely affect the operation of the
inverter.
•The inverter can become very hot during operation. Install the inverter on a surface that is fire-
resistant or flame-retardant and with sufficient clearance around the inverter to allow air to
circulate.The illustrations below detail the required installation clearances.

Preparing the Installation
7
•Ensure sufficient air circulation is provided around the inverter when it is installed. If the
inverter is to be installed inside a panel, enclosure, or cabinet rack, carefully consider the
position of the inverter’s cooling fan and the ventilation louver.The cooling fan must be
positioned to efficiently transfer the heat generated by the operation of the inverter.