Watt Drive V2500 Series Manual
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Watt Drive V2500 Series Manual

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FREQUENCY INVERTER
Series V2500
MANUAL

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Summary of Contents for Watt Drive V2500 Series

  • Page 1 FREQUENCY INVERTER Series V2500 MANUAL...
  • Page 2 BA.FBE.UR.024.001.07.03 V2500 Kurzanleitung dt/engl. Watt Drive operates a policy of continuous development. Therefore, we reserve the right to make changes and improvements to any of our products described in this manual without prior notice. Any changes, improvements and typing errors justify no claims for compensation.
  • Page 3 DANGER! The user is responsible that all driven machinery, drive train mechanism not supplied by WATT Drive Antriebstechnik and process line material are capable of safe operation at an applied frequency of 150% of the maximum selected frequency range to the AC motor. Failure to do so can result in destruction of equipment and injury to personnel should a single point failure occur.
  • Page 4 The top surface of the enclosures or barrier that is easily accessible shall meet at least the requirements of the Protective Type IP40). (V2500 series corresponds with this regulation.) CAUTION! The rated voltage of power system that is installed on AC drive must be equal to or less than 240 Volts (400 / 460V model is 480 Volts) and the current must be equal to or less than 5000A RMS.
  • Page 5 DANGER! The AC drive may be destroyed beyond repair if incorrect cables are connected to the input/output terminals. Never connect the AC drive output terminals U/T1, V/T2, and W/T3 directly to the AC main circuit power supply. CAUTION! Turn power on only when the DC-link capacitors are fully discharged. CAUTION! Heat sink may heat up over 70°C, during the operation.
  • Page 7 TABLE OF CONTENTS • Chapter 1 – receiving and inspection • Chapter 2 – storage and installation • Chapter 3 – wiring • Chapter 4 – digital keypad operation • Chapter 5 – parameters • Chapter 6 – maintenance and inspections •...
  • Page 8 CHAPTER 1: RECEIVING AND INSPECTION CHAPTER 1 RECEIVING AND INSPECTION This V2500 AC drive has gone through rigorous quality control tests at the factory before shipment. After receiving the AC drive, please check for the following: Receiving ! Check to make sure that the package includes an AC drive, the User Manual, dust covers and rubber bushings.
  • Page 9 CHAPTER 2 STORAGE AND INSTALLATION 2.1 Storage The AC drive should be kept in the shipping carton before installation. In order to retain the warranty coverage, the AC drive should be stored properly when it is not to be used for an extended period of time.
  • Page 10 CHAPTER 2: STORAGE AND INSTALLATION 2.2 Installation: CAUTION The control, power supply and motor leads must be laid separately. They must not be fed through the same cable conduit / trunking. High voltage insulation test equipment must not be used on cables connected to the drive.
  • Page 11 Wait five minutes for DC bus capacitors discharge. Any electrical or mechanical modification to this equipment without prior written consent of WATT Drive Antriebstechnik GmbH will void all warranties and may result in a safety hazard in addition to voiding the UL listing or CE conformity.
  • Page 12 Please refer to the V2500 installation manual. D) Installation • For V2500 series inverters, the filters described hereafter have to be used and the installation notes have to be observed. If installed according to the following directions, the frequency inverters comply...
  • Page 13 Observe the following provisions for an electromagnetically compatible setup of your drive system: 1. As user you must ensure that the HF impedance between frequency inverter, filter and ground is as small as possible. • Take care it that the connections are metallic and have the largest possible areas (zink-plated mounting plates) 2.
  • Page 14 CHAPTER 3: WIRING 6. Safety measures Ensure that the protective conductor terminal (PE) of the filter is properly • connected with the protective conductor terminal of the frequency inverter. An HF ground connection via metal contact between the housings of the filter and the frequency inverter, or solely via cable shield, is not permitted as protective conductor connection.
  • Page 15 Modem or telephone line to the RS-485 communication port, permanent damage may result. Terminals 1 & 2 are the power sources for the optional copy keypad and should not be used while using RS-485 communication. Figure 1 for models of V2500 Series 1~0.75/1.5; 3~0.75-2.2kW DC choke...
  • Page 16 CHAPTER 3: WIRING Figure 2 for models of V2500 Series 1~2.2; 3~4.0kW * Three phase input power may apply to single phase drives. * For the single phase application, the AC input line can be connected to any two of the three input terminals R,S,T...
  • Page 17 Figure 3 for models of V2500 Series 5.5kW - 75kW VFDB DC chock (optional) Jumper Fuse/NFB(None Fuse Breaker) Motor R(L1) R(L1) U(T1) S(L2) S(L2) V(T2) T(L3) T(L3) W(T3) Please refer to “Control Terminal Explanation” see page 3-10 +24V Factory Default:...
  • Page 18 CHAPTER 3: WIRING Figure 4 for all models V2500 SINK Mode and SOURCE Mode 1 /2 Accel/Decel Sink Source 1 /2 Accel/Decel...
  • Page 19 AC drive output terminals motor connections +1,+2 Connections for DC Link Reactor (optional) +2/B1-B2 Connections for Braking Resistor (optional) +2 - -(minus sign) Connections for External Braking Unit (V2500 series) +2/B1- -(minus sign) Earth Ground 3.3 Control Terminals Explanations Terminal Symbols Terminal Functions...
  • Page 20 CHAPTER 3: WIRING Terminal Symbols Terminal Functions Factory Settings Multi-function Relay output Resistor Load (N.O.) a 5A(N.O.)/3A(N.C.) 240VAC Multi-function Relay output 5A(N.O.)/3A(N.C.) 24VDC (N.C.) b Inductive Load 1.5A(N.O.)/0.5A(N.C.) 240VAC Multi-function Relay common 1.5A(N.O.)/0.5A(N.C.) 24VDC Refer to Pr.03-01 to Pr.03-03 Multi-function output 1 (Photocoupler) Multi-function output 2 Maximum 48VDC, 50mA...
  • Page 21 3.4 Main Circuit Wiring 0.75 – 2.2 kW (1 ~ 0.75 – 1.5 kW; 3 ~ 0.75 – 2.2 kW) / B1 / T3 Control Terminal Torque: 0.4 Nm (3 in-lbf) Wire: 12-24 AWG (0.25 – 4 mm²) Power Terminal Torque: 1.8 Nm (15.6 in-lbf) Wire Gauge: 10-18 AWG (0.75 –...
  • Page 22 CHAPTER 3: WIRING 2.2 – 4.0 kW (1 ~ 2.2 kW; 3 ~ 4 kW) M03M02M01 MCM AFM AUI ACM ACI AVI +10V +24V +2 B U/T1 V/T2 W/T3 Screw Torque : 18Kgf-cm Wire Gauge : 18~10AWG R/L1 S/L2 T/L3 Control Terminal Torque: 0.4 Nm (3 in-lbf) Wire: 12-24 AWG (0.25 –...
  • Page 23 5,5 kW – 11 kW POWER MOTOR Control Terminal Torque: 0.4 Nm (3 in-lbf) Wire: 12-24 AWG (0.25 – 4 mm²) Power Terminal Torque: 3 Nm (26 in-lbf) Wire: 8-12 AWG (4.0 – 10mm²) Wire Type: stranded copper only, 75°C NOTE: If wiring of the terminal utilizes the wire with a 6AWG-diameter (13mm²), it is thus necessary to use the Recognized Ring Terminal to conduct a proper wiring.
  • Page 24 CHAPTER 3: WIRING 15 – 22 kW R/L1 S/L2 T/L3 +1 V/T2 W/T3 ( ) + - ( ) POWER MOTOR Control Terminal Torque: 0.4 Nm (3 in-lbf) Wire: 12-24 AWG (0.25 – 4 mm²) Power Terminal Torque: 3 Nm (26 in-lbf) Wire: 2-8 AWG (10 –...
  • Page 25 30 – 45 kW POWER ALARM CHARGE R/L1 S/L2 T/L3 U/T1 V/T2 2/T3 POWER MOTOR Control Terminal Torque: 0.4Nm (3 in-lbf) Wire: 12-24 AWG (0.25 – 4 mm²) Power Terminal Torque: 5.8Nm (50.9 in-lbf) Wire Gauge: 2-4 AWG Wire Type: Stranded copper only, 75°C 3-15...
  • Page 26 CHAPTER 3: WIRING 55-75 kW R/L1 S/L2 T/L3 U/T1 V/T2 W/T3 Screw Torque: POWER MOTOR 200kgf-cm ( 173in- lbf) Control Terminal Torque: 0,4 Nm (3 in-lbf) Wire: 12-24 AWG (0.25 – 4 mm²) Power Terminal Torque: 20 Nm (173 in-lbf) Wire Gauge: 2/0-3/0AWG Wire Type: Stranded copper only, 75°C 3-16...
  • Page 27 U/T1, V/T2, W/T3, side of AC drive. Do not use a Capacitor or L-C Filter (Inductance-Capacitance) or R-C Filter (Resistance-Capacitance), unless approved by Watt Drive. 16. When using a GFCI (Ground Fault Circuit Interrupt), select current sensor with sensitivity of 200mA, and not less than 0.1-second detection to avoid nuisance...
  • Page 28 CHAPTER 3: WIRING 3.6 Motor Operation Precautions 1. When using the AC drive to operate a standard 3-phase induction motor, notice that the energy loss is greater than for an inverter duty motor. 2. Avoid running a standard induction motor at low speed. Under these conditions, the motor temperature may rise above the motor rating due to limited airflow produced by the motor’s fan.
  • Page 29 CHAPTER 4 DIGITAL KEYPAD OPERATION This chapter describes the various controls and indicators found on the digital keypad/display . The information in this chapter should be read and understood before performing the start–up procedures described in the chapter of parameter settings. ! Description of the Keypad ! Description of Display ! Keypad Operation Modes &...
  • Page 30 CHAPTER 4: DIGITAL KEYPAD OPERATION 4.1 Description of the Digital Keypad LED Display Display frequency, current, voltage and error, etc. Part Number Status Display Display the driver's current status MODE By pressing JOG key. hanges between different Initiates jog operation. MODE display mode.
  • Page 31 Display Message Descriptions Display the output current present at terminals U/T1, V/T2, and W/T3. Display the AC drive forward run status. The AC drive reverse run status. The counter value (C). Display the specified parameter setting. Display the actual value stored within the specified parameter. External Fault.
  • Page 32 CHAPTER 4: DIGITAL KEYPAD OPERATION 4.2 Operation steps of the Digital Keypad Selecting mode START MODE MODE MODE MODE MODE GO START Note: In the selection mode, press PRO G to set the parameters. DATA Setting parameters Success to set parameter. PROG PROG PRO G...
  • Page 33 CHAPTER 5’ – QUICK START GUIDE The parameters of the inverter drives V2500 are pre-set by factory to application based values that usually occur in standard environment. When following the Warnings in the Introduction of this manual and the storage and installation guidelines in chapter 2 as well as the wiring notes in chapter 3, the start-up will usually be executed in very short time because of the parameters factory settings.
  • Page 34 CHAPTER 5’: QUICK START GUIDE Para- Factory Actual Explanation Settings meter Setting Setting 00: Determined by digital keypad 01: Master frequency determined by external terminal, keypad STOP enabled. 02: Master Frequency determined by external terminal, keypad STOP Source of First Operation 02-01 disabled.
  • Page 35 Para- Factory Actual Explanation Settings meter Setting Setting 26: Forced Stop (N.O.) 27: Parameter lock enable (N.C.) (Open: Lock, Close: Unlock) 28: PID function disabled 29: Jog Fwd/Jog Rev (it is enabled at external terminal JOG command) 30: Reset (N.C) 31: Source of second frequency command enabled 32: Source of second operation...
  • Page 36 CHAPTER 6: MAINTENANCE AND INSPECTIONS CHAPTER 6 MAINTENANCE AND INSPECTIONS Modern AC drives are based on solid state electronics technology, preventive maintenance is required to operate this AC drive in its optimal condition, and to ensure a long life. It is recommended to perform a monthly check up of the AC drive by a qualified technician.
  • Page 37 CHAPTER 7 Troubleshooting and Fault Information The AC drive has a comprehensive fault diagnostic system that includes several different alarms and fault messages. Once a fault is detected, the corresponding protective functions will be activated. The following faults are displayed as shown on the AC drive digital keypad display.
  • Page 38 CHAPTER 7: TROUBLESHOOTING AND FAULT INFORMATION Fault Name Fault Descriptions Corrective Actions The AC drive detects that the DC bus voltage has Check whether the input voltage falls within the fallen below its minimum rated AC drive’s input voltage. value. The AC drive detects excessive drive output 1.
  • Page 39 Fault Name Fault Descriptions Corrective Actions Over-current during steady state operation: 1. Short-circuit at motor 1. Check for possible poor insulation at the output. output line. 2. Sudden increase in 2. Check for possible motor stall. motor loading. 3. Replace the AC drive with one that has a 3.
  • Page 40 CHAPTER 7: TROUBLESHOOTING AND FAULT INFORMATION Fault Name Fault Descriptions Corrective Actions Ground fault : The AC drive output is abnormal. When the output terminal is Ground fault : grounded (short circuit current is 50% more than 1. Check whether the IGBT power module is the AC drive rated damaged.
  • Page 41 CHAPTER 8 SUMMARY OF PARAMETER SETTINGS !: The parameter can be set during operation. *: Twice the value or higher value for 400/460V class Group 0: User Parameters Para- Factory Actual Explanation Settings meter Setting Setting 00-00 Identity Code of AC Drive Read-only 00-01 Rated Current Display Read-only...
  • Page 42 CHAPTER 8: PARAMETER SUMMARY Group 1: Basic Parameters Para- Factory Actual Explanation Settings meters Setting Setting 01-00 Maximum Output Freq. (Fmax) 50.00 to 400.00 Hz 50.00 Maximum Voltage Frequency 01-01 0.10 to 400.00 Hz 50.00 (Base Freq) (Fbase) Maximum Output Voltage 230V series: 0.1V to 255.0V 230.0 01-02...
  • Page 43 Group 2: Operation Method Parameters Para- Factory Actual Explanation Settings meters Setting Setting 00: Digital keypad or Inc./Dec. Frequ. 01: 0 to +10Vdc from AVI 02: 4 to 20mA from ACI 03: -10 to +10Vdc from AUI Source of First Frequency 04: RS-485 communication interface 02-00 Command...
  • Page 44 CHAPTER 8: PARAMETER SUMMARY Para- Factory Actual Explanation Settings meters Setting Setting 00: Digital keypad 01: 0 to +10V from AVI Source of the Master Frequency 02-10 02: 4 to 20mA from ACI Command (FCHA) 03: -10 to +10Vdc from AUI 04: RS-485 communication interface 00: Digital keypad or Inc./Dec.
  • Page 45 Group 3: Output Function Parameters Para- Factory Actual Explanation Settings meters Setting Setting 01: AC Drive Operational Multi-Function Output (Relay 03-00 02: Master Freq. Attained Output) 03: Zero Speed 04: Over Torque Detection 05: Base-Block (B.B.) Indication 03-01 Multi-Function Output DO1 06: Low-Voltage Indication 07: AC Drive Operation Mode (1 = drive operation by terminals)
  • Page 46 CHAPTER 8: PARAMETER SUMMARY Group 4: Input Function Parameters Para- Factory Actual Explanation Settings meters Setting Setting 04-00 AVI Analog Input Bias 0.00 to 100.00 % 0.00 00: Positive bias 04-01 AVI Bias Polarity 01: Negative bias 04-02 AVI Input Gain 1 to 200 % 00: no AVI Negative bias command AVI Negative Bias,...
  • Page 47 Para- Factory Actual Explanation Settings meters Setting Setting 36: Output Shutoff Stop (N.C) 00: No functions 04-10 Digital Input Delay Time 1 to 20 (*2ms) 04-11 ACI Analog Input Bias 0.00 to 100.00 % 0.00 00: Positive bias 04-12 ACI Bias Polarity 01: Negative bias 04-13 ACI Input Gain 1 to 200 %...
  • Page 48 CHAPTER 8: PARAMETER SUMMARY Group 5: Multi-Step Speed and PLC Parameters Para- Factory Actual Explanation Settings meters Setting Setting 05-00 Step Speed Freq. ! 0.00 to 400.00 Hz 0.00 05-01 Step Speed Freq. ! 0.00 to 400.00 Hz 0.00 05-02 Step Speed Freq.
  • Page 49 Group 6: Protection Parameters Para- Factory Actual Explanation Settings meters Setting Setting 230V-series: 330V ~ 410V Over-Voltage Stall Prevention 06-00 400/460V-series: 660V ~ 820V 390* Level 0: Disable 20 to 250% Over-Current Stall Prevention CAUTION: High current will reduce the 06-01 during Accel inverters lifetime and/or may...
  • Page 50 CHAPTER 8: PARAMETER SUMMARY Para- Factory Actual Explanation Settings meters Setting Setting 16: CPU WRITE failure CF2 17: external Base Block stop (b.b) 18: Motor over load oL2) 19: Auto Accel/Decel Failure (CFA) 20: Software/Password Protection (code) Fourth Most Recent 21: EF1 (External Emergency Stop) 06-11 Fault Record...
  • Page 51 Group 7: Motor Parameters Para- Factory Actual Explanation Settings meters Setting Setting 07-00 Motor Rated Current 30 to 120% (of AC drive output current) 0 to 90% (of AC drive output current – 07-01 Motor No-Load Current less than Pr.07-00) 07-02 Torque Compensation 0.0 to 10.0...
  • Page 52 CHAPTER 8: PARAMETER SUMMARY Group 8: Special Parameters Para- Factory Actual Explanation Settings meters Setting Setting 08-00 DC Braking Current Level 00 to 100% DC Braking Time during 08-01 0.0 to 60.0 Sec Start-Up DC Braking Time during 08-02 0.0 to 60.0 Sec Stopping 08-03 Start-Point for DC Braking...
  • Page 53 Group 9: Communication Parameters Para- Factory Actual Explanation Settings meters Setting Setting 09-00 Communication Address ! 1 to 254 00: Baud Rate 4800bps 01: Baud Rate 9600bps 09-01 Transmission Speed 02: Baud Rate 19200bps 03: Baud Rate 38400bps 00: Warn and keep Operating Transmission Fault 01: Warn and Ramp to Stop 09-02...
  • Page 54 CHAPTER 8: PARAMETER SUMMARY Group 10: PID Control Parameters Para- Factory Actual Explanation Settings meters Setting Setting 00: Inhibit PID operation 01: Input negative PID feedback from external terminal (AVI) 0 to +10V 02: Input negative PID feedback from 10-00 Input for PID Feedback external terminal (ACI) 4 to 20mA 03: Input positive PID feedback from...
  • Page 55 Group 11: Fan & Pump Control Parameters Para- Factory Actual Explanation Settings meters Setting Setting 00: V/F Curve determined by Pr.01-00 to Pr.01-06 01: 1.5 Power Curve 11-00 V/F Curve Selection 02: 1.7 Power Curve 03: Square Curve 04: Cube Curve Start-Up Frequency of the 11-01 0.00 to 120.00 Hz...
  • Page 57 APPENDIX A: TECHNICAL SPECIFICATIONS 400/460V class Voltage Class 230V Class OPTI-line V2500-0_ _ _ _yW1 007S 015S 022S 007T 015T 022T 037T Max. Applicable Motor Output (kW) 0.75 0.75 Max. Applicable Motor Output (HP) Rated Output Capacity (kVA) Rated Output Current (A) 11.0 Recommended 50 Hz...
  • Page 58 APPENDIX A: TECHNICAL SPECIFICATIONS Voltage Class 400/460V class (ff) OPTI-line V2500-0_ _ _ _yW1 055T 075T 110T 150T 185T 220T 300T 370T 450T 550T 750T Max. Applicable Motor Output (kW) 18.5 Max. Applicable Motor Output (HP) Rated Output Capacity (kVA) 13.7 18.3 24.4...
  • Page 59 APPENDIX B: ACCESSORIES B.1 Non-fuse Circuit Breaker Chart Recommended by WATT DRIVE (UL 508C, paragraph 45.8.4, part a) For 1-phase drives, the current rating of the breaker shall be four times maximum of input current rating. For 3-phase drives, the current rating of the breaker shall be four times maximum of output current rating.
  • Page 60 APPENDIX B: ACCESSORIE I (A) I (A) Line Fuse Model (Input) (Output) I (A)*1 I (A)*2 V2500-0220TFW1 V2500-0300TGW1 V2500-0370TGW1 V2500-0450TGW1 V2500-0550THW1 V2500-0750THW1 Note: *1) Use “ultra rapid fuses” when working according to uL and CuL standards (e.g. Bussmann Type JJN/JJS) *2) Fuse characteristics - “gL”...
  • Page 61 B.2 All Braking Resistors & Braking Units Use in AC Drives Note: Please use resistors recommended by WATT DRIVE Antriebstechnik GmbH. Other resistors and values will void WATT DRIVE Antriebstechnik GmbH warranty. Please contact your nearest WATT DRIVE Antriebstechnik GmbH representative for use of special resistors..
  • Page 62 APPENDIX B: ACCESSORIE B.4 Feedback Card (Refer to Pr.10-10 to 10-15 of related parameter settings) Section 1 Installation 1.1) 0.75kW to 1.5kW 1.2) 2.2kW to 3.7kW...
  • Page 63 1.3) 5.5kW and above...
  • Page 64 APPENDIX B: ACCESSORIE Section 2 FEEDBACK Card (UDZ-FEEDBACK) 2.1) Basic Wiring Diagram R/L1 R/L1 U/T1 Motor S/L2 V/T2 S/L2 T/L3 W/T3 T/L3 Feedback +12V Factory Default Pulse Generator Output 12V DC FB-02 and Pulse Generator Connections 2.2) Basic Wiring Diagram with RPM Meter Attached. None Fused Breaker Motor R(L1)
  • Page 65 Section 3 FB Terminal Descriptions 3.1) Terminals Terminal Symbols Descriptions Power source of FB (FSW1 can be switched to 12V or 5V) Output Voltage: (+12VDC ±5% 200mA) or (+5VDC ±2% 400mA) Power source (VP) and input signal (A, B) common Input signal from Pulse Generator.
  • Page 66 APPENDIX B: ACCESSORIE 3.4) Types of Pulse Generators TSW1 and TSW2 switches Types of Pulse Generators...
  • Page 67 APPENDIX C: DIMENSIONS STOP MODE PROG DATA ECO-line OPTI-line STOP RESET ACHTUNG HOCHSPANNUNG: VOR DEM ÖFFNEN DES UMRICHTERS MINDESTENS 5 MINUTEN WARTEN. BETRIEBSANLEITUNG BEACHTEN V2500-0220TDA1 WARNIN G - HIGH VOLTAGE: WAIT AT LEAST 5 MIN UTES BEFORE OPENING. FOLLOW USER MANUAL...
  • Page 68 APPENDIX C: DIMENSIONS [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] Model (inch) (inch) (inch) (inch) (inch) (inch) (inch) (inch) (inch) 2.75 V2500-0007SBW1 (4.65) (4.25) (7.28) (6.81) (6.3) (0.22) (0.22) (0.11) 2.75 V2500-0015SBW1 (4.65) (4.25) (7.28) (6.81) (6.3) (0.22) (0.22) (0.11) 244.3 160.2 11.3...

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