Bedford W505 Series Simple Manual

Sensorless vector control controller

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W505 SERIES
SENSORLESS VECTOR CONTROL CONTROLLER
SIMPLE MANUAL
GUANGZHOU BEDFORD ELECTRIC EQUIPMENT CO.,LTD.
V1.0.1

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Summary of Contents for Bedford W505 Series

  • Page 1 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL GUANGZHOU BEDFORD ELECTRIC EQUIPMENT CO.,LTD. V1.0.1...
  • Page 3: Table Of Contents

    CONTENTS 1 SAFETY PRECAUTIONS ................1 1.1 Safety Precautions .................... 1 2 INTRODUCTION ..................3 2.1 Technology Features ..................3 2.2 Description of Name Plate ................3 2.3 Selection Guide ....................4 2.4 Parts Description ....................5 2.5 External Dimension ..................5 3 INSTALLATION ...................6 3.1 Environmental Requirement ................6 3.2 Installation Space .....................
  • Page 4 5.2.2 Stand-by ..................19 5.2.3 Password Setting .................19 5.2.4 Keypad Shortcut Key Setting ............20 5.3 Running State ....................20 5.3.1 Power-on initialization ..............20 5.3.2 Fault reset ..................20 5.3.3 Run Command Source ..............20 5.3.4 Start Mode ................... 21 5.3.5 Stop Mode ..................21 5.4 Motor Parameter Auto-tuning ..............
  • Page 5: Safety Precautions

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL 1 SAFETY PRECAUTIONS Please read this manual carefully before installation, operation, maintenance or inspection. In this manual, the safety precautions were sorted to “WARNING” or “CAUTION”. It reminds that safety precautions when handling, transporting, inspecting, and installing this product.
  • Page 6 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Check that the following requirements are met: –The voltage class of the power supply is consistent with the rated voltage class of the controller. –The input terminals (R, S, T) and output terminals (U, V, W) are properly connected.
  • Page 7: Introduction

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL 2 INTRODUCTION 2.1 Technology Features ● Input & Output ◆Input Voltage Range: 220V/380V ±15% ◆Input Frequency Range: 47Hz~63Hz ◆Output Voltage Range: 0V~rated input voltage ◆Output Frequency Range: 0Hz~600Hz ● Peripheral Interface Characteristics Programmable Digital Input: Provide 6 digital input terminals...
  • Page 8: Selection Guide

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL 2.3 Selection Guide Rated Input Rated Output Rated Input Rated Output Motor Power Model No. Voltage (V) Power (kW) Current (A) Current (A) (kW) W505-2001 0.75 0.75 1AC: 220V W505-2002 11.1 -15%~+15% W505-2003 15.8...
  • Page 9: Parts Description

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL 2.4 Parts Description Figure 2.4.1 Parts of controllers (220V: 22.0kW and below, 380V: 37.0kW and below) Figure 2.4.2 Parts of controllers (220V: 30.0kW and above, 380V: 45.0kW and above) 2.5 External Dimension Figure 2.5.1 220V: 0.75kW~22.0kW,...
  • Page 10: Installation

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Installation Dimension External Dimension Installation Power(kW) Hole (mm) A (mm) B (mm) H (mm) W (mm) D (mm) 220V: 0.75kW~2.2kW 163.8 380V: 0.75kW~2.2kW 220V: 3.0kW~3.7kW 380V: 4.0kW~5.5kW 220V: 5.5kW 176.5 380V: 7.5kW 220V: 7.5kW...
  • Page 11: Disassembly

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Figure 3.2.2 Installation of multiple controllers Notice: Add the air deflector when apply the up-down installation. 3.3 Disassembly Figure 3.3.1 Dimension of plastic keypad Figure 3.3.2 Dimension of metal plate cover 4 WIRING ...
  • Page 12: Connection Of Peripheral Devices

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL  Check to be sure that the voltage of the main AC power supply satisfies the rated voltage of the Controller.  Connect power supply cables and motor cables tightly. 4.1 Connection of Peripheral Devices...
  • Page 13: Wiring At Input Side Of Main Circuit

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL 4.1.1 Wiring at Input Side of Main Circuit 4.1.1.1 Circuit breaker It is necessary to connect a circuit breaker (MCCB) which is compatible with the capacity of controller between 3ph AC power supply and power input terminals (R, S, T). The capacity of breaker is 1.5~2 times to the rated current of controller.
  • Page 14: Wiring Of Common Dc Bus

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Figure 4.1.4 Wiring of regenerative unit 4.1.4 Wiring of Common DC bus Common DC bus method is widely used in the paper industry and chemical fiber industry which need multi-motor to coordinate. In these applications, some motors are in driving status while some others are in regenerative braking (generating electricity) status.
  • Page 15: Ground Wiring

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL 4.1.5 Ground Wiring In order to ensure safety and prevent electrical shock and fire, must be grounded with ground resistance. The ground wire should be big and short, and it is better to use copper wire (>3.5mm ).
  • Page 16 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Figure 4.2.8 Main circuit terminals (30.0kW ~37.0kW) POWER MOTOR Figure 4.2.9 Main circuit terminals (45.0kW ~110.0kW) POWER MOTOR Figure 4.2.10 Main circuit terminals (132.0kW ~200.0kW) Figure 4.2.11 Wiring diagram of main circuit Function description of main circuit terminals: Main circuit terminal functions are summarized according to the terminal to the terminal symbols in the following table.
  • Page 17: Control Circuit Terminals

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL 4.2.3 Control Circuit Terminals 485- 485+ +24V +10V GND COM Figure 4.2.12 Control circuit terminals Figure4.2.13 Control circuit wiring diagram Description of Wiring of Signal Input Terminals: 1) Wiring of AI Terminals: Weak analog voltage signals are easy to suffer external interference, and therefore the shielded cable must be used, and the cable length must be less than 20m, as shown in Figure 4.2.14.
  • Page 18 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL 2) Wiring of DI Terminals: Generally, select shielded cable no longer than 20m. When active driving is adopted, necessary filtering measures shall be taken to prevent the interference to the power supply. It is recommended to use the contact control mode.
  • Page 19: Installation Guideline To Emc Compliance

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL T/A-T/B Relay T/A-T/C Relay output, T/A-T/B, P/A-P/B NC terminal, T/A-T/C, P/A-P/C NO terminal Output Contact driving capacity: AC 250V/3A, DC 30V/1A P/A-P/B P/A-P/C Commu- 485+ 485 communication terminal, please use twisted-pair or shielding wire.
  • Page 20: Site Wiring

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL clips. It is strictly prohibitive to connect the twisted shielding layer to the ground of controller, which greatly decreases or loses the shielding effect. Connect controller and motor with the shielded wire or the separated cable tray. One side of shield layer of shielded wire or metal cover of separated cable tray should connect to ground, and the other side should connect to the motor cover.
  • Page 21: Operation

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL 5 OPERATION 5.1 Keypad Description 5.1.1 Keypad schematic diagram Figure 5.1.1 Keypad schematic diagram 5.1.2 Key function description Button Symbol Name Function Description Programming Key Entry or exit of first-level menu. Enter the menu interfaces level by level, and confirm the parameter Enter Key setting.
  • Page 22: Indicator Light Description

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL 5.1.3 Indicator light description 1) Function Indicator Light Description Indicator Light Name Indicator Light Description Extinguished: Stop status; RUN/TUNE Light on: Operation status; Flickering: Parameter auto-tuning status. Extinguished: Forward operation; FWD/REV Light on: Reverse operation.
  • Page 23: Stand-By

    5.2.3 Password Setting W505 series controller offers user’s password protection function. When F7.00 is set to be nonzero, it will be the user’s password, and after exiting function code edit mode, it will become effective. If pressing the PRG/ESC again to try to access the function code edit mode, “0.0.0.0.0.”...
  • Page 24: Keypad Shortcut Key Setting

    FWD, REV etc. And F0.01 is set to 1. W505 series controller provides a variety of terminal control modes. The control operation mode is determined by function code F5.08, and the input ports of start-stop control signals are determined by function codes F5.00~F5.06.
  • Page 25: Start Mode

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL 3. Communication start-stop control is through communication operation to set function code F0.01=2. The related function code of communication setting as shown in the following figure: When FC.04 is set to a non-zero value, the function of automatic controller stop upon communication timeout is enabled.
  • Page 26: Quick Testing

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL F2.06: motor stator resistance; F2.07: motor rotor resistance; F2.08: motor stator and rotor inductance; F2.09: motor stator and rotor mutual inductance; F2.10: motor current without load; If the motor cannot be completely disconnected from the load, set F0.15 to 1 (Asynchronous motor static tuning) and press ENTER to confirm, and then press RUN on the operation panel to start the motor auto-tuning operation.
  • Page 27: Maintenance And Troubleshooting

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL 6 MAINTENANCE and TROUBLESHOOTING 6.1 Faults and Solutions Fault Fault Type Possible Causes Solutions Code 1.The output circuit is grounded or short Eliminate the external faults; circuited; Install a reactor or an output filter;...
  • Page 28 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Fault Fault Type Possible Causes Solutions Code 1.The input voltage is too high; Adjust the voltage to normal range; Over-voltage at 2.An external force drives the motor during Cancel the external force or install Constant Speed operation.
  • Page 29: Common Faults And Solutions

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Fault Fault Type Possible Causes Solutions Code 1.The cabling of the main control board is in Check the connector and plug the bad contact; cable again; Current 2.Auxiliary power supply is damaged;...
  • Page 30: Maintenance

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Check the CHARGE light. If the light is off, the fault is mainly in the rectify bridge or the buffer resistor. If the light is on, the fault may be lies in the switching power supply. Please ask for support.
  • Page 31: Periodic Maintenance

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL 3.Controller output 4.Point thermometer 4.Temperature rise is lower than 40℃ current 4.Internal temperature 7.2 Periodic Maintenance Customer should check the drive every 3 months or 6 months according to the actual environment.
  • Page 32: Circuit Breaker And Contactor

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Recommended Cable Dimensions (mm²) Screw Model R, S, T, Terminal Screw Torque of U, V, W Specification Torque Driver (N.m) W505-2040 31~40 W505-2050 31~40 W505-2060 31~40 W505-2075 31~40 W505-4001 1.2~1.5 W505-4002 1.2~1.5 W505-4003 1.2~1.5...
  • Page 33: List Of Function Parameters

    W505-4270G/4300P 9 LIST OF FUNCTION PARAMETERS W505 series controller functional parameters divide into group, consists of F0 to FE total 16 groups, each functional group includes some functional code. The functional code uses 3 levels menu, such as “F8.08” is expressed as the eighth functional code of the F8 group function, FE group is the factory functional code, the user have no right to access this group parameter.
  • Page 34: Function Parameters Of W505

    W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL The forth column “the default value” : As the original setting value of function parameter before factory delivery. The fifth column “modification” : As the modification property of function parameter, that is if allow to modify and modify condition or not, the description follows below: “○”...
  • Page 35 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Function Factory Name Description Modify Code Setting off) 2: AI1 3: AI2 4~5: Reserved 6: Multi-Step speed 7: Simple PLC 8: PID 9: Communications control When stacking, B 0: Relative to maximum output frequency F0.04...
  • Page 36 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Function Factory Name Description Modify Code Setting 1: Rotational speed tracking restart 2: Pre-excited start (asynchronous motor) Starting frequency of F1.01 0.00 Hz ~10.00Hz 0.00Hz ○ direct start Hold time of starting F1.02...
  • Page 37 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Function Factory Name Description Modify Code Setting (the controller power>55kW) 0.01mH~655.35mH Motor mutual (the controller power≤55kW) Depend F2.09 ◎ inductance 0.001mH~65.535mH on model (the controller power>55kW) 0.01A~F2.05 (the controller power≤55kW) Depend F2.10 Current without load ◎...
  • Page 38 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Function Factory Name Description Modify Code Setting 6: 1.6-power V/F 8: 1.8-power V/F 9: Reserved 10: V/F complete separation 11: V/F half separation Depend F4.01 Torque boost 0.0%: (auto) , 0.1%~30.0% ○...
  • Page 39 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Function Factory Name Description Modify Code Setting 10: Run pause 11: Reserved 12: Multi-speed 1 13: Multi-speed 2 14: Multi-speed 3 15: Multi-speed 4 16: Terminal 1 for acceleration/ deceleration time selection...
  • Page 40 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Function Factory Name Description Modify Code Setting corresponding setting F5.14 AI1 filter time constant 0.00s~10.00s 0.10s ○ F5.15 AI2 lower limit 0.00V~F5.17 0.00V ○ AI2 lower limit F5.16 -100.0%~100.0% 0.0% ○ corresponding setting F5.17...
  • Page 41 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Function Factory Name Description Modify Code Setting 25: Reserved F6.04 Reserved 0: Running frequency 1: Set frequency F6.05 AO1 Output selection ○ 2: Output current 3: Output torque 4: Output power 5: Output voltage...
  • Page 42 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Function Factory Name Description Modify Code Setting 0~0xFFFF Running status display F7.03 0x001F ○ selection 1 If a parameter needs to be displayed during the running, set the corresponding bit to 1, and set F7.03 to the hexadecimal equivalent of this binary number.
  • Page 43 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Function Factory Name Description Modify Code Setting If a parameter need to be displayed during the stop, set the corresponding bit to 1, and set F7.05 to the hexadecimal equivalent of this binary number.
  • Page 44 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Function Factory Name Description Modify Code Setting 43: Motor Over-speed 45: Motor Overheat 51: Reserved Output frequency at F7.13 Output frequency at current fault —— ● current fault Output current at F7.14 Output current at current fault ——...
  • Page 45 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Function Factory Name Description Modify Code Setting Swing Frequency 0: Relative to the central frequency F8.11 ○ Setting Mode 1: Relative to the maximum output frequency F8.12 Swing amplitude 0.0%~100.0% 0.0% ○...
  • Page 46 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Function Factory Name Description Modify Code Setting 8: MIN (|AI1|, |AI2|) 0: Positive ○ F9.03 PID action direction 1: Negative F9.04 Proportional gain (Kp) 0.0~100.0 20.0 ○ F9.05 Integral time (Ti) 0.01s~10.00s 2.00s...
  • Page 47 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Function Factory Name Description Modify Code Setting 1: Yes Tens position: retentive upon stop 0: No 1: Yes Running time of simple 0.0s~6500.0s 0.0s ○ FA.19 PLC reference 0 or 0.0min~6500.0min (min) Acceleration/decelerati ○...
  • Page 48 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Function Factory Name Description Modify Code Setting Running time of simple 0.0s~6500.0s 0.0s FA.37 ○ PLC reference 9 or 0.0min~6500.0min (min) Acceleration/decelerati FA.38 on time of simple PLC ○ reference 9 Running time of simple 0.0s~6500.0s...
  • Page 49 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL Function Factory Name Description Modify Code Setting Output phase failure 0: Disabled Fb.04 ○ protection selection 1: Enabled Action selection at 0: Invalid Fb.05 instantaneous power 1: Decelerate ◎ failure 2: Decelerate to stop...
  • Page 50: Communication Protocol

    ● 10 COMMUNICATION PROTOCOL W505 series controller provide RS485 communication interface, using international standard ModBus protocol to communicate between the master and the auxiliary. The user can realize centralized control (setting the controller control command, running frequency, modifying relative functional code, the controller working status and monitoring the fault message etc.) through PC/PLC and the upper computer etc.to accommodate the specific...
  • Page 51 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL 2. Command: 06H(0000 0110), write a word For example, write 5000(1388H) to the 0008H RAM address of auxiliary No.2 which local address is 02H, frame description as follows: RTU Host command information...
  • Page 52 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL not only simple in program but also has high arithmetic speed, shortness is data sheet may occupy large ROM space, be caution with this. 4. COMMUNICATION DATA ADDRESS This section introduces how to operate controller, read controller status and setting controller related parameter via communication.
  • Page 53 W505 SERIES SENSORLESS VECTOR CONTROL CONTROLLER SIMPLE MANUAL 3007H Output torque 3008H PID preset value 3009H PID feedback value 300AH Input terminal status 300BH Output terminal status 300CH Input of AI1 300DH Input of AI2 300EH Reserved 300FH count value...
  • Page 56 Agent:...

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