Instruction ManualMD60 AC DriveUser ManualVersion 3.0D2-3499-3

VIII MD60 AC Drive User Manual

B-4 MD60 AC Drive User Manual

Parameters Cross-Referenced by Name C-1APPENDIX CParametersCross-Referencedby NameParameter Name No.Parameter GroupDefault ValuePage No.0 - 10 V Analo

C-2 MD60 AC Drive User ManualDB Resistor Select A082 Advanced 0 = Disabled 9-15DC Brake Level A081 Advanced Amps x 0.5 9-14DC Brake Time A080 Advance

Parameters Cross-Referenced by Name C-3Preset Frequency 1 A071 Advanced 0.0 Hz 9-13Process Display d010 Display Read Only 9-29Process Factor A099 Adva

C-4 MD60 AC Drive User Manual

CE Conformance Requirements D-1APPENDIX D CE ConformanceRequirementsConformity with the Low Voltage (LV) Directive and Electromagnetic Compatibility (

D-2 MD60 AC Drive User ManualEssential Requirements for CE ComplianceThe following conditions must be satisfied for MD60 drives to meet the requireme

CE Conformance Requirements D-3EN61000-3-2• 0.75 kW (1 HP) 240 V 1-phase and 3-phase drives and 0.37 kW (1/2 HP) 240 V 1-phase drives are suitable for

D-4 MD60 AC Drive User Manual

Accessories E-1APPENDIX E AccessoriesE.1 Dynamic Brake Modules Table E.1 – Dynamic Brake ModulesDrive RatingsModel Number11The resistors listed in thi

Introduction 1-1CHAPTER 1IntroductionThis manual is intended for qualified electrical personnel familiar with installing, programming, and maintaining

E-2 MD65 AC Drive User Manual Figure E.1 – Dynamic Brake Modules: DimensionsFrame Model NumberA AK-R2-091P500, AK-R2-047P500, AK-R2-360P500B AK-R2-03

Accessories E-3E.2 EMC Line Filters Table E.2 – EMC Line FiltersDrive RatingsS Type FilterModel Number 1 1This filter is suitable for use with a cable

E-4 MD65 AC Drive User ManualFigure E.2 – Frame A EMC Line Filters: DimensionsDimensions are in mm and (in).Model Numbers: 6MDF-9P5AS, -AL; 6MDF-5P7A

Accessories E-5Figure E.3 – Frame B EMC Line Filters: Dimensions5.5 (0.22)17.8(0.70)24.0(0.94)78(3.07)100(3.94)50(1.97)29.8(1.17)229(9.02)216(8.50)217

E-6 MD60 AC Drive User ManualE.3 Operator Interface Modules (OIMs)Table E.3 – Operator Interface Modules/AccessoriesDescription Model NumberRemote Pa

Accessories E-7Figure E.4 – Remote OIM (M/N MD4ALCD)Dimensions are in mm and (in).67,0 (2.63)60,0 (2.36)77,0 (3.03)77,0 (3.03)53,5 (2.11)∅19,1 (0.75)∅

E-8 MD60 AC Drive User ManualFigure E.5 – NEMA Type 1 Bezel (M/N MDBZL-N1): DimensionsDimensions in mm and (in).93(3.66)25.2(0.99)2m180(7.09)11.1(0.4

RS485 (MDI) Protocol F-1APPENDIX F RS485 (MDI)ProtocolMD60 drives support the RS485 (MDI) protocol to allow efficient operation with Rockwell Automati

F-2 MD60 AC Drive User ManaulWiring terminations on the master controller will vary depending on the master controller used and “TxRxD+” and “TxRxD-”

RS485 (MDI) Protocol F-3Supported Modbus Function CodesThe peripheral interface (MDI) used on MD60 drives supports some of the Modbus function codes.

1-2 MD60 AC Drive User Manual

F-4 MD60 AC Drive User ManaulWriting (06) Logic Command DataThe MD60 drive can be controlled via the network by sending Function Code 06 writes to re

RS485 (MDI) Protocol F-5Writing (06) ReferenceThe Speed Reference to a MD60 drive can be controlled via the network by sending Function Code 06 writes

F-6 MD60 AC Drive User ManualReading (03) FeedbackThe Feedback (Output Frequency) from the MD60 drive can be read via the network by sending Function

RS485 (MDI) Protocol F-7Reading (03) Drive Error CodesThe MD60 Error Code data can be read via the network by sending Function Code 03 reads to regist

F-8 MD60 AC Drive User ManualReading (03) and Writing (06) Drive ParametersTo access drive parameters, the Modbus register address equals the paramet

RJ45 Splitter Cable G-1APPENDIX GRJ45 Splitter CableThe MD60 drive provides a RJ45 port to allow the connection of a single peripheral device. The RJ4

G-2 MD60 AC Drive User ManualCable AccessoriesFigure G.1 – RJ45 Splitter Cable (M/N AK-U0-RJ45-SCI)Slave PortMaster PortPIN 8PIN 1MSFigure G.2 – RJ45

RJ45 Splitter Cable G-3Connecting One Temporary PeripheralConnecting One Temporary Peripheral andOne Permanent Peripheral Figure G.4 – Connecting One

G-4 MD60 AC Drive User ManualConnecting Two Permanent Peripherals Connecting an RS485 Network Figure G.6 – Connecting Two Permanent PeripheralsMSNEMA

Index Index-1INDEXNumerics0 - 10 V Analog Input (d020), 9-320 - 10 V Analog Input High (A111), 9-240 - 10 V Analog Input Low (A110), 9-244 - 20 mA Ana

About the MD60 Drive 2-1CHAPTER 2About the MD60 DriveThis chapter provides information about the MD60 AC drive, including:• How to identify the drive•

Index-2 MD60 AC Drive User ManualEElapsed Run Time (d018), 9-31EMC Line Filters, E-3EMC/RFIgrounding, filter, 4-2EMI filters, 2-3Ffaultbuffers, see,

Index Index-3NNEMA 1/IP30 Kit, 2-3OOIMs, E-6operating conditions, 3-2Operator Interface Modules (OIMs), E-6Output Current (d003), 9-27output disconnec

Index-4 MD60 AC Drive User ManualUUnderVoltage fault, 10-3ungrounded distribution systems, 5-2unshielded power cables, 5-8Wweight, drive, 3-3wiringI/

U.S. Drives Technical Support Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: [email protected], Online: www.ab.com/support/abdrives

2-2 MD60 AC Drive User Manual 2.2 MD60 Drive Ratings, Model Numbers, and Frame SizesSimilar MD60 drive sizes are grouped into frame sizes to simplify

About the MD60 Drive 2-32.3 KitsTable 2.2 lists kits for the MD60 drive. Contact Reliance Electric for more information about these kits.Table 2.2 – S

2-4 MD60 AC Drive User Manual 2.4 Storage GuidelinesIf you need to store the drive, follow these recommendations to prolong drive life and performanc

Mounting the Drive 3-1CHAPTER 3Mounting the DriveThis chapter provides information that must be considered when planning an MD60 drive installation an

3-2 MD60 AC Drive User Manual 3.1.1 Operating ConditionsBefore deciding on an installation site, consider the following guidelines:• Protect the cool

Mounting the Drive 3-33.1.3 Mounting Dimensions for the MD60 DriveOverall dimensions and weights are illustrated in figures 3.2 and 3.3 as an aid to

©2003 Rockwell Automation. All rights reserved.The information in this manual is subject to change without notice.Throughout this manual, the followi

3-4 MD60 AC Drive User Manual 3.2 Mounting the DriveMount the drive upright on a flat, vertical, and level surface.• Install on 35 mm DIN railor• Ins

Grounding the Drive 4-1CHAPTER 4Grounding the DriveThe drive Safety Ground - must be connected to system ground. Ground impedance must conform to the

4-2 MD60 AC Drive User Manual Ground Fault MonitoringIf a system ground fault monitor is to be used, only Type B (adjustable) devices should be used

Installing Power Wiring 5-1CHAPTER 5Installing Power WiringThis chapter provides instructions on wiring output wiring to the motor and installing AC i

5-2 MD60 AC Drive User Manual Step 2. Remove the finger guard (refer to figure 5.2).a. Press in and hold the locking tab.b. Slide finger guard down a

Installing Power Wiring 5-3Disconnecting MOVsTo disconnect MOVs, you must remove the external jumper located on the lower left side of the front of th

5-4 MD60 AC Drive User Manual 5.2.2 Input Power ConditioningThe drive is suitable for direct connection to input power within the rated voltage of th

Installing Power Wiring 5-55.3 Power Wiring Specifications5.4 Power Terminal Block ConnectionsTable 5.2 – Power Wiring SpecificationsPower Wire Rating

5-6 MD60 AC Drive User Manual 5.5 Fuses and Circuit BreakersThe MD60 drive does not provide branch short circuit protection. This product should be i

Installing Power Wiring 5-7Circuit BreakersThe “other devices” listings in table 5.4 include both circuit breakers (inverse time or instantaneous trip

Contents ICONTENTSChapter 1 Introduction1.1 Getting Assistance from Reliance Electric... 1-1Chapter 2 About the MD60 Drive2.1 Id

5-8 MD60 AC Drive User Manual 5.6 Motor Cable Types Acceptable for 200-600 Volt InstallationsGeneralA variety of cable types are acceptable for drive

Installing Power Wiring 5-95.7 Reflected Wave ProtectionThe drive should be installed as close to the motor as possible. Installations with long motor

5-10 MD60 AC Drive User Manual 5.8 Output DisconnectThe drive is intended to be commanded by control input signals that will start and stop the motor

Installing Control Wiring 6-1CHAPTER 6Installing Control WiringThis chapter describes how to wire the signal and I/O terminal strip for stop, speed fe

6-2 MD60 AC Drive User Manual 6.1.1 Compliance with Machinery Safety Standard EN 60204-1:1992This section applies to you if you must comply with mach

Installing Control Wiring 6-3Important: I/O terminals labeled “Common” are not referenced to the safety ground (PE) terminal and are designed to great

6-4 MD60 AC Drive User Manual 6.4 Wiring the Control Terminal BlockNo. Signal Default Description ParameterR1 Relay N.O. Fault Normally open contact

Installing Control Wiring 6-56.4.1 I/O Wiring ExamplesInput/Output Connection Example Potentiometer1-10k Ohm Pot. Recommended(2 watt minimum)P038 (Spe

6-6 MD60 AC Drive User Manual 2 Wire SRC Control - Run FWD/Run REVP036 (Start Source) = 2, 3, or 4Input must be active for the drive to run. When inp

Installing Control Wiring 6-76.4.2 Typical Multiple Drive Connection Examples3 Wire SNK Control - ReversingInternal Supply (SNK)Input/Output Connectio

II MD60 AC Drive User Manual6.4.2 Typical Multiple Drive Connection Examples... 6-76.5 Start and Speed Reference Control...

6-8 MD60 AC Drive User Manual 6.5 Start and Speed Reference ControlThe drive speed command can be obtained from a number of different sources. The so

Installing Control Wiring 6-96.6 Accel/Decel Selection The selection of Accel/Decel rates can be made through digital inputs, RS485 communications and

6-10 MD60 AC Drive User Manual

Completing the Installation 7-1CHAPTER 7Completing the InstallationThis chapter provides instructions on how to perform a final check of the installat

7-2 MD60 AC Drive User Manual • Verify that the Sink (SNK)/Source (SRC) Setup DIP Switch is set to match your control wiring scheme. See figure 6.1 f

Using the Integral Keypad to Program and Control the Drive 8-1CHAPTER 8Using the Integral Keypadto Program and Control the DriveFactory-default parame

8-2 MD60 AC Drive User Manual 8.1.1 Display DescriptionThe alpha-numeric display indicates the following:• Parameter number• Parameter value • Fault

Using the Integral Keypad to Program and Control the Drive 8-38.1.3 Key DescriptionsRefer to figure 8.1 for the location of the keys described in tabl

8-4 MD60 AC Drive User Manual 8.2 About ParametersTo program the drive for a specific application, you adjust the appropriate parameters. The paramet

Using the Integral Keypad to Program and Control the Drive 8-58.4 Viewing and Adjusting Basic (P) and Advanced (A) ParametersUse the following procedu

Contents IIIAppendix D CE Conformance Requirements ...D-1Appendix E Accessories ...

8-6 MD60 AC Drive User Manual 8.5 Viewing the Display (d) ParametersUse the procedure in table 8.4 to view Display parameters.To view additional Disp

Parameter Descriptions 9-1CHAPTER 9Parameter DescriptionsThe following information is provided for each parameter along with its description: What the

9-2 MD60 AC Drive User Manual 9.1 Basic Program Group ParametersThe Basic Program Group contains the most commonly used parameters to simplify the st

Parameter Descriptions 9-3Sets the control scheme used to start the drive. Refer to section 6.6, Start and Speed Reference Control, for details about

9-4 MD60 AC Drive User Manual 4 = 2-Wire High-Speed: Outputs are kept in a ready-to-run state. The drive will respond to a Start command within 10 ms

Parameter Descriptions 9-5Active stop mode for all stop sources except as noted below.When this parameter is set to option 0, 1, 2, or 3, the stop inp

9-6 MD60 AC Drive User Manual Sets the source of the speed reference to the drive.Important: When A051 or A052 (Digital Inx Select) is set to option

Parameter Descriptions 9-7Sets the rate of acceleration for all speed increases. See figure 9.1.Maximum Frequency / Accel Time = Accel RateSets the ra

9-8 MD60 AC Drive User Manual 9.2 Advanced Group ParametersSelects the function for the digital inputs. Refer to the flowchart in section 6.6 for mor

Parameter Descriptions 9-96 = RS485 Port: When active, sets communications device as default start/speed command source. 7 = Clear Fault: When active,

IV MD60 AC Drive User Manual

9-10 MD60 AC Drive User Manual Sets the condition that changes the state of the output relay contacts.0 = Ready (Not Faulted) (Default): Relay change

Parameter Descriptions 9-11Sets the trip point for the output relay if the value of Relay Output Select (A055) is 6, 7, 8, 10 or 20. See table 9.1.Set

9-12 MD60 AC Drive User Manual Sets the rate of deceleration for speed decreases if A051 or A052 is set to option 1 (Accel 2 and Decel 2). See figure

Parameter Descriptions 9-13Provides a fixed frequency command value when Digital Inx Select (A051, A052) is set to option 4 (Preset 1 & 2). Digita

9-14 MD60 AC Drive User Manual .Sets the length of time DC brake current is “injected” into the motor. Refer to A081 (DC Brake Level). Defines the ma

Parameter Descriptions 9-15Enables/disables external dynamic braking.Sets the percentage of acceleration or deceleration time that is applied to the r

9-16 MD60 AC Drive User Manual Sets the boost voltage (% of P031 (Motor NP Volts)) and redefines the Volts per Hz curve. Note that the drive may add

Parameter Descriptions 9-17Sets the highest voltage the drive will output.Maximum output current allowed before current limiting occurs.Drive provides

9-18 MD60 AC Drive User Manual .Sets the carrier frequency for the PWM output waveform. Figure 9.9 provides derating guidelines based on the PWM freq

Parameter Descriptions 9-19Sets the time between restart attempts when Auto Restart Tries (A092) is set to a value other than zero. Refer to section 1

Contents VList of FiguresFigure 2.1 – Identifying the Drive by Model Number... 2-1Figure 3.1 – Minimum Mounting Clearan

9-20 MD60 AC Drive User Manual Enables/disables feature that allows the drive to reconnect to a spinning motor at actual RPM.Enables/disables correct

Parameter Descriptions 9-21Enables/disables a software instantaneous (within 100 ms) current trip.Scales the value displayed by Process Display (d010)

9-22 MD60 AC Drive User Manual Used by Rockwell Automation field service personnel.Sets the serial port rate for the RS485 port. Important: Cycle pow

Parameter Descriptions 9-230 = Fault (Default): Drive will fault on an F81 Comm Loss and coast to stop.1 = Coast to Stop: Stops the drive via coast to

9-24 MD60 AC Drive User Manual Sets the analog input level that corresponds to Minimum Freq. (P034) if a 0-10V input is used by Speed Reference (P038

Parameter Descriptions 9-25Parameters A112 and A113 enable scaling of the 4 - 20 mA analog input. The drive reaches minimum frequency at the current s

9-26 MD60 AC Drive User Manual Scales the time value when the drive is running at Minimum Freq. (P034). When set to a value other than zero, Process

Parameter Descriptions 9-279.3 Display Group ParametersThe output frequency present at terminals T1, T2, and T3 (U, V, and W).The value of the active

9-28 MD60 AC Drive User Manual The present DC bus voltage level.The present operating status of the drive.A code that represents a drive fault. The c

Parameter Descriptions 9-29The output frequency scaled by A099 (Process Factor).Output Frequency x Process Factor = Process DisplayDisplays the active

VI MD60 AC Drive User Manual

9-30 MD60 AC Drive User Manual The status of the control terminal block control inputs.Important: Actual command may come from a source other than th

Parameter Descriptions 9-31The status of the communications device.The Main Control Board software version.Used by Rockwell Automation field service p

9-32 MD60 AC Drive User Manual The present value of the function selected in Testpoint Select (A102).The value present at the drive’s 0 - 10 V analog

Troubleshooting the Drive 10-1CHAPTER 10Troubleshooting the DriveThe MD60 constantly monitors its status and provides the following ways to determine

10-2 MD60 AC Drive User Manual 10.1.1 Manually Clearing FaultsStep 1. Note the number of the fault code flashing on the display. Step 2. Press on t

Troubleshooting the Drive 10-3Use caution when enabling this feature since the drive will attempt to issue its own start command based on user-selecte

10-4 MD60 AC Drive User Manual F8 Heatsink OverTempY Heatsink temperature exceeds a predefined value.• Check for blocked or dirty heat sink fins. Ver

Troubleshooting the Drive 10-5F48 Params DefaultedN The drive was commanded to write default values to EEPROM.• Clear the fault or cycle power to the

10-6 MD60 AC Drive User Manual 10.2 Troubleshooting TablesUse the following tables to troubleshoot the drive. If you cannot resolve the problem using

Troubleshooting the Drive 10-710.2.2 Problem: Drive Does Not Start From Integral Keypad10.2.3 Problem: Drive Does Not Respond to Changes in Speed Comm

Contents VIIList of TablesTable 2.1 – Drive Ratings, Model Numbers, and Frame Sizes... 2-2Table 2.2 – Standard Kits ...

10-8 MD60 AC Drive User Manual 10.2.4 Problem: Motor and/or Drive Will Not Accelerate to Commanded Speed10.2.5 Problem: Motor Operation is UnstableTa

Troubleshooting the Drive 10-910.2.6 Problem: Drive Will Not Reverse Motor Direction.Table 10.7 – Problem: Drive Will Not Reverse Motor DirectionCause

10-10 MD60 AC Drive User Manual

Technical Specifications A-1APPENDIX ATechnical SpecificationsEnvironmentAltitude: 1000 m (3300 ft) maximum without deratingAmbient Operating Temperat

A-2 MD60 AC Drive User ManualInput/Output RatingOutput Frequency: 0-240 Hz (Programmable) Efficiency: 97.5% (Typical)Digital Control Inputs (Inputs

Technical Specifications A-3Under Voltage: • 100-120 V AC Input – Trip occurs at 210 V DC bus voltage (equivalent to 75 V AC incoming line)• 200-240 V

A-4 MD60 AC Drive User Manual

Record of User Settings B-1APPENDIX BRecord ofUser SettingsB.1 Basic Parameter GroupNo. Parameter NameDefault ValuePage No. User SettingP031 Motor NP

B-2 MD60 AC Drive User ManualB.2 Advanced Parameter GroupNo. Parameter NameDefault ValuePage No. User SettingA051 Digital In1 Select 4 = Preset Frequ

Record of User Settings B-3A100 Fault Clear 0 = Ready 9-21A101 Program Lock 0 = Unlocked 9-21A102 Testpoint Select 0000 9-22A103 Comm Data Rate 4 = 19