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Worldwide WorldDrive 4X VFD User Manual

Worldwide WorldDrive 4X VFD
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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: (800) 808-2131
Fax: (800) 711-1616
www.worldwideelectric.net

Table of Contents

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Worldwide WorldDrive 4X VFD Specifications

General IconGeneral
Frequency Range0-400 Hz
Cooling MethodFan Cooled
Enclosure RatingIP20
Protection FeaturesOvervoltage, Undervoltage, Short Circuit, Overheating
Operating Temperature-10°C to 50°C
Humidity5-95% (Non-condensing)
Storage Temperature-20°C to 60°C (-4°F to 140°F)

Summary

Safety Information

Safety symbols in this manual

Explains the meaning of safety symbols used in the manual, such as Danger, Warning, and Caution.

Safety information

Provides general safety instructions to avoid unsafe operating conditions, property damage, injury, or death.

1 Preparing the Installation

1.1 Product Identification

Details on identifying the inverter model and specifications via the rating label.

1.2 Part Names

Illustration and identification of the inverter's components like keypad, inverter body, and cooling fan.

1.3 Installation Considerations

Details ideal environmental and operational conditions for the inverter's lifespan and reliability.

1.4 Selecting and Preparing a Site for Installation

Guidelines for choosing and preparing the installation location, including weight support and air circulation clearances.

1.5 Cable Selection

Information on selecting appropriate power and signal cables for safe and reliable operation.

2 Installing the Inverter

Installation Flowchart

Sequence of steps for equipment installation and testing the product.

Basic Configuration Diagram

Illustrates a typical system configuration showing the inverter and peripheral devices.

2.1 Mounting the Inverter

Procedures for mounting the inverter on a wall or inside a panel, considering clearance specifications.

2.2 Cable Wiring

Instructions for connecting power and control cables to the inverter terminals, including safety precautions.

Step 2 Ground Connection

Instructions for correctly installing the ground connection for the inverter and motor.

Step 3 Power Terminal Wiring

Details the terminal layout and wiring connections for the power terminal block.

Step 4 Control Terminal Wiring

Shows the detailed layout of control wiring terminals and control board switches.

Step 5 PNP/NPN Mode Selection

Explains how to select PNP or NPN modes for sequence inputs using the selection switch.

Step 6 Re-assembling the Cover

Procedure to re-assemble the cover after completing wiring and basic configurations.

2.3 Post-Installation Checklist

A checklist to verify safe and correct installation of the inverter.

2.4 Test Run

Instructions to follow after the post-installation checklist to test the inverter's functionality.

3 Learning to Perform Basic Operations

3.1 About the Keypad

Describes the keypad layout, including the display and operation keys.

3.1.1 About the Display

Lists display part names and their functions, along with character representations.

3.1.2 Operation Keys

Lists the names and functions of the keypad's operation keys like RUN, STOP/RESET, ENT, ESC.

3.1.3 Control Menu

Introduces the control menu structure using groups and their descriptions.

3.2 Learning to Use the Keypad

Explains how to navigate between groups and codes, and set parameter values.

3.2.1 Group and Code Selection

Details how to switch between groups and codes using the keypad's navigation keys.

3.2.2 Navigating Directly to Different Codes

Provides an example of navigating directly to a specific code number within a group.

3.2.3 Setting Parameter Values

Explains how to enable/disable features by setting or modifying parameter values.

3.2.4 Configuring the [ESC] Key

Describes how the [ESC] key can be configured for various functions, like jog operation.

3.3 Actual Application Examples

Provides examples for basic operations like acceleration time and frequency reference configuration.

3.3.1 Acceleration Time Configuration

Demonstrates how to modify the ACC (Acceleration time) code value.

3.3.2 Frequency Reference Configuration

Demonstrates configuring a frequency reference value using the keypad.

3.3.5 Frequency Setting (Keypad) and Operation (via Terminal Input)

Demonstrates setting frequency using the keypad and operating via terminal input.

3.3.6 Frequency Setting (Potentiometer) and Operation (Terminal Input)

Demonstrates setting frequency using a potentiometer and operating via terminal input.

3.4 Monitoring the Operation

Explains how to monitor the inverter's operation status.

3.4.1 Output Current Monitoring

Demonstrates how to monitor the output current in the Operation group using the keypad.

3.4.2 Fault Trip Monitoring

Demonstrates how to monitor fault trip conditions in the Operation group using the keypad.

4 Learning Basic Features

Frequency reference source configuration for the keypad

Configures the inverter to allow setup or modification of frequency reference using the keypad.

Frequency reference source configuration for the terminal block (input voltage)

Configures inverter to allow input voltages at terminal block (V1, V2) for frequency reference setup.

Motor rotation control

Configures the inverter to limit a motor's rotation direction.

Automatic start-up at power-on

Configures the inverter to start operating automatically after power-up.

Deceleration stop

Describes the typical method used to stop a motor by decelerating to 0Hz.

Stopping by DC braking

Configures the inverter to apply DC braking during motor deceleration.

4.5 Command Source Configuration

Selects various devices like keypad, terminal, or communication as command input devices.

4.5.1 The Keypad as a Command Input Device

Selects the keypad as a command input device to send command signals to the inverter.

4.5.2 Terminal Block as a Command Input Device (Fwd/Rev Run Commands)

Selects multi-function terminals as a command input device for forward/reverse run commands.

4.5.3 Terminal Block as a Command Input Device (Run and Rotation Direction Commands)

Selects multi-function terminals for run and rotation direction commands.

4.5.4 RS-485 Communication as a Command Input Device

Selects internal RS-485 communication as a command input device.

4.6 Local/Remote Mode Switching

Configures switching between local and remote operation modes using the [ESC] key.

4.7 Forward or Reverse Run Prevention

Configures motors to prevent running in only one direction.

4.8 Power-on Run

Sets a power-on command to start inverter operation after powering up.

4.9 Reset and Restart

Sets reset and restart operations for inverter operation following a fault trip.

4.10 Setting Acceleration and Deceleration Times

Configures Acc/Dec times based on maximum frequency or operation frequency.

4.10.1 Acc/Dec Time Based on Maximum Frequency

Sets Acc/Dec time values based on maximum frequency, not operation frequency.

4.10.2 Acc/Dec Time Based on Operation Frequency

Sets Acc/Dec times based on the time required to reach the next step frequency.

4.10.3 Multi-step Acc/Dec Time Configuration

Configures multi-step Acc/Dec times via a multi-function terminal.

4.10.4 Configuring Acc/Dec Time Switch Frequency

Switches between two different Acc/Dec times by configuring the switch frequency.

4.11 Acc/Dec Pattern Configuration

Configures Acc/Dec gradient level patterns to enhance acceleration and deceleration curves.

4.12 Stopping the Acc/Dec Operation

Configures multi-function input terminals to stop acceleration or deceleration.

4.13 V/F(Voltage/Frequency) Control

Configures output voltages, gradient levels, and patterns for target output frequency.

4.13.1 Linear V/F Pattern Operation

Configures inverter to increase/decrease output voltage at a fixed rate for different frequencies.

4.13.2 Square Reduction V/F pattern Operation

Provides non-linear acceleration/deceleration patterns for loads like fans and pumps.

4.13.3 User V/F Pattern Operation

Allows configuration of user-defined V/F patterns for special motors.

4.14 Torque Boost

Enables users to adjust output voltage during low-speed operation or motor start.

4.14.1 Manual Torque Boost

Adjusts output voltage to improve low-speed torque or starting properties.

4.14.2 Auto Torque Boost-1

Automatically calculates output voltage for torque boost based on motor parameters.

4.14.3 Auto Torque Boost-2

Adjusts output voltage if operation is unavailable due to low output voltage.

4.15 Output Voltage Setting

Sets output voltage when motor's rated voltage differs from inverter input voltage.

4.16 Start Mode Setting

Selects the start mode to use when the operation command is input with the motor stopped.

4.16.1 Acceleration Start

A general acceleration mode where the motor accelerates to the frequency reference.

4.16.2 Start After DC Braking

Supplies DC voltage for a set time to provide DC braking before acceleration.

4.17 Stop Mode Setting

Selects a stop mode to stop the inverter operation.

4.17.1 Deceleration Stop

A general stop mode where the motor decelerates to 0Hz and stops.

4.17.2 Stop After DC Braking

Stops the motor by supplying DC power when the operation frequency reaches a set value.

4.17.3 Free Run Stop

Stops output to the motor using a stop command; motor slows due to residual inertia.

4.17.4 Power Braking

Adjusts deceleration gradient or reaccelerates motor to reduce regenerated energy.

4.18 Frequency Limit

Limits operation frequency by setting maximum, start, upper, and lower limits.

4.18.1 Frequency Limit Using Maximum Frequency and Start Frequency

Sets the lower and upper limits for speed unit parameters.

4.18.2 Frequency Limit Using Upper and Lower Limit Frequency Values

Sets upper and lower frequency limits for all speed unit parameters.

4.18.3 Frequency Jump

Avoids mechanical resonance frequencies by jumping through frequency bands.

4.19 2nd Operation Mode Setting

Applies two types of operation modes and switches between them as required.

4.20 Multi-function Input Terminal Control

Configures filter time constants and input terminal types to improve response.

4.21 P2P Setting

Shares input and output devices between multiple inverters.

4.22 Multi-keypad Setting

Controls multiple inverters with one keypad.

4.23 User Sequence Setting

Creates a user-defined group and registers user-selected parameters.

5.2 Jog operation

Allows temporary control of the inverter using multi-function terminals or the keypad.

5.2.1 Jog Operation 1-Forward Jog by Multi-function Terminal

Lists parameter settings for forward jog operation using multi-function terminals.

5.2.2 Jog Operation 2-Fwd/Rev Jog by Multi-function Terminal

Starts operation using a terminal set for forward or reverse jog.

5.2.3 Jog Operation by Keypad

Allows jog operation to start by pressing the [RUN] key after configuring settings.

5.3 Up-down Operation

Controls Acc/Dec time through input at the multi-function terminal block.

5.4 3-Wire Operation

Latches signal input and is used when operating the inverter with a push button.

5.5 Safe Operation Mode

Allows operation commands to be entered only in safe mode for careful control.

5.6 Dwell Operation

Maintains torque during application and release of brakes on lift-type loads.

5.7 Slip Compensation Operation

Compensates for motor slip as load increases to maintain constant speed.

5.8 PID Control

Uses PID control for automated system process control to maintain speed, pressure, flow, temperature, and tension.

5.8.1 PID Basic Operation

Controls output frequency through automated system process control.

5.8.2 Pre-PID Operation

General acceleration occurs until set frequency; PID operation begins when controlled variables increase.

5.8.3 PID Operation Sleep Mode

PID operation sleep mode starts if operation continues at a frequency lower than the set condition.

5.8.4 PID Switching (PID Openloop)

PID operation stops and switches to general operation when a multi-function terminal is turned on.

5.9 Auto Tuning

Measures motor parameters automatically for auto torque boost or sensorless vector control.

5.10 Sensorless Vector Control for Induction Motors

Operation to carry out vector control without rotation speed feedback for induction motors.

5.10.1 Sensorless Vector Control Operation Setting for Induction Motors

Sets up sensorless vector control operation for induction motors.

5.11 Sensorless Vector Control for PM (Permanent-Magnet) Synchronous Motors

Carries out vector control without rotation speed feedback for PM synchronous motors.

5.11.1 Detecting the Initial Pole Position

Matches rotor position calculated by the inverter with the actual rotor position.

5.11.2 Sensorless Vector Control Mode Settings for PM Synchronous Motors

Sets up sensorless vector control mode for PM synchronous motors.

5.11.3 Guidelines for Running a PM Synchronous Motor in Sensorless Vector Control Mode

Provides guidance for running PM synchronous motors in sensorless vector control mode.

5.12 Kinetic Energy Buffering Operation

Maintains DC link voltage during power interruptions using regenerative energy.

5.13 Torque Control

Controls the motor to maintain the preset torque value.

5.14 Energy Saving Operation

Saves energy by reducing voltage supplied to motors during low-load conditions.

5.14.1 Manual Energy Saving Operation

Reduces output voltage when inverter output current is lower than no-load current.

5.14.2 Automatic Energy Saving Operation

Automatically calculates energy saving amount based on rated motor current.

5.15 Speed Search Operation

Prevents fault trips when inverter output voltage is disconnected and the motor is idling.

5.16 Auto Restart Settings

Automatically restarts the inverter when a trip condition is released after stopping.

5.17 Operational Noise Settings (carrier frequency settings)

Adjusts motor operational noise by changing carrier frequency settings.

5.18 2nd Motor Operation

Used when a single inverter operates two motors.

5.19 Supply Power Transition

Switches the power source for the motor from inverter output to main supply or vice versa.

5.20 Cooling Fan Control

Turns the inverter's heat-sink cooling fan on and off.

5.21 Input Power Frequency and Voltage Settings

Selects the frequency for inverter input power.

5.22 Read, Write, and Save Parameters

Uses read, write, and save function parameters to copy parameters between inverter and keypad.

5.23 Parameter Initialization

Resets parameters to factory default settings on all or selected groups.

5.24 Parameter View Lock

Hides parameters after registering and entering a user password.

5.25 Parameter Lock

Prevents unauthorized modification of parameter settings.

5.26 Changed Parameter Display

Displays parameters different from factory defaults to track changes.

5.27 User Group

Creates a user-defined group and registers user-selected parameters.

5.28 Easy Start On

Easily sets up basic motor parameters required to operate a motor in a batch.

5.29 Config(CNF) Mode

Configures LCD keypad related features.

5.30 Timer Settings

Sets multi-function input to timer and controls output relay/terminal based on timer settings.

5.31 Brake Control

Controls the On/Off operation of electronic brake load system.

5.32 Multi-Function Output On/Off Control

Sets reference values for analog input and control output relay or terminal status.

5.33 Press Regeneration Prevention

Prevents braking during regeneration process in press operations.

5.34 Analog Output

Provides output of 0–10V voltage, 4–20mA current, or 0–32kHz pulse.

5.34.1 Voltage and Current Analog Output

Adjusts output size by selecting an output option at the AO terminal.

5.34.2 Analog Pulse Output

Selects output item and adjusts pulse size for the TO (Pulse Output) terminal.

5.35 Digital Output

Configures digital outputs and relay functions.

5.35.1 Multi-function Output Terminal and Relay Settings

Sets reference values for output terminal and relay functions.

5.35.3 Multi-function Output Terminal Delay Time Settings

Sets on-delay and off-delay times for output terminal and relay operations.

5.36 Keypad Language Settings

Selects the language displayed on the LCD keypad.

5.37 Operation State Monitor

Monitors inverter operation condition using the LCD keypad.

Operation State Monitor Setting Details

Selects items to display on the top-right side of the LCD keypad screen.

5.38 Operation Time Monitor

Monitors inverter and fan operation time.

6 Learning Protection Features

Explains protection features for the inverter, categorized into motor protection and inverter malfunction protection.

6.1 Motor Protection

Categorizes protection features for overheating damage to the motor.

6.1.1 Electronic Thermal Motor Overheating Prevention (ETH)

A protective function predicting motor temperature rise based on heat characteristics.

6.1.2 Overload Early Warning and Trip

Warns or trips when the motor reaches an overload state based on rated current.

6.1.3 Stall Prevention and Flux Braking

Prevents motor stall caused by overloads by adjusting inverter operation frequency.

6.2 Inverter and Sequence Protection

Categorizes protection features against inverter malfunction.

6.2.1 Open-phase Protection

Prevents overcurrents from open-phase in input power supply or output.

6.2.2 External Trip Signal

Allows the inverter to stop operation when abnormal operating conditions arise.

6.2.3 Inverter Overload Protection

Activates protective function when inverter input current exceeds rated current.

6.2.4 Speed Command Loss

Selects inverter operation for situations when the speed command is lost.

6.2.5 Dynamic Braking (DB) Resistor Configuration

Describes the braking resistor circuit integrated inside the inverter.

6.3 Under load Fault Trip and Warning

Identifies underload fault trips and warnings.

6.3.1 Fan Fault Detection

Detects cooling fan faults.

6.3.2 Lifetime diagnosis of components

Registers a capacitance reference for inspection.

6.3.3 Low Voltage Fault Trip

Stops output and trips when inverter input power is lost and DC link voltage drops.

6.3.4 Output Block by Multi-Function Terminal

Stops operation when the multi-function input terminal is set as the output block signal terminal.

6.3.5 Trip Status Reset

Restarts the inverter using the keypad or analog input terminal to reset the trip status.

6.3.6 Inverter Diagnosis State

Checks component diagnosis for inverter replacement needs.

6.3.7 Operation Mode on Option Card Trip

Sets inverter operation mode upon communication error or option card detachment.

6.3.8 No Motor Trip

Performs protective operation when the motor is disconnected from the inverter output terminal.

6.3.9 Low voltage trip 2

Displays trip notification for low voltage trip, even if DC Link voltage is higher than trip level.

6.4 Fault/Warning List

Lists types of faults and warnings that can occur with the WD4X inverter.

7 RS-485 Communication Features

Explains how to control the inverter with a PLC or computer using RS-485 communication.

7.1 Communication Standards

Explains RS-485 communication standards and features like multi-drop link system.

7.2 Communication System Configuration

Describes the PLC or computer as master and inverter as slave device in an RS-485 system.

7.2.1 Communication Line Connection

Instructions for connecting RS-485 communication line to S+/S-/SG terminals.

7.2.2 Setting Communication Parameters

Sets communication parameters after connecting communication lines properly.

7.2.3 Setting Operation Command and Frequency

Selects RS485 communication as command source and sets parameters for operation command and frequency.

7.2.4 Command Loss Protective Operation

Configures command loss decision standards and protective operations during communication problems.

7.2.5 Setting Virtual Multi-Function Input

Controls multi-function input using a communication address.

7.2.6 Saving Parameters Defined by Communication

Saves changes made via communication, retaining values after power cycle.

7.2.7 Total Memory Map for Communication

Lists communication areas and their memory maps.

7.2.8 Parameter Group for Data Transmission

Defines parameter groups for data transmission using communication function group addresses.

7.3 Communication Protocol

Explains built-in RS-485 communication protocols: INV485 and Modbus-RTU.

7.3.1 INV 485 Protocol

Describes how the slave device responds to read/write requests from the master.

7.3.2 Modbus-RTU Protocol

Details the Modbus-RTU protocol structure.

7.4 Compatible Common Area Parameter

Lists common area parameters for communication.

7.5 WD4X Expansion Common Area Parameter

Lists common area parameters for WD4X expansion.

7.5.1 Monitoring Area Parameter (Read Only)

Parameters for monitoring inverter status, capacity, voltage, etc.

7.5.2 Control Area Parameter (Read/Write)

Parameters for controlling inverter operation, including frequency and command source.

7.5.3 Inverter Memory Control Area Parameter (Read and Write)

Parameters for controlling inverter memory, including saving and initialization.

Table of Functions

Lists all function settings for WD4X series inverter.

8.1 Operation Group

Lists functions used in the basic keypad mode.

8.2 Drive group (PAR→dr)

Lists functions related to motor drive control.

8.3 Basic Function group (PAR→bA)

Lists basic functions for inverter operation.

8.4 Expanded Function group (PAR→Ad)

Lists expanded functions for specific applications.

8.5 Control Function group (PAR→Cn)

Lists functions for controlling sensorless vector features.

8.6 Input Terminal Block Function group (PAR→In)

Lists functions related to input terminals, including digital and analog inputs.

8.7 Output Terminal Block Function group (PAR→OU)

Lists functions related to output terminals, such as relays and analog outputs.

8.8 Communication Function group (PAR→CM)

Lists functions for RS-485 or other communication options.

8.11 2nd Motor Function group (PAR→M2)

Lists features for operating a second motor.

8.12 User Sequence group (US)

Lists functions for implementing simple sequences using various function blocks.

8.13 User Sequence Function group(UF)

Lists function block settings for user sequences.

8.14 Groups for LCD Keypad Only

Groups related to LCD keypad operation.

8.14.1 Trip Mode (TRP Last-x)

Configures trip mode settings.

8.14.2 Config Mode (CNF)

Configures various settings related to the LCD keypad.

9 Troubleshooting

Explains how to troubleshoot problems with inverter protective functions, fault trips, or warnings.

9.1 Trips and Warnings

Explains how to interpret and handle inverter trips and warnings.

9.1.1 Fault Trips

Lists protection functions related to output current and input voltage.

9.2 Troubleshooting Fault Trips

Provides a table of possible causes and remedies for fault trips.

10 Maintenance

Explains how to replace the cooling fan, perform regular inspections, and store/dispose of the product.

10.1 Regular Inspection Lists

Lists regular inspection procedures for the inverter.

10.1.1 Daily Inspections

Details daily inspection items, methods, standards, and equipment.

10.1.2 Annual Inspections

Details annual inspection items and methods.

10.1.3 Bi-annual Inspections

Details bi-annual inspection items and methods.

10.2 Storage and Disposal

Provides guidance on storing and disposing of the product.

10.2.1 Storage

Instructions for storing the product for extended periods, including environmental conditions.

10.2.2 Disposal

Guidelines for disposing of the product as industrial waste and recycling materials.

11 Technical Specification

Provides detailed technical specifications for the WD4X series inverter.

11.1 Input and Output Specification

Lists electrical specifications for the inverter's input and output.

11.2 Product Specification Details

Provides detailed specifications of the product, including control methods and functions.

11.3 External Dimensions (IP 66 / N4X Type)

Shows external dimensions of the inverter in IP66/N4X type.

11.4 Peripheral Devices

Lists external protection devices (e.g., circuit breakers) not provided with the inverter.

11.5 Fuse and Reactor Specifications

Lists specifications for fuses and reactors used with the inverter.

11.6 Terminal Screw Specification

Details terminal screw sizes and recommended torque for input/output and control circuits.

11.7 Braking Resistor Specification

Lists specifications for braking resistors.

11.8 Continuous Rated Current Derating

Explains current derating based on carrier frequency and input voltage.

11.9 Heat Emmission

Shows the inverters' heat emission characteristics by product capacity.

Product Warranty

Provides warranty information, including product details, period, and service information.

Non-Warranty Service

Outlines cases where a service fee will be incurred for malfunctions.