Manual Etrac
Manual Etrac
® ®
WFC
AC Inverter
HT
WFC1000 Series – 1 HP
WFC2000 Series – FHP to 25 HP
WFC4000 Series – 1 to 75 HP
Installation, Operation and
Maintenance Instructions
for CE Marked Version
Quality Made
in the U.S.A.
TB WOOD’S INCORPORATED
Chambersburg, Pennsylvania
Program Code Summary (Level 1-2)
Section 6 – Applications
6.1 Connection Diagrams.................................................................................................................... 50
6.2 Options and Accessories .............................................................................................................. 52
6.3 Application Hints ........................................................................................................................... 53
Section 7 – Troubleshooting
7.1 Fault Codes................................................................................................................................... 54
7.2 Troubleshooting ............................................................................................................................ 55
7.3 Maintenance and Inspection ......................................................................................................... 56
7.4 Replacement Parts........................................................................................................................ 57
Section 8 – Appendix A
8.1 Additional Publications .................................................................................................................. 59
8.2 Hassle Free Warranty ................................................................................................................... 59
Section 10 – Appendix C
CE Declaration of Conformity........................................................................................................ 68
SECTION 1
GENERAL INFORMATION
1.1 Preface
This manual contains the specifications, installation instructions, description of operation, and troubleshooting
procedure for the WFCHT Series AC Inverters. Before installing the drive, read this manual carefully to ensure
correct installation and maximum performance. The information contained herein is considered current with
the release of version 4.2 (02-RVLVL) of the drive software.
1.2 Inspection
A. Upon receipt of the product, unpack the AC inverter and carefully inspect for any damage sustained in
transit (depression in the enclosure, damage to parts, missing parts). If damage is apparent, the freight or
express agent should be notified within 15 days of receipt of the product and a request be made that he
make an inspection of the merchandise; then a claim should be filed against the carrier. For UPS shipment
damage, save the box and packing material and notify TB Wood’s Incorporated immediately.
B. Next remove the AC inverter cover, if supplied, and inspect for any loose screws, nuts, or connectors.
C. Read the technical data plate and verify the correct horsepower size for the application and note the input
voltage and current required for the inverter.
D. If the inverter is to be stored for a long period of time, repack the inverter and store in a clean, dry place,
free from direct sunlight or corrosive fumes, and in a location where the ambient temperature will not be
less than -20° C (-4° F) nor more than 60° C (140° F).
TABLE 1.5
NOTES:
(1) Required data for sizing input wiring.
(2) CT Amps = Value stored in parameter 03-IRAT. Each model is capable of continuous operation at VT amps
rating. Required data for sizing motor wiring.
(3) For chassis models, ratings are for 1 minute @ +50°C. (40°C external ambient when enclosed.)
(4) Control rated for 110% of motor rating (continuous).
(5) For single phase applications greater than 5 HP, consult factory.
(6) Motor thermal overload relay rating – 1.1 x continuous motor nameplate amps. (Necessary only in multi-
motor applications.)
(7) If the KVA rating of the power source exceeds ten times this value, the use of an isolation transformer or a
line inductor is recommended.
5
1.6 AC Inverter Fundamentals
The principle of operation of the WFCHT, or any AC inverter, is to provide both an adjustable voltage and an
adjustable frequency to the AC motor. The WFCHT automatically maintains the required volts/hertz ratio,
allowing the AC motor to run at its optimum efficiency and providing rated torque capability throughout the
motor’s speed range. The basic formula that relates the output frequency to motor speed is:
Ns = 120 x f Ns = Synchronous Speed (RPM)
P f = Frequency (Hertz)
P = Number of Poles in Motor
For Induction Motors:
Motor RPM = Synchronous Speed – Motor Slip (RPM)
The number of poles of a particular motor, and the amount of slip for a given load torque, are set by the
motor’s design and manufacturer.
FIGURE 1.7
6
SECTION 2
INSTALLATION AND ENCLOSURE DIMENSIONS
7
2.2 Dimensional Data
The following pages show the dimensional data for the NEMA 4 and chassis style WFCHT Inverters. Use this
data and the General Rules for Installation to select a suitable mounting location.
FHP-5 HP
NEMA 4 & CHASSIS MODELS
FIGURE 2.2
8
8.33
B. Line Starting
WFCHT is designed to provide controlled starting and stopping of AC motors by use of the keypad or
external contacts connected to the control terminal strip. WFCHT may also be started by applying AC power
to terminals L1, L2, and L3. The inverter has line-start-lockout as a standard feature, to prevent automatic
starting when line power is applied. This provision can be defeated by appropriate programming. The
inverter may be started once every two minutes in this mode.
12
2.4 Inverter Watt Loss
The operation of the inverter generates heat Max. Switching Watt Loss Watt Loss
due to inefficiencies within the system. This Model Amp Frequency at Default at Highest
Number Rating at Max. Amp Switching Switching
heat must be accounted for when mounting
WFC20007xHT 3.1 16kHz 58 131
the inverter within another enclosure. The
WFC20010xHT 4 16kHz 72 163
following table shows the watts generated by
the inverter when at full current and at WFC20020xHT 7.5 16kHz 121 273
various switching frequencies. For specific WFC20030xHT 10.6 8kHz 161 238
switching frequencies, use worst case WFC20050xHT 16.7 8kHz 216 320
scenarios or consult the factory. WFC20075xHT 24.2 16kHz 299 671
WFC20100xHT 30.8 16kHz 402 902
2.5 Line Fuse or Circuit Breaker Sizing WFC20150xHT 48.2 16kHz 603 1353
WFC20200xHT 59.4 16kHz 712 1598
The user must provide either a circuit
breaker or a fused disconnect switch in WFC20250xHT 74.8 16kHz 1005 2256
accordance with the National Electric WFC40010xHT 2.2 16kHz 62 140
Code or Canadian Electrical Code and all WFC40020xHT 4.1 16kHz 99 222
local codes. The following rules should WFC40030xHT 6.1 16kHz 114 256
be used to select the correct size of the WFC40050xHT 9.9 8kHz 181 267
input line fuses or circuit breaker. WFC40075xHT 14.3 16kHz 255 573
WFC40100xHT 19.8 16kHz 350 785
A. Sizing/Fuse Type WFC40150xHT 26.4 16kHz 468 1051
The WFCHT Inverter is able to withstand WFC40200xHT 33 8kHz 608 900
a 150% overload for 60 seconds. WFC40250xHT 42.9 16kHz 752 1688
For maximum protection of the inverter, WFC40300xHT 49.5 16kHz 864 1940
use the fuses listed in Table 2.5. WFC40400xHT 67.1 4kHz 1152 1253
Recommended suppliers are Bussman WFC40500xHT 82.5 4kHz 1439 1566
for 230 VAC, and for 460 VAC installa- WFC40600xHT 98 4kHz 1727 1879
tions. Equivalent values from other man- WFC40750xHT 121 2.5kHz 2223 2223
ufacturers may be substituted.
WFC4075-0 JKS-200
13
B. Power Wiring
Power wiring is those wires which are connected during installation to the power circuit terminals, L1, L2,
L3, M1, M2, and M3. Power wiring must be selected as follows:
1. Use only UL® recognized wire.
2. Wire voltage rating must be a minimum of 300 V for 230 VAC systems, and 600 V for 460 VAC
systems.
3. Wire gauge to be selected based on continuous input and output currents. See Table 1.5 for
current information.
4. Grounding must be in accordance with NEC and CEC.
NOTE: Power delivered from variable frequency controls contains high frequencies which may
cause interference with other equipment. Control wiring and line wiring should not be run in the
same conduit or raceway with inverter-to-motor wiring.
Where power wiring is longer than 50 feet, increase the wire size to the next larger gauge size to reduce
the voltage drop in the wire.
C. Control Wiring
Control wiring is wiring connected during installation to the control terminal strip (30 terminals). Control
wiring must be selected as follows:
1. Shielded, twisted wire is recommended to prevent electrical noise interference from causing
improper operation or nuisance tripping. Recommended wires are Belden types; equivalents may
be substituted:
8761 (300V – 60°C – UL®-2-wire)
8771 (300V – 60°C – UL®-3-wire)
8719 (600V – 60°C – UL®-2-wire)
2. Use only UL® recognized wire.
3. Wire voltage rating must be a minimum of 300 V for 230 VAC systems, and 600 V for 460 VAC
systems. This is Class 1 wire.
4. Never run the control wiring in the same conduit or raceway with power wiring. See NOTE above.
5. Connect shield to inverter COM terminal only.
Connection Diagram
for AC and DC Relay
Coils and Solenoids
FIGURE 2.7
For magnetic contactors, relays and solenoids which are energized from a DC source, a free-wheeling diode
should be used. The diode should be a high-speed, fast recovery type. Connect the diode across the coil as
shown above. The diode current and voltage should be selected by the following formulae:
Diode Current Rating (A) Coil Capacity (VA)
Rated Voltage of Coil (V)
Diode Voltage Rating Rated Voltage of Coil (V) x 2
14
2.8 Function and Use of Terminals
A. Power Circuit Terminals
The power terminals are located on the WFCHT Power Board and are labeled L1, L2, and L3 for incoming
three phase AC line power, (L1 and L3 for single phase models), and M1, M2, and M3 for the motor
connections. Two other terminals B+ and B- provide access to the DC bus plus and minus rails for the
addition of external dynamic braking kits, or extra bus capacitors for custom applications. GND is located
in the lower left-hand internal corner of the control casting. It is a green screw with brass cup washer and
must be connected to earth ground in accordance with the NEC and CEC.
B. Control Terminals
The control terminals are located on the bottom edge of the inverter’s control board. (See Figure 2.8.)
These terminals are available for use with external control devices if remote operation is desired.
NOTE: All control terminals are isolated from earth ground. Do not exceed 50 VAC potential
between any terminal and GND.
1. Control terminal impedance:
a. VIN Terminal – 100 kΩ
b. CIN Terminal – 237 Ω
c. All Logic Terminals – 4.5 kΩ
2. Logic input levels:
a. ACTIVE – 10 to 30 VDC
b. INACTIVE – 0 to 5 VDC
The input logic will accommodate either 12 or 24 VDC logic signals.
J 7 O P T IO N
CO N NECTO R J6
J 11
0 -2 V
0-1 0 V
CO NTR O L
T E R M IN A LS
BU S R LY
S IO +
COM
COM
COM
S IO -
MET
P S2
CO M
FWD
PS1
PS3
MOL
REF
A RT
L IM
R EV
C IN
C TS
6 FS
R ST
+24
+24
ST3
S T1
V IN
R /J
S T2
C HG
L1 L2 L3 B+ B- M1 M2 M3
C P U A C T IV IT Y L E D
P O W E R T E R M IN A L S
FIGURE 2.8
15
DESCRIPTION OF TERMINALS See Page
Analog MET This analog output varies from 0 to full scale and is referenced to COM terminal. It 33, 48
Terminals may be programmed via parameter 71-METER to read output frequency, output
voltage, output current, output load in percent of inverter capacity and output motor
torque. The maximum full scale adjustment is calibrated by parameter 70-MCAL and
can be adjusted while the inverter is running. Maximum full scale adjustment is from
approximately 0-16.5 VDC. The output is rated at 5 mA. If proper wiring practices are
followed, no noise should be detectable on meter output. However, in some
applications noise can be observed. In this case, a 10µF capacitor can be inserted at
the terminal strip between MET and COM to minimize this effect.
COM Circuit common, isolated. –
CIN Speed Reference input, 4 to 20 mA, 237Ω load referenced to COM. The current input 27, 48
signal is calibrated by parameters 31-FMIN and 32-FMAX. FMIN sets the frequency 4
mA should generate, and FMAX sets the frequency 20 mA should produce. Operation
can be inverted, 20 mA = min. frequency, and 0 mA = max. frequency. (See
24-FSEL.)
VIN Speed Reference input, 0 to 10 VDC or 0 to 2 VDC, selectable by jumper (J11). It will 27, 48
also accept pulse train inputs: 0 to 1 kHz or 0 to 10 kHz, (6-10 V peak min.) and the
6FS output from another control. Operation can be inverted, 10 VDC = min.
frequency, and 0 V = max. frequency. (See 24-FSEL.)
REF This terminal is a +10 VDC power supply with 10 mA capacity and may be used as 27, 48
the Torque Limit Reference supply or the reference for VIN, in which case the drive
can be programmed to shut down if the common line to the remote speed
potentiometer opens. (See 24-FSEL.)
LIM Torque Limit input terminal. It will accept 0 to 10 VDC. 10 VDC equals 150% output 28, 48
torque. Defaults to +10 VDC with no input connected.
Digital FWD Forward Direction Selection terminal. May be connected for two-wire maintained or 48, 49
Input three-wire momentary operation.
Terminals REV Reverse Direction Selection terminal. May be connected for two-wire maintained or 48, 49
three-wire momentary operation.
+24 Reference Voltage for Digital inputs FWD, REV, R/J (Run/Jog), PS1, PS2, PS3, MOL 48, 49
and ART, rated 200 mA. Overloading this terminal will result in fault F04. May be
used to power relays tied to open collector outputs ST1, ST2, and ST3.
R/J Run/Jog Selector. When this terminal is connected to +24, momentarily connecting 48, 49
either FWD or REV to +24 results in a latched run mode (3-wire operation).
PS1 Preset Speed #1 input • Preset Speed #2 input • Preset Speed #3 input 28, 48
PS2 Eight preset speeds are attainable; one from the main speed setter, six programmed
PS3 speeds, and FMAX. Preset speeds can be programmed from 0 to 400 Hz, but FMAX 49
sets the actual operating range. (1 is closed to +24, 0 is open.) All may be obtained
from the following switching matrix:
PS1 PS2 PS3 Effective speed reference
0 0 0 Basic speed setpoint 24-FSEL (Default)
1 0 0 33-F2 (5 Hz)
0 1 0 34-F3 (20 Hz)
1 1 0 35-F4 (40 Hz)
0 0 1 36-F5 (60 Hz)
1 0 1 37-F6 (0 Hz)
0 1 1 38-F7 (0 Hz)
1 1 1 32-FMAX (60 Hz)
ART Alternate Ramp Time Selector. Separate acceleration and deceleration ramps can be 26, 29
selected by connecting this terminal to +24. These ramps are programmed by
parameters 41, 44 and 45. See parameter 21-MODE for more information on when
this function is active.
TABLE 2.8
16
DESCRIPTION OF TERMINALS See Page
Digital MOL Motor Overload input terminal. Requires N.C. contact for operation, referenced to 5,
Input +24. Connected to +24 by a jumper wire at the factory. 48, 49
Terminals Coast to Stop. Connecting this terminal to +24 turns the drive output OFF,
CTS 29, 49
allowing the motor to coast to a stop. The inverter’s output is cut off, not ramped
to a stop. When the terminal is set to 0 V (open), the drive output is reinstated
and the output will ramp to the programmed frequency. This function may be
used when electro-mechanical brakes are required. This feature can also be
accessed in programming by the 41-RSEL parameter to automatically coast to a
stop on a stop command.
RST External Fault Reset input terminal. After a fault, connecting this terminal to +24 48
will reset any fault.
Digital ST1 Open collector NPN transistor output connections. Each output can be 34, 49
Output ST2 individually programmed to respond to any one of eleven conditions. (See
Terminals ST3 parameters 72-ST1, 73-ST2 and 74-ST3.) Each output can sink up to 50 mA
from a 24 VDC source.
6FS This terminal provides a 24 VDC pulse train output which is 6X or 48X the output 48
frequency of the inverter. Selected by parameter 88-FRO.
Serial COM Control circuit common, electrical isolated from the AC line terminals. 42, 48
Communi-
cation SIO+ Positive connection for the Serial Input/Output Operation communication link.
Port Responds to RS485 protocol. (See Section 5.)
Terminals SIO- Negative connection for the Serial Input/Output Operation communication link.
Responds to RS485 protocol. (See Section 5.)
Auxiliary Normally Open contact for the Auxiliary Relay. Will close when the relay is
Relay activated. Rating is 115 VAC at 1 Amp or 250 VAC at 0.5 Amp. 34
Terminals
(RLY) Auxiliary Relay Common terminal. This relay is factory programmed to act as a
Fault Relay but may be reprogrammed to any one of eleven conditions. (See
parameter 75-STR.)
Normally Closed contact for the Auxiliary Relay. Will open when the relay is
activated. Rating is 115 VAC at 1 Amp or 250 VAC at 0.5 Amp.
TABLE 2.8 (Con’t.)
2.9 Environmental Considerations
The WFCHT Series Inverter is rated NEMA 4 (through 50 HP), indoor use. This is a sealed unit providing a
degree of protection against falling, splashing and hose-directed water.
If your inverter will be subjected to high-pressure wash-down or atmospheric contaminants such as
acid or caustic vapors, or carbon, metallic, or corrosive dust, contact TB Wood’s Application
Engineering Department for specific instructions.
In order to maintain the NEMA 4 integrity of the WFCHT Inverter enclosure, some care must be exercised when
the cover is installed.
With the smaller chassis configurations (WFC1000 series, WFC2000 series thru 10 HP and WFC4000 series
thru 20 HP), the following cover installation procedure shall be employed:
1. Snug each of the four (4) cover screws into place.
2. Sequentially tighten each screw until the gasket is compressed evenly. Tighten first one corner then
the opposing corner to minimize the chance of pinching the gasket.
3. Tighten these screws to 18-inch pounds of torque.
With the larger chassis configurations, the cover should be installed according to the following procedure:
1. Swing the hinged door closed making sure that the gasket is not pinched.
2. Sequentially tighten each screw until the gasket begins to compress. Alternate sides of the enclosure
when tightening to assure even compression.
3a.If drive serial number is 98279999 or lower, tighten these screws to 10-inch pounds of torque
3b.If drive serial number is 98280000 or higher, tighten these screws to 18-inch pounds of torque.
If the conduit entries are not used, utilize the hole plugs (supplied with the NEMA 4 models and the WCK01
thru WCK04 Chassis Mounting Kits) to close the unused holes. This will assure the enclosure’s environmental
integrity.
17
SECTION 3
GETTING STARTED
D V G O P
FW RE JO ST
T R
OG IF TE C
PR SH EN LO EM
R
FIGURE 3.2
The digital keypad controls the WFCHT in both the operating and programming modes. A detailed description of
all the keys and displays follows:
18
3.3 Operation Mode (STOP and RUN modes)
KEY FUNCTION
Initiates forward run when pressed momentarily. If the drive is running in reverse when FWD is
pressed, it will decelerate to zero speed, change direction and accelerate to the set speed.
D
FW
Initiates reverse run when pressed momentarily. If the drive is running in forward when REV is
pressed, it will decelerate to zero speed, change direction and accelerate to the set speed. May
be disabled by the setting of 21-MODE (factory setting).
V
RE
Note: If both keys are pressed and held at the same time,
the drive follows the first key pressed.
Press to enter the JOG mode when stopped. When in the JOG mode, the drive will ramp in the
forward direction to a programmable JOG speed (33-F2) while the FWD key is held. The drive
will ramp to a stop when the FWD key is released. Pressing the REV key causes a similar
G
JO
operation. The ramp will be at a rate set for normal acceleration and deceleration. To leave the
JOG mode, press STOP or the JOG key a second time.
Causes a Ramp-To-Stop when pressed. This function can be programmed to cause a Coast-
To-Stop when pressed (41-RSEL). If the drive has stopped due to a Fault condition, pressing
OP
the STOP key will reset the fault. Also functions as an emergency stop when the drive is
ST
remotely controlled.
In the Stop mode, pressing this key increases the desired running speed of the drive. That is,
the speed to which the drive will accelerate when a Run is initiated. In the Run mode, pressing
this key dynamically adjusts the running speed of the drive. Setting resolution is 0.01 Hz. If the
key is pressed and held for five (5) seconds, the setting frequency will scroll automatically at an
increased rate. Also see SHIFT description below.
In the Stop mode, pressing this key decreases the desired running speed of the drive. That is,
the speed to which the drive will accelerate when a Run is initiated. In the Run mode, pressing
this key dynamically adjusts the running speed of the drive. Setting resolution is 0.01 Hz. If the
key is pressed and held for five (5) seconds, the setting frequency will scroll automatically at an
increased rate. Also see SHIFT description below.
In the Stop or Run modes, pressing this key will “Lock-in” the frequency selected by the UP and
DOWN arrow keys so that if power is removed and reapplied, that frequency will be the initial
R
TE
default speed setting. The display will show **STORED** for 1 second when the command is
EN
completed.
Shifts drive control between the LOCal and REMote control modes as selected by the 21-
MODE parameter. Can be programmed to shift:
1) The Run/Stop command (either FWD or REV) or
2) The speed reference signal or
RELOC
3) Both or
M
UP and DOWN arrow keys will work as described in the Programming section of this
PR
document. Operation of the motor will not be affected while viewing the information in these
parameters, and parameter changes cannot be made.
Pressing SHIFT momentarily while holding either the UP or DOWN arrows will initiate the fast
scroll without waiting for the five second delay. Pressing it a second time will start the fastest
FT
scroll rate.
I
SH
19
3.4 Program Mode
KEY FUNCTION
When in the STOP mode, pressing this key will enter the PROGRAM mode at Level 1.
Pressing this key at any time while in the PROGRAM mode will return the unit to the
OG OPERATION mode. Pressing the SHIFT and PROG keys simultaneously will enter Level 2. If
PR
an Access Code has been entered, re-entry is required to change program data.
In the PROGRAM mode, pressing this key will move forward through the successive
Parameter Addresses. When changing Data in a Parameter, this key will increment the data
value. The ENTER key must be pressed to store the new value.
In the PROGRAM mode, pressing this key will move backward through the successive
Parameter Addresses. When changing Data in a Parameter, this key will decrement the data
value. The ENTER key must be pressed to store the new value.
NOTE: At all parameters except 85-UNITS, momentarily pressing both the UP-arrow and
DOWN-arrow keys simultaneously will return the parameter setting to factory defaults.
Pressing this key while a Parameter is displayed will allow that Parameter to have its data
changed by use of the UP and DOWN arrow keys.
T
IF
SH
Pressing this key after data has been changed in a Parameter will store that information in
nonvolatile memory.
R
TE
EN
LED INDICATION/LOCATION
The red Stop LED, located in the STOP key, illuminates whenever a stop command has been
given. If the inverter has stopped due to a fault, this LED will flash to call attention to the digital
P
display.
O
ST
The green Forward LED, located in the FWD key, illuminates whenever a forward command
has been given. When both the Forward and Reverse LED’s are on, the DC braking function is
active.
D
FW
The green Reverse LED, located in the REV key, illuminates whenever a reverse command
has been given. When both the Forward and Reverse LED’s are on, the DC braking function is
active.
V
RE
The green Jog LED, located in the JOG key, illuminates to signify the inverter is in the JOG
mode of operation.
G
JO
20
3.6 Description of Displays
The WFCHT Series Inverter has been designed to provide the POWER-UP AND FAULT RESET MODES
greatest level of information possible to the operator through an
easily readable 2x16 character Back Lit LCD alpha-numeric RESTART
display, including data on drive and motor status, fault
information and parameter values. This section will give a brief
description of the various display formats that may be seen
during startup, operation and programming.
The restart display is present whenever OPERATING DISPLAY Status
power is applied to the inverter or a fault Control
condition is reset. It will be displayed for
about one second during which time the
LOC STOP
computer is checking various functions within SET 0.00 Hz 0%
the inverter.
During normal operation, the operating Mode Frequency Load
display will provide important information
about the inverter and load.
CONTROL
The first three characters of the top line denote the source of control for the inverter:
LOC Local control via the Keypad
REM Remote control from the terminal strip
SIO Remote control via the RS485 Serial SIO Link
SEQx Control via the Program Sequencer
ADJ Auto-tune mode for Parameter 5B-IMAG
STATUS
Twelve characters are dedicated to the current status of the inverter output. This includes normal operating
conditions and warning messages:
STOP The inverter is in the STOP mode.
ACCELERATE The motor is increasing in speed.
DECELERATE The motor is decreasing in speed.
AT SPEED Motor speed is at the desired set point.
ZERO SPEED The inverter is in the RUN mode, but the motor is not turning.
JOG Motor runs only while the FWD or REV keys are pressed. (Displayed only while
JOGGING).
TORQ LIMIT The output torque of the inverter has reached its programmed limit level.
DYN BRAKE The Dynamic Braking circuit is helping to decelerate the motor and load.
HI TEMP The temperature of the drive is near the maximum limit point.
HI CURRENT The output current is near the overcurrent cutoff point.
HI VOLTAGE The voltage on the DC bus is near the high voltage cutoff point.
LO VOLTAGE The voltage on the DC bus is near the low voltage cutoff point.
SPD SEARCH Autostart has been programmed to 82-START, and the inverter is attempting to
synchronize its output with the motor speed.
IDLE#xx SIO mode of operation only. The drive is programmed to SIO address (92-SIOA) = xx.
It is awaiting either a program or run command.
LS LOCKOUT Line Start Lockout. A run command was detected when power was applied.
MODE
The first three characters on the second line denote the present operating mode of the inverter:
FWD A Forward run command has been given.
REV A Reverse run command has been given.
SET The inverter is waiting to have, or is having, the running frequency set.
FREQUENCY
The standard display shows the inverter operating frequency in Hertz. This can be custom tailored to any
engineering or machine units by the setting of parameters 84-DISP and 85-UNITS.
LOAD
The last four characters in line 2 display the percentage of maximum continuous inverter output current that is
being delivered. If a custom display is programmed on this line, this information is not displayed but is still
viewable at parameter 15-LOAD.
21
When the programming mode is accessed by pressing the PROG PROGRAMMING ACCESS
key for LEVEL 1 or SHIFT and PROG keys for LEVEL 2 or 3, the
display to the right will appear for one second. PARAMETERS
RIGHTS PROGRAM LEVEL 1
This section explains the operator’s access rights after the
program mode has been entered: Rights Access
PROGRAM This indicates that while in the programming
mode parameter data can be changed.
VIEW If the inverter is in the run mode (forward or reverse) when the PROG key was pressed,
parameters may be viewed but not changed.
ACCESS
This denotes the access level that is being entered. It may show Level 1 or Level 2 (Section 4) or Level 3
(Section 5).
Once the program mode has been accessed, the PROGRAMMING DISPLAYS Description
display shown to the right will provide information on
each parameter: MIN FREQUENCY
PROG 31: 0.0 Hz
DESCRIPTION
The top line will give a full 16 character description of
the parameter that is being accessed. Rights Parameter Data
RIGHTS
The first four characters of the second line will indicate if the particular parameter can be changed (PROG) or
only examined (VIEW). If an attempt is made to change data while in the VIEW mode, the message **NO
ACCESS** will be displayed for one second.
PARAMETER
This is the actual parameter number being displayed. When data is being changed, this number will blink on
and off. See inside the front cover for a listing of all Level 1 and Level 2 parameters.
DATA
Up to eight characters are used to display the information stored in the parameter. Some parameters have a
unit designator such as:
s – Seconds h – Hours C – Degrees centigrade
Hz – Hertz % – Percent A – Amperes
When the inverter stops due to a fault trip, a unique FAULT DISPLAY – PAGE 1
error message will be displayed along with a flashing Code
STOP LED indicator. Two “pages” of information are
available concerning the actual fault and drive FAULT F07 ^
status. Page one is shown at right. Next Page
MOL CONTACT OPEN
CODE
The top line signifies that a fault has occurred and Description
displays one of 19 fault codes. See Section 7 –
Troubleshooting for a complete list of all codes and explanations of each.
NEXT PAGE
The “^” symbol indicates that pressing the Up Arrow will shift the display to Page 2.
DESCRIPTION
The second line provides a full 16 character description of the cause of the fault.
Page 2 of the fault display will show the operating conditions of AT SPEED
the inverter at the time of the fault. All other operating parameters FWD 49.60 Hz 80%
are “frozen” until the drive is reset.
22
3.7 OPERATING TIPS
Parameter Access
• When the PROG (or SHIFT-PROG) key is pressed after application of power, 21-MODE will always be the
first parameter displayed.
• If a different parameter is accessed and the Program mode is exited, that parameter will be the point of
entry the next time the programming mode is accessed.
• The WFCHT will remember different “last parameters” for Levels 1, 2, and 3.
• If no key is pressed for 10 minutes while in the programming mode, the WFCHT will automatically revert
back to the operating mode.
Display Scroll Rate
• Three scroll rates are used to speed entry of information into the WFCHT.
• If either the UP or DOWN arrow is pressed and held for five seconds, the rate of change of the display will
increase.
• If the SHIFT key is momentarily pressed while holding one of the arrow keys, the five second delay will be
bypassed.
• If the SHIFT key is pressed a second time while holding an arrow key, the display will scroll at the fastest
rate. This is useful for entering very large numbers as in parameter 84-DISP.
Restoring Factory Settings
• Whenever a parameter’s data is being changed (noted by the Parameter number blinking), the original
factory setting for that parameter can be restored by pressing both the UP and DOWN arrows
simultaneously and pressing the ENTER key.
• To restore ALL parameters to their factory settings, see parameter 81-PRGNO.
Help
• For Application Assistance, call TB Wood’s Incorporated Electrical Engineering at 800-789-6637 to talk to
an Electrical Application Engineer.
After one second, only the STOP LED will stay on and the
display will change to: LOC STOP
SET 0.00 Hz 0%
C. The factory settings for the WFCHT Series are for keypad only
operation in the forward direction. This means that the REV key and the LOC/REM key are disabled.
Press the FWD key; the display will change to:
D. Press the UP arrow to increase the desired running fre- LOC ZERO SPEED
quency. When the motor starts to turn, note the direction of SET 0.00 Hz 0%
rotation. If the motor is turning in the wrong direction, STOP
THE DRIVE, REMOVE AC POWER AND WAIT FOR THE
BUS CHARGE INDICATOR TO GO OUT. After the Charge indicator is extinguished, reverse any two of
the motor leads at M1, M2 or M3.
E. The length of time that the UP arrow is depressed determines the scroll rate of the display. After it is held
for five seconds, the rate of change will increase. The five second time can be circumvented by
momentarily pressing the SHIFT key while holding the UP (or DOWN) arrow.
F. The inverter is preset to run a “typical” NEMA B induction motor to a maximum speed of 60.00 Hz with
both Acceleration and Deceleration times set to 3.0 seconds. The Jog frequency is set for 5.0 Hz.
G. Use the Arrow keys to set the proper running speed of the motor and the FWD and STOP keys to control
its operation.
23
3.9 High Torque Set Up Procedure
The following procedure allows the WFCHT series AC inverter to be set up for low speed, high torque operation.
1. Program Parameter 51-VSEL to Data Code 6 (see page 30).
2. Program Parameter 65-SLIP per the formula on page 32.
3. Run the drive at 15 Hz setpoint and minimal loading (free shaft operation if possible). Enter Level 2
programming and scroll to parameter 5B-IMAG. ‘ADJ’ should appear in the lower left corner of display.
Press the ‘ENTER’ key on keypad to have the drive Auto-tune the 5B-IMAG value. The drive will measure
the magnetizing currents and place a value into parameter 5B-IMAG. Although not required, repeating the
process to verify consistent results is recommended.
Check the system for performance. For most applications, the above procedure is sufficient for ideal drive-
motor performance. For additional fine-tune adjustments, see the following steps.
1. Run the motor in the 2-6 Hz range. If the drive appears to draw excessive currents at low speeds with no
load, decrease the setting of 5B-IMAG. Too much 5B-IMAG can result in unstable motor operation.
2. Run the motor in the 2-6 Hz range under full load conditions. If the drive draws greater than motor name-
plate current, reduce the value of 52-BOOST. If it appears the motor is not developing sufficient torque,
increase the value to 52-BOOST. Note: For proper performance at frequencies below 6 Hz, inverter duty
motors are recommended. 52-BOOST is set at a value predetermined for premium efficiency motors.
When using inverter and vector duty motors, the value of 52-BOOST may need to be adjusted.
If additional problems arise, contact TB Wood’s Electronics Applications Engineering at 888-829-6637 for
assistance.
24
SECTION 4
PARAMETER DESCRIPTIONS AND PROGRAMMING
4.1 Programming
To change the default programming for a given parameter: INPUT MODE
PROG 21: 0
A. Press the STOP key, if the inverter is running. Some parameters
(see the individual parameter description) can be changed while the inverter is operating.
B. To enter Level 1 programming, press the PROGram key. To enter Level 2, hold the SHIFT key and
press the PROGram key.
C. Use the UP/DOWN arrow keys to select the program parameter for change.
D. Press the SHIFT key. The program number will blink indicating that the data value may be changed.
E. Use the UP/DOWN arrow keys to select the new data code.
F. Press the ENTER key. The display will indicate **STORED** for one second, then revert to the normal
parameter display.
G. Press the PROGram key to exit the programming mode or the UP/DOWN arrow keys to select a new
parameter for change.
Notes:
1. Data codes 0 thru 5 define the type and response characteristic of input speed signal connected to the
terminal strip of the inverter.
2. If speed control is programmed from the keypad at parameter 21-MODE, the selection at parameter 24
is ignored.
3. Frequency of input signal determined by parameter 88-FRO. If parameter 24-FSEL is set data code 19,
adjust the J2 jumper (see page 15, figure 2.8) to the 0-2V position for better resolution. The table that
follows notes the maximum operating frequency when using this data code and parameter 83-PWM.
Consult the factory with any questions.
The maximum running frequency available when using data code 19 (48x pulse train from another WFCHT
series inverter) is limited by the operating carrier frequency. When selecting the carrier frequency at
parameter 83-PWM and parameter 24-FSEL is set to data code 19, the maximum operating frequency will
be limited by the following values.
For all models except the WFC4075-0: For the WFC4075-0 only:
83-PWM data code 1 (3kHz) ---- 62 Hz max. 83-PWM data code 1 (2.3 kHz) ---- 48 Hz max.
83-PWM data code 2 (4kHz) ---- 83 Hz max. 83-PWM data code 2 (2.5 kHz) ---- 52 Hz max.
83-PWM data code 3 (6kHz) ---- 125 Hz max. 83-PWM data code 3 (4.6 kHz) ---- 95 Hz max.
83-PWM data code 4 (8kHz) ---- 166 Hz max. 83-PWM data code 4 (5 kHz) ---- 104 Hz max.
83-PWM data code 5 (12kHz) ---- 250 Hz max. 83-PWM data code 5 (9.2 kHz) ---- 191 Hz max.
83-PWM data code 6 (16kHz) ---- 332 Hz max. 83-PWM data code 6 (10 kHz) ---- 208 Hz max.
27
Parameter Units Level
27-TLSEL - Torque Limit Reference Selector L2
TLSEL selects one of seven combinations of six torque limit setpoints to be effective during driving and
regenerative operation. Torque limit may be different for forward and reverse operation. Parameter 21-
MODE can override this selection when it dictates that the drive operates under keypad control.
The proper usage of this parameter is dependent on the selection made at 21-MODE. Typically no
changes are necessary at this parameter.
28
Parameter Units Level
39-FTL - Minimum Frequency in Torque Limit Hz L2
When the drive's output current exceeds the limits defined by 27-TLSEL, the motor will be decelerated at a
rate determined by 46-DECTL to the frequency programmed at this parameter. If this parameter is set to a
value greater than parameter 32-FMAX, TORQUE LIMITING WILL BE DISABLED.
41-RSEL - Ramp Selector L2
This parameter defines the acceleration and deceleration characteristics of the drive. The following table
outlines the possibilities:
29
Parameter Units Level
48-DCVLT - DC Brake Voltage % L2
The parameter controls the amount of DC voltage applied to the motor windings by 47-DCBRK. Factory
setting is 2/3 of 52-BOOST. It is adjustable between 0 and 15% of full voltage.
CAUTION: If DC braking is used as a holding brake, excessive motor heating may result.
51-VSEL - Volts/Hertz Characteristic Selector L2
This parameter selects between the HT mode (Vector Control) and Volts/Hertz operation. By selecting Data
Code 6, the WFCHT activates the Vector Control scheme. When selecting Data Codes 0 through 5, the
Volts/Hertz mode is initiated and one of the three Volts/Hertz characteristics and one of two Torque Boost
modes are enabled. The following table defines these selections. Their actions are shown graphically below.
100% 100%
STANDARD 51-VSEL = 0
L1NEAR 51-VSEL = 1
BOOST BOOST
0% FKNEE 0% FKNEE
100% 100%
PUMPS
MIXED 51-VSEL = 2 51-VSEL = 3
LIN/QUAD
BOOST BOOST
0% 0%
FKNEE FKNEE
100% 100%
FANS
QUADRATIC 51-VSEL = 4 51-VSEL = 5
BOOST BOOST
0% 0%
FKNEE FKNEE
31
Parameter Units Level
65-SLIP - Slip Compensation
Slip compensation is used to provide a more constant output speed as motor loading changes. This
parameter is used in both the Volts/Hertz and High Torque modes of operation. Too much slip
compensation may result in unstable motor operation. It is not intended for use with a synchronous
motor. In Volts/Hertz mode, the inverter’s output frequency is increased as the motor loading increases. In
HT mode (Vector Control), the setting of 65-SLIP is the nominal full load speed compensation for the motor.
This setting is required for optimum performance at low speeds.
65-SLIP is programmable in 0.01% increments from 0.00 to 10.00%. See the following formula and example
to determine the proper setting of parameter 65-SLIP:
Example: Assume the use of a 1740 RPM motor with a nameplate current (Im) rating of 9.6 amperes. From
Section 1.5 or parameter 03-IRAT, we determine that the drive is rated at 15.2 amperes. From Section 1.6,
we can determine that the synchronous (unloaded) speed of the motor to be 1800 RPM. Using the formula,
we find:
65-SLIP = ___________
RPMs - RPM1 x ____ IRAT x 100(%) = __________
1800 - 1740 x 15.2
____ x 100% = 5.27%
RPMs Im 1800 9.6
66-STAB - Current Stability Adjustment L2
Lightly loaded motors may tend to oscillate and become unstable due to electro-mechanical relationships in
the motor. This may be more prevalent when the inverter capacity is larger than the motor. This adjustment
will stabilize the motor current in these conditions. The range of adjustment is 0 through 4, with the default
being 2. Some 2-pole (3600 RPM synchronous speed) motors have proven to require alteration of this
parameter to assure stable operation.
67-TOL - Timed Overload Trip Point % L1
67-TOL is the timed overload trip
point. This parameter defines the
load point beyond which a timed
electronic trip can occur. The trip
time depends on the amount of
overload and is 1 minute for 150%
of the setting, longer for lesser
degrees of overload. A 10%
overload will not cause the drive to
trip. Parameter 67-TOL is
adjustable in 1% increments from 5
to 100% of drive capacity. The
factory setting is 0, inactive.
The action of 67-TOL is presented
graphically in the Trip Time chart to
the right. See also parameter 6A-
TOLC for information on setting
timed overload appropriately for
your motor.
The proper setting of parameter 67-
TOL is calculated using the value
stored at 03-IRAT and the motor
nameplate current (Im) according to
the following formula:
67-TOL =____
Im x 100%
IRAT
WARNING
WHEN USING MULTIPLE MOTORS ON A SINGLE INVERTER, USE SEPARATE EXTERNAL
PROTECTION ON EACH MOTOR AND SET 67-TOL TO 0 (DISABLED).
AVERTISSEMENT
AVEC L’UTILISATION DE PLUSIEURS MOTEURS SUR UN SEUL INVERSEUR, UTILISEZ UNE
PROTECTION EXTRENE SÉPARÉE SUR CHAQUE MOTEURS ET PROGRAMMEZ 67-TOL À 0.
32
Parameter Units Level
68-NRST - Trip Restart Number L2
Providing the inverter is operated from a maintained run command, this parameter will allow the drive to be
automatically restarted, after a fault, up to a programmed number of attempts. This limit is from zero (0) up to
a maximum of eight (8) tries within a 10 minute time frame. In each case, the drive will wait for the delay
programmed at 69-DRST. Only fault codes F11 thru F20 are effected by this process. Once the programmed
value of 68-NRST has been exceeded, the drive will display a F10 fault and wait for a manual reset.
When 68-NRST is active, the function of parameters 72-ST1, 73-ST2, 74-ST3 and 75-STR is altered.
Data Code (2) for each parameter will not activate the respective output for every fault, only for fault
codes 1-10. To maintain a similar, yet inverse function with 68-NRST active, use data code 1.
WARNING
INSURE THAT AUTOMATIC RESTARTING WILL NOT CAUSE DAMAGE TO EQUIPMENT OR
INJURY TO PERSONNEL.
AVERTISSEMENT
ASSUREZ VOUS QU’UN DEPART AUTOMATIQUE N’ENDOMMAGERA PAS L’EQUIEMENT OU DE
BLESSURE AU PERSONNEL.
34
NOTES: EMOP2/EMOP3
1. When data codes 1-29 are invoked, 81-PRGNO will Data Code 32/33
revert to "0" upon exiting the program mode. When Functional
data codes greater than 29 are used, 81-PRGNO will Description Terminals
retain the data setting. FWD REV PS1 PS2
2. Data code 1 allows all program parameters to be
returned to factory defaults. When the program mode Off 0 0 X X
is exited, the display will indicate "INIT
PARAMETERS" then "RESTART". Speed = 0 1 1 X X
3. Data code 2 allows storage of the current set of FWD Decrease Speed 1 0 1 X
program parameters. Data code 3 allows a previously
stored set of program parameters to be retrieved. Data FWD Hold Speed 1 0 0 0
code 4 allows the current and stored set of program FWD Increase Speed 1 0 0 1
parameters to be exchanged.
4. Data code 5 allows the WFC2005-0x to be re- REV Decrease Speed 0 1 1 X
calibrated for use on a 3 HP motor when powered
from a single phase source. Use data code 1 to return REV Hold Speed 0 1 0 0
to the 5 HP calibration. REV Increase Speed 0 1 0 1
5. Parameter 21-MODE must be set to a code that
permits MODE 2 (REMote) operation. Also, the drive 0 = Inactive 1 = Active X = Ignored
must be operated in REMote mode.
6. Data codes 32 and 33 select the WFCHT's EMOP control programs. With code 32 selected, commanded output
frequency returns to 31-FMIN when the drive is stopped. With code 33 selected, commanded output frequency
remains at the previous setpoint. See the table above for proper usage.
7. These codes permits both speed and direction control from an analog speed input. Order Form 1042 for more
details.
Program Sequencer
The Program Sequencer function can be thought of as a simple programmable logic controller (PLC). It
permits the drive to execute up to nine (9) sequential program steps. Each program step can be an
independent combination of direction, speed and ramp. The duration of any one program step can be
controlled by: time, digital comparison, pulse (event) count or an analog voltage level. Use of the pulse count
and voltage level comparisons requires the use of either the WPC04 – Encoder Interface Board or WPC05 –
Process Control Interface Board (see Table 4.2 for details). An Event Control parameter (C1-CNTL1...C9-
CNTL9) and an Event Count parameter (E1-ECNT1...E9-ECNT9) serve to define each program step
independently.
BIT NUMBER 7 6 5 4 3 2 1 0
0 0 0 0 0 0 0 0 PROGRAM DATA
Bit # Optional
Description of Event Count Parameter Units Equipment
5 4 Required?
0 0 Time Base – The operating condition outlined in the Event Control parameter will be No
executed for a time interval of up to 18 hours (dependent on the setting of
81-PRGNO). The next event will then be executed, up through Event #9.
81-PRGNO Time Base Increments Maximum Sequence Time
60 1 second 18.2 hour
61 0.1 second 1.8 hour
62 0.0082 second 8.9 minutes
0 1 Pulse Count – The operating condition outlined in the Event Control parameter will be Yes –
executed until the set number of pulses have been counted. The pulse count is WPC04
provided by either an encoder or proximity sensor mounted on the driven machine.
1 0 Analog Input – The operating condition outlined in the Event Control parameter will Yes –
be executed until a voltage is greater or less than a programmed value. The limits of WPC04 or
the analog level are 0-10.00 VDC. WPC05
Ex-ECNTx
Range Description
(DC voltage)
00000-01000 Lower Limit – The Event Control parameter will be executed until a
(0-10 VDC) voltage equal to or LESS than the programmed value is sensed.
10000-11000 Upper Limit – The Event Control parameter will be executed until a
(0-10 VDC) voltage equal to or GREATER than the programmed value is sensed.
1 1 Digital Comparison – The operating condition outlined in the Event Control No, but
parameter will be executed until a set digital combination of terminals PS1, PS2 and compatible
PS3 is sensed by the inverter. The limits of this configuration are 0 thru 7, signifying with
the binary combinations of PS1, PS2 and PS3. WPC02 &
WPC06
Ex-ECNTx Description Control Terminals
Code PS1 PS2 PS3
0 All inputs inactive 0 0 0
1 PS1 Active 1 0 0
2 PS2 Active 0 1 0
3 PS1 & PS2 Active 1 1 0
4 PS3 Active 0 0 1
5 PS1 & PS3 Active 1 0 1
6 PS2 & PS3 Active 0 1 1
7 PS1, PS2 & PS3 Active 1 1 1
TABLE 4.1
Activating the Program Sequencer function requires that a selection of 81-PRGNO = 60, 61 or 62 be
made. This must be done regardless of the type of event count used for the individual sequence
steps. After 81-PRGNO is set to 60, 61, or 62, exit the program mode by pressing the PROG key. The
Event Control and Event Count parameters will be visible upon re-entering Level 2 programming.
Programming the Event Control Parameter
Determine the coding of the control byte for each program step using Figure 4.1. Enter the first code into
parameter C1-CNTL1. When you access parameter C1, the display will resemble the following:
To program this parameter:
1. Press SHIFT to open the parameter. The parameter number will flash and bit
number 7, or the left-most character will be underlined, indicating that this EVENT CONTROL
character may be changed. PROG C1: 00000000
2. Use the up arrow to increment the character. Use the down arrow to decrement
the character.
3. Press SHIFT again to move on to the next character, bit number 6, and repeat step 2.
4. Once all the characters or bit numbers have been changed, press ENTER to store the result.
36
Programming Example
A machine is required to run in
the forward direction at 50 Hz
for one hour, then quickly SEQ1 SEQ2 SEQ3
decelerate to a stop. After two
(2) minutes, the machine must Direction Selection Forward Stop Reverse
accelerate in the reverse Event Definition 1 Hour 2 Minutes Until PS1 Active
direction to 5 Hz until a limit
switch is activated causing the Ramp Selection Primary Alternate Primary
drive to decelerate to a stop. Speed Selection F6 (50 Hz) N/A F2 (5 Hz)
The following three (3) sequen-
tial steps can be programmed TABLE 4.2
using only the basic inverter and
no optional equipment.
First, since two of the sequential steps are time based, the proper 81-PRGNO setting must be determined.
Determine the
resolution and the
maximum time re- PARAMETER DATA CODE EXPLANATION
quired, in this case
81-PRGNO 60 1 Second Time Increments
one (1) hour. If a
resolution of one C1-CNTL1 01000101 FWD/Timed/Primary Ramp/Preset Speed F6
second is sufficient, C2-CNTL2 00001000 STOP/Timed/Alt. Ramp/Speed Setting Ignored
set 81-PRGNO =
60. If a greater set- C3-CNTL3 10110001 REV/Digital Comparison/Primary Ramp/Preset Speed F2
ting resolution is E1-ENCT1 3600 1 Hour = 3600 Seconds
necessary, 81-
PRGNO can be set E2-ENCT2 120 2 Minutes = 120 Seconds
to 61 (0.1 second E3-ENCT3 1 Terminal PS1 Active
TABLE 4.3
FIGURE 4.2
37
WFCHT Operation Under Program Sequencer Control
The WFCHT can be operated under control of 21-MODE Transfer
the Program Sequencer from either the key- Setting LOCal REMote by
pad or from the terminal strip. See
Parameter 21-MODE (Section 4.2 and 0/10 Sequencer operation N/A N/A
from keypad
Table 4.4).
1/11 Normal keypad Sequencer operation LOC/REM
When operating from the keypad, pressing operation from keypad key
the FWD key will command the drive to
2/12 Normal keypad Sequencer operation LOC/REM
cycle through the programmed steps of the 3/13 operation from terminal strip key
Program Sequencer one time only. Pressing
the SHIFT and FWD keys simultaneously 4/14 N/A Sequencer operation N/A
24/34 from terminal strip
will cause the programmed sequence to
repeat until the stop key is pressed. 21/31 Normal keypad Sequencer operation PS3
operation from keypad (Note 1)
When operating from the terminal strip using
22/32 Normal keypad Sequencer operation PS3
remote operators, the same possibilities 23/33 operation from terminal strip
exist. If operating under three wire control, (Note 1)
with the R/J terminal active, momentarily
activating the FWD terminal will force the Note 1: Terminal PS3 is not available under these selections of
21-MODE for digital comparison.
programmed sequence to be executed
once. If the FWD terminal is activated TABLE 4.4
continuously, the programmed sequence will be repeated. When a stop command is issued to the drive, it
will reset the Program Sequencer to the beginning and await the next start command. If the CTS terminal is
activated, the Program Sequencer pauses at the Current Step.
The Program Sequencer cannot be run under SIO control. The individual program parameters may
be downloaded to the control via SIO communication.
The program sequence can be single-stepped through by repeatedly pressing the LOCal/REMote key. If, for
example, long time delays were programmed at several steps of the Program Sequencer, it would be
possible to disregard these long-time intervals to verify program functions.
Other Software Features
During program sequence operation the first four (4) characters of the keypad display will show the
sequence step being executed (SEQ1, SEQ2 … SEQ9). See Section 3.6 description of displays.
Parameter A8-OPTA8 is available for viewing during the execution of the programmed sequence steps. This
parameter allows the viewing of elapsed time during the sequence, if using the time base option. If using the
event count option, this will be a real time events counter. Parameter A8 can allow the user to monitor where
the drive is operating relative to the entire sequence and when you can expect the next step to begin.
Parameter A9-OPTA9 can be Event # Param/Bit # 7 6 5 4 3 2 1 0
used in conjunction with A8 since
it displays the actual step 1 C1-CNTL1
number of the sequence (0-9). E1-ECNT1
Parameter B7-NENC is used as 2 C2-CNTL2
a prescaler for the Event Count
parameter when operating in the E2-ECNT2
Pulse Count mode (using the 3 C3-CNTL3
WPC04 Encoder Interface
Board). For example, if B7 is set E3-ECNT3
to 10, the inverter will receive 10 4 C4-CNTL4
pulses before considering one
(1) event complete. This is useful E4-ECNT4
when very high pulse counts are 5 C5-CNTL5
needed. The maximum fre-
E5-ECNT5
quency of the input pulses is
60 Hz. 6 C6-CNTL6
Event Sequencer Worksheet E6-ECNT6
Refer to the previous discussion 7 C7-CNTL7
and fill in the appropriate codes
for Cx-CNTLx and Ex-ECNTx in E7-ECNT7
Table 4.5. To skip all remaining 8 C8-CNTL8
events, ensure that the respec-
tive Cx and Ex values are set to E8-ECNT8
zero. 9 C9-CNTL9
TABLE 4.5 E9-ECNT9
38
Parameter Units Level
82-START - Inverter Start Options L2
This parameter selects options such as line start lockout, line starting or starting a rotating motor. 82-START
also allows the keypad STOP key to function as an emergency stop when operating the inverter from the
terminal strip. Various options for 82-START include:
WARNING
INSURE THAT AUTOMATIC RESTARTING WILL NOT CAUSE DAMAGE TO EQUIPMENT OR
INJURY TO PERSONNEL.
ADVERTISSEMENT
ASSUREZ VOUS QU’UN DEPART AUTOMATIQUE N’ENDOMMAGERA PAS L’EQUIEMENT OU
DE BLESSURE AU PERSONNEL.
Note: When data codes 2, 3, 6 or 7 are selected, the display will indicate SPD SEARCH upon the initiation of
a run command.
39
Parameter Units Level
83-PWM - PWM Carrier Frequency Selector L2
This parameter sets the carrier frequency of the Pulse-Width-Modulation waveform supplied to the motor.
Low carrier frequencies provide better low end torque but produce audible noise from the motor. Higher
carrier frequencies produce less audible noise, but cause more heating in the inverter. The WFCHT is rated to
produce continuous full load current at rated ambient temperatures when parameter 83-PWM is set to carrier
frequencies 3, 4, 6 or 8 kHz. At higher carrier frequencies (12 and 16 kHz), the inverter will auto-
matically switch to a lower carrier frequency when load conditions exceed the derating levels. When
the load is reduced, the carrier frequency will return to its previous setting. Data Code 0 (Autoselect)
automatically selects the highest carrier frequency permitted without overheating the inverter. Note:
Autoselect will also adjust the carrier frequency to 8 kHz at 75° C and to 4 kHz at 90° C. When using Data
Codes 5 & 6, the carrier frequency will shift to 1/2 of the selected carrier frequency when the output voltage
is less than 6% of nominal rating. When using Data Codes 7 and 8, the carrier frequency will shift to 1/2 of
the selected carrier frequency when the output voltage is less than 12% of nominal rating and to 1/4 of the
selected carrier at 6% of nominal output voltage. For low speed high torque applications, the best
performance can be achieved by selecting Data Codes 1, 2, 7 or 8. Adjustments are as follows:
40
Drive Derating at high carrier frequencies
The chart below shows the derating of the WFCHT Series AC inverters at the designated carrier frequencies.
Note that the derating at certain carrier frequencies is identical to an adjacent frequency. Therefore, there
are three derating values over the six carrier frequency selections.
42
Parameter Units Level
86-LANG - Display Language L2
This parameter sets the language for the display readout. The factory can supply a complete listing of
displays in all languages. The options include:
43
SECTION 5
LEVEL 3 PARAMETER DESCRIPTIONS AND PROGRAMMING
The following is a summary of the parameters associated with SIO communication. Consult Form 997 - SIO Serial
Link Protocol or the factory for more information on the use of WFCHT Series inverters in serial communication
applications.
5.2 Programming
To change the default programming for a given parameter from the keypad:
A. Press the STOP key, if the inverter is running. Some parameters (see the
SIO SLAVE ADDR
individual parameter description) can be changed while the inverter is PROG 92: 1
operating.
B. To enter Level 1 programming, press the PROGram key. To enter Level 3, hold the SHIFT key and press the
PROGram key.
C. Use the UP/DOWN arrow keys to select the program parameter for change.
D. Press the SHIFT key. The program number will blink indicating that the data value may be changed.
E. Use the UP/DOWN arrow keys to select the new data code.
F. Press the ENTER key. The display will indicate **STORED** for one second, then revert to the normal parameter
display.
G. Press the PROGram key to exit the programming mode or the UP/DOWN arrow keys to select a new parameter for
change.
44
5.3 Parameter Descriptions
This section provides a functional description of all WFCHT programming parameters at Level 3. Those with a
level indication including an asterisk (*) cannot be programmed, but can be viewed while the drive is operating.
Parameter Units Level
04-TMAX - Maximum Heatsink Temperature C L3*
This parameter is factory set to the maximum heat sink temperature that the processor will allow continuous
operation of the drive. The inverter's display will indicate HI TEMP at TMAX minus 8ÞC. The data type for
04-TMAX is a real number.
0A-CFLT - Current Fault L3
This parameter is accessible serially in the event of a fault to determine the cause of a fault. It is stored as an
integer value with fault code (See Section 7) and elapsed time available to the host computer. Refer to
Section 4 for a more thorough discussion of fault codes (07-FLT3, 08-FLT2 and 09-FLT1).
11-STAT - Inverter Status Byte L3
This parameter is accessible to determine the present conditions in which the inverter is operating. The data
is stored as an integer, but represents a binary word. Bit #7, the most significant bit, when active indicates
that the drive is operating within the 8ÞC limit of 04-TMAX. Bit #6, when active, indicates that the drive is
operating in torque limit. When bit #5 is active, the drive is operating at an output frequency in excess of that
programmed at parameter 36-F5. Bit #4 being active indicates that the drive is "AT SPEED".
The remaining bits (3 thru 0) combine to indicate multiple conditions as outlined in the following table:
BIT NUMBER
DESCRIPTION
3 2 1 0
0 0 0 0 Power applied to the inverter and it is in IDLE, awaiting either an operation or
programming instruction.
0 0 0 1 The inverter has faulted.
0 0 1 0 The inverter is in the STOP condition.
0 1 0 0 The FORWARD direction has been selected.
1 0 0 0 The REVERSE direction has been selected.
1 1 1 0 DC voltage is presently applied to the motor.
1 1 1 1 Writing this value into 11-STAT can be used to reset all faults.
45
Parameter Units Level
21-MODE - Input Mode L1/L3
21-MODE defines the operating functions that are active from the Keypad, the Terminal Strip, and the SIO
Serial Link in both the LOCal and REMote operating modes. Also the mode transfer mechanism is defined
by your selection at this parameter. Proper setting of this parameter is the first step in customizing the
inverter to your application. The following table defines the combinations available to the SIO user.
46
Parameter Units Level
23-CNTL - Control Information Byte L3
This RAM parameter is the mechanism thru which actual SIO control of the inverter is achieved. It is
represented by a binary word. The activation of each binary bit is read by the inverter as if the respective
terminal were activated at the terminal strip. The breakdown is as follows:
47
Parameter Units Level
7A-CIN - Control Board Terminal Status L3
7B-CIN2 - Option Board Terminal Status
The binary word represented by this integer value can be used to determine the status of the input terminal
function. Parameter 7A-CIN relates to the control board inputs, parameter 7B relates to the option board
inputs. The functions detected by this parameter are represented as active bits according to the following:
48
Parameter Units Level
94-SIOF - SIO Fault Byte L3
The integer value stored at this location may be decoded to a binary word to detect faults associated with
SIO communication. When various bits become active, they represent various faults that are SIO
communication related. The significant bits and their indication are as follows:
49
SECTION 6
APPLICATIONS
The following sections show various typical wiring connections of external controls to the WFCHT Series Inverter.
Section 6.1 contains wiring diagrams for various speed control, torque control, start/stop and direction control, as
well as options available from the inverter’s terminal strip. Refer to Section 2.7 Function and Use of Terminals.
WARNING
TWIST WIRES TOGETHER BEFORE INSERTING IN TERMINAL.
ADVERTISSIMENT
ENROULEZ LE FILS ENSEMBLE AVANT DE LES INTRODUIRE DANS LA BORNE.
PRESET SPEED
SELECTIONS
MET COMCIN COMVIN REF LIM COMFWD REV +24 R/J PS1 PS2 PS3 ART +24 MOLCTS RST ST1 ST2 ST3 6FS COM SIO+ SIO-
AUXILIARY
CW CW
RELAY
OUTPUTS
SPEED TORQUE
CUSTOMER POT LIMIT
DISPLAY POT
METER (NOTE 1) ALTERNATE
(NOTE 4) DIGITAL
RAMP TIME FREQUENCY
SELECTOR METER
4-20 mA FORWARD
PROCESS
SOURCE
(NOTE 2)
REVERSE COAST
TO STOP
SELECTOR SIO
STOP SERIAL
RUN JOG INPUT / OUTPUT
LINK
REMOTE
RESET RS485
PUSHBUTTON
GROUND
GND L1 L2 L3 B+ B- M1 M2 M3
MOTOR
THERMAL
FUSES OVERLOAD
(NOTE 6)
SINGLE OR
THREE PHASE
AC POWER MOTOR
(NOTE 5)
DISCONNECT
WDBxxx
NOTES:
1. THE TOTAL RESISTANCE CONNECTED BETWEEN TERMINALS REF AND COM SHALL
AUXILIARY
NOT BE LESS THAN 1000 OHMS.
DB PACKAGE
2. DO NOT CONNECT A POTENTIOMETER IF INPUTS SUCH AS 4-20 mA OR 0-10 VDC
ARE USED.
3. ALL CONTROL BOARD CONNECTIONS SHOULD USE TWISTED AND SHIELDED WIRE
WITH THE SHIELD CONNECTED TO TERMINAL COM.
4. THE FACTORY SETTING FOR THE CUSTOMER METER IS 10 VDC FULL SCALE,
INDICATING OUTPUT FREQUENCY. THE FULL SCALE OUTPUT MAY BE ADJUSTED
USING PARAMETER 70-MCAL. SEE SECTION 4.11
FOR FURTHER INFORMATION.
5. THE USE OF SINGLE OR THREE PHASE POWER IS MODEL DEPENDENT. SEE
SECTION 1.5 FOR FURTHER INFORMATION.
6. EXTERNAL OVERLOADS ARE OPTIONAL WHEN USING SINGLE MOTORS (SEE PARAMETER 67).
50
The following diagram shows a two wire starting control along with the implementation of preset speeds and
open collector outputs. In addition, it shows the connection of various customer supplied speed command
signals.
PRESET SPEED
SELECTIONS
MET COM CIN COM VIN REF LIM COM FWD REV +24 R/J PS1 PS2 PS3 ART +24 MOL CTS RST ST1 ST2 ST3 6FS COM SIO+ SIO-
AUXILIARY
RELAY
OUTPUTS
CR4
MASTER CR1
CONTROL
RELAY CR5
CR2
(SEE NOTE 3)
CR6
CR3
(NOTE 5)
GROUND
GND L1 L2 L3 B+ B- M1 M2 M3
MOTOR
THERMAL
FUSES OVERLOAD
MOTOR
DISCONNECT
WDBxxx
AUXILIARY
DB PACKAGE
51
6.2 WFCHT Series Options
WPC Plug-In Option Boards
WPC Plug-In Option Boards are specifically designed to work with WFCHT Series AC Inverters. They install
inside any WFC model inverter above the control board in the J7 option connector.
WPC01 – Isolated Output Board
The WPC01 Isolated Output Board has two functions. One section is used to convert the three open collector
transistor outputs (ST1, ST2 & ST3) to Form C contacts rated 115 VAC @ 1 Amp for customer use. Each relay
can be individually programmed to indicate one of eleven (11) inverter states. The other section provides two
isolated, 4-20 mA output signals for customer use. One output varies proportionally to output load, and the
other is programmable to follow either frequency, volts, current, load or torque.
WPC02 – 115 Volt Input Interface Board
This option card is used to allow the inverter to be controlled by 115 VAC signals instead of the normal +24
VDC logic. It provides isolated control of FWD, REV, R/J, PS1, PS2, PS3, ART, MOL, CTS and RST.
Additionally, two relays are provided with one Form C contact each rated 115 VAC @ 1 Amp. These are
controlled by the settings of ST1 and ST3. A Triac output is also supplied which is controlled by the setting of
ST2.
WPC03 – Relay/Line Transfer Board
This option board provides three relays to convert the three open collector transistor outputs (ST1, ST2, &
ST3) to Form C contacts rated at 115 VAC @ 1 Amp for customer use. It also allows for synchronous transfer
of a motor from inverter power to AC line power and back when used with external contractors (not supplied).
WPC04 – Encoder Interface Board
The WPC04 option allows the user to interface the WFCHT or WFC Series Inverter to a shaft mounted encoder
or magnetic pickup. It permits such advanced control functions as: Closed loop speed control, Master/Follower
operation, and Event counting.
WPC05 – Process Control Board
The WPC05 board adds two additional functions to the WFCHT or WFC Series Inverters: a bi-polar speed
reference input with trim and an interface with process signals for speed regulation. The bi-polar speed
reference allows a ± 10 VDC signal or potentiometer to be used to control both the speed and direction of the
motor. The process control function permits set-point with proportional and integral gain adjustment, of pumps,
fans, winders, etc., using standard analog feedback signals.
WPC06 – Logic Interface Board
This option board has similar features and functions as WPC02 – 115 VOLT Input Interface Board but is
scaled for use with 24 volts AC or DC control signals. It also permits the WFC HT to be controlled by open
collector “pull-down” transistor circuits if required. The Triac output used on the WPC02 is not provided.
WKM01 – Keypad Mounting Kit
The WKM01 option is intended for use when the standard WFCHT is mounted inside another enclosure and it is
desired to have the standard keypad remotely mounted on that enclosure. It allows the keypad to be remotely
mounted from the control. The kit includes a mounting bezel, instructions, a 10 foot cable for installation, and a
terminal “fan-out” strip. When used with WBP01 (see below), the keypad can be mounted more than 100 feet
from the control. If property installed, the keypad will retain its NEMA 4 rating.
WKM02 – Keypad Remote Control Kit
The WKM02 option is intended for use when it is desired to have the standard keypad remotely mounted from
the NEMA 4 WFCHT unit. It allows the keypad to be mounted in its own enclosure up to 100 feet from the
control. The kit includes the mounting enclosure (5.35" x 6.78" x 2.5" HxWxD), keypad connector fan-out
board, WBP01 Keypad Blank Plate Option and instructions for installation. When properly installed, the keypad
and unit will retain their NEMA 4 ratings.
WBP01 – Keypad Blank Plate Option
This option is used to replace the digital keypad in NEMA 4 models when the keypad has been remotely
mounted. When properly installed, the WFCHT will retain its NEMA 4 rating.
WDB211/WDB411 – External Dynamic Brake Assembly
The WDBxxx assemblies are designed to increase the capacity of the WFCHT to absorb the regenerated
energy from a motor during rapid deceleration or overhauling loads. The WDB211 is designed to connect to
any 230 Volt WFCHT Inverter and provide 10 horsepower of braking capacity at a 10% duty cycle. Similarly, the
WDB411 is intended for use on 460 volt models. For capacities greater than 10 horsepower, units can be
connected in parallel.
52
WCK-01/02/03/04 – Chassis Mounting Kits
This option allows the WFCHT Series Inverter to be mounted with the heat sink fins protruding through the back
of another enclosure. This mounting scheme allows the cabinet size to be minimized since most of the energy
dissipated by the inverter will be channeled through the fins to the outside of the cabinet. Gasketing is supplied
to allow the package to maintain its environmental integrity. The WCK01 Chassis Mounting Kit fits all models
through 5 HP; the WCK02 fits 460 VAC models from 7.5 through 20 HP and 230 VAC models 7-1/2 and 10
HP. WCK03 is used for the 20 HP 230 VAC and 25-30 HP 460 VAC models. WCK04 is used for the 25 HP
230 VAC and 40-75 HP 460 VAC models.
SIOC01 – Serial Interface Converter
This is a stand-alone converter module which will translate the RS232 communications protocol used in many
personal computers to the industrial RS485 protocol used in the WFCHT Series Inverter.
WARNING
DISCONNECT POWER BEFORE SERVICING THIS CONTROL.
HAZARDOUS VOLTAGES EXIST UNTIL CHARGE LIGHT GOES OUT.
AVERTISSEMENT
COUPER L’ALIMENTATION AVANT D’ENRERENORE LE DEPANNAGE DU SYSTEME ELECTRIQUE.
VOLTAGE DANGEUREUX EXISTE TANT QUE LA LUMIERE INDICATRICE RESTE ALLUMÉ.
TABLE 7.1
NOTES:
1. Faults F01-F08 are checked during the power-up sequence.
• F02 is also checked during the programming.
• F04 is also checked in the run and stop modes.
2. Faults F11-F20 will be reset and the inverter restarted if the Auto-Restart function is selected.
54
7.2 Troubleshooting
FAULT
NUMBER CAUSE REMEDY
F01 Noise on Power Line 1. Reset the drive using the stop key or remote reset.
2. Remove power, wait for the BUS CHG indicator to extinguish
and re-establish power.
3. If the problem persists, install a line noise filter.
F02 Excessive Ambient Electrical 1. Verify the proper use of shielded wire for remote signal
Noise or an Invalid 59-MVOLT connections.
Setting 2. Remove power, wait for the BUS CHG indicator to extinguish
and re-establish power.
3. Verify the setting of 59-MVOLT and reset to a valid number.
F03 Excessive DC Bus Current 1. Verify the proper sizing of the inverter for the driven load.
2. Determine the reason for the overload.
F04 Logic Power Supply Overload 1. Check for/reduce excessive load on the +24 VDC supply.
2. Remove power 10-15 min.; then reapply.
F05 No DC Bus Voltage 1. Check for proper source voltage.
2. Check for DB component or output transistor failure.
3. Check for shorted DC bus.
4. Remove power 10-15 min.; then reapply.
F06 Output Short Circuit or Ground 1. Check motor wiring. 4. Increase 53-FKNEE value.
Fault 2. Extend the acceleration time. 5. Isolate line and load wires.
3. Reduce 52-BOOST value. 6. Consult factory.
F07 External Fault Mechanism (i.e. 1. Check connections on MOL terminal.
Motor Overload Relay [MOL] 2. Verify the sizing of MOL.
Tripped) 3. Check motor temperature.
F08 Option Board Fault 1. Verify the proper connection and usage of applicable option
board.
F10 Auto-Restart (68-NRST) 1. Check the fault log (07-FLT3, 08-FLT2, and 09-FLT1).
Number Exceeded 2. Institute corrective action for those faults.
F11 Ground Fault 1. Check motor wiring.
2. Extend the acceleration time.
3. Check for and remove any capacitive load.
4. Reduce 52-BOOST value.
5. Increase 53-FKNEE.
6. Isolate line and load wires.
7. Check for output contactor. (See Section 6.3.)
F12 External Interference 1. Verify line voltage.
2. Look for electrical noise sources in proximity to the drive. (See
Section 2.6.)
3. Install line reactor or isolation transformer.
4. Consult factory.
F13 Overvoltage on DC Bus 1. Motor is decelerating too quickly.
2. Check input line voltage.
3. Increase deceleration time or add optional external DB
package.
F14 Undervoltage on DC Bus 1. Verify applied line voltage.
2. Check for possible DB failure.
F15 DB Overload 1. Reduce the braking duty cycle.
2. Verify line voltage.
3. Install optional external DB package.
F16 Acceleration Overcurrent 1. Increase acceleration ramp time.
2. Check motor wiring for short circuit.
F17 Deceleration Overcurrent 1. Increase deceleration ramp time.
2. Install optional external DB package.
55
7.2 Troubleshooting (continued)
FAULT
NUMBER CAUSE REMEDY
F18 Running Overcurrent 1. Locate the cause of a mechanical overload on the motor.
F19 Heat Sink Overtemperature 1. Check for excessive load on the motor.
2. Verify the proper sizing of the WFCHT for the application.
3. Locate the WFCHT in a cooler location, out of direct sunlight.
F20 Timed Overload 1. Check for WFCHT sizing for the application.
2. Reduce the loading on the motor.
3. Check for DB component or output transistor failure.
4. Check for shorted DC bus.
5. Check setting of 67-TOL.
56
7.4 Replacement Parts
The tables on the following pages reflect those replacement parts compatible with WFCHT Series AC Inverters.
57
WFCHT4000 Series Replacement Parts
Description Part Number 4001-0 4002-0 4003-0 4005-0 4007-5 4010-0 4015-0 4020-0 4025-0 4030-0 4040-0 4050-0 4060-0 4075-0
Control Board PC505 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Keypad PC233 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Power Card PC398 1
PC399 1
PC400 1
PC401 1
PC402 1
PC403 1
PC404 1
PC406 1
PC407 1
PC408 1
PC409 1
PC410 1
PC412 1
PC413 1
Aux. Power Card PC415 1 1 1 1 1 1
Snubber Card PC464 1 1 1 1
PC261 1 1
Fan Kit FANKIT5HP 1 1
INTFANKIT20HP 1 1 1 1
EXTFANKIT20HP 2 2 2 2
INTFANKIT50HP 1 1 1 1 1 1
EXTFANKIT50HP 3 3 3 3
EXTFANKIT75HP 1 1
DB Kit DB4005 1 1 1 1
DB4020 1 1 1 1
Cover Kit COVERKIT5HP 1 1 1 1
COVERKIT20HP 1 1 1 1
MOV Board PC166 1 1 1 1
PC188 1 1 1 1
Cur. Sense Asmbly. U6200R 1 1 1 1
U6199R 1 1
Capacitor Board PC156 1 1
PC157 1 1
PC158 1
PC164 1
Output Module U8591CR 3 3
U8577CR 3
U8583CR 3 3
U8584CR 3
U8585CR 3
U8589CR 3 3
U8593CR 3
Relay U6513R 1 1
U6519R 1 1
U6516R 1 1 1 1
U6528R 1 1
Rectifier Module E56204R 1 1 1
E56207R 1
E56210R 3
E56211R 3 3
E56212R 3 3 3
Voltage Share Bd. PC219 1 1 1 1 1 1
Power Intfc. Bd. PC436 1
PC437 1
PC438 1
PC439 1
Power Supply Mod. PSMOD04 1 1 1 1
PSMOD05 1 1
PSMOD06 1 1 1 1 1 1 1 1
PSMOD08 1 1 1 1 1 1
ES Board PC260 1 1
58
SECTION 8
APPENDIX A
59
APPENDIX B
SECTION 1
INTRODUCTION
This Appendix documents the specifications for TB Wood’s WLF Series line filters. The Appendix also
contains installation and usage information relative to these products.
Proper installation of these filters with the correct model of E-trAC® WFCHT Series inverter or XFC Series
micro-inverter will aid in complying with CE (Conformite Europeen) EMC directives. These filters will limit
emissions, per EMC Directive 89/336 EEC, to meet the following specifications:
To assure compliance with the EMC directive, the following procedures must be observed:
• Installation of a line filter with properly matched WFCHT inverter.
• To meet the B Emission Curve for EMC (Commercial) Compliance, an output reactor may also be
required. No output filter or reactor is required to meet the A Emission Curve for EMC (Industrial)
Compliance (reduces leakage current to a level below 3.5 mA).
• Installing shielded motor cable and correctly grounding the shield.
• Observe general RFI suppression measures (refer to Section 5 – Interference suppression
measures/EMC [Electromagnetic Compatibility] ).
Note that the WLF series of line filters does not bear the CE mark. Although the filters have been tested with
the inverters for compliance, installation practices and other wiring concerns make CE compliance with EMC
directives the responsibility of the installer of the equipment.
In addition, motor output wiring considerations required to meet the CE directives are also presented.
Similarly, the WLF series of line filters is not UL listed or recognized. If local codes permit, the filters may be
used in the United States as a solution for EMI and RFI problems either caused by or effecting the operation
of an E-trAC® series inverter.
60
SECTION 2
SPECIFICATIONS
TB Wood’s WLF line filters are provided in both IP20 and IP54 type enclosures. They can operate over a
temperature range of -10 to +50°C (-23 to +122°F). The mounting options for the filters can be parallel or
perpendicular to the control panel. For some filter / inverter combinations, it is possible to mount the
inverter on top of the filter enclosure. Details of the WFC inverter line compatibility can be found in the
table below:
61
SECTION 3
INSTALLATION
Upon receipt of the filter, unpack it and carefully inspect for any damage sustained in transit. If damage is
apparent, the freight or express agent should be notified within 15 days of receipt of the product and a
request be made that he make inspection of the
merchandise; then a claim should be filed against the
carrier. For UPS shipment damage, save the box and
packing material and contact TB Wood’s Incorporated
immediately.
TB Wood’s WLF Series line filters are designed to
mount directly to a flat surface such as an enclosure
panel. Metal hardware should be used to assure that
the case of the filter is at earth ground potential. The
filters can be mounted parallel to the panel or
perpendicular to the panel.
The filter should be installed as close as possible to
the inverter. When mounting the filters parallel to the
panel, the inverter can be mounted to the top of the
filter module with the hardware provided (see figure Figure 1
1).
Dimensions
(IP20 versions
to 20HP)
Figure 2
62
IP20 versions - 25 to 75HP
Figure 3
63
IP54 versions - up to 20HP
Figure 4
64
SECTION 4
CONNECTIONS
Wire Sizing Requirements
Model Line Conductor Ground Conductor Ground Conductor
Single Conductor 2 Parallel Conductors
WLF40050H 14 AWG, 600 V 6 AWG, 600 V 14 AWG, 600 V
WLF40050D
WLF40200H 6 AWG, 600 V 6 AWG, 600 V N/A
WLF40200D
WLF40300H 6 AWG, 600 V 6 AWG, 600 V N/A
(90°C wire) (90°C wire)
WLF40400H 2 AWG, 600 V 2 AWG, 600 V N/A
WLF40500H 1/0 AWG, 600 V 1/0 AWG, 600 V N/A
WLF40600H 2/0 AWG, 600 V 2/0 AWG, 600 V N/A
WLF40750H 3/0 AWG, 600 V 3/0 AWG, 600 V N/A
Additional requirements may be necessary, dependent on CEC, CE, VDE, or local codes.
Figure 5 shows the connections required for compliance to the CE EMC directive. Due to the leakage current
associated with these filters (>3.5 mA), one of the following measures must be taken to be in compliance with
specification EN 50178:
• The filter must be connected by a cable which is electrically parallel with the earth ground conductor.
This conductor must meet the requirements of IEC 364-5-543 on its own.
• The ground conductor must have a cross section of at least 10 mm2 (#6 AWG), or two parallel ground
conductors must be used of the same size as the line conductors.
• The ground conductor must be monitored by a fault detection device that isolates the inverter from
the power source in the event of a fault.
The inverter must always be connected permanently (EN 50178) when using a WLF Series line filter,
due to the leakage currents involved.
Figure 5
65
SECTION 5
INTERFERENCE SUPPRESSION MEASURES (ELECTROMAGNETIC COMPATIBILITY)
Electrical/electronic devices are capable of influencing or disturbing each other through connecting cables or
other metallic connections. “Electromagnetic Compatibility” consists of two parts, “interference resistance”
and “interference emission.” Correct installation of the inverter in conjunction with any possible local
interference suppression measures has a crucial effect on minimizing or suppressing mutual
interference.
The following notes refer to a power source that is not “contaminated” by high frequency interference. Other
measures may be necessary to reduce or suppress interference if the power source is “contaminated.” No
general valid recommendations can be given in such cases. Please consult TB Wood’s Electronics Applica-
tion Engineering if all recommended interference suppression measures should not produce the desired
result.
When dealing with RFI (radio frequency interference), the surface area of the conductors is a more critical
parameter than the cross-sectional area. Since high frequency interference does not flow through the entire
cross section of the conductor, but tends to stay toward its outer surface (skin effect), braided copper tapes of
equal cross section should be used.
The inverter and all components used for interference suppression, particularly the shield of the motor cable,
should be connected over as large a surface area as possible when passing over metallic surfaces. Remove
the paint from contact surfaces to assure a good electrical connection. See Figure 6 for recom-
mended connection technique.
Paint/varnish removed
Shielded motor cable
Large contact area with shield
Figure 6
A central grounding point should be used for interference suppression. The ground cables are routed
radially from this point. Loops in these lines are undesirable, and may lead to interference.
The shield cross section must not be damaged when the shield is connected to the continuing lines. This
would raise the RF resistance of the shield and as such, radiate rather than discharge the RF energy
traveling on the shield. Shields, particularly those on control cables, must not be routed through pin contacts
(plug connectors). When shielded cables must pass through a plug connection, the metallic hand guard of
the plug is used for the continuation of the shield. It is strongly recommended that the shield be
uninterrupted whenever possible.
Use a shielded motor cable which is grounded over a large surface area at both ends. The shield on this
cable should be uninterrupted. If a shielded motor cable can not be used, the unshielded motor line should
be laid in a metal conduit or duct which is uninterrupted and grounded at both ends.
When selecting shielded cable for use as motor leads, it is important to select a cable which is designed for
operation at the frequencies and power levels involved. Improper selection of motor cable can cause high
potential to exist on the shield. This could cause damage to the inverter or other equipment, as well as being
a potential safety hazard. Cables such as OLFlex1 Series 150CY, 110CY, 110CS, 100CY, 100CS, and
540CP will work for this purpose. Siemens2 Cordaflex (SM) also are acceptable. Some of these cables are
VDE approved only; others carry VDE, UL, CSA, and combinations of these ratings. Be sure to confirm that
the cable you are using meets the certification of the agency required.
If the installation requires the use of an output reactor, the reactor, like the line filter, should be placed as
close as possible to the inverter.
Control wires longer than 3 feet must be run in shielded cable, and the shield must be terminated at common
(COM) in the inverter. (Note that connection to COM, the circuit common, rather than earth ground, is
allowed because E-trAC® inverters have isolated control inputs. If the inputs were not electrically isolated, the
shield would have to be connected to earth ground). If the signal run exceeds 30 feet, a 0-20 mA or 4-20 mA
signal should be used, as it will have better noise immunity than a low level voltage.
1. OLFlex Wire & Cable, 30 Plymouth Street, Fairfield, NJ 07004 (800) 774-3539
2. Siemens Energy and Automation, Inc., Power Cables, 3333 State Bridge Road, Atlanta, GA 30202 (800) 777-3539
66
Other loads connected to the power source may produce voltage transients (spikes) that may interfere with or
damage the inverter. Line reactors or filters can be used on the input power to protect the inverter from such
transients.
If the inverter is operated from switchgear devices or is in close proximity to switchgear devices (in a common
cabinet), the following procedures are recommended as a precaution to prevent these devices from
interfering with the inverter’s operation:
• Wire the coils of DC devices with freewheeling diodes. The diodes should be placed as close as
possible to the physical coil of the device.
• Wire the coils of AC devices with RC type snubber networks. Place the snubbers as close as
possible to the physical coil of the device.
• Use shielded cables on all control and monitoring signals.
Route distribution cables (e.g., power and contactor circuits) separately and as far away from control and
monitoring signal cables as possible.
67
®
APPENDIX C
WFC4075-0
The products referenced above are for use of control of the speed of AC motors.
For Application information, consult the following document from TB Wood’s Incorporated -- Form
1226.
Via internal mechanisms and Quality Control, it is verified that these products conform to the
requirements of the Directive and applicable standards
Rick Kirkpatrick
Director of Marketing
Electronics Division
68
69
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