General Information – AF-300 Micro-$aver II ™ Drive Instructions
These instructions do not purport to cover all details or variations in equipment, nor to provide for
every possible contingency to be met during installation, operation, and maintenance. Should
further information be desired or should particular problems arise that are not covered sufficiently for
the purchaser's purpose, the matter should be referred to GE Fuji Electric, Customer Service.
This document contains proprietary information of GE Fuji Electric and is furnished to its customers
solely to assist that customer in the installation, testing, and/or maintenance of the equipment
described. This document shall not be reproduced in whole or in part nor shall its contents be
disclosed to any third party without the written approval of GE Fuji Electric.
NOTE: The terms "inverter", "controller", and "drive" are sometimes used interchangeably throughout the industry. We will use the term "Drive" in this document.
AF-300 Micro-Saver II™ and X$D™ are trademarks of General Electric Company. Energy Saver®
is a registered trademark of General Electric Company.
The terms "AF-300 Micro-Saver II" and AF-300M$II will be used interchangeably throughout this
document.
WARNING: Always read the complete instructions
prior to applying power or troubleshooting the equipment
and follow all procedures step by step.
SHOCK HAZARD
voltage may be present. (Refer to Section 1: Safety Precautions for Warnings and Cautions.)
Blank space has been intentionally left at the bottom of each page for the convenience of the user
in documenting notes.
labels may be located on or inside the Drive to alert people that dangerous
AF-300M$II Spare Parts List ...........................................................................9-3
10.CE MARK .............................................................................................. 10-1
iii
Section 1
SAFETY PRECAUTIONS
DANGER, WARNING, CAUTION AND NOTES
The following format is used on the equipment or found
in this manual. Read all labels and follow the directions
whenever working on the equipment.
WARNS ABOUT HAZARDS THAT
WILL RESULT IN IMMEDIATE SERIOUS PERSONAL
INJURY OR DEATH IF IGNORED.
Denotes operating procedures and
practices that may result in personal injury or loss of
life if not correctly followed.
Denotes operating procedures and
practices that, if not strictly observed, may result in
damage to, or destruction of the equipment.
NOTE: Notes call attention to information that is
especially significant in understanding and operating
the equipment.
DANGER, WARNING, CAUTION
AND NOTE P ARAGRAPHS WITHIN
THIS INSTRUCTION MANUAL
The above paragraphs list some general safety
reminders and safety recommendations to be followed
when operating or installing this equipment. These
safety precautions will be repeated throughout this
instruction book where applicable.
Due to CSA requirements, pertinent warnings are also provided in French and set off by ( )
1-1
WARNINGS
MECHANICAL MOTION
HAZARD: Drive systems cause mechanical
motion. It is the responsibility of the user to
insure that any such motion does not result in
an unsafe condition. Customer provided
interlocks, and operating limits should not be
bypassed or modified.
ELECTRICAL SHOCK
AND BURN HAZARD: When using
instruments such as oscilloscopes to work on
live equipment, the oscilloscope’s chassis
should be grounded and a differential amplifier
input should be used. Care should be used in
the selection of probes and leads and in the
adjustment of the oscilloscope so that accurate
readings may be made. See instrument
manufacturer’s instruction book for proper
operation and adjustments to the instrument.
FIRE AND EXPLOSION
HAZARD: Fires or explosions might result
from mounting Drives in hazardous areas such
as locations where flammable or combustible
vapors or dusts are present. Drives should be
installed away from hazardous areas, even if
used with motors suitable for use in these
locations.
STRAIN HAZARD:
Improper lifting practices can cause serious or
fatal injury. Lift only with adequate equipment
and trained personnel.
ELECTRICAL SHOCK
HAZARD: All motor bases and equipment
enclosure housings should be grounded in
accordance with the National Electric Code or
equivalent.
(AVERTISSEMENT)
HAZARD OF ELECTRICAL SHOCK
(RIS QUE DE CHOC ELECTRIQUE)
- Separate motor overcurrent, overload, and
overheating protection is required to be
provided in accordance with the Canadian
Electrical Code, Part 1.
- (Le moteur dolt etre muni d'une protection
distincte contre les surintensites, la
surcharge et la surchauffe confrmement au
Code Canadian de L'electricite, premierb
partie.)
The Drive leakage current to
ground is higher than 3mA. Use grounding
conductor as specified in Table 250-95 of
National Electric Code, ANSI/NFPA 70-1993 or
Table 31 CSA22.2, No. 14-M91.
HAZARD OF MOTOR
OVERSPEED:
ANY APPLICATIONS REQUIRING OPERATION
ABOVE 120 HZ MUST BE APPROVED BY THE
MOTOR MANUFACTURER.
Bias frequency setting is available when analog
frequency setting method (i.e. the Function
code "01" data is set at 1) is selected. At the
stop condition, the reference frequency will be
blinking on the LED display. If the Bias
frequency is set at a certain level and the
reference frequency is Zero, during the stop
condition, the display will be blinking Zero.
Thus, when a RUN command is given to the
Drive, the motor will run at the Bias frequency
setting (up to 400 Hz) even if the reference
frequency is Zero.
With 400 Hz Drive output possible, the Drive will
allow the motor to run up to 6 - 7 times its base
speed. Never operate the motor above its top
mechanical speed or a catastrophic failure may
occur.
Before disassembling,
disconnect and lock out power from the Drive.
Failure to disconnect power may result in death
or serious injury. A bus charge Light "CRG"
provides visual indication that bus voltage is
present; verify the bus voltage level by
measuring the voltage between power terminals
P(+) and N(-) using an analog meter. Do not
attempt to service the Drive until the charge
indicator ("CRG" lamp) has extinguished and
the bus voltage has discharged to zero volts.
Replace all covers before
applying power to the Drive. Failure to do so
may result in death or serious injury.
1-2
CAUTIONS
This product is suitable for use
on a circuit capable of delivering not more than
1,000 (1HP or less) or 5,000 (2 HP or more) rms
symmetrical amperes.
AC input fuses to be customer supplied and may
be branch circuit protection fused. The maximum
allowance fuse ratings per TABLE 4.
Do not connect power supply
voltage that exceeds the standard specified
voltage permissible. If excessive voltage is
applied to the Drive, damage to the internal
components will result.
Do not connect power supply to
the output terminals (U, V, W). Connect power
supply only to the power terminals (L1, L2, L3).
Do not connect power supply to
the breaking resistor connection terminals (P (+),
DB). Never short-circuit between P (+) – DB
terminals, and do not connect any resistance with
an ohm and/or wattage value less than standard
application breaking resistor.
Do not connect a power supply
to the control circuit terminals (except 30A, B, C,
maximum rating 250 volts, 0.3A ac/dc).
For RUN and STOP, use the
FWD-CM (forward) and REV-CM (reverse)
terminals. Do not use a contactor (ON/OFF)
installed on the line side of the Drive for RUN and
STOP.
Do not use a switch on the
output side of the Drive for ON/OFF operation.
Do not connect power factor
correcting capacitors on the output side of the
Drive.
Do not operate the Drive
without the ground wire connected. The motor
chassis should be grounded to earth through a
ground lead separate from all other equipment
ground leads to prevent noise coupling. The
grounding connector shall be sized in accordance
with the NEC or Canadian Electrical Code. The
connection shall be made by a UL listed or CSA
certified closed-loop terminal connector sized for
the wire gauge involved. The connector is to be
fixed using the crimp tool specified by the
connector manufacturer.
Do not perform a megger test
between the Drive terminals or on the control
circuit terminals.
The Drives are an IGBT drive
which develops an adjustable frequency via pulse
width modulation. While this does not present a
problem on 200-240 VAC applications, it may on
380-480 VAC applications. When using the
Drives on 380-480 VAC, get the motor
manufacturer's approval that his insulation system
can withstand the voltage spikes (up to twice the
dc bus voltage 2 x 621 VDC for a 480 VAC power
source of the Drive, in conjunction with the long
motor cable lengths). If the insulation system
does not meet this limit, utilize a RLC filter.
Because the ambient
temperature greatly affects Drive life and
reliability, do not install the Drive in any location
that exceeds the allowable temperature. Leave
the ventilation covers attached for temperatures
of 40 degrees C or below, and remove the
ventilation port side and top covers for
temperatures of between 40 (104° F) and 50
(122° F) degrees C. If the covers need to be
removed, another type of enclosure may be
required for safety purposes.
If the Drive’s Fault Alarm is
activated, consult the TROUBLESHOOTING
section of this instruction book, and after
correcting the problem, resume operation. Do
not reset the alarm automatically by external
sequence, etc.
Be sure to remove the desic-
cant packet(s) when unpacking the Drive. (If not
removed these packets may become lodged in
the fan or air passages and cause the Drive to
overheat.)
1-3
CAUTIONS (continued)
AC induction motors require
that they be sized based on the applications speed
range and associated torque requirements for the
motor-Drive system; this is to avoid excessive
motor heating. Observe motor manufacturer's
recommendations when operating any ac induction
motor with the Drive. Also observe motor
manufacturer's recommended voltage/torque boost
at lower operating frequencies.
The available power source con-
nected to the Drive is not to exceed 500KVA. If the
ac power source is greater than 500KVA and the
Drive's rated (HP) is less than 10% of the power
source's KVA; ac line reactors will have to be installed
in L1, L2 & L3 power leads of the Drive.
NOTES
NOTE:
① When terminal operation mode (Function code
F_02 setting is 1) - RUN and STOP are being
controlled by a maintained contact (e.g., selector
switch, toggle switch, etc.) which is connected
between the terminal CM and FWD or REV:
• Closing/opening the maintained contact starts/
stops the Drive.
The Drive must be mounted on
a building or enclosure wall that is constructed of
heat resistant material. While the Drive is operating, the temperature of the Drive's cooling fins can
rise to a temperature of 90°C (194°F.)
If the Drive protective function
is activated, consult Section 8 "Troubleshooting",
and after correcting the problem, resume operation. Do not reset the alarm automatically by
external sequence, etc.
Be sure to provide fuses, as
specified on "Application of Wiring And Equipment"
in Section 4, on line terminals of Drive. Provide
power line disconnect or contactor as needed.
➂ Total wiring between the Drive and the motor must
not exceed the length shown below.
Function200V Series400V Series
F_12 data
F_12 = 0, 1, 2 or 3538 ft. 754 ft.
F_12 = 4 – 15
Hp
1/4 1/21235 1/21 2 3 5
1076 ft.
213 ft.
1076 ft.
➁ Function code F_02 setting can be changed only
when connection between the terminals CM and
FWD or REV is open. (i.e. STOP MODE).
Drive ships with shorting bar between
terminals FWD-CM.
UL/CSA Drive Caution Label
Use 60/70°C copper wire only. Use Class 1 wire only.
Suitable for use on a circuit capable of delivering not more than 1,000
(1HP or less) or 5,000 (2 HP or more) rms symmetrical amperes.
WARNING: HAZARD OF ELECTRICAL SHOCK. DISCONNECT INCOMING
POWER BEFORE WORKING ON THIS CONTROL.
ADVERTISSEMENT: RISQUE DE CHOC ELECTRIQUE COUPER
L'ALIMENTATION AVANT LE DEPANNAGE DE CETTE COMMANDE.
CAUTION: DANGEROUS VOLTAGE EXIST UNTIL CHARGE "CRG" LIGHT IS OFF.
ATTENTION: PRESENCE DE TENSIONS DANGEREUSES TANT QUE LE
VOYANT N'EST PAS ETEINT.
WARNING: MORE THAN ONE LIVE CIRCUIT. SEE DIAGRAM.*
AVERTISSEMENT: CET EQUIPEMENT RENFERME PLUSIEURS CIRCUITS
SOUS TENSION. VOIR LE SCHEMA. SA523154-01
*See diagram on page 4-6.
➃ Error in current detection may increase when;
a) A specially designed motor is used.
b) A Drive's capacity is 2 Hp ratings or greater than
the motor capacity.
1-4
Section 2
DESCRIPTION, COMPONENT
IDENTIFICATION, and SPECIFICATION
The Drive is available in ratings of 1/4 to 3 HP 200-240 VAC single phase input, 1/4 to 5 HP 200-230 VAC three phase,
and 1/2 to 5 HP 380-480 VAC three phase. The Drive incorporates advanced Pulse Width Modulated (PWM)
"TORQUE VECTOR" control for high starting torque. The Drives are housed in either a NEMA 1 or NEMA 4 type
enclosure and all Drives are furnished with a detachable cover to allow ease of accessing control and power wiring.
Drive operation and Function Code setting is performed from the “Keypad Panel” that features a Digital Display and
6 dual function keys. The 6 function keys are used for Drive programming and operation.
General data and specifications for each Drive are listed on the nameplate attached to the Drive.
Refer to TABLE 1, for complete Drive specification listing.
INSPECTION PROCEDURES UPON DELIVERY
Upon receipt of your Drive, inspect the equipment for the following items:
1. Check the nameplate to insure that the specifications correspond to those
ordered, and to application requirements.
2. Inspect the unit for any damage that may have occurred during shipment.
– If shipping damage is found or the wrong Drive is received, contact the
Distributor from which the equipment was purchased.
™
AF-300M$
MODEL NO.
SERIAL NO.
INPUT:OUTPUT:
VOLTSVOLTS
*IN CASE OF "L.V. DIRECTIVE 73/23/EEC"FREQ RANGE (HZ)
AMPSHP
FREQ (HZ)AMPS CONT.
PHASE (S)PHASE
ROTATION
MAX 60 SEC. AMPS
INSTRUCTION BOOK GEI-100272MADE IN JAPAN
All models are UL Listed and CSA Approved. CE MARK applies to the 240 VAC single-phase and 480 VAC 3-phase
Figure 2-1. NAMEPLATE DATA IDENTIFICATION
7898
IND. CONT. EQ.
II
69489
2-1
(1) Keypad Part Names and Functions
Operation Mode Indicator
Program Mode
Program/Reset Key
Function Key (Data Key)
Digital Display (4 digits) -
Displays the various Function
Codes and data values during
setting of the program. During
operation, it displays the output
frequency, current, voltage, etc.
If a fault occurs the cause of the
problem will be displayed as a
code.
PROGRAM Key (Reset Key) -
Normal mode or program setting
mode select key. When any of
the protection functions are
activated; this key is used to reset
the fault.
FUNCTION Key (Data Key) -
During the normal mode, this key
can be used to change the display
unit while operation is either
stopped or running.
During the program mode, this
key can be used to read and write
the Function Codes and the data.
DOWN Key
RUN Key - Key used for starting
operation. The LED (green) lights up
during operation.
This key does not function when
terminal operation control is selected.
F 0 2 = 1
or
F 0 2 = 2
STOP Key - This key is used for
stopping drive operation. When set
as follows:
F 0 2 = 0
operation command input is
accepted from the Keypad (RUN
and STOP keys).
When function 2 is set to 1:
F 0 2 = 1
Operation command input by
means of the external signal
terminal (FWD, REV). STOP key
on the keypad is active. If
selection "1" is chosen, and the
stop button is depressed while the
drive is running, the drive will
perform the normal stop
sequence until the output
frequency reaches zero at which
point an "Er6" fault shall be
indicated on the LED. To reset the
Digital Display
Unit Display
Drive RUN Indicator
RUN Key
UP Key
STOP Key
drive you must remove the RUN
command and press RESET.
When function 2 is set to 2:
F 0 2 = 2
operation command input is
accepted by means of the
external signal terminal (FWD,
REV). STOP key on the keypad
is inactive.
UP / DOWN Keys - These keys
increase or decrease the
frequency reference. When unit is
in program setting mode, they
change the Function Code or data
values.
Unit Display - Unit information is
displayed by the LED (red). All
three LEDs flash to indicate that
the unit is in the program mode.
Operation Mode Indicator -
The LED (green) lights up when
keypad panel operation is
selected.
Drive RUN Indicator -
The LED (green) lights up in the
RUN mode.
2-2
(2) Controlling Method for Keypad Panel
When the power supply is activated, the keypad panel display will be as shown
in the figure on the right (60.00 FLASHING).
RUN
If the key is pressed, the Drive will start and accelerate up to 60 Hz
according to the factory setting. Use the key to stop operation.
STOP
WARNING - RUN and STOP keys function only in Keypad operation mode. (Function Code F_02 setting is 0)
Drive Components
5
1
3
2
6
4
Figure 2-3. TYPICAL DRIVE COMPONENTS
1. Unit Cover (Middle)
2. Unit Cover (Top)
3. Keypad Panel (Optional)
4. Heat Sink and Mounting Tabs
5. Mounting Screw Holes
6. Top Cover Screw
NOTE: NEMA 1 unit does not include keypad. Keypad is sold separately.
Keypad type is 6KM$2KP1 for NEMA 1 unit.
2-3
TABLE 1: Standard Specifications
ITEM
SPECIFICATION
Environmental Conditions
EnclosureNEMA 1or NEMA 4
Installation Location: NEMA 1Suitable for indoor mounting only, less than 1000 meters (3281 feet) elevation,
not in contact with corrosive gas, oil mist, or dust.
NEMA 4
Stored Temperature-20° to +65°C (-4° to +149°F)
Ambient Temperature-10° to +50°C (+14° to +122°
Humidity20% to 95% relative humidity (non-condensing)
Vibration0.6G or less
Cooling Method1/4 to 1 HP – Convection
Suitable for use indoors or outdoors to protect the enclosed equipment against
splashing water, seepage of water, falling or hose directed water and severe
external condensation. Installation should be less than 1000 meters (3281 feet)
elevation, not in contact with corrosive gas, or oil mist.
F) (remove ventilation covers if temperature is
over (+40°C +104° F)
2 HP and greater – Forced air (Integral fan)
Output
Rated Output Voltage3-Phase, 3-Wire, 80-240 VAC or 160-480 VAC
(Can not exceed power supply voltage)
Frequency Range0 - 400 Hertz (0.2 to 15 Hz Start Frequency; 15 to 400 Hz Base Frequency)
Above 120 Hz, contact the motor manufacturer for approval of application
Overload Current Rating150% for 1 minute duration (inverse time characteristic)
200% for 0.5 seconds
Power Supply
Rated Input AC Voltage– 200 to 240 VAC 50/60 Hz, 1 phase (1/4 to 3 HP)
– 200 to 230 VAC 50/60 Hz, 3 phase (1/4 to 5 HP)
– 380 to 480 VAC 50/60 Hz, 3 phase (1/2 to 5 HP)
Voltage: +10% to -15%; Voltage Unbalance: Within 3%; Frequency ±5%
Control SystemSinusoidal PWM "TORQUE VECTOR" Control
Control
Frequency Setting– Analog: 0.02 Hz step at Maximum frequency of 60 Hz
Resolution– Digital Keypad: 0.01 Hz Maximum frequency up to 99.99 Hz; 0.1 Hz (100
Hz or more)
Accuracy (Stability)Analog setting: ± 0.2% of Maximum frequency (59° to 95° F)
Digital Keypad setting: ± 0.01% of Maximum frequency (14° to 122° F)
2-4
ITEM
SPECIFICATION
Control (continued)
Voltage/FrequencyVoltage - 80-240 VAC or 160-480 VAC
Characteristics (V/F)Frequency - 0.2 to 400 Hz
Torque Boost0: Automatic torque boost or 1 to 31.0 code settings (includes selection for
variable torque load)
Acceleration/Deceleration0.01 to 3600 seconds (independent acceleration/deceleration)
CharacteristicsAlternative accel/decel time available as well as linear or 2 S-curves (selectable)
Motor SoundThe pitch of the motor sound can be changed by selecting Carrier frequency
(F_12: 0 to 15)
Frequency Meter AdjustmentScale calibration of externally connected analog meter or pulse
frequency
Data ProtectionData lock is possible to ensure that the function codes are not changed
High/Low Frequency LimiterOutput frequency upper and lower range limit 0 to 400 Hz; 1 Hz step settings
BiasMagnitude of the zero offset can be set from 0 to ±100% of maximum
frequency (1Hz steps)
GainOutput frequency gain corresponding to the reference signal can be
– Surge input– Overcurrent
– Drive overheating– Overvoltage
– External faults– Short circuit for output terminals
– CPU malfunction– Communication error
– Motor overload– Ground fault (at start)
(electronic thermal)– Output wiring not connected
– Memory error (during auto tuning only)
KeypadDigital Display - 4 digit LED
Drive OperationOutput frequency, output current, output voltage, motor speed, line speed
(m/min), machine speed (r/min) can be displayed
Drive SettingFunction Code and Setting Data can be displayed
Data InitializingResets all Function Codes to initial factory settings
Drive Fault– OC1 - Acceleration overcurrent
– OC2 - Deceleration overcurrent
– OC3 - Constant speed overcurrent
– LU (LV) - Undervoltage
– OU1 - Overvoltage during acceleration
– OU2 - Overvoltage during deceleration
– OU3 - Overvoltage at constant speed
– OH1 - Drive overheat
– OH2 - External alarm input
– OLU - Electronic Overload - Semiconductor Overload Protection
– OL - Electronic Overload - 4 Pole Motor Overload Protection
– Er1 - Setting error
– Er2 - Communication error
– Er3 - CPU error
– Er4 - Optional circuit board communication error with Drive
– Er5 - Optional Problem - when a link error etc. is detected
– Er6 - Operating Proc. error
– Er7 - Output wiring error
Charge "CRG" Lamp (LED)Illuminates when DC Link capacitor voltage is present
2-6
Table 2: Drive Dimensions
240 Volt – Single Phase
HPWeightHeightWidthDepthDim. Figure
Model
Const LBSKGSInchesMMInchesMMInchesMM
Pages
NEMA 1NEMA 4
TRQ
3-2 to 3-5
6KM$221F25N1A1 6KM$221F25X4A1 1/42.71.26.221584.291093.15801 and 4
6KM$221F50N1A1 6KM$221F50X4A1 1/23.81.76.221585.671444.291092 and 6
6KM$221001N1A16KM$221001X4A114.01.86.221585.671444.291092 and 6
6KM$221002N1A16KM$221002X4A126.22.86.221588.032045.281343 and 8
6KM$221003N1A16KM$221003X4A136.42.96.221588.032045.281343 and 8
230 Volt – Three Phase
6KM$223F25N1A1 6KM$223F25X4A1 1/42.41.16.221584.291093.15801 and 4
6KM$223F50N1A1 6KM$223F50X4A1 1/22.91.36.221584.291093.54901 and 5
6KM$223001N1A16KM$223001X4A113.31.56.221584.291094.691191 and 7
6KM$223002N1A16KM$223002X4A124.62.16.221585.671444.691192 and 7
36KM$223003N1A1 6KM$223003X4A136.22.86.221588.032045.281343 and 8
36KM$223005N1A1 6KM$223005X4A157.03.36.221588.032045.871493 and 9
480 Volt – Three Phase
6KM$243F50N1A1 6KM$243F50X4A1 1/24.21.96.221585.671444.291092 and 6
6KM$243001N1A16KM$243001X4A114.21.96.221585.671444.291092 and 6
6KM$243002N1A16KM$243002X4A126.22.86.221588.032045.281343 and 8
6KM$243003N1A16KM$243003X4A136.22.86.221588.032045.281343 and 8
6KM$243005N1A16KM$243005X4A1573.36.221588.032045.871493 and 9
Table 3: Drive Rating Efficiency and Watts Loss Table
Install the Drive in an indoor location that meets the
following requirements:
— The ambient temperature is between -10° C and
+50° C (+14° F to +122° F). Remove the ventilation covers when the temperature exceeds +40° C
[+104° F].
— The relative humidity is between 20% and 95%.
Avoid any location subject to condensation, freezing,
or where the Drive would come in contact with water.
— Do not install in any location subject to direct sunlight,
dust, corrosive gas, inflammable gas, or oil mist.
— Vibration should be less than 0.6G.
— The Drive should be installed at an elevation below
1000 meters (3281 feet). For installation above 1000
meters (3300 feet) the Drive will need to be derated
1% per 333 feet.
Example: 5 HP, 460 VAC, output current 9 amps.
Application altitude 3900 feet.
3900 - 3300
% derate = x 1% = 1.8%
(9 amps) x = 8.84 amps
derated output current.
( )
333
100 - 1.8
( )
100
INSTALLATION MOUNTING
CLEARANCE
— Install at a sufficient distance from other equip-
ment, walls, or wiring ducts as shown in Figure
3-1 (these clearances are required to allow the
heat generated by the Drive to escape).
— Install the Drive perpendicular to the ground and
with the lettering right side up. (If the Drive is
installed upside-down or horizontally, heat buildup will occur.)
— Mounting screws or bolts should be of appropriate
size for weight of Drive.
— See the appropriate figures on pages 3-2 and
3-3 for the location of mounting holes.
— After removing the knockouts in the wiring lead-in
plate, install the rubber bushings supplied to prevent cable damage and to minimize dust entry.
CAUTION:The mounting wall for the Drive must be
constructed of heat resistant material because during
operation, the temperature of the Drive's cooling fins
rises to approximately 90 degrees C (194° F).
Motor derate may also be required,
contact motor manufacturer.
CAUTION: Because the ambient temperature greatly
affects Drive life and reliability, do not install the Drive in
any location that exceeds the allowable temperatures.
2"
or more
➛
5" or more
➛
➛
5" or more
➛
NOTE:
proximity, allow sufficient space as shown in Figure 3-1
and install them in a horizontal row. If they must be
installed in a vertical column, at least 19.7 inches (50cm)
internal space must be provided between each one or a
ventilation baffle should be provided to prevent the
ambient temperature from rising.
When installing two or more Drives in close
2"
or more
➛
Figure 3-1. DRIVE MOUNTING CLEARANCE
3-1
NOTE: NEMA 1 unit does not have Keypad.
Shown with optional Keypad
Dimensions
4.29 (109)
4.13 (105)
3.66 (93)
0.24 (6)
5.91 (150)
5.43 (138)
6.22 (158)
0.08 (2)
0.24 (6)
5.67 (144)
5.51 (140)
5.04 (128)
2-ø5 (0.20)
0.08 (2)
0.24 (6)
0.24 (6)
5.43 (138)
0.08 (2)
5.91 (150)
6.22 (158)
Figure 1
0.08 (2)
0.24 (6)
0.20 (5)
0.24 (6)
0.24 (6)
0.20 (2-ø5)
8.03 (204)
7.87 (200)
7.40 (188)
0.08 (2)
0.24 (6)
0.08 (2)
0.24(6)
5.43 (138)
5.91 (150)
6.22 (158)
0.20 (5)
0.24 (6)
0.24 (6)
Figure 2 Figure 3
Note: Inches (MM)
3-2
0.20 (5)
0.24 (6)
0.24 (6)
Dimensions
4.29 (109)
3.15 (80)
0.20 (5)
3.54 (90)
0.20 (5)
Figure 4Figure 5Figure 6
0.24 (6)
5.28 (134)
4.69 (119)
0.24 (6)
0.24 (6)
Figure 7Figure 8Figure 9
Note: Inches (MM)
5.87 (149)
0.24 (6)
3-3
Dimensions of Keypad and Keypad Mounting Holes
Keypad Part #6KM$2KP1 for NEMA 1 unit
6KM$2KP4 for NEMA 4 unit
3-4
Mounting Hole (panel cut-out)
Inches (MM)
Section 4
WIRING PROCEDURES
To access Main and Control Circuit Terminals remove the top
cover as follows (see Figure 4-1):
1. Loosen the screw located at the bottom of the top cover.
2. Press upward on the bottom of the top cover (see arrows
Figure 4-1 step 2) and lift off.
3. See Figure 4-1 for the location of the Main Circuit
Terminal Block and the Control Circuit Terminal Block.
WARNING: Some printed circuit boards and Drive components may contain hazardous voltage levels. If LED
light "CRG" on the Base Driver Board is illuminated,
hazardous voltages are present in the Drive circuit boards.
Remove and lock out power before you disconnect or
reconnect wires, and before you remove or replace fuses
and circuit boards. Do not attempt to service the Drive
until the "CRG" indicator has extinguished and the bus
voltage has discharged to zero volts.
Removing T op Cover
Mounting Screw
Holes
Step 1:
Loosen Top Cover
screw. (1 to 2 turns)
Unit Cover (Middle)
Step 2:
Press Upward at the locations indi-
cated by the arrows to remove the top
cover.
and Mounting Tabs
→
Heat Sink
→
Keypad Panel
Unit Cover (Top)
Top Cover Screw
Main Circuit
Teminal Block
Control
Circuit
Terminal
Block
Drive
Charge "CRG" Lamp
Figure 4-1. REMOVING THE TOP COVER
4-1
Control Circuit Wiring
Drive is wired at shipment for operation and frequency
setting through the keypad panel (frequency is set at 60
Hz.)
– See Figure 4-2, and 4-4 for wiring connections.
– See TABLE 5 for description of all terminals.
Make wire connections as shown in Figure 4-4 through 4-6
for desired mode of external operation through Control
Circuit Terminals.
CAUTION: The Control Circuit Terminal wiring should be
kept as far away as possible from the main power wiring to
prevent operational error due to noise interference. Never
install both types of wiring in the same duct or conduit. (A
separation distance of 4 inches [10 centimeters] or more is
recommended.) If the control circuit wiring must cross the
main power wiring, it should cross at a right angle.
CAUTION: Use shielded or twisted wire for the control
circuit wiring (wiring should be as short as possible, i.e. 65
feet or less [20 meters.]) Connect outer covering of the
shielded wires to the Drive ground terminal and leave the
other end open, but taped with electrical insulating tape.
DC RELAY
Figure 4-2. CONNECTION OF SURGE SUPPRESSION DEVICES
AC CONTACTOR
CAUTION: Install a suppressor in parallel with any relay or
solenoid type coil as shown above, that may be close to the
Drive to prevent noise from causing erratic Drive operation.
4-2
Main Circuit Wiring
CAUTION: Be sure that the power supply is never
connected to the U, V, W terminals or the P (1), P (+),
DB terminals.
1. Connect the ground terminal as shown in the appropriate view of Figure 4-3. (Do not operate without
the unit being grounded.)
— The ground wire must be minimum 14 AWG
and short as possible
2. Connect the power supply wires to the L1, L2, and
L3 terminals of the Main Circuit Terminal Block as
shown in the appropriate view of Figure 4-3. (See
TABLE 5 for description of all terminals and TABLE
4 for recommended wire sizes.) Note that L1 and L2
terminals only, are available on single phase input
models.
NOTE:
the shaft end when connected normally. If the motor rotates in
reverse direction, interchange any two of the U, V, or W terminal
connections.
Motor will rotate counterclockwise when viewed from
3. Connect the 3-phase motor wires to the U, V, and
W terminals of the Main Circuit Terminal Block as
shown in the appropriate view of Figure 4-3. (See
TABLE 5 for description of all terminals and TABLE
4 for recommended wire sizes.)
4. Suitable for use on a circuit capable of delivering not
more than 1000A (1 HP or less) or 5000A (2 HP or
more) RMS symmetrical.
5. AC input fuses are to be customer supplied and may
be branch circuit protection fuses. The maximum
allowance fuse rating per TABLE 4.
240V – Single Phase 1/4 to 3 HP
L1 L2 P1 P(+) DB* U V W
E (G)
230 & 480V – Three Phase 1/4 to 5 HP
L1 L2 L3 P1 P(+) DB U V W
E (G)
Fuses: Rating per TABLE 4
Reference UL power circuit
protection requirements.
CB
50/60 Hz, 3–Phase AC
✟ Factory installed jumper (Remove when installing DC Reactor)
* The DB resistor connection is not available on models 6KM$221F25X1A1,
6KM$221F25A4A1, 6KM$223F25X1A1, 6KM$223F25A4A1.
# Optional
Figure 4-3. MAIN CIRCUIT TERMINAL LAYOUT
✟
✟
Thermal Relay
3–Phase Motor
#
4-3
Table 4:
ing
lly
Wire Size Recommendations
& Circuit Protection Ratings
240V – Single Phase and 230V Three Phase
DB Incoming Power
ModelPHHPOutput CurrentPowerResistor**AC – Line Devices
WARNING - Device ratings such as system coordination, short-circuit
rat
and type must be carefu
NOTE:
75° C for over 100 amps in 30° C ambient and 1.25 times Drive rated amps. These
are minimum wire sizes; consult and conform to local and national codes.
*NOTE: AC input fuses are required to validate the drive's UL and CSA approvals.
** Optional Item.
Wire size from NEC table 310-16. Copper wire rated 60° C for 100 amps or less,
The fuse should be Class J type such as Bussman, JKS or equivalent. Circuit breaker
ratings are shown for reference, but UL and CSA approval can only be validated by
the use of Class J fuses.
reviewed by the user.
4-4
30A 30B Y1 FMA PLC BX RST C1 13 12 11
30C FMP X1 X2 X3 X4 REV FWD THR CM
#1
*
* Factory installed jumper
*
CONTROL CIRCUIT TERMINAL BLOCK LAYOUT
#1 CAUTION:
Remove jumper from between terminals THR and CM when
a motor overload or a motor temperature switch is used.
Wire the device thermal switch in series with the THR and
CM terminals.
#2 NOTE:
FWD to CM jumper required for operation using keypad
RUN-STOP.
#2
Figure 4-4.
L1 L2 L3 P1 P(+) DB* U V W
DB
E(G)
* Not available on 6KM$221F25X1A1, 6KM$221F25A4A1, 6KM$223F25X1A1, 6KM$223F25A4A1.
Figure 4-5. DYNAMIC BRAKING RESISTOR CONNECTIONS
RESISTOR
4-5
1 or 3PH
50/60 Hz
230/480 Vac
(Based on
Model selected)
DIGITAL METER
DISCONNECT/
CIRCUIT
BREAKER #
FUSE
✟
DO NOT CONNECT
TO CM
DC REACTOR #
P1
BRAKING RESISTOR
1/2 TO 5HP #
BRAKING RESISTOR
THERMAL SWITCH
ALARM RELAY OUTPUT
#
GROUND
BX
RST
X4(HLD)
PROGRAMMABLE LOGIC
PLC
CONTROL POWER
Y1
ANY ADDITIONAL NORMALLY
CLOSED PROTECTIVE
INTERLOCKS SHOULD BE
ADDED IN SERIES
* Terminal 11 should not be connected to CM.
✟ L3 not supplied on single phase units.
# Optional
Figure 4-6. WIRING DIAGRAM
CAUTION:
1. The Control Circuit Terminal wiring should be kept as far as possible from the main circuit wiring to prevent
operation error due to noise interference. Never install them in the same duct or conduit. A separation distance
of 4 inches or more is recommended. If the control circuit wiring must cross the main circuit wiring, make sure
it crosses at a right angle.
2. Use shielded wire for the control circuit wiring, which should be as short as possible (66 feet or less). Connect
shield to the Drive ground terminal and leave the other end open but taped.
3. Install a surge protector in parallel with any magnetic contactors, solenoids, relays or timer coils which are close
to the Drive.
4-6
TABLE 5: Terminal Identification/Function
Terminal Terminal
Label Name Function
POWER TERMINAL BOARD
L1, L2,AC Supply LineConnection for 200-230 VAC or 380-480 VAC, 3-phase, 50/60 Hz;
L3Input TerminalsL1 & L2 for single phase input, 200-240 VAC 50/60 Hz
U, V, WDrive OutputConnection for 3-phase induction motor
Terminals
P+, DBExternal BrakingConnection for external braking resistor option for single phase and
Resistor Terminalsthree phase drives (Only on 1⁄2 HP to 5 HP; not on 1/4 HP)
P1, P+DC Reactor Terminals Connection for external DC reactor for power factor improvement
(Option). (Remove factory installed jumper)
CONTROL TERMINAL BOARD
11Frequency Setting &Common connector for terminals 12, 13, C1 and FMA (Do not
Analog Freq. Meterconnect to CM terminal or electrical noise immunity may be lost).
Common Terminal
12Frequency SettingWhen 0 to +10 VDC (0 to 5V*) is applied, the maximum frequency is
Voltage Inputreached at +10 VDC (5V*) and is proportional to output frequency
down to 0 VDC. Input impedance is 22K ohm ( *250% gain setting F_35)
13Frequency SettingRegulated +10 VDC power supply for frequency setting potentiometer,
Voltage Output Term.10mA or less (13 to terminal 11)
C1Frequency SettingWhen the input signal is +4 to +20mA dc, the maximum frequency is
Current Input (+)reached at 20mA and is proportional down to a minimum frequency
setting at 4mA. Input impedance is 250 ohm, must be isolated source
CMControl CircuitCommon terminal for control input commands, X1-X4, FWD, REV, BX,
Common TerminalRST, THR, Y1 and FMP pulse output signal
(Do not connect to terminal 11)
FWDForward Command
Input TerminalForward command via FWD-CM (closed). Reverse command via
REV-CM (closed). When FWD-CM and REV-CM are closed
Reverse Commandat the same time, the Drive will decelerate to stop
REVInput Terminal
BXMotor Coast-To-StopMotor will coast-to-stop with BX-CM (closed). (For use when
Command Inputapplying mechanical brake with Drive in operation.) Note: If BX-CM is
Terminalopened with FWD or REV closed, the Drive will start the motor
RSTFault Reset InputAfter removal of fault condition, Faults are reset when a momentary
Terminalcontact closure is made between the RST-CM terminals for more
than 0.1 seconds
If there is an input to the FWD or REV terminals with F_02 = 1 OR
2 and F_14 = 4 or 5 the Drive will suddenly restart.
THRExternal thermal tripWith THR-CM (open), OH trip will occur and the motor will
commandcoast-to-stop.
NOTE:
thermostat, the THR-CM terminals must be closed or the Drive
will not operate. THR-CM is factory pre-jumpered, remove prior to
connecting an external NC contacts.
FMA*Analog FrequencyProvides an output of 0 to +10 VDC (+10VDC at max frequency),
Meter Connectionavailable for connection of a voltmeter with internal resistance of
F_40=010K ohms. See Function Code 41 for monitoring selection. Meter
connects between terminal FMA & 11. Note: FMP cannot be used
FMP*Digital FrequencyPulse frequency output equal to Drive output frequency.
Meter ConnectionPulse voltage: Peak 5 VDC, 50% duty, Adjustable range = 600 to
F_40=16000 Hz (Max) See Function Code 42 Pulse Rate Multiplier.
Meter connects between FMP and CM. Note: FMA cannot be used
With no external thermal relay or external braking resistor
30AFault Relay OutputDuring normal operation, the relay is not energized and contact is made
30BTerminalsbetween 30B and 30C. When a fault is detected, the relay is energized
30Cand contact is made between 30A and 30C. (Contact rating resistive
load: 250 VAC, 0.3 Amps)
X1-X3Multistep FrequencySeven individual preset frequency selections via binary combination
Input Function(closure) between X1, X2, X3, and CM.
SelectionFrequency selections determined using functions F_21 thru F_27.
X4Function ExtensionF_43=0 acceleration/deceleration time #2 is selected when X4-CM is
(Input)closed. When not closed #1 setting is activated.
(F_43=1) 8 additional frequencies can be selected by X1, X2, X3 and X4.
(F_43=2) 2nd Motor selection when X4 - CM is closed.
(F_43=3) Functions as hold signal if 3-wire operation is desired.
Y1Output FunctionOutputs one of the following signals depending on setting of F_54;