115VIF-3
115 VAC Input Interface Board
Instruction Manual
For Crane & Hoist Pendant Applications
• SJ200 Series
• SJ700 Series
NOTE: REFER ALSO TO SJ200 OR SJ700 SERIES INSTRUCTION MANUAL
Manual Number: HAL1055C
August 2009
Hitachi America, Ltd.
After reading this manual,
keep it handy for future reference.
Table of Contents
Table of Contents
Table of Contents................................................................................................................... 2
Chapter 1 – General Description.......................................................................................... 3
Chapter 2 – Installation and Wiring...................................................................................... 5
Chapter 3 – Configuring the Inverter ................................................................................... 9
Chapter 4 – Operation......................................................................................................... 13
Index..................................................................................................................................... 15
Document History
Rev A, March 2009 – modified Figure 2-2; modified table on page 9; deleted SJ300
references; other minor changes.
Rev B, April 2009 – added 3-position pushbutton pendant control.
Rev C, August 2009 – added programming for C004 for 2-speed operation, page 11; changed
web address, back cover.
Page 2 of 16
Chapter 1
Chapter 1 – General Description
The 115VIF-3 interface board is used to translate 115 VAC control signals – from crane and
hoist operator pendant stations – to the 24 VDC logical input signals required by the SJ200 or
SJ700 series of Hitachi inverters.
The board provides optical isolation between the 115 VAC pendant voltages and the inverter
control inputs. It also incorporates the necessary logic functions to perform application-specific
crane and hoist functions, as described in a later section of this manual.
Before using this product, please read this manual and the inverter manual, and be sure to follow all safety
precautions noted therein. After unpacking the 115VIF-3 board, carefully inspect it for any defect or damage.
115VIF-3 Carton Contents
(1) 115VIF-3 Interface Board
IMPORTANT: To use the 115VIF-3 interface in an SJ700 Series inverter, you will also require the
115VIF-KIT, purchased separately:
OPTIONAL 115VIF-KIT Carton Contents (one required per 115VIF-3)
(1) Pigtail wiring harness, 9” long
(1) M3 x 8mm screw and wave washer
WARRANTY
The warranty period under normal installation and handling conditions shall be eighteen (18) months
from the date of purchase, or twelve (12) months from the date of installation, whichever occurs first.
The warranty shall cover repair or replacement, at Hitachi’s sole discretion, of the 115VIF-3 interface
board.
Service in the following cases, even within the warranty period, shall be to the customers account:
1. Malfunction or damage caused by misuse, modification or unauthorized repair.
2. Malfunction or damage caused by mishandling, dropping, etc., after delivery.
3. Malfunction or damage caused by fire, earthquake, flood, lightning, abnormal input voltage,
contamination, or other natural disasters.
If service is required for the product at your worksite, all expenses associated with field repair are the
purchaser’s responsibility. This warranty only covers service at Hitachi designated service facilities.
If making a warranty claims in reference to the above, please contact the distributor from whom you
purchased the 115VIF-3, and provide the model number, purchase date, installation date, failure date
and description of damage, malfunction, or missing components.
Page 3 of 16
SAFETY PRECAUTIONS
HIGH VOLTAGE: This symbol indicates high voltage. It calls your attention to items or operations
that could be dangerous to you and other persons operating this equipment. Read the message and
follow the instructions carefully.
WARNING: Indicates a potentially hazardous situation that, if not avoided, can result in serious
injury or death.
CAUTION: Indicates a potentially hazardous situation that, if not avoided, can result in minor to
moderate injury, or serious damage to the product. The situation described in the CAUTION may, if
not avoided, lead to serious results. Important safety measures are described in CAUTION (as well as
WARNING), so be sure to observe them.
HIGH VOLTAGE: Motor control equipment and electronic controllers are connected to hazardous
line voltages. When servicing drives and electronic controllers, there may be exposed components
with housings or protrusions at or above line potential. Extreme care should be taken to protect
against shock. Stand on an insulating pad and make it a habit to use only one hand when checking
components. Always work with another person in case an emergency occurs. Disconnect power
before checking controllers or performing maintenance. Be sure equipment is properly grounded.
Wear safety glasses whenever working on electronic controllers or rotating machinery.
WARNING: This equipment should be installed, adjusted, and serviced by qualified electrical
maintenance personnel familiar with the construction and operation of the equipment and the hazards
involved. Failure to observe this precaution could result in bodily injury.
WARNING: HAZARD OF ELECTRICAL SHOCK. DISCONNECT INCOMING POWER
BEFORE WORKING ON THIS CONTROL.
WARNING: Wait at least ten (10) minutes after turning OFF the input power supply before
performing maintenance or an inspection. Otherwise, there is the danger of electric shock.
WARNING: Do not install or remove the 115VIF-3 interface board while the inverter or external
control circuits are energized. Otherwise there is the danger of electric shock and/or fire.
WARNING: Never modify the board. Otherwise, there is a danger of electric shock and/or injury.
CAUTION: Alarm connection may contain hazardous live voltage even when inverter is
disconnected. When removing the front cover for maintenance or inspection, confirm that incoming
power for alarm connection is completely disconnected.
WARNING: Do not touch the surface or terminals of the 115VIF-3 interface board while the inverter
or external control circuit is energized; otherwise there is the danger of electric shock.
Chapter 1
Page 4 of 16
A
A
A
A
A
A
OUTPUTS
2
(
Chapter 2
Chapter 2 – Installation and Wiring
Orientation to Product Features
Figure 2-1 below shows the physical layout of the 115VIF-3 interface board.
To Inverter
Terminals
P24
FW/1*
2
3
4
5
6
CM1
* See Instructions
starting on Page 7
No connection.
Terminals to inverter
24 Vdc logic outputs
for custom versions
VIOLET
BLUE
GREEN
YELLOW
ORANGE
RED
BROWN
BLACK
IN
GND
OC IN
MATING CONN
NC
NEU
24VDC
UP
DN
ACCEL
DECEL
SPSET
RS
GND
C6
GND
C5
RS
C4
DECEL
SPSET
C3
ACCEL
C2
DN
UP
C1
AC INPUTS
24VDC
The optional 115VIF-KIT
includes this
eight-conductor, 9” long
pigtail connector, used to
connect the board to the
SJ700 logic inputs
Figure 2-1, Board Layout
Installing the Interface Board
WARNING: Remove power from the inverter and wait at least five minutes before moving to the next
step. Open and remove the lower terminal cover. Confirm that the DC bus is fully discharged before
proceeding further. Also confirm that the external 115 VAC control circuits are deactivated and locked
out before proceeding. Otherwise, there is danger of electric shock, injury or death.
General
The 115VIF-3 interface board may be used with either the SJ200 or SJ700 series of inverters. Follow the
appropriate installation instructions on the next pages for the particular model series in which you are installing
the board. The boards 115 VAC-side wiring (from the pendant) and the corresponding AC input functions are the
same, regardless of which inverter series you are using.
Note: In the standard version of the 115VIF-3, no connections are made to the terminals marked IN and GND,
or to terminal AC6.
Terminals AC1 to AC5
and NEU connect to
115VAC control lines
from pendant. AC6 – no
zzz
zzz
Screw hole for securing
board when used in
SJ700. Screw is supplied
with 115-VIF-KIT
Page 5 of 16
Chapter 2
AC Input Wiring – Connecting the Pendant to the 115VIF-3 Interface Board
Connect the pendant 115 VAC input wiring to the terminals marked AC1 through AC5 on the 115VIF-3, with
NEU (neutral of the pendant control signals) as their common terminal. AC1 thru AC5 are connected to the
HOT side of the pendant control signals, coming from the pendant’s pushbutton contacts. The board’s AC input
terminal functions are as follows:
INPUT HOIST TRAVERSE
AC1
(Note 1)
AC2
(Note 1)
AC3
Increase/2
AC4
(Note 2)
Up over-travel photo limit (NC sensor
AC5
(Note 2)
input; open-circuit stops/prevents UP
motion – only DOWN motion is possible)
AC6
NC
IN
Not used/no connection Not used/no connection
GND
Note 1: Inputs AC1 and AC2 functions are symmetrical with respect to direction in traverse applications. In hoist applications, however, AC1 must be
Note 2: AC4 and AC5 inputs are intended to be used with over-travel limit sensors. These are secondary safeties, over and above N.C. limit switches
Note 3: AC4 may also be used for 3-Step Hoist Control. Refer to page 11.
used for UP and AC2 must be used for DOWN.
that would be wired in series with the AC1 and AC2 pendant inputs. They are “fail-safe” inputs, for use with N.C. type sensors. In this way, a
cut wire will have the same effect (inhibited of motion) as a sensor being triggered.
Up PB Forward/Left PB
Down PB Reverse/Right PB
nd
speed Increase/2nd speed
Jumpered to HOT
(Note 3)
Horizontal over-travel limit (NC sensor input;
open-circuit forces inverter to MIN speed)
Jumpered to HOT
Important: If you will not use the
AC4 or AC5 for end-of-travel safety
inputs, then both these inputs must
be jumpered to the pendant HOT
supply, otherwise motor rotation will
be prevented. When end of travel
limit switches ARE used, they should
be wired in place of these jumpers.
Figure 2-2,
Pendant AC
Wiring
PENDANT
Page 6 of 16
Chapter 2
Connecting the Board to the Inverter
The method of connection of the 115VIF to the inverter depends on the inverter model. Refer to the appropriate
section below for the inverter model you have.
SJ200
The eight “fingers” on the 115VIF-3, as shown at the bottom of Figure 2-1, are designed to mate directly with
the input terminal strip of the SJ200 series inverter. It is best to remove the terminal strip from the inverter first.
Then loosen all the terminals to allow the fingers to be easily inserted. The correct orientation for the board is
with the integrated circuits facing upward, and the AC input terminals facing downward toward the inverter.
Insert the eight fingers until you feel them hit that back of the terminal wiring chambers. Do not try to force
them – they should enter easily. Tighten all eight terminals securely. Be careful to not over-tighten.
Connect the AC signal wires from the pendant controls to the terminal as shown in the table on page 6. After
carefully tightening all terminals, reinstall the terminal strip with attached board into the inverter mating
connector, and route pendant AC wiring carefully out the bottom of the inverter.
Figure 2-3 shows the correctly installed 115VIF-3. Make sure the SR/SK DIP switch is in the default “SR”
position. Replace the inverter lower terminal cover, and energize the inverter and external control circuits for
configuration and testing.
Figure 2-3, 115VIF-3 Correctly Installed in SJ200 Inverter
J700
S
When installed in an SJ700 inverter, the 115VIF-3 must be mounted behind the inverter top front cover in the
area where option boards are installed, as shown in Figure 2-4. Install the board in the lower position (c
terminal strip) as shown. This will leave the upper option slot free should a SJ-FB feedback board (for
closed-loop operation), or other option board be required. The optional 115VIF-KIT mounting kit is required
when mounting the interface board in these inverter series. The kit includes a pigtail cable and a M3 x 8mm
mounting screw. Plug the pigtail connector into the mating OUTPUTS2 connector on the board. Align the
losest to
Page 7 of 16
Chapter 2
mounting hole in the board with the threaded insert as shown in the figure. Secure the board to the inverter wi
the M3 screw supplied with the mounting kit. Connect the pigtail leads to the I/O terminal strip of the SJ700
inverter. Connect the leads one b
own in Figure 2-1 on page 5.
sh
pen-Loop vs. Closed-Loop SJ700
O
For open-loop applications: the UP (blue) wire from the pigtail is connected to the FW
ere is no connection to intelligent input 1, which is configured for no function [NO].
th
For closed-loop (encoder feedback) applications: the UP (blue) wire from the pigtail is connected to
telligent input terminal 1, which is configured for [MI1] function. Refer to parameter tables in Chapter 3.
in
inking/Sourcing Input Set-up
S
On the SJ700, the factory default setting for the intelligent inputs is for sinking logic. The 115VIF-3 interface
requires the inputs be set for sourcing logic for proper operatio
m
etal jumper bar on the intelligent input terminal strip. Then:
1) Remove the jumper from its default position between the P24 terminal
2) Reinstall the jumper between the PLC terminal and the CM1 terminal
S e
ink/Sourc
Jumper
y one to intelligent input terminals on the inverter following the color coding
terminal. In this case
n. To change the logic setting, locate the small
and PLC terminal.
(1) M
3 x 8 mm
screw
th
Fi y
gure 2-4, 115VIF-3 Correctl
Installed in SJ700 Inverter
Page 8 of 16
Chapter 3
Chapter 3 – Configuring the Inverter
The configuration of inverter parameters will depend on the specific functionality and performance required for
your application. The basic functionality of the board is designed to interface with a two pushbutton,
two-position (two-speed) momentary contact type pendant commonly used for crane and hoist applications. This
is the basis for the descriptions of the functions of the board presented in this manual. The setup in the table
below will result in infinitely variable speed between the programmed MIN and MAX speeds. The defined
functions of the pushbuttons are as follows:
UP
DOWN
Pushing either the UP or DOWN pushbutton to the first position causes the inverter to go to the minimum
configured speed in that direction. Pushing that button further to its second position will cause speed to increase
in that direction. Releasing back to first position will hold that last speed. Releasing the pushbutton all the way
will cause the inverter to come to a stop. If that button is re-pressed to the first position before stop is reached,
that speed will be maintained.
In order to achieve this basic functionality, certain parameters must be set differently from factory default
values, as described in the following table.
Parameter
Code
F002 Acceleration Time Note 1 Set a value between 1 and 3600 seconds, depending on application
F003
A001
A002 Run Command 01 Tells the inverter to take the RUN command from the control terminals
A004
A061
A062
B091
C001
C002
C003 27 [UP] Accelerate speed input
C004
UP, first detent: UP – accelerate to minimum speed
UP, second detent: UP – increase speed while held, up to MAX speed (or go to second speed, see page 10)
DOWN, first detent: DOWN – accelerate to minimum speed (RESET fault when inverter is
STOPPED and in a fault state)
DOWN, second detent: DOWN – increase speed, up to MAX speed (or go to second speed, see page 10)
Function Setting Comment
Deceleration
Time
Frequency
Command
Maximum
Frequency
Upper Frequency
Limit
Lower Frequency
Limit
Stop Mode
Selection
Terminal 1
Function
Terminal 2
Function
Terminal 3
Function
Terminal 4
Function
Note 1 Set a value between 1 and 3600 seconds, depending on application
02 Tells the inverter to read speed reference from internal register
Note 1
Note 1 Usually the same value as A004
Note 1
00 For Non-Load Brake Hoist, or for traverse applications: 00 (factory default)
01 For Load Brake Hoist applications: 01 (free-run or coast to stop)
00 SJ200 = [FW] Forward run
no SJ700 Open Loop = [NO] No function
56 SJ700 Closed Loop = [MI1]
01 SJ200&SJ700 Open Loop = [RV] Reverse run
57 SJ700 Closed Loop = [MI2]
28 [DN] Decelerate speed input
Depending on the motor limits and application requirements, set the
appropriate value
Lowest speed for continuous operation (MIN speed), usually 6 to 10 Hz or
so. This is the speed that will be commanded at the first pushbutton position.
Page 9 of 16
Chapter 3
C005
C006
C007
C008
C011 thru
C016[DN]
C102
Note 1: Actual setting is dependent on inverter capacity and your design requirements
Note 2: C011 to C018 in the case of SJ700 series
Terminal 5
Function
Terminal 6
Function
Terminal 7
Function
Terminal 8
Function
T erminal Active
State
Reset function
selection
255 (no) No Function – SJ200 (SJ700)
18 [RS] Reset
no [NO] No Function – SJ700 only
no [NO] No Function – SJ700 only
00
2
All inputs should be configured for N.O. (normally open = active on)
operation (Note 2)
Makes the RESET [RS] input terminal (input 6) active only when the inverter
is in the fault state. In this way, the pendant DOWN pushbutton can also
used to reset an inverter fault.
Other Required Settings
The following were previously noted in the Installation and Wiring chapter, but are important and bear
repeating. Make sure the following steps were performed.
SJ200
The SR/SK DIP switch next to the input terminal strip must be in the default “SR” position for proper operation
of the 115VIF-3 interface board. Verify that it is in the correct position. Confirm the correct setting of B091 for
load-brake vs. non-load-brake applications.
SJ700
Confirm that the silver source/sink jumper bar is between PLC and CM1, as explained in Chapter 2. Confirm the
correct setting of B091 for load-brake vs. non-load-brake applications.
Page 10 of 16
Chapter 3
Alternative Set Ups
Two-Speed Operation
The inverter can easily be configured for two-speed operation rather than infinitely variable speed operation by
using the following parameter settings in lieu of or in addition to those in the table above:
Parameter
Code
A021 Multi-speed 01 XX.X Desired second (high) speed, in Hz
C003
C004
Function Setting Comment
Terminal 3
Function
Terminal 4
Function
02 [CF1] function – multi-speed select bit 1
255 [no] No function
This set-up is applicable to pendant stations with two-position pushbuttons, and can be applied to hoist
and/or traverse axes. With the above settings, at the first pushbutton position, the inverter will ramp to
MIN speed and hold. On depressing the button to the second pushbutton position, the inverter will
accelerate to the A021 speed and hold. Releasing the pushbutton back to the first position will cause
the inverter to decelerate back to the MIN speed and hold. Releasing the pushbutton will cause the
inverter to come to a stop.
Three-Step Hoist Control
Some pendant stations utilize 3-position pushbuttons for the hoist control. This is what is traditionally called
“three-step control.” This is simple to implement with the 115VIF-3 and inverter. No programming changes are
required in the inverter. The jumper from AC4 to HOT that would be used in normal 2-step operation is not
needed in this case. The output wire from the pushbutton second contact is wired to AC4 instead. The increase
speed input signal will be taken from the third pushbutton contact for this setup, instead of the second as in
2-step control. To implement this function, refer to Figure 3-1 and the following table which summarizes the
connections that are used:
INPUT THREE-STEP HOIST CONTROL
AC1
AC2
AC3
AC4
AC5
AC6
NC
IN
GND
Up over-travel photo limit (NC sensor input; open-circuit
stops/prevents UP motion – only DOWN motion is possible)
Up PB (first contact)
Down PB (first contact)
Increase speed (third contact)
Hold speed (second contact)
Not used/no connection
Page 11 of 16
Chapter 3
Three-Step Control Wiring
115VAC HOT
Hoist Up (AC1)
Hoist Down (AC2)
Hold Speed (AC4)
Figure 3-1
Hoist Increase Speed (AC3)
Page 12 of 16
Chapter 4
Chapter 4 – Operation
Normal Operation
Once the inverter parameters are set as described in Chapter 3, you are ready to verify proper operation. It is
recommended to first test the system with the motor mechanically disconnected from the crane or hoist, to
ensure that any unexpected behavior will not damage the equipment or risk injury.
Energize the inverter and the pendant or other external control circuit power supplies, and press the pushbutton
connected to input terminal AC1. This is the UP hoist or FORWARD/LEFT traverse input. Observe motor
rotation. If direction is NOT correct, remove power from the inverter and wait 10 minutes for the capacitors to
discharge. Then interchange any two motor leads. Restore power and repeat the initial test. Direction should
now be correct.
With the AC1 pushbutton pressed to the first detent, the motor will accelerate in the forward direction,
(corresponding to UP motion for the hoist), to the frequency set in A062 (MIN speed), and remain at that speed,
unless:
• The pushbutton is released, in which case the motor will come to a stop, OR
• Ramp to a higher speed, while pushbutton is pushed to the second detent (AC3). If AC1 is maintained,
and AC3 is subsequently released, the speed attained at that time will be maintained.
• Releasing AC1 at this point will cause the motor speed to ramp down.
• If AC1 remains off long enough, the motor will come to a stop.
• If AC1 is re-activated at any speed above the MIN speed, then that speed will be maintained for the
duration. If AC1 is reactivated at a speed below the MIN speed, the motor will accelerate to MIN speed
and maintain that speed until one of the above events occurs.
The function of AC2 pushbutton is the same as the AC1 pushbutton, with the exception that rotation direction is
reversed (corresponding to DOWN operation for a hoist).
In addition to its normal function, the AC2 (DOWN) pushbutton input doubles as the FAULT RESET if the
inverter should enter an alarm (trip) condition for any reason. This eliminates the need to access the inverter
keypad itself to clear a fault.
Troubleshooting
Symptom Remedy
Inverter will not accelerate beyond minimum speed Input AC4 is not jumpered to HOT
Inverter will only turn the motor in one direction Input AC5 is not jumpered to HOT
Note: For other troubleshooting tips, refer to Chapter 6 of the pertinent inverter Instruction Manual
Electrical Specifications
The board is internally powered from the inverter’s internal 24 Vdc power supply, drawing approximately 21
mA. The AC inputs are optically isolated, and draw approximately 2 mA each. The outputs to the inverter have a
100 mA maximum capacity.
Page 13 of 16
Chapter 4
Software State Diagram
Ver. 3.7
Page 14 of 16
Version 3.6
Index
Index
A
AC Input Wiring · 6
C
Closed-loop · 8
Configuration, inverter · 9
Contents, carton · 3
D
DIP switch · 10
E
Electrical Specifications · 13
F
Faults, resetting · 13
Functionality, basic · 9
H
Hoist · 6, 11
M
MIN speed · 6, 9, 13
O
Open-loop · 8
Operation · 13
P
Pendant · 9, 13
R
Reset, fault · 13
Rotation, direction of · 13
S
Safety Precautions · 4
Sensor, over-travel · 6
Sinking/sourcing · 8
SJ200 · 7, 10
SJ700 · 7
Software State Diagram · 14
Speed, minimum · 9
SR/SK · 10
I
Input functions · 13
Installing · 5
Inverter parameters · 9
J
Jumper bar · 8
L
Layout, board · 5
Load-brake · 9, 10
T
Three-step hoist control · 11
Traverse · 6
Trip reset · 13
Troubleshooting · 13
Two-speed operation · 11
W
Warranty · 3
Wiring · 5
Page 15 of 16
Hitachi America, Ltd.
Tarrytown, NY 10591
© 2009
http://www.hitachi-america.us/inverters
August 2009 HAL1055C
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