Hitachi L100 User Manual

HITACHI

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L100 Series Inverter Instruction Manual

• Single-phase Input 200V Class

• Three-phase Input 200V Class

• Three-phase Input 400V Class

Manual Number: NB576XA

After reading this manual,

keep it handy for future reference.

Hitachi, Ltd.

Tokyo Japan

L100 Inverter

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Table of Contents

Safety Messages .................................................................................................................. iii

Hazardous High Voltage ....................................................... ........ ........ ........ . ...... ........ .......iii

General Precauti o n s - Read Th ese First! ...................... .............. ........................... .............. .iv

Precautions for EMC (Electromagnetic Compatibility) .......................................................vi

Index to Warnings and Cautions in This Manual ....................... .............. ............... ........... v ii

General Warnings an d Ca u tio n s .................. ............... .......................... ............... ............... xii

Revisions .......................................................................................................................... xvii

Chapter 1: Getting Started

Introduction .......................................................................................................................1–2

L100 Inverter Specifications .............................................................................................1–4

Introduction to Variable-Frequency Drives ......................................................................1–7

Frequently Asked Questions ...........................................................................................1–12

Chapter 2: Inverter Mounting and Installation

Orientation to Inverte r Features ............ .............. ............... .............. ........................... ......2– 2

Basic System Description ..................................................................................................2–5

Step-by-Step Basic Installation .........................................................................................2–6

Powerup Test ...................................................................................................................2–17

Using the Front Panel Keypad ........................................................................................2–19

Chapter 3: Configuring Drive Parameters

Choosing a Progr amming Device ................................ .......................... ...........................3–2

Using Keypad Devi ces .......................... ....................................... .....................................3–3

Using the PC Software — DOP Plus .......... ............... .............. .............. ...........................3–6

“D” Group: Monitoring Functions ....................................................................................3–8

“F” Group: Main Profile Parameters .................................................................................3–9

“A” Group: Standard Functions ......................................................................................3–10

“B” Group: Fine Tuning Functions .................................................................................3–21

“C” Group: Intelligent Terminal Functions ....................................................................3–27

Chapter 4: Operations and Monitoring

Introduction .......................................................................................................................4–2

Connecting to PLCs an d Other Devices .......... ............... ....................................... ............4–4

Using Intelligent Input Terminals ........... ................... ................ ............................... ........ 4–6

Using Intelligent Output Terminals ........... .. ................................. ................ ................. ..4–18

Analog Input Operation ...................................................................................................4–24

Analog and Digital Monitor Output ................................................................................4–25

PID Loop Operation .......................................... ......................... .............. .......................4–27

Configuring the Inverter for Multiple Motors .................................... .......... ...................4–28

xvi

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Table of Contents

Chapter 5: Motor Control Accessories

Introduction ... ................ ................. ................ ............... ................ ................ ............... .....5–2

Component Descriptions ...................................................................................................5–3

Chapter 6: Troubleshooting and Maintenance

Troubleshooting ................................................................................................................6–2

Monitoring Trip Events, History, & Conditions ...............................................................6–5

Restoring Factory Default Settings ...................................................................................6–8

Maintenance and In s p ection .................... .............. ........................... .............. ..................6–9

Warranty .........................................................................................................................6–14

Appendix A: Glossary and Bibliography

Glossary ...........................................................................................................................A–2

Bibliography ....................................................................................................................A–8

Appendix B: Drive Parameter Settings Tables

Introduction ... ................ ................. ................ ............... ................ ................ ............... .... B–2

Parameter Settings fo r Ke y p a d En try ............ ............... .............. .............. ............... ........ B–2

Parameter Settings fo r DO P/DRW/DOP Plus .................... .............. .............. ................. B–7

Index

Safety Messages

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For the best results with the L100 Series inverter, carefully read this manual and all of the warning labels attached to the inverter before installing and operating it, and follow the instructions exactly. Keep this manual handy for quick reference.

Definitions and Symbols

A safety instruction (message) includes a hazard alert symbol and a signal word, WARNING or CAUTION. Each signal word has the following meaning:

HIGH VOLTAGE: This symbol indicates high voltage. It calls your attention to items or operations that could be dangerous to you and other persons operation this equipment. Read the message and follow the ins tructions carefully.

This symbol is the “Safety Alert Symbol.” It occurs with either of two signal words: CAUTION or WARNING, as described below.

WARNING: Indicates a potentially haza rdous situation which, if not a voided, can result in serious injury or death.

L100 Inverter

CAUTION: Indicates a potentially hazardous situation which, 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 sa fety measures are described in CAUTION (as well as WARNING), so be sure to observe them.

1 Step 1: Indicates a step in a series of action steps to accomplish a goal.

NOTE: Notes indicate an area or subject of special merit, emphasizing either the

product’s capabilities or common errors in operation or maintenance.

TIP: Tips give a special instruction that can save time or provide other benef its while installing or using the product. The tip calls attention to an idea that may not be obvious to first-time users of the product.

Hazardous High Voltage

HIGH VOLT A GE: Motor control equipment and electronic c ontrollers 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 emergenc y occurs. Disconnect power before checking controllers or performing maintenance. Be sure equipment is properly grounded. Wear safety glasses whenever wor king on electronic controllers or rotating machinery.

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General Precautions - Read These First!

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 inv olved. Failure to observe this precaution could result in bodily injury.

WARNING: The user is responsible for ensuring that all driven machinery, drive train mechanism not supplied by Hitachi, Ltd., and process line material are capable of safe operation at an applied frequency of 150% of the maximum selected frequency range to the AC motor. Failure to do so can result in destruction of equipment and injury to personnel should a single-point failure occur .

WARNING: For equipment protection, install a ground leak age type break er with a f ast response circuit capable of handling large currents. The ground f ault protection circuit is not designed to protect against personal injury.

HIGH VOLTAGE: HAZARD OF ELECTRICAL SHOCK. DISCONNECT I NCOMING POWER BEFORE WORKING ON THIS CONTROL .

WARNING: Wait at least five (5) minutes after turning off the input power supply before performing maintenance or an inspection. Otherwise, there is the danger of electric shock.

CAUTION: These instructions should be read and clearly understood before working on L100 series equipment.

CAUTION: Proper grounds, disconnecting devices and other safety devices and their location are the responsibility of the user and are not provided by Hitachi, Ltd.

CAUTION: Be sure to connect a motor thermal cutoff switch or overload device to the L100 series controller to assure that the inverter will shut down in the event of an overload or an overheated motor.

HIGH VOLTAGE: Dangerous voltage exists until power light is off. Wait at least 5 minutes after input power is disconnected before performing maintenance.

WARNING: This equipment has high leakage current and must be permanently(fixed) hard-wired to earth via two independent cables.

WARNING: Rotating shafts and above-ground electrical potentials can be hazardous. Therefore, it is strongly recommended that all electrical work conform to the National Electrical Codes and local regulations. Installation, alignment and maintenance should

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be performed only by qualified personnel. Factory-recommended test procedures included in the instruction manual should be followed. Always disconnect electrical po wer before working on the unit.

CAUTION:

a) Class I motor must be connected to protective earth via low resistive path (< 0.1ohm) b) Any motor used must be of a suitable rating. c) Motors may have hazardous moving parts. In this event suitable protection must be provided.

CAUTION: Alarm connection may contain hazardous live v oltage e ven when inverter is disconnected. When removing the front cover for maintenance or inspection, confirm that incoming power for alarm connection is completely disconnected.

CAUTION: Hazardous (main) terminals for any interconnection (motor, contact breaker , filter, etc.) must be inaccessible in the final installation.

iii

CAUTION: This equipment should be installed in IP54 or equivalent (see EN60529) enclosure. The end application must be in accordance with BS EN60204-1. Refer to the section on inverter mounting, starting on page 2–6. The diagram dimensions are to be suitably amended for your application.

CAUTION: Connection to field wiring terminals must be reliably fixed having two independent means of mechanical support. Using a termination with cable support (figure below), or strain relief, cable clamp, etc.

Terminal (spade lug) Cable support

Cable

CAUTION: A double-pole disconnection device must be fitted to the incoming mains supply close to the inverter. Additionally, a protection device meeting IEC947-1/ IEC947-3 must be fitted at this point (protection device data shown in page 2–13).

NOTE: The above instructions, together with any other requirements are highlighted in this manual, and must be followed for continued LVD (European Low Voltage Directive) compliance.

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Precautions for EMC (Electromagnetic Compatibility)

You are required to satisfy the EMC directive (89/336/EEC) when using an L100 inv erter in a European country. To satisfy the EMC directive and to comply with standard, follow the checklist below.

WARNING: This equipment should be installed, adjusted, and serviced by qualified personal familiar with construction and operation of the equipment and the hazards involved. Failure to observe this precaution could result in bodily injury.

1. The power supply to L100 inverter must meet these specifications: a. Voltage fluctuation+/- 10% or less b. Voltage imbalance +/- 3% or less c. Frequency variation +/- 4% or less d. Voltage distortion THD = 10% or less

2. Installation measure: a. Use a filter designed for L100 inverter

3. Wiring: a. Shielded wire (screened cable) is required for motor wiring, and the length must

be less than 50 meters.

b. The carrier frequency setting must be less than 5 kHz to satisfy EMC require-

ments.

c. Separate the main circuit from the signal/process circuit wiring.

4. Environmental conditions - when using a filter, follow these guidelines: a. Ambient temperature: -10 to 40 °C b. Humidity: 20 to 90% RH (non-condensing)

c. Vibration: 5.9 m/sec d. Location: 1000 meters or less altitude, indoors (no corrosive gas or dust)

(0.6 G) 10 ~ 55Hz

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Index to Warnings and Cautions in This Manual

Installation - Cautions for Mounti ng Procedures

CAUTION: Be sure to install the unit on flame-resistant material such as a steel plate. Otherwise, there is the danger of fire.

CAUTION: Be sure not to place any flammable materials near the inverter. Otherwise, there is the danger of fire.

CA UTION: B e sure not to let the foreign matter enter vent openings in the inv erter housing, such as wire clippings, spatter from welding, metal shavings, dust, etc. Otherwise, there is the danger of fire.

CAUTION: Be sure to install the inverter in a place which can bear the weight according to the specifications in the text (Chapter 1, Specifications Tables). Otherwise, it may fall and cause injury to personnel.

CA UTION: Be sure to install the unit on a perpendicular w all which is not subject to vibration. Otherwise, it may fall and cause injury to personnel.

CAUTION: Be sure not to install or operate an inverter which is damaged or has missing parts. Otherwise, it may cause injury to personnel.

CAUTION: Be sure to install the inverter in a well-ventilated room which does not have direct exposure to sunlight, a tendenc y for high temperature, high humidity or dew condensation, high lev els of dust, corrosive gas, e xplosive gas, inflammable gas, grinding-fluid mist, salt damage, etc. Otherwise, there is the danger of fire.

........... 2–6

Wiring - Warnings for Electrical Practices and W ire Specifications

WARNING: “Use 60/75°C Cu wire only” or equivalent. ......... 2–12

WARNING: “Open Type Equipment.” ......... 2–12

WARNING: “A Class 2 circuit wired with Class 1 wire” or equivalent.

WARNING: “Suitable for use on a circuit capable of delivering not more than 5,000 rms symmetrical amperes, 240 V maximum.” For models with suffix N or L.

......... 2–12

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Index to Warnings and Cautions in This Manual

WARNING: “Suitable for use on a circuit capable of delivering not more than 5,000 rms symmetrical amperes, 240 V maximum.” For models with suffix N or L.

HIGH VOLTAGE: Be sure to ground the unit. Otherwise, there is a danger of electric shock and/or fire.

HIGH VOLTAGE: Wiring work shall be carried out only by qualified personnel. Otherwise, there is a danger of electric shock and/or fire.

HIGH VOLTAGE: Implement wiring after checking that the power supply is off. You may incur electric shock and/or fire.

HIGH VOLTAGE: Do not connect wiring to an inverter or operate an inverter that is not mounted according the instructions given in this manual. Otherwise, there is a danger of electric shock and/or injury to personnel.

WARNING: Make sure the input power to the inverter is off. If the drive has been po were d, leave it off for five minutes before continuing.

........ 2–12

........ 2–16

Wiring - Cautions for Electrical Practices

CAUTION: Be sure that the input voltage matches the inverter specifications: • Single/Three phase 200 to 240 V 50/60 Hz (up to

2.2kW) • Three phase 200 to 230V 50/60Hz (abo ve 2.2kW) • Th ree phase 380 to 460 V 50/60Hz

CAUTION: Be sure not to input a single phase to a three-phaseonly type invert er. Otherwise, there is the danger of fire.

CAUTION: Be sure not to connect an AC power supply to the output terminals. Otherwise, there is the danger of injury and/or fire.

Power Input Power Output

(L) (N)

L1 L2 L3

T1 T2 T3

UVW

NOTE: L, N:

L1, L2, L3:

........ 2–14

Single-phase 200 to 240V 50/60 Hz Three-phase 200 to 240V 50/60 Hz Three-phase 380 to 460V 50/60 Hz

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vii

CA UTION: Fasten the screws with the specified fastening torque (see the following table). Check for any loosening of scre ws. Otherwise, there is the danger of fire.

CA UTION: Rema rks for using earth leaka ge c ircuit breakers in the mains supply: Frequency inverters with CE-filters (RFI-filter) and shielded (screened) motor cables have a higher leakage current toward Earth GND. Especially at the moment of switching on this can cause inadvertent tripping of earth leakage circuit breakers. Because of the rectifier on the input side of the inverter there is the possibility to stall the switch-off function through small amounts of DC current. Please observe the following: • Use only short timeinvariant and pulse current-sensitive earth leakage circuit breakers with higher trigger current. • Other components should be secured with separate earth leakage circuit breakers. • Earth leakage circuit breakers in the power input wiring of an inverter are not an absolute protection against electric shock by direct touching.

CAUTION: Be sure to install a fuse in the wire for each phase of the main power supply to the inverter. Otherwise, there is the danger of fire.

CA UTION: For motor leads, earth leakage breakers and electromagnetic contactors, be sure to size these components properly (each must have the capacity for rated current and voltage). Otherwise, there is the danger of fire.

......... 2–15

Powerup Test Caution Messa ges

CAUTION: The heat sink fins will have a high temperature. Be careful not to touch them. Otherwise, there is the danger of getting burned.

CAUTION: The operation of the inverter can be easily changed from low speed to high speed. Be sure check the capability and limitations of the motor and machine before operating the inverter. Otherwise, there is the danger of injury.

CA UTION: If you operate a motor at a frequency higher than the inve rte r standard def ault setting (50Hz/60Hz), be sure to check the motor and machine specifications with the re specti v e manufacturer. Only operate the motor at elevated frequencies after getting their approval. Otherwise, there is the danger of equipment damage.

CA UTION: Check the following before and during the powerup test. Otherwise, there is the danger of equipment damage. • Is the shorting bar between the +1 and + terminals installed? DO NOT power or operate the inverter if the jumper is removed. • Is the direction of the motor correct? • Did the inverter trip during acceleration or deceleration? • Were the rpm and frequency meter readings as expected? • Were there any abnormal motor vibrations or noise?

......... 2–17

......... 2–18

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Index to Warnings and Cautions in This Manual

Warnings for Operations and Monitoring

WARNING: Be sure to turn on the input power supply after closing the front case. While being energized, be sure not to open the front case. Otherwise, there is the danger of electric shock.

WARNING: Be sure not to operate the switches with wet hands. Otherwise, there is the danger of electric shock.

WARNING: While the inv erter is ener gized, be sure not to touch the inverter terminals even when the motor is stopped. Otherwise, there is the danger of electric shock.

WARNING: If the Retry Mode is selected, the motor may suddenly restart during the trip stop. Do not approach the machine (be sure to design the machine so that safety for personnel is secure even if it restarts.) Otherwise, it may cause injury to personnel.

WARNING: If the power supply is cut off for a s hort period of time, the inv erter may restart operation after the po wer supply reco ve rs if the command to operate is active. If a restart may pose danger to personnel, so be sure to use a lock-out circuit so that it will not restart after power recovery. Otherwise, it may cause injury to personnel.

WARNING: The Stop Key is effective only when the Stop function is enabled. Be sure to enable the Key separately from the emergency stop. Otherwise, it may cause injury to personnel.

.......... 4–3

WARNING: After the operation command is given, if the alarm reset is conducted, it will restart suddenly. Be sure to set the alarm reset after verifying the operation command is off. Otherwise, it may cause injury to personnel.

WARNING: Be sure not to touch the inside of the energized inve rter or to put any conductive object into it. Otherwise, there is a danger of electric shock and/or fire.

WARNING: When the power is turned on when the running command is already active, the motor will suddenly start rotation and is dangerous. Before turning the power on, confirm that the running command is not enabled.

WARNING: When the Stop key function is disabled, pressing the Stop key does not cancel the stop and trip.

WARNING: Be sure to provide a separate, hard-wired emergency stop switch. When the operation command source is a digital operator, this selection is ineffective.

WARNING: If the power is turned on and the Run command is already active, the motor starts rotation and is dangerous! Before turning power on, confirm that the Run command is not active.

.......... 4–3

.......... 4–6

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WARNING: After the Reset command is given and the alarm reset occurs, the motor will restart suddenly if the Run command is already active. Be sure to set the alarm reset after verifying that the Run command is off to prevent injury to personnel.

Cautions for Operations and Monitoring

CAUTION: The heat sink fins will have a high temperature. Be careful not to touch them. Otherwise, there is the danger of getting burned.

CA UTION: It is possible to da mage the inverter or other devices in your application if the maximum current or voltage characteristics of a connection point are exceeded.

......... 4–16

........... 4 –2

........... 4 –4

Warnings and Cautions for Troubleshooting and Maintenance

WARNING: Wait at least fiv e (5) minutes after turning of f the input power supply before performing maintenance or an inspection. Otherwise, there is the danger of electric shock.

WARNING: Make sure that only qualified personnel will perform maintenance, inspection, and part replacement. (Before starting to work, remove any metallic objects from your person (wristwatch, bracelet, etc.). Be sure to use tools with insulated handles. Otherwise, there is a danger of electric shock and/or injury to personnel.

WARNING: Neve r remo ve connectors by pulling on its wire leads (wires for cooling fan and logic p.c.board). Otherwise, there is a danger of fire or injury due to wire breakage.

CA UTION: When removing connectors, nev er pull the wires (wires for the cooling fan and logic P.C. board. Otherwise, there is danger of fire due to wire breakage and/or injury to personnel.

CAUTION: Never test the withstand voltage (HIPOT ) on the inve rter. The inv erter has a sur ge protector be tween the ma in circuit terminals above and the chassis ground.

........... 6 –2

......... 6–12

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General Warnings and Cautions

HIGH VOLTAGE: Be careful not to touch wiring or connector terminals when working with the inverters and taking measurements. Be sure to place the measurement circuitry above in an insulated housing before using them.

General Warnings and Cautions

WARNING: Never modify the unit. Otherwise, there is a danger of electric shock and/ or injury.

CAUTION: Withstand voltage tests and insulation resistance tests (HIPOT) are executed before the units are shipped, so there is no need to conduct these tests before operation.

CAUTION: Do not attach or remove wiring or connectors when po wer is applied. Also, do not check signals during operation.

CAUTION: Do not stop operation by switching off electromagnetic contactors on the primary or secondary sides of the inverter.

........ 6–13

Earth leakage

breaker

Power Input

When there has been a sudden power f ailure while an operation instruction is acti ve, then the unit may restart operation automatically after the power f ailure has ended. If there is a possibility that such an occurrence may harm humans, then install an electromagnetic contactor (Mgo) on the power supply side, so that the circuit does not allow automatic restarting after the power supply recovers. If the optional remote operator is used and the retry function has been selected, this will also cause automatic restarting when an operation instruction is active. So, please be careful.

L1, L2, L3

Inverter

U, V, W

Motor

P24

L100 Inverter

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CAUTION: Do not insert leading power factor capacitors or surge absorbers between the output terminals of the inverter and motor.

Earth leakage

breaker

Surge absorbe r

Power Input

L1, L2, L3

U, V, W

Motor

Inverter

Leading power

GND lug

factor capacitor

CAUTION: Be sure to connect the grounding terminal to earth ground.

CAUTION: When inspecting the unit, be sure to wait five minutes after tuning off the

power supply before opening the cover.

CAUTION: MOTOR TERMINAL SURGE VOLTAGE SUPPRESSION FILTER (For the 400 V CLASS)

In a system using an inv er ter with the voltage control PWM system, a voltage surge caused by the cable constants such as the cable length (especially when the distance between the motor and inverter is 10 m or more) and cabling method may occur at the motor terminals. A dedicated filter of the 400 V class for suppressing this voltage surge is available. Be sure to install a filter in this situation.

CAUTION: SUPPRESSION FOR NOISE INTERFERENCE FROM INVERTER

The inve rter uses many semiconductor switching elements such as transistor s and IGBTs. Thus, a radio receiver or measuring instrument located near the inverter is susceptible to noise interference. To protect the instruments from erroneous operation due to noise interference, they should be used well away from the inverter. It is also effective to shield the whole inverter structure. The addition of an EMI filter on the input side of the inverter also reduces the effect of noise from the commercial power line on external devices. Note that the external dispersion of noise from the power line can be minimized by connecting an EMI filter on the primary side of inverter.

xii

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General Warnings and Cautions

CA UTION: EFFECTS OF DISTRIBUTOR LI NES ON INVERTERS

Power source

EMI filter Inverter

L1(L1) L2 L3(N)

Motor

Power source

Terminal for grounding

EMI filter

Noise

Inverter

Ground the frame.

Remote

operator

Noise

Completely ground the shield made of metal screen, enclosed panel, etc. with as short a wire as possible.

Piping (to be grounded) or shielded wire

Motor

In the cases belo w in v o lving a general-purpos e inverter, a lar ge peak current fl ows on the power supply side, sometimes destroying the converter module. Where such situations are foreseen, or the paired equipment must be highly reliable, install an AC reactor between the power supply and the inverter.

1. The unbalance factor of the power supply is 3% or higher.

2. The power supply capacity is at least 10 times greater than the inverter capacity (and

the power supply capacity, 500 kVA or more).

3. Abrupt power supply changes are expected.

Some examples include:

a.Several inverters are interconnected with a short bus. b.A thyristor converter and an inverter are interconnected with a short bus. c:An installed phase advance capacitor opens and closes.

In cases (1), (2), and (3) we recommend installing an AC reactor of 3% (at a voltage drop at rated current) with respect to the supply voltage on the power supply side.

CAUTION: When the EEPROM error E8 occurs, be sure to confirm the setting value again.

CAUTION: When setting b contact to the forward or reverse command [FW], [RV] terminal, the inverter starts automatica lly. Do not set to b contact without a purpose.

General Caution

CAUTION: In all the illustrations in this manual, covers and safety devices are occasionally removed to describe the details. While operating the product, make sure that the covers and safety devices are placed as they were specified originally and operate it according to the instruction manual.

Revisions

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Revision History Table

L100 Inverter

xvii

No. Revision Comments Date of Issue

Initial Release of Manual NB576X May 1999 NB576X

1 Revision A

Pages 1-4 – Specs tables: added row for input curent, changed rated input voltage tolerance, corrected dynamic braking %torque, corrected product weight (lbs) Page 2-8 – Corrected H dimension for -002 models

August 1999 NB576XA

Operation

Manual No.

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Getting Started

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In This Chapter.... page

— Introduction ...................................................... 2

— L100 Inverter Specifications............................. 4

— Introduction to Variable-Frequency Drives....... 7

— Frequently Asked Questions.......................... 12

1–2

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Getting S tarted

Introduction

Main Features

Congratulations on your purchase of an L100 Series Hitachi inverter! This inverter drive features state-of-the-art circuitry and components to provide high performance. The housing footprint is exceptionally small, given the size of the corresponding motor. The Hitachi L100 product line includes more than a dozen inverter models to cover motor sizes from 1/4 horsepo wer to 10 horsepower, in either 230 VAC or 460 VAC power input versions. The main features are:

• Convenient keypad for parameter settings

• Built-in RS-422 communications interface to

allow configuration from a PC and for f ield bus external modules.

• Sixteen programmable speed levels

• Two-step acceleration and deceleration curves

• PID control adjusts motor speed automatically to maintain a process variable value

The design in Hitachi inverters overcomes many of the traditional trade-offs between speed, torque and efficiency. The per formance characteristics are:

• V/F (volts-per-hertz) control algorithm, selectable for either constant or reduced

torque loads

• Output frequency range from 0.5 to 360 Hz

• Continuous torque operation at 100% within a 1:10 speed range (6/60 Hz / 5/50 Hz)

without motor derating

A full line of accessories from Hitachi is available to complete your application:

• Digital remote operator keypad

• Dynamic braking unit

• Radio noise filters and EMI filters (shown below)

• CE compliance filters

• DIN rail mounting adapter (35mm rail size)

Model L100-002NFU

EMI Filter

Inverter Specifications Label

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The Hitachi L100 inverters have product labe ls located on the right side of the housing, as pictured below. Be sure to verify that the specifications on the labels match your power source, motor, and application safety requirements.

Specifications label

Inv erter model number

L100 Inverter

1–3

Getting Started

Regulatory agency approvals

Motor capacity for this model Power Input Rating:

frequency, voltage, phase, current Output Rating:

Frequency, voltage, current Manufacturing codes:

Lot number, date, etc.

Model Number Convention

The model number for a specific in verter contains useful information about its operating characteristics. Refer to the model number legend below:

L100 004 H F U 5

Series name

Version number (_, 1, 2, ...) Restricted distribution:

E=Europe, U=USA Configuration type

F = with digital operator (keypad) Input voltage:

N = single or three-phase 200V class H = three-phase 400V class L = three phase only, 200V class

Applicable motor capacity in kW

001 = 0.1 kW 002 = 0.2 kW 004 = 0.4 kW 005 = 0.55 kW 007 = 0.75 kW 011 = 1.1 kW 015 = 1.5 kW

022 = 2.2 kW 030 = 3.0 kW 037 = 3.7 kW 040 = 4.0 kW 055 = 5.5 kW 075 = 7.5 kW

1–4

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L100 Inverter Specifications

Model-specific tables for 200V and 400V class inverters

The following three tables are specific to L100 in verters for the 200V and 400V class model groups. The table on page 1–6 gives the general specificat ions that apply to both voltage class groups. Footnotes for all specifications tables are on the next page.

Getting S tarted

L100 inverters, 200V models 002NFE

Applicable motor size *2 kW 0.2 0.4 0.55 0.75 1.1

Rated capacity (240V) kVA *10 0.5 1.0 1.2 1.6 2.0 Rated input voltage 1-phase: 200 to 240V +5%/-10%, 3-phase: 200 to 230V ±10%,

Rated input current (A), (1-ph / 3-ph) 3.1 / 1.8 5.8 / 3.4 6.7 / 3.9 9.0 / 5.2 11.2 / 6.5 Rated output voltage *3 3-phase 200 to 240V (corresponding to input voltage) Rated output current (A) 1.4 2.6 3.0 4.0 5.0 Braking Dynamic braking,

Weight kg / lb 0.8 / 1.9 0.8 / 1.9 1.3 / 2.9 1.3 / 2.9 2.2 / 4.8

Item 200V Class Specifications

004NFE

002NFU

HP 1/4 1/2 3/4 1 1 1/2

50/60 Hz ±5% (037LFU, 055LFU & 075LFU 3-phase only)

approx. % torque, (short time, stopping from 50 / 60 Hz) *5

DC braking Variable operating frequency, time, and braking force

Capacitive feedback type, dynamic braking unit and braking resistor optional, individually installed

004NFU

005NFE

—

100%: ≤ 50Hz,

50%: ≤ 60 Hz

007NFE 007NFU

011NFE

—

Item 200V Class Specifications, continued

L100 inverters, 200V models 015NFE

015NFU

Applicable motor size *2 kW 1.5 2.2 3.7 5.5 7.5

HP2357.510 Rated capacity (240V) kVA *10 2.9 4.1 6.3 9.6 12.7 Rated input voltage 1-phase: 200 to 240V ±10%, 3-phase: 200 to 230V ±10%,

50/60 Hz ±5% (037LFU, 055LFU & 075LFU 3-phase only) Rated input current (A), (1-ph / 3-ph) 16.0 / 9.3 22.5 / 13.0 – / 20.0 – / 30.0 – / 40.0 Rated output voltage *3 3-phase 200 to 240V (corresponding to input voltage) Rated output current (A) 7.1 10.0 15.9 24 32 Braking Dynamic braking,

approx. % torque, (short time, stopping from 50 / 60 Hz) *5

DC braking Variable operating frequency, time, and braking force

Weight kg / lb 2.2 / 4.8 2.8 / 6.2 2.8 / 6.2 5.5 / 12.1 5.7 / 12.6

100%: ≤ 50Hz

50%: ≤ 60Hz

Capacitive feedback type, dynamic braking unit and braking resistor optional, individually installed

022NFE 022NFU

40%: ≤ 50Hz 20%: ≤ 60Hz

—

037LFU

—

055LFU

20%: ≤ 50Hz 20%: ≤ 60Hz

—

075LFU

L100 Inverter

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Item 400V Class Specifications

L100 inverters, 400V models

Applicable motor size *2 kW 0.4 0.75 1.5 2.2 3 .0 4.0 5.5 7.5

Rated capacity (460V) kVA *10 1.1 1.9 3.0 4.3 6.2 6.8 10.4 12.7 Rated input voltage 3-phase: 380 to 460V ±10%, 50/60 Hz ±5% Rated input current (A) 2.0 3.3 5.0 7.0 10.0 11.0 16.5 20.0 Rated output voltage *3 3-phase: 380 to 460V (corresponding to input voltage) Rated output current (A) 1.5 2.5 3.8 5.5 7.8 8.6 13 16 Braking Dynamic braking,

approx. % torque, (short time, stopping from 50 / 60 Hz) *5

DC braking Variable operating frequency , time, and braking force

Weight kg / lb 1.3/2.9 1.7/3.7 1.7/3.7 2.8/6.2 2.8/6.2 2.8/6.2 5.5/12.1 5.7/12.5

004HFE 004HFU

HP1/2123457.510

Capacitive feedback type, dynamic braking unit and braking resistor optional, individually installed

007HFE 007HFU

100%: ≤ 50Hz

50%: ≤ 60Hz

015HFE 015HFU

022HFE 022HFU

030HFE—040HFE

40%: ≤ 50Hz,

20%: ≤ 60Hz

040HFU

055HFE 055HFU

20%: ≤ 50Hz 20%: ≤ 60Hz

075HFE 075HFU

Footnotes for the preceding tables and the table on the following page:

*1: The protection method conforms to JEM 1030. *2: The applicable motor refers to Hitachi standard 3-phase motor (4-pole). To use other

motors, care must be taken to prevent the rated motor current (50/60 Hz) from exceeding the rated output current of the inverter.

*3: The output voltage decreases as the main supply voltage decreases (except for use of the

AVR function). In any case, the output voltage cannot exceed the input power supply voltage.

*4: To operate the motor beyond 50/60 Hz, consult the motor manufacturer about the maximum

allowable rotation speed.

*5: The braking torque via capacitive feedback is the average deceleration torque at the shortest

deceleration (stopping from 50/60 Hz as indicated). It is not continuous regenerative braking torque. And, the average deceleration torque varies with motor loss. This value decreases when operating beyond 50 Hz. Note that a braking unit is not included in the inverter. If a large regenerative torque is required, the optional regenerative braking unit should be used.

*6: The frequency command is the maximum frequency at 9.8V for input voltage 0 to 10 VDC,

or at 19.6 mA for input current 4 to 20 mA. If this characteristic is not convenient for your application, contact your Hitachi sales representative.

*7: If operating the inverter in an ambient temperature of 40–50

to 2.1 kHz, derate the output current by 80%, and remove the top housing cover. Note that

removing the top cover will nullify the NEMA rating for the inverter housing. *8: The storage temperature refers to the short-term temperature during transport. *9: Conforms to the test method specified in JIS C0911 (1984). For the model types excluded in

the standard specifications, contact your Hitachi sales representative . *10:The input voltage of xxLFU is 230V.

C, reduce the carrier frequency

Getting Started

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Getting S tarted

L100 Inverter Specifications

General Specifications

The following table applies to all L100 i nverters.

Item General Specifications

Protective housing *1 IP20 Control method Sine wave pulse-width modulation (PWM) control Output frequency range *4 0.5 to 360 Hz Frequency accuracy Digital command: 0.01% of the maximum frequency

Analog command: ±0.2% of the maximum frequency (25°C ± 10°C) Frequency setting resolution Digital: 0.1 Hz; Analog: max. frequency/1000 Volt./Freq. characteristic V/F optionally variable, V/F control (constant torque, reduced torque) Overload current rating 150%, 60 seconds Acceleration/deceleration time 0.1 to 3000 sec., (linear accel/decel), second accel/decel setting available Input

signal

Output signal

Alarm output contact ON for inverter alarm (1C contacts, both normally open or closed avail.) Other functions AVR function, curved accel/decel profile, upper and lower limiters, 16-stage

Protective function Over-current, over-voltage, under-voltage, overload, extreme high/low

Operating Environment

Coating color L ight purple, cooling fins in base color of aluminum Options Remote operator unit, copy unit, cables for the units, dynamic braking unit,

Freq. setting

FWD/ REV Run

Intelligent input terminal

Intelligent output terminal RUN (run status signal), FA1,2 (frequency arrival signal), OL (ove rload

Frequency monitor PWM output; Select analog output frequency m onitor, analog output current

Ambient storage humidity -10 to 50°C (*7) / -25 to 70°C (*8) / 20 to 90% humidity (non-condensing) Vibration *9

Location Altitude 1,000 m or less, indoors (no corrosive gasses or dust)

Operator panel Potentiometer External signal *6

Operator panel External signal

Up and Down keys / Value settings

Analog setting

0 to 10 VDC (input impedance 10k Ohms), 4 to 20 mA (input impedance

250 Ohms), Potentiometer (1k to 2k Ohms, 2W)

Run/Stop (Forward/Reverse run change by command)

Forward run/stop, Reverse run/stop

FW (forward run command), RV (reverse run command), CF1~CF4 (multi-

stage speed setting), JG (jog command), 2CH (2-stage accel./decel.

command), FRS (free run stop command), EXT (external trip), USP (startup

function), SFT (soft lock), AT (analog current input select signal), RS (reset),

PTC (thermal protection)

advance notice signal), OD (PID error deviation signal), AL (alarm signal)

monitor or digital output frequency monitor

speed profile, fine adjustment of start frequency, carrier frequency change

(0.5 to 16 kHz) frequency jump, gain and bias setting, process jogging,

electronic thermal leve l adjustment, retry function, trip history monitor

temperature, CPU error, memory error, ground fault detection at startup,

internal communication error, electronic thermal

5.9 m/s

braking resistor, AC reactor, DC reactor, noise fil ter, DIN rail mounting

(0.6G), 10 to 55 Hz

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1–7

Introduction to Variable-Frequency Drives

The Purpose of Motor Speed Control for Industry

Hitachi inv erters pro vide spee d control for 3-phase AC induction motors. You connect AC po w er to the inverter, and connect the inverter to the motor. You’re probably familiar with the way a light dimmer works to vary the power sent to a light bulb, and thus the light intensity. At a basic le vel, the modern inv erter serves the same role for a motor.

Many industrial applications use AC motors of all sizes to do many different things. In some cases, the motor connects directly to an AC power source — running at full speed whenever it is on. Ho we ver, many applications benefit from a motor with variable speed, in several ways:

• Energy savings - HVAC

• Need to coordinate speed with an adjacent process - textiles and printing presses

• Sensitive loads - eleva t ors, food processing, pharmaceutica ls Over the years, industry has f ound many ways to achieve variable speed when it

benefited the process. Solutions varied from mechanical (belts and gears), hydraulic (pumps and motors), and electrical (two-speed motor windings, etc.) While these solutions provided some control over speed, there were unwanted side effects as well:

• Wasted energy from losses in speed-adjusting mechanisms (gearboxes, etc.)

Getting Started

• Wasted energy from on/off control trying to approximate an average

• Noise from belts and gears or start/stop operations

• Messy machinery with fluid leaks

• High maintenance and/or unreliable components

• Could set the speed, but acceleration and deceleration wa s still uncontrollable

• Not enough speed lev els

• Poor torque performance at low speeds Most of the unwanted side effects came from mechanical or hydraulic machinery, and

could be solved with a purely electronic solution. But early electronic components had reliability shortcomings due to the large currents and high voltages imposed on the devices. Ho wever, the modern power components in use today have changed all that. The state-of-the-art components in Hitachi drives provide all the benefits of speed control, while overcoming the classical problems listed above.

What is an Inverter?

The term inverter and variable-frequency drive are related and somewhat interchange- able. An electronic motor drive for an AC motor can control the motor’s speed by varying the frequency of the power sent to the motor. F or example, a particular motor may be designed for 60 Hz operation. We say it is a synchronous motor if its speed of revolution is directly related to its power input frequenc y. When the motor design is synchronous, a variable frequency drive is able to control the speed by controlling the frequency.

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Getting S tarted

Introduction to Variable-Frequency Drives

An inve rter, in general, is a device that converts DC power to AC po wer. The popular consumer power inverter is designed for powering an AC appliance from a car battery; put 12VDC in, and get 115VAC 50/60 Hz out, for example. The figure below sho ws ho w the variable-frequency drive employes an internal inverter. The dri ve first converts incoming AC po wer to DC through a rectifier c ircuit, creating a high-v oltage internal DC bus. Then the inv e rter circuit inverts the DC back to AC again to power the motor. However, this special inverter varies its output frequency and voltage according to the desired motor speed.

Power Input

L1 L2 L3

Converter

Rectifier

Variable-frequency Drive

High-voltage

DC Bus

Inverter

Motor U/T1 V/T2

W/T3

–

The simplified drawing of the inverter shows three double-throw swit ches. Usually implemented with six power transistors, outputs U/T1, V/T2, and W/T3 may switch positively or neg ati vely. Using a commutation algorithm, the microprocessor in the drive switches the power transistors on and of f at a very high speed to create the desired output waveforms. The reactance of the motor windings helps smooth out the pulses.

Torque and Constant Volts/Hertz Operation

In working with industrial motors we often discuss the motor torque. That is simply the rotational force the motor exerts at any given time. The goal of the inverter is to control motor speed, but the L100 inverter only has direct control over the output frequenc y and voltage. The no-load speed will be equal to the inverter output frequency minus a small amount of slip in the motor (slip is the difference between theoretical motor speed and actual speed). As the load increases, the slip and the delivered torque also increase . If the inve rter can create strong motor torque over most or all of the speed range, then it is relatively easy for the system to achieve any desired speed. Speed regulation is a measure of the accuracy speed control, given as a percent difference from a fixed value. The L100 delivers speed regulation (no load to full load) within 3% of the (full scale) motor nameplate speed value.

When varying the output frequency, the inverter drive also must vary the output voltage in proportion to the frequency. It does so because of the motor’s characteristic inductive reactance. If the drive maintains a constant volts-per -hertz ratio, the motor will have constant torque characteristics. Constant torque is desirable for most applications, because it transfers power to the load consistently across the entire speed range.

Output

voltage

100%

Constant torque

Output frequency

100%

In verter Input and Three-Phase Power

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Heavy industrial machinery often needs the additional power available from higher voltage/current sources, and from three-phase power. The Hitachi L100 Series of inve rters includes two sub-groups: the 200V class and the 400V class inverters. The drives described in this manual may be used in either the United States or Europe, although the exact voltage level for commercial power may be slightly different from country to country. Accordingly, a 200V class in verter requires (nominal) 200 to 240VAC , and a 400V class inv erter requires from 380 to 460VAC. Some 200V class inverters will accept single-phase or three-phase power, but all 400V class inverters require a three-phase power supply.

The common terminology for single phase power is Line (L) and Neutral (N). Threephase power connections are usually labeled Line 1 (L1), Line 2 (L2) and Line 2 (L3). In any case, the power source should include an earth ground connection. That ground connection will need to connect to the inverter chassis and to the motor frame (description given on page 2–16).

Inverter Output to the Motor

L100 Inverter

1–9

Getting Started

The AC motors also use three-phase power, but they must connect only to the in verter’s output terminals. The output terminals are uniquely labeled (to differentiate them from the input terminals) with the designations U/ T1, V/T2, and W/T3. This corresponds to typical motor lead connection designations T1, T2, and T3. It is generally not critical to connect a particular inverter output to a particular motor lead for a new application. The consequence of swapping any two of the three connections is the reversal of the motor direction. For safety reasons, you must connect the motor chassis ground to the ground connection at the bottom of the inverter housing.

Notice the three connections to the motor do not include one marked “Neutral” or “Return.” The motor represents a balanced “Y” impedance to the inverter, so there is no need for a separate return. In other words, each of the three “Hot” connections serves also as a return for the other connections, because of their phase relationship.

The Hitachi inverter is a rugged and reliable device. The intention is for the inverter to assume the role of switching power to the motor during all normal operations. Therefore, this manual instructs you not to switch off power to the inverter while the motor is running (unless it is an emergency stop). Also, do not install or use cut-off switches in the wiring from the inverter to the motor (except thermal cut-off). Of course, safetyrelated devices such as fuses must be in the design to break power during a malfunction.

U/T1

3-Phase

AC Motor

V/T2

Earth GND

W/T3

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Intelligent Functions and Parameters

Getting S tarted

Introduction to Variable-Frequency Drives

Much of this manual is devoted to describing how to use inverter functions and how to configure inv erter parameters. The inverter is microprocessor-controlled, and has many independent functions. The microprocessor has an on-board EEPROM for parameter storage. The inv e rter’s front panel keypad provides access to all functions and parameters, which you can access through other devices as well. The general name for all these devices is the digital operator, or digital operator panel. Chapter 2 will show you how to get a motor running, using a minimal set of function commands or configuring parameters.

The optional read/write programmer will let you read and write inverter EEPROM contents from the programmer. This feature is particularly useful for OEMs who need to duplicate a particular inverter’s settings in many other inverters in assembly-line fashion.

Braking

In general, braking is a force that attempts to slow or stop motor rotation. So it is associated with motor deceleration, but may also occur even when the load attempts to drive the motor faster than the desired speed. If you need the motor and load to decelerate quicker than their natural deceleration during coasting, we recommend installing an optional dynamic braking unit. See pages 5–2 and 5–5 for more information on the BRD–E2 and BRD–EZ2 braking units. The L100 inv erter sends excess motor energy into the resistor in the dynamic braking unit to slow the motor and load. If you have a load that tries to drive the motor continuously for some period of time, that will require a different type of in verter with continuous regenerativ e capability. As an example, elevator control usually requires fast acceleration and deceleration profiles, so you may need to add a dynamic braking unit. However, an application such as running an HVAC fan may just coast to a stop in most cases.

The inverter parameters include acceleration and deceleration, which you can program to match the needs of the application. For a particular inverter, motor, and load, there will be a range of practically achievable accelerations and decelerations.

Velocity Profiles

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The L100 inverter is capable of sophisticated speed control. A graphical representation of that capability will help you understand and program the associated parameters. This manual makes use of the velocity profile graph used in industry (shown at right). In the example, the acceleration is a ramp to a set speed, and the deceleration is a decline to a stop.

Speed

L100 Inverter

1–11

Getting Started

Fixed speed

DecelAccel

Time

Velocity Profile

The L100 inverter can store up to 16 preset speeds. And, it can apply separate accelera tion and deceleration transitions from any prese t to any other preset speed. For example, a motor with a small load could use high accel/decel values, but a heavy load will generally use slower speed changes. A multi-speed profile (shown at right) uses two or more preset speeds in one motion of the load. There is no limit to the number of speed changes for one motion; that is up to the control input to the inverter. Also note that speed can be infinitely variable across the speed range. You can use the potentiometer control on the keypad for manual control. The drive also acc epts analog 0-10V signals and 4-20 mA control signals as well.

The inverter can drive the motor in either direction. Separate FWD and REV commands select the direction of rotation. The motion profile example shows a forward motion followed by a reverse motion of shorter duration. The speed presets and analog signals control the magnitude of the speed, while the FWD and REV commands determine the direction before the motion starts.

Speed

Speed 2

Speed 1

Time

Multi-speed Profile

Forward move

Time

Reverse move

Bi-directional Profile

NOTE: The L100 can move loads in both directions. However, it is not designed for use in servo-type applications that use a bipolar velocity signal which determines direction.

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Frequently Asked Questions

Getting S tarted

Frequently Asked Questions

Q. What is the main advantage in using an inverter to drive a motor, compared to

alternative solutions? A. An inverter can vary the motor speed with v ery little loss of eff iciency, unlike

mechanical or hydraulic speed control solutions. The resulting energy savings usually pays for the inverter in a relatively short time.

Q. The term “inverter” is a little confusing, since we also use “drive” and “amplifier”

to describe the electronic unit that controls a motor. What does “inverter” mean? A. The terms inverter, drive, and amplifier are used somewha t interchange ably

in industry. But there are subtle differences. A drive can refer to the motor, the control electronics, or both. This term is used particularly when the motor and electronics are integrated in the same housing. The term variable speed drive can include many types of de vices – anything that has a variable speed output, which includes the Hitachi inv erter. Amplifier more commonly refers to a linear amplifier for servo motor control, or a stepper motor driver IC. Finally, we use inverter to describe the Hitachi motor controller because of the way the switching electronics alternately inverts or directly couples its internal DC voltage bus to generate a variable AC output.

Q. Although the L100 inverter is a va riable speed drive, can I use it in a fixed-speed

application? A. A fixed speed application usually is a result of cost-sensitivity or negligible

benefits if variable speed were used (consumer products are examples). In those cases, the power source connects directly to the motor (no special driv e needed). Howe ver, using a variable speed driv e can benefit many type of industrial and commercial motor applications, by providing controlled acceleration and deceleration, high torque at low speeds, and energy savings over alternative solutions.

Q. Can I use an inverter and AC induction motor in a positioning application?

A. That depends on the required precision, and the slowest speed the motor will

must turn and still deliver torque. If you set the torque boost, the L100 can develop starting torque at 100% of its rating. However, DO NOT use an inv erter if you need the motor to stop and hold the load position without the aid of a mechanical brake (use a servo or stepper motion control system).

Q. Does the optional digital operator interface or the PC software (DOP Plus) provide

features beyond what is available from the keypad on the unit? A. Yes. However, note first that the same set of parameters and functions are

equally accessible from either the unit’s keypad or from remote devices. The DOP Plus PC software lets you save or load in verter configurations to or from a disk file. And, the hand-held digital operator provides hard-wired terminals, a safety requirement for some installations.

L100 Inverter

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Q. Why does the manual or other documentation use terminology such as “200V

class” instead of naming the actual voltage, such as “230 VAC?” A. A speci fic inverter model is set at the factory to work across a voltage range

particular to the destination country for that model. The model specifications are on the label on the side of the inverter. A European 200V class inverter (“EU” marking) has different parameter settings than a USA 200V class inverter (“US” marking). The initialization procedure (see page 6–8) can set up the inverter for European or US commercial voltage ranges.

Q. Why is there not a 100V class version of the L100 inv erter , so it would work with a

USA 115VAC power source, for example? A. A 100V version of the L100 may be available in the future. However, most

industrial, commercial, or heavy appliance applications use 230VAC in the USA. Also, a built-in advantage is that using the higher voltage means less current to deliver the same amount of power. This allows you to use smaller diameter (and less expensive) wire for power and motor wiring.

Q. I live in a country where the domestic utility power is 115 VAC. Is there a way to

conveniently access a 230 VAC power source for a test bench to develop a motor application?

Getting Started

A. A 1:2 step-up transformer is available from a number of sources (check your

local electrical supply house). The transformer will be designed to develop 230 VAC from 115 VAC, for example. Be s ure the power output rating (kW) of the transformer is greater than 1.73 times the three-phase current of the motor you intend to power . We recommend doing this for motors 1/2 horsepower or smaller , with small loads. F or 400 V class in v erters, we recommend only using a utility power source of the correct voltage.

Q. Some models of Hitachi inverters will accept either single phase or three-phase

power input. How do I know which input power type to use? A. If three-phase power is conveniently available for your application, we

recommend using that (the in v erter can develop its three-phase output power most eff iciently from three-phase input power). In the absence of three-phase power, you can use a single-phase power source with slightly less efficiency but the power output rating is the same for N models (single or three-phase).

Q. If I decide to use single-phase input power for the inverter, can I also use a single-

phase motor? A. No. All Hitachi inverters dev elop a v ariable three-phase output, requiring the

use of a three-phase AC induction motor.

Q. Why doesn’t the motor have a neutral connection as a return to the inverter?

A. T h e motor theoretically represents a “balanced Y” load if all three stator

windings have the same impedance. The Y connection allows each of the three wires to alternately serve as input or return on alternate half-cycles.

Q. Does the motor need a chassis ground connection?

A. Yes, for several reasons. This is for protection in the event of a short in the

motor that puts a live voltage on its housing. Motors and other components

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