Hitachi SJ100 User Manual

Cover

HITACHI

SJ100 Series Inverter Instruction Manual

• Single-phase Input 200V Class

• Three-phase Input 200V Class

• Three-phase Input 400V Class

Manual Number: NB585XF

December 2003

After reading this manual,

keep it handy for future reference.

Hitachi Industrial Equipment Systems Co., Ltd.

Safety Messages

For the best results with the SJ100 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 “Safety Alert Symbol” and a signal word or phrase such as 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 instructions carefully.

WARNING: Indicates a potentially hazardous situation that, if not avoided, can result in serious injury or death.

SJ100 Inverter

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.

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

number of the step will be contained in the step symbol.

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 benefits 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 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.

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 involved. 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 Industrial Equipment Systems Co., 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 leakage type breaker with a fast response circuit capable of handling large currents. The ground fault protection circuit is not designed to protect against personal injury.

WARNING: HAZARD OF ELECTRICAL SHOCK. DISCONNECT INCOMING 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 SJ100 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 Industrial Equipment Systems Co., Ltd.

CAUTION: Be sure to connect a motor thermal disconnect switch or overload device to the SJ100 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 five (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 ground via two independent cables.

SJ100 Inverter

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

CAUTION:

a) Class I motor must be connected to earth ground via low resistive path (< 0.1Ω) 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 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.

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 “ be suitably amended for your application.

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

CAUTION: A double-pole disconnection device must be fitted to the incoming main power 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 “

Wire and Fuse Sizes” on page 2–14).

Choosing a Mounting Location” on page 2–7. The diagram dimensions are to

Terminal (ring lug) Cable support

Cable

Determining

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

Index to Warnings and Cautions in This Manual

Installation - Cautions for Mounting Procedures

CAUTION: The inverter is shipped with a plastic cover over the top vent grill. REMOVE this cover after the installation is complete. Operation with this cover in place will not allow proper cooling, and damage to the inverter may result.

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.

CAUTION: Be sure not to let the foreign matter enter vent openings in the inverter 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 that can bear the weight according to the specifications in the text (Chapter 1, Specifications Tables). Otherwise, it may fall and cause injury to personnel.

CAUTION: Be sure to install the unit on a perpendicular wall that is not subject to vibration. Otherwise, it may fall and cause injury to personnel.

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

....... 2–6

....... 2–7

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

CAUTION: Be sure to maintain the specified clearance area around the inverter and to provide adequate ventilation. Otherwise, the inverter may overheat and cause equipment damage or fire.

....... 2–7

....... 2–8

Wiring - Warnings for Electrical Practices and Wire Specifications

WARNING: “Use 60/75°C Cu wire only” or equivalent. ..... 2–13

WARNING: “Open Type Equipment.” ..... 2–13

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.

..... 2–13

SJ100 Inverter

WARNING: “Suitable for use on a circuit capable of delivering not more than 5,000 rms symmetrical amperes, 480 V maximum.” For models with suffix H.

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. Otherwise, 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 powered, leave it OFF for five minutes before continuing.

Wiring - Cautions for Electrical Practices

.... 2–13

.... 2–19

CAUTION: Fasten the screws with the specified fastening torque in the table below. Check for any loosening of screws. Otherwise, there is the danger of fire.

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 (above 2.2kW) • Three phase 380 to 460 V 50/60Hz

CAUTION: Be sure not to power a three-phase-only inverter with single phase power. Otherwise, there is the possibility of damage to the inverter and the danger of fire.

CAUTION: Be sure not to connect an AC power supply to the output terminals. Otherwise, there is the possibility of damage to the inverter and 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:

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

.... 2–15

.... 2–16

.... 2–17

CAUTION: Remarks for using ground fault interrupter breakers in the main power supply: Adjustable frequency inverters with CE-filters (RFIfilter) and shielded (screened) motor cables have a higher leakage current toward Earth GND. Especially at the moment of switching ON this can cause an inadvertent trip of ground fault interrupters. 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 time-invariant and pulse current-sensitive ground fault interrupters with higher trigger current. • Other components should be secured with separate ground fault interrupters. • Ground fault interrupters in the power input wiring of an inverter are not an absolute protection against electric shock.

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

CAUTION: For motor leads, ground fault interrupter 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.

Powerup Test Caution Messages

..... 2–17

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 to check the capability and limitations of the motor and machine before operating the inverter. Otherwise, there is the danger of injury.

CAUTION: If you operate a motor at a frequency higher than the inverter standard default setting (50Hz/60Hz), be sure to check the motor and machine specifications with the respective manufacturer. Only operate the motor at elevated frequencies after getting their approval. Otherwise, there is the danger of equipment damage and/or injury.

CAUTION: 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 rotation 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?

..... 2–20

.... 2–20,

..... 2–24

..... 2–20

Warnings for Configuring Drive Parameters

SJ100 Inverter

vii

WARNING: When parameter B_12, level of electronic thermal setting, is set to device FLA rating (Full Load Ampere nameplate rating), the device provides solid state motor overload protection at 115% of device FLA or equivalent. Parameter B_12, level of electronic thermal setting, is a variable parameter.

Cautions for Configuring Drive Parameters

CAUTION: Be careful to avoid specifying a braking time that is long enough to cause motor overheating. If you use DC braking, we recommend using a motor with a built-in thermistor, and wiring it to the inverter’s thermistor input (see “Thermistor Thermal Protection” on page 4–22). Also refer to the motor manufacturer’s specifications for duty-cycle recommendations during DC braking.

Warnings for Operations and Monitoring

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

.... 3–26

.... 3–16

...... 4–3

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

WARNING: While the inverter is energized, 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 after a trip stop. Be sure to stop the inverter before approaching 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 short period of time, the inverter may restart operation after the power supply recovers if the Run command 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 Stop Key separately from the emergency stop. Otherwise, it may cause injury to personnel.

WARNING: During a trip event, if the alarm reset is applied and the Run command is present, the inverter will automatically restart. Be sure to apply the alarm reset only after verifying the Run command is OFF. Otherwise, it may cause injury to personnel.

...... 4–3

viii

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

WARNING: If power is turned ON when the Run command is already active, the motor will automatically start and injury may result. Before turning ON the power, confirm that the RUN command is not present.

WARNING: When the Stop key function is disabled, pressing the Stop key does not stop the inverter, nor will it reset a trip alarm.

WARNING: Be sure to provide a separate, hard-wired emergency stop switch when the application warrants it.

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.

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.

WARNING: You may need to disconnect the load from the motor before performing auto-tuning. The inverter runs the motor forward and backward for several seconds without regard to load movement limits.

....... 4–3

....... 4–9

..... 4–21

..... 4–35

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.

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, it may cause injury to personnel.

CAUTION: It is possible to damage the inverter or other devices if your application exceeds the maximum current or voltage characteristics of a connection point.

....... 4–2

....... 4–4

SJ100 Inverter

Warnings and Cautions for Troubleshooting and Maintenance

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.

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: Never remove connectors by pulling on its wire leads (wires for cooling fan and logic P.C.board). Otherwise, there is a danger of fire due to wire breakage and/or injury to personnel.

CAUTION: Do not connect the megger to any control circuit terminals such as intelligent I/O, analog terminals, etc. Doing so could cause damage to the inverter.

CAUTION: Never test the withstand voltage (HIPOT) on the inverter. The inverter has a surge protector between the main circuit terminals above and the chassis ground.

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 components above in an insulated housing before using them.

...... 6–2

.... 6–10

.... 6–14

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 power is applied. Also, do not check signals during operation.

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

Ground fault

interrupter

Power

Input

L1, L2, L3

Inverter

U, V, W

P24

Motor

When there has been a sudden power failure while an operation instruction is active, then the unit may restart operation automatically after the power failure 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 a Run command is active. So, please be careful.

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

Power

Input

Ground fault

interrupter

L1, L2, L3

U, V, W

Inverter

GND lug

Surge absorber

Motor

Leading power

factor capacitor

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

In a system using an inverter 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.

SJ100 Inverter

CAUTION: SUPPRESSION FOR NOISE INTERFERENCE FROM INVERTER

The inverter uses many semiconductor switching elements such as transistors 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.

EMI Filter Inverter

Motor

noise

EMI Filter

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

Inverter

Remote

Operator

Motor

Grounded frame

Conduit or shielded cable—to be grounded

CAUTION: EFFECTS OF POWER DISTRIBUTION SYSTEM ON INVERTER

In the cases below involving a general-purpose inverter, a large peak current can flow on the power supply side, sometimes destroying the converter module:

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 (or the power supply capacity is 500 kVA or more).

3. Abrupt power supply changes are expected, due to conditions such as: 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.

Where these conditions exist or when the connected equipment must be highly reliable, you MUST install an input-side AC reactor of 3% (at a voltage drop at rated current) with respect to the supply voltage on the power supply side. Also, where the effects of an indirect lightning strike are possible, install a lightning conductor.

xii

CAUTION: When the EEPROM error E08 occurs, be sure to confirm the setting values again.

CAUTION: When using normally closed active state settings (C_11 to C_16) for exter- nally commanded Forward or Reverse terminals [FW] or [RV], the inverter may start automatically when the external system is powered OFF or disconnected from the inverter! So, do not use normally closed active state settings for Forward or Reverse terminals [FW] or [RV] unless your system design protects against unintended motor operation.

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.

UL® Cautions, Warnings, and Instructions

Wiring Warnings for Electrical Practices and Wire Sizes

The Cautions, Warnings, and instructions in this section summarize the procedures necessary to ensure an inverter installation complies with Underwriters Laboratories guidelines.

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

WARNING: “Open Type Equipment.”

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.

WARNING: “Suitable for use on a circuit capable of delivering not more than 5,000 rms symmetrical amperes, 480 V maximum.” For models with suffix H.

Terminal Tightening Torque and Wire Size

The wire size range and tightening torque for field wiring terminals are presented in the table below.

SJ100 Inverter

xiii

Input

Voltage

200V

400V

Motor Output

Inverter Model

kW HP ft-lbs (N-m)

0.2 1/4 SJ100-002NFE/NFU

0.55 3/4 SJ100-005NFE

0.75 1 SJ100-007NFE/NFU

1.1 1 1/2 SJ100-011NFE

1.5 2 SJ100-015NFE/NFU 12

2.2 3 SJ100-022NFE/NFU 10

3.7 5 SJ100-037LFU 12

5.5 7 1/2 SJ100-055LFU 10

7.5 10 SJ100-075LFU 8

0.4 1/2 SJ100-004HFE/HFU

0.75 1 SJ100-007HFE/HFU

1.5 2 SJ100-015HFE/HFU

2.2 3 SJ100-022HFE/HFU

3.0 4 SJ100-030HFE

4.0 5 SJ100-040HFE/HFU

Wiring Size

Range (AWG)

16 0.6 0.80.4 1/2 SJ100-004NFE/NFU

Torq ue

0.9 1.2

1.5 2.0

0.9 1.2

5.5 7 1/2 SJ100-055HFE/HFU

7.5 10 SJ100-075HFE/HFU

Wire Connectors

WARNING: Field wiring connections must be made by a UL Listed and CSA Certified ring lug terminal connector sized for the wire gauge being used. The connector must be fixed using the crimping tool specified by the connector manufacturer.

12 1.5 2.0

Terminal (ring lug)

Cable support

Cable

xiv

Circuit Breaker and Fuse Sizes

The inverter’s connections to input power must include UL Listed inverse time circuit breakers with 600V rating, or UL Listed fuses as shown in the table below.

Input

Voltage

200V

Motor Output

Inverter Model

kW HP

0.2 1/4 SJ100-002NFE/NFU 10

0.4 1/2 SJ100-004NFE/NFU 10

0.55 3/4 SJ100-005NFE 10

0.75 1 SJ100-007NFE/NFU 15

1.1 1 1/2 SJ100-011NFE 15

1.5 2 SJ100-015NFE/NFU 20 (single ph.)

2.2 3 SJ100-022NFE/NFU 30 (single ph.)

3.7 5 SJ100-037LFU 30

5.5 7 1/2 SJ100-055LFU 40

7.5 10 SJ100-075LFU 50

0.4 1/2 SJ100-004HFE/HFU 3

0.75 1 SJ100-007HFE/HFU 6

1.5 2 SJ100-015HFE/HFU 10

Fuse (A)

(UL-rated,

class J, 600V)

15 (three ph.)

20 (three ph.)

400V

2.2 3 SJ100-022HFE/HFU 10

3.0 4 SJ100-030HFE 15

4.0 5 SJ100-040HFE/HFU 15

5.5 7 1/2 SJ100-055HFE/HFU 20

7.5 10 SJ100-075HFE/HFU 25

Motor Overload Protection

Hitachi SJ100 inverters provide solid state motor overload protection, which depends on the proper setting of the following parameters:

• B_12 “electronic overload protection”

• B212 “electronic overload protection, 2nd motor”

Set the rated current [Amperes] of the motor(s) with the above parameters. The setting range is 0.5 * rated current to 1.2 * rated current.

WARNING: When two or more motors are connected to the inverter, they cannot be protected by the electronic overload protection. Install an external thermal relay on each motor.

SJ100 Inverter

Safety Messages

Hazardous High Voltage i General Precautions - Read These First! ii Index to Warnings and Cautions in This Manual iv General Warnings and Cautions ix UL® Cautions, Warnings, and Instructions xii

Table of Contents

Revisions xvii Contact Information xviii

Chapter 1: Getting Started

Introduction 1–2 SJ100 Inverter Specifications 1–5 Introduction to Variable-Frequency Drives 1–18 Frequently Asked Questions 1–23

Chapter 2: Inverter Mounting and Installation

Orientation to Inverter Features 2–2 Basic System Description 2–5 Step-by-Step Basic Installation 2–6 Powerup Test 2–19 Using the Front Panel Keypad 2–21

Chapter 3: Configuring Drive Parameters

Choosing a Programming Device 3–2 Using Keypad Devices 3–3 “D” Group: Monitoring Functions 3–6 “F” Group: Main Profile Parameters 3–8 “A” Group: Standard Functions 3–9 “B” Group: Fine Tuning Functions 3–24 “C” Group: Intelligent Terminal Functions 3–34 “H” Group: Motor Constants Functions 3–43

xvi

Chapter 4: Operations and Monitoring

Introduction 4–2 Connecting to PLCs and Other Devices 4–4 Example Wiring Diagram 4–5 Using Intelligent Input Terminals 4–8 Using Intelligent Output Terminals 4–24 Analog Input Operation 4–32 Analog and Digital Monitor Output 4–33 Auto-tuning for Sensorless Vector Control 4–35 PID Loop Operation 4–39 Configuring the Inverter for Multiple Motors 4–40

Chapter 5: Inverter System Accessories

Introduction 5–2 Component Descriptions 5–3 Dynamic Braking 5–5

Chapter 6: Troubleshooting and Maintenance

Troubleshooting 6–2 Monitoring Trip Events, History, & Conditions 6–5 Restoring Factory Default Settings 6–8 Maintenance and Inspection 6–9 Warranty 6–16

Appendix A: Glossary and Bibliography

Glossary A–2 Bibliography A–8

Appendix B: Drive Parameter Settings Tables

Introduction B–2 Parameter Settings for Keypad Entry B–2

Appendix C: CE–EMC Installation Guidelines

CE–EMC Installation Guidelines C–2 Hitachi EMC Recommendations C–6

Index

Revisions

Revision History Table

SJ100 Inverter

xvii

No. Revision Comments Date of Issue

Initial release of manual NB585X April 1999 NB585X

1 Revision A

Added 7.5 and 10 HP models to tables and drawings in Chapt. 1 and 2, Minor corrections throughout manual

2 Revision B

Pages 1-4, 5 – Specs tables: corrected weights (lbs), added row for input current, corrected dynamic braking % torque Page 2-11 – Added note about fans at bottom of page Page 2-15 – Added torque specs for 7.5 and 10 HP models Page 3-36 – Added larger motor sizes to H_03/H203 motor capacity settings in table Page 3-41 – Added note about SLV operation at top of page Pages 4-30, 31 – Changed text in notes for Steps 1, 2, and 10 in table to clarify auto-tuning procedure Pages 4-31, 32 – Added auto-tuning notes at bottom of 4-31 and new page 4-32 about motor parameters, frame size, etc. Page 5-5 – Added braking res. specs for 7.5/10 HP models

3 Revision C

Updated company name on cover, contact page, and nameplate photo Updated text, figures, and tables throughout manual per technical corrections or usability improvements Pages xii to xiv – Added UL Instructions Page xviii – Contact page update Pages 1-5 to 1-8 – Added watt loss, efficiency data to tables Pages 1-10 to 1-15 – Added derating graphs Page 2-16 – Added power terminal diagrams Page 4-5 – Added system wiring diagram Page 4-7 – Added terminal index listing Page 4-8 – Added input terminal wiring diagrams Page 4-24 – Added output terminal wiring diagrams Pages 5-5 to 5-10 – Added braking tables and figures Page 6-10 – Added megger test procedure and figure Page 6-15 – Added IGBT test method, figure, and table Pages C-1 to C-6 – Added appendix on CE-EMC Removed DOP+ info from Ch3 and Appendix B

May 1999 NB585XA

August 1999 NB585XB

May 2002 NB585XC

Operation

Manual No.

4 Revision D

Minor corrections throughout

5 Revision E

Minor corrections throughout

5 Revision F

Minor corrections throughout

Nov. 2002 NB585XD

July 2003 NB585XE

Dec. 2003 NB585XF

xviii

Contact Information

Hitachi America, Ltd. Power and Industrial Division 50 Prospect Avenue Tarrytown, NY 10591 U.S.A. Phone: +1-914-631-0600 Fax: +1-914-631-3672

Hitachi Europe GmbH Am Seestern 18 D-40547 Düsseldorf Germany Phone: +49-211-5283-0 Fax: +49-211-5283-649

Hitachi Asia Ltd. 16 Collyer Quay #20-00 Hitachi Tower, Singapore 049318 Singapore Phone: +65-538-6511 Fax: +65-538-9011

Hitachi Australia Ltd. Level 3, 82 Waterloo Road North Ryde, N.S.W. 2113 Australia Phone: +61-2-9888-4100 Fax: +61-2-9888-4188

Hitachi Industrial Equipment Systems Co, Ltd. International Sales Department WBG MARIVE WEST 16F 6, Nakase 2-chome Mihama-ku, Chiba-shi, Chiba 261-7116 Japan Phone: +81-43-390-3516 Fax: +81-43-390-3810

Hitachi Industrial Equipment Systems Co, Ltd. Narashino Division 1-1, Higashi-Narashino 7-chome Narashino-shi, Chiba 275-8611 Japan Phone: +81-47-474-9921 Fax: +81-47-476-9517

Hitachi Asia (Hong Kong) Ltd. 7th Floor, North Tower World Finance Centre, Harbour City Canton Road, Tsimshatsui, Kowloon Hong Kong Phone: +852-2735-9218 Fax: +852-2735-6793

NOTE: To receive technical support for the Hitachi inverter you purchased, contact the Hitachi inverter dealer from whom you purchased the unit, or the sales office or factory contact listed above. Please be prepared to provide the following inverter nameplate information:

1. Model

2. Date of purchase

3. Manufacturing number (MFG No.)

4. Symptoms of any inverter problem If any inverter nameplate information is illegible, please provide your Hitachi contact with any other legible nameplate items. To reduce unpredictable downtime, we recommend that you stock a spare inverter.

Getting Started

In This Chapter... page

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

— SJ100 Inverter Specifications.......................... 5

— Introduction to Variable-Frequency Drives .... 18

— Frequently Asked Questions ......................... 23

1–2

Getting Started

Introduction

Main Features

Congratulations on your purchase of an SJ100 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 SJ100 product line includes more than a dozen inverter models to cover motor sizes from 1/4 horsepower to 10 horsepower, in either 230 VAC or 460 VAC power input versions. The main features are:

• 200V and 400V Class inverters

• UL or CE version available

• Sensorless vector control

• Regenerative braking circuit

• Convenient keypad for parameter settings

• Built-in RS-422 communications interface to

allow configuration from a PC and for field bus external modules.

• Sixteen programmable speed levels

• Motor constants are programmable, or may be set via auto-tuning

• 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 performance characteristics are:

• High starting torque of 200% rating or greater

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

without motor derating

• Fan has ON/OFF selection to provide longer life for cooling fan (on models with fan)

Model SJ100-004NFU

A full line of accessories from Hitachi is available to complete your motor application. These include:

• Digital remote operator keypad

• Braking resistors (shown at right)

• Radio noise filters

• CE compliance filters

• DIN rail mounting adapter (35mm rail size)

Operator Interface Options

The optional SRW-0EX digital operator / copy unit is shown to the right. It has the additional capability of reading (uploading) the parameter settings in the inverter into its memory. Then you can connect the copy unit on another inverter and write (download) the parameter settings into that inverter. OEMs will find this unit particularly useful, as one can use a single copy unit to transfer parameter settings from one inverter to many.

SJ100 Inverter

1–3

Getting Started

Braking Resistor

Other digital operator interfaces may be available from your Hitachi distributor for particular industries or international markets. Contact your Hitachi distributor for further details.

Digital Operator / Copy Unit

1–4

Getting Started

Introduction

Inverter Specifications Label

The Hitachi SJ100 inverters have product labels 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.

Regulatory agency approvals

Specifications label

Inverter model number

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 inverter contains useful information about its operating characteristics. Refer to the model number legend below:

SJ100 004 H F U

Series name

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

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

SJ100 Inverter

1–5

SJ100 Inverter Specifications

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

The following tables are specific to SJ100 inverters for the 200V and 400V class model groups. Note that “ groups. Footnotes for all specifications tables follow the table below.

Item 200V Class Specifications

SJ100 inverters, 200V models

Applicable motor size *2 kW 0.2 0.4 0.55 0.75 1.1

Rated capacity (kVA) *12

Rated input voltage 1-phase: 200 to 240V +5/-10%, 50/60 Hz ±5%,

Rated input current (A)

CE version 002NFE 004NFE 005NFE 007NFE 011NFE

UL version 002NFU 004NFU — 007NFU —

230V 0.6 1.0 1.1 1.5 1.9

240V 0.6 1.0 1.2 1.6 2.0

1-phase 3.5 5.8 6.7 9.0 11.2

3-phase 2.0 3.4 3.9 5.2 6.5

General Specifications” on page 1–9 apply to both voltage class

HP 1/4 1/2 3/4 1 1.5

3-phase: 200 to 240V +5/-10%, 50/60 Hz ±5%,

(037LFU, 055LFU, and 075LFU 3phase only)

Getting Started

Rated output voltage *3 3-phase: 200 to 240V (corresponding to input voltage)

Rated output current (A) 1.6 2.6 3.0 4.0 5.0

Efficiency at 100% rated output (%) 90.5 92.8 93.6 94.1 95.4

Watt loss, approximate (W)

Starting torque *6 200% or more

Dynamic braking approx. % torque, short time stop *7

DC braking Variable operating frequency, time, and braking force

Weight kg 0.7 0.85 0.85 1.3 1.3

at 70% output 15 21 25 31 38

at 100% output 19 29 32 41 51

without resistor, from 50 / 60 Hz

with resistor 150%

lb 1.54 1.87 1.87 2.87 2.87

100%: ≤ 50Hz

50%: ≤ 60Hz

70%: ≤ 50Hz 50%: ≤ 60Hz

1–6

Getting Started

SJ100 Inverter Specifications

Footnotes for the preceding table and the tables that follow:

Note 1: The protection method conforms to JEM 1030. Note 2: The applicable motor refers to Hitachi standard 3-phase motor (4-pole). When

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

Note 3: The output voltage decreases as the main supply voltage decreases (except

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

Note 4: To operate the motor beyond 50/60 Hz, consult the motor manufacturer for

the maximum allowable rotation speed.

Note 5: When SLV is selected, please set the carrier frequency higher than 2.1 kHz. Note 6: At the rated voltage when using a Hitachi standard 3-phase, 4-pole motor

(when selecting sensorless vector control—SLV).

Note 7: 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. The average deceleration torque varies with motor loss. This value decreases when operating beyond 50 Hz. If a large regenerative torque is required, the optional regenerative braking resistor should be used.

Note 8: 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 satisfactory for your application, contact your Hitachi sales representative.

Note 9: If operating the inverter at 40 to 50° C, reduce the carrier frequency 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.

Note 10: The storage temperature refers to the short-term temperature during transport. Note 11: Conforms to the test method specified in JIS C0911 (1984). For the model

types excluded in the standard specifications, contact your Hitachi sales representative.

Note 12: The input voltage of xxLFU is 230V.

SJ100 Inverter Specifications, continued...

Item 200V Class Specifications, continued

SJ100 Inverter

1–7

Getting Started

SJ100 inverters, 200V models

Applicable motor size *2 kW 1.5 2.2 3.7 5.5 7.5

Rated capacity (kVA) *12

Rated input voltage 1-phase: 200 to 240V +5/-10%, 50/60 Hz ±5%,

Rated input current (A)

Rated output voltage *3 3-phase: 200 to 240V (corresponding to input voltage)

Rated output current (A) 8.0 11.0 17.5 24 32

Efficiency at 100% rated output (%) 94.7 95.1 95.1 96.1 96.2

Watt loss, approximate (W)

Starting torque *6 200% or more 180% or more

Dynamic braking approx. % torque, short time stop *7

CE version 015NFE 022NFE — — —

UL version 015NFU 022NFU 037LFU 055LFU 075LFU

HP 2 3 5 7.5 10

230V 3.1 4.3 6.9 9.5 12.7

240V 3.0 4.5 7.2 9.9 13.3

3-phase: 200 to 240V +5/-10%, 50/60 Hz ±5%,

(037LFU, 055LFU, 075LFU 3-phase only)

1-phase 17.5 24.0 — — —

3-phase 10.0 14.0 22.0 30.0 40.0

at 70% output 57 78 130 152 204

at 100% output 79 107 181 216 288

without resistor, from 50 / 60 Hz

with resistor 150% 100% 80%

70%: ≤ 50Hz 50%: ≤ 60Hz

20%: ≤ 50Hz 20%: ≤ 60Hz

DC braking Variable operating frequency, time, and braking force

Weight kg 2.2 2.8 2.8 5.5 5.7

lb 4.85 6.17 6.17 12.13 12.57

1–8

SJ100 Inverter Specifications

Item 400V Class Specifications

Getting Started

SJ100 inverters, 400V models

Applicable motor size *2 kW 0.4 0.75 1.5 2.2

Rated capacity (460V) kVA 1.1 1.9 2.9 4.2

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

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

Efficiency at 100% rated output (%) 92.0 93.7 95.7 95.8

Watt loss, approximate (W)

Starting torque *6 200% or more

Dynamic braking approx. % torque, short time stop *7

DC braking Variable operating frequency, time, and braking force

CE version 004HFE 007HFE 015HFE 022HFE

UL version 004HFU 007HFU 015HFU 022HFU

HP 1/2 1 2 3

at 70% output 25 33 48 68

at 100% output 32 44 65 92

without resistor, from 50/60 Hz

with resistor 150% 100%

100%: ≤ 50Hz

50%: ≤ 60Hz

70%: ≤ 50Hz 20%: ≤ 60Hz

Weight kg 1.3 1.7 1.7 1.8

lb 2.87 3.75 3.75 3.97

SJ100 Inverter

1–9

Item 400V Class Specifications, continued

SJ100 inverters, 400V models

Applicable motor size *2 kW 3.0 4.0 5.5 7.5

Rated capacity (460V) kVA 6.2 6.6 10.3 12.7

Rated input voltage 3-phase: 380 to 460V ±10%, 50/60 Hz ±5%

Rated input current (A) 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) 7.8 8.6 13 16

Efficiency at 100% rated output (%) 95.4 96.2 96.0 96.5

Watt loss, approximate (W)

Starting torque *6 180% or more

Dynamic braking approx. % torque, short time stop *7

CE version 030HFE 040HFE 055HFE 075HFE

UL version — 040HFU 055HFU 075HFU

HP 4 5 7.5 10

at 70% output 100 108 156 186

at 100% output 138 151 219 261

without resistor, from 50/60 Hz

with resistor 100% 80%

20%: ≤ 50Hz 20%: ≤ 60Hz

Getting Started

DC braking Variable operating frequency, time, and braking force

Weight kg 2.8 2.8 5.5 5.7

lb 6.17 6.17 12.13 12.57

General Specifications

The following table applies to all SJ100 inverters.

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: 0.1% of the maximum frequency (25°C ± 10°C)

Frequency setting resolution Digital: 0.1 Hz; Analog: max. frequency/1000

Volt./Freq. characteristic *5 V/f optionally variable, V/f control (constant torque, reduced

torque), sensorless vector control

Overload current rating 150%, 60 seconds

Acceleration/deceleration time 0.1 to 3000 sec., (linear accel/decel), second accel/decel setting

available

1–10

SJ100 Inverter Specifications

Item General Specifications

Getting Started

Input signal

Output signal

Alarm output contact ON for inverter alarm (1C contacts, both normally open or closed

Other functions AVR function, curved accel/decel profile, upper and lower limiters,

Freq. setting

FWD/ REV Run

Intelligent input terminal

Intelligent output terminal

Frequency monitor PWM output; Select analog output frequency monitor, analog output

Operator panel Up and Down keys / Value settings

Potentiometer Analog setting

External signal *80 to 10 VDC (input impedance 10k Ohms), 4 to 20 mA (input

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

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

External signal 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), DB (external DC braking command), SET (2nd setting selection), UP (remote control, accel.), DWN (remote control, decel.)

RUN (run status signal), FA1,2 (frequency arrival signal), OL (overload advance notice signal), OD (PID error deviation signal), AL (alarm signal)

current monitor or digital output frequency monitor

avail.)

16-stage 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 level adjustment, retry function, trip history monitor, 2nd setting selection, auto tuning, fan ON/OFF selection

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

low temperature, CPU error, memory error, ground fault detection at startup, internal communication error, electronic thermal, CT error

Operating Environ ment

Coating color Munsell 8.5YR6.2/0/2, cooling fins in base color of aluminum

Options Remote operator unit, copy unit, cables for the units, braking unit,

Temperature Operating (ambient): -10 to 50°C (*9) / Storage: -25 to 70°C (*10)

Humidity 20 to 90% humidity (non-condensing)

Vibration *11

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

5.9 m/s

braking resistor, AC reactor, DC reactor, noise filter, DIN rail mounting

(0.6G), 10 to 55 Hz

SJ100 Inverter

1–11

Signal Ratings

Detailed ratings are in “Specifications of Control and Logic Connections” on page 4–6.

Signal / Contact Ratings

Built-in power for inputs 24VDC, 30 mA maximum

Discrete logic inputs 27VDC maximum

Discrete logic outputs 50mA maximum ON state current, 27 VDC maximum OFF state voltage

PWM (analog/digital) output 0 to 10VDC, 1 mA, PWM and 50% duty digital

Analog input, current 4 to 19.6 mA range, 20 mA nominal

Analog input, voltage 0 to 9.6 VDC range, 10VDC nominal, input impedance 10 kΩ

+10V analog reference 10VDC nominal, 10 mA maximum

Alarm relay contacts 250 VAC, 2.5A (R load) max., 0.2A (I load, P.F.=0.4) max.

100 VAC, 10mA min. 30 VDC, 3.0A (R load) max., 0.7A (I load, P.F.=0.4) max. 5 VDC, 100mA min.

Getting Started

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