Hitachi WJ200-007L, WJ200-001L, WJ200-015S, WJ200-022S, WJ200-004H Instruction Manual

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WJ200

Series Inverter

Instruction Manual

• Single-phase Input 200V class

• Three-phase Input 200V class

• Three-phase Input 400V class

Hitachi Industrial Equipment Systems Co., Ltd.

Manual Number: NT325X

May 2010

After read this manual,

Keep it handy for future reference.

Safety Messages

For the best results with the WJ200 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 operating this equipment. Read the message and follow the instructions carefully.

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

CAUTION: Indicates a potentially hazardous situation that, if not avoided, can result in minor to moderate injury or serious damage to the product. The situation described in the CAUTION may, if not avoided, lead to serious results. Important safety measures are described in CAUTION (as well as WARNING), so be sure to observe them.

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 indicates an area or subject of special merit, emphasizing either the product’s capability 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 i

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 housing 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.

Caution when using Safe Stop Function

When using Safe Stop function, make sure to check whether the safe stop function properly works when installation (before starting operation). Please carefully refer to page Appendix E

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: HAZARDOUS 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 WJ200 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 WJ200 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-wire to earth ground via two independent cables.

iii

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.

CAUTION:

a) Class I motor must be connected to earth ground via low resistive path (<0.1) b) Any motor used must be of a suitable rating. c) Motors may have hazardous moving path. 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.

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 “Choosing a Mounting Location” on page 2-7

. 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. 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 meet IEC947-1/ IEC947-3 must be fitted at this point (protection device data shown in “Determining Wire and Fuse Sizes” on page 2-16).

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

Index to Warnings and Cautions in This Manual iv

Cautions and Warnings for Orientation and Mounting Procedures

HIGH VOLTAGE: Hazard of electrical shock. Disconnect incoming power before working on this control. Wait five (5) minutes before removing the front cover.

…2-3

HIGH VOLTAGE:

Hazard of electrical shock. Never touch the naked PCB (printed circuit board) portions while the unit is powered up. Even for switch portion, the inverter must be powered OFF before you change.

…2-4

…2-8

WARNIN G: 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.

…2-9

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

the power supply capacity is 500kVA or more).

3. Abrupt power supply changes are expected, due to the 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.

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.

…2-9

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.

…2-9

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.

…2-9

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.

…2-9

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

…2-9

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.

…2-9

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.

…2-10

Wiring – Warnings for Electrical Practice and Wire Specifications

WARNIN G: “USE 60/75C Cu wire only” or equivalent. For models WJ200-001L, -002L,

-004L, -007L, -015S, -022S, -004H, -007H, -015H, -022H and -030H.

WARNIN G: “USE 75C Cu wire only” or equivalent. For models WJ200-001S, -002S,

-004S, -007S, -015L, -022L, -037L, -055L, -075L, -110L, -150L, -037H, -040H, -055H,

-075H, -110H and -150H.

WARNIN G: “Open Type Equipment.”

WARNIN G: “Suitable for use on a circuit capable of delivering not more than 100k rms symmetrical amperes, 240V maximum when protected by Class CC, G, J or R fuses or circuit breaker having an interrupting rating not les than 100,000 rms symmetrical amperes, 240 volts maximum”. For models with suffix S, N or L.

WARNIN G: “Suitable for use on a circuit capable of delivering not more than 100k rms symmetrical amperes, 480V maximum when protected by Class CC, G, J or R fuses or circuit breaker having an interrupting rating not les than 100,000 rms symmetrical amperes, 480 volts 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 operate an inverter that is not mounted according to the instructions given in this manual. Otherwise, there is a danger of electric shock and/or injury to personnel.

WARNIN G: Make sure the input power to the inverter is OFF. If the drive has been powered, leave it OFF for five minutes before continuing.

CAUTION: Power terminal assignment is different compared to old models such as L100, L200 series, etc,. Pay attention when wiring the power cable.

…2-18

…2-23

…2-11

~21

Wiring – Cautions for Electrical Practice

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.

… 2-18

CAUTION: Be sure that the input voltage matches the inverter specifications;

 Single phase 200V to 240V 50/60Hz (up to 2.2kW) for SFEF model  Single/Three phase 200V to 240V 50/60Hz (up to 2.2kW) for NFU model  Three phase 200V to 240V 50/60Hz (7.5kW) for LFU model  Three phase 380V to 480V 50/60Hz (up to 7.5kW) for HFx model

… 2-20

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.

… 2-20

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.

… 2-20

Power Input

Output to Motor

WJ200 Inverter

vii

CAUTION: Remarks for using ground fault interrupter breakers in the main power supply: Adjustable frequency inverter with integrated CE-filters 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.

… 2-20

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.

… 2-20

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.

… 2-20

Powerup Test Caution Messages

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

… 2-23

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.

… 2-23

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.

… 2-23 … 2-29

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 vibration or noise?

… 2-23

viii

Warnings for Configuring Drive Parameters

WARNIN G: When parameter b012, level of electronic thermal setting, is set to motor FLA rating (Full Load Ampere nameplate rating), the inverter provides solid state motor overload protection at 115% of motor FLA or equivalent. If parameter B012 exceeds the motor FLA rating, the motor may overheat and damaged. Parameter B012, level of electronic thermal setting, is a variable parameter.

… 3-34

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 4-24). Also refer to the motor manufacturer’s specifications for duty-cycle recommendations during DC braking.

… 3-19

HIGH VOLTAGE: When set RDY function ON, there will be a voltage appear at motor output terminals U, V and W even if the motor is in stop mode. So never touch the inverter power terminal even the motor is not running.

… 3-47

CAUTION: Do not change Debug mode for safety reasons. Otherwise unexpected performances may occur.

… 3-62

Warnings for Operations and Monitoring

WARNIN G: 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.

… 4-3

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

… 4-3

WARNIN G: 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.

… 4-3

WARNIN G: 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.

… 4-3

WARNIN G: If the power supply is cut OFF for a short period of time, the inverter may restart operating 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.

… 4-3

WARNIN G: 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.

… 4-3

WARNIN G: 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

WARNIN G: 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.

… 4-3

WARNIN G: 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.

… 4-3

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

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

… 4-3

WARNIN G: 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.

… 4-11

WARNIN G: 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.

… 4-22

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.

… 4-2

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.

… 4-4

CAUTION: Be sure to turn OFF power to the inverter before changing the short circuit bar position to change SR/SK. Otherwise, damage to the inverter circuitry may occur.

… 4-8

CAUTION: Be careful not to turn PID clear ON and reset the integrator sum when the inverter is in Run mode (output to motor is ON). Otherwise, this could cause the motor to decelerate rapidly, resulting in a trip.

… 4-26

… 4-31

CAUTION: The digital outputs (relay and/or open collector) available on the drive

must not be considered as safety related signals. The outputs of the external safety relay must be used for integration into a safety related control/command circuit

… 4-32

HIGH VOLTAGE: Dangerous voltage exists even after the Safe Stop is activated.

It does

NOT

mean that the main power has been removed.

… 4-34

Warnings and Cautions for Troubleshooting and Maintenance

WARNIN G: 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.

… 6-2

WARNIN G: 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.

… 6-2

WARNIN G: 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.

… 6-2

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

… 6-10

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.

… 6-10

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.

… 6-10

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.

… 6-10

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.

… 6-14

General Warnings and Cautions iv

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

CAUTION: Withstand voltage test 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 turning OFF the power supply before opening the cover.

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

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.

Ground fault

interrupter

CAUTION: MOTOR TERMINAL SURGE VOLTAGE SUPPRESSION FILTER (For the 400V 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 the inverter is 10m or more) and cabling method may occur at the motor terminals. A dedicated filter of the 400V class for suppressing this voltage surge is available. Be sure to install a filter in this situation.

Power

Input

Inverter

U, V, W

L1, L2, L3

Motor

PCS

Power

Input

Ground fault

interrupter

L1, L2, L3

Inverter

U, V, W

Motor

Surge absorber

GND lug

Leading power factor capacitor

xii

CAUTION: EFFECTS OF POWER DISTRIBUTION SYSTEM ON INVERTER In the case 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 500kVA 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 lightening strike are possible, install a lightening conductor.

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 the inverter.

 SFEF model has integrated filter complies to EN61800-3 category C1.  HFEF model has integrated filter complies to EN61800-3 category C2.

EMI Filter

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

CAUTION: When using normally closed active state settings (C011 to C017) for externally 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.

R1 S1 T1

R2 S2

Inverter

L1 L2 L3

U V

Motor

EMI Filter Inverter

Motor

Remote

Operator

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

noise

Grounded frame

Conduit or shielded cable

-- to be grounded

xiii

CAUTION: In all the instrumentations 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.

CAUTION: Do not discard the inverter with household waste. Contact an industrial waste management company in your area who can treat industrial waste without polling the environment.

UL Cautions, Warnings and Instructions xii Warnings and Cautions for Troubleshooting and Maintenance

The warnings and instructions in this section summarizes the procedures necessary to ensure an inverter installation complies with Underwriters Laboratories



guidelines.

WARNIN G: Use 60/75C Cu wire only. (for models: WJ200-001L, -002L, -004L, -007L, -015S,

-022S, -004H, -007H, -015H, -022H and -030H)

WARNIN G: Use 75C Cu wire only. (for models: WJ200-001S, -002S, -004S, -007S, -015L, -022L,

-037L, -055L, -075L, -110L, -150L, -040H, -055H, -075H, -110H and -150H)

WARNIN G: Suitable for use on a circuit capable of delivering not more than 100,000 rms

Symmetrical Amperes, 240 or 480V maximum.

WARNIN G: When protected by CC, G, J, or R class Fuses, or when Protected By A Circuit Breaker Having An Interrupting Rating Not Less Than 100,000 rms Symmetrical Amperes, 240 or 480 Volts Maximum.

WARNIN G: Install device in pollution degree 2 environment.

WARNIN G: Maximum Surrounding Air Temperature 50C

WARNIN G: Solid state motor overload protection is provided in each model

WARNIN G: Integral solid state short circuit protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the National Electric Code and any additional local codes

xiv

Terminal symbols and Screw size

Inverter Model Screw Size

Required

Torque (N-m)

Wire range

WJ200-001S WJ200-002S WJ200-004S

M3.5 1.0 AWG16 (1.3mm

)

WJ200-007S M4 1.4 AWG12 (3.3mm2) WJ200-015S WJ200-022S

M4 1.4 AWG10 (5.3mm

)

WJ200-001L WJ200-002L WJ200-004L WJ200-007L

M3.5 1.0 AWG16 (1.3mm

)

WJ200-015L M4 1.4 AWG14 (2.1mm2) WJ200-022L M4 1.4 AWG12 (3.3mm2) WJ200-037L M4 1.4 AWG10 (5.3mm2) WJ200-055L WJ200-075L

M5 3.0 AWG6 (13mm

)

WJ200-110L M6 5.9 to 8.8 AWG4 (21mm2) WJ200-150L M8 5.9 to 8.8 AWG2 (34mm2)

WJ200-004H WJ200-007H WJ200-015H

M4 1.4 AWG16 (1.3mm

)

WJ200-022H WJ200-030H

M4 1.4 AWG14 (2.1mm

)

WJ200-040H M4 1.4 AWG12 (3.3mm2) WJ200-055H WJ200-075H

M5 3.0 AWG10 (5.3mm

)

WJ200-110H WJ200-150H

M6 5.9 to 8.8 AWG6 (13mm

)

Fuse Sizes

The inverter shall be connected with a UL Listed Cartridge Nonrenewable fuse, rated 600Vac with the current ratings as shown in the table below.

Inverter Model Type Rating

WJ200-001S WJ200-002S WJ200-004S

Class J

10A, AIC 200kA

WJ200-007S 15A, AIC 200kA WJ200-015S WJ200-022S

30A, AIC 200kA

WJ200-001L WJ200-002L WJ200-004L

10A, AIC 200kA

WJ200-007L WJ200-015L

15A, AIC 200kA

WJ200-022L 20A, AIC 200kA WJ200-037L 30A, AIC 200kA

WJ200-055L

WJ200-075L

40A, AIC 200kA

WJ200-110L

WJ200-150L

80A, AIC 200kA

WJ200-004H WJ200-007H WJ200-015H WJ200-022H

10A, AIC 200kA

WJ200-030H WJ200-040H

15A, AIC 200kA

WJ200-055H

WJ200-075H

20A, AIC 200kA

WJ200-110H

WJ200-150H

40A, AIC 200kA

xvi

Table of Contents

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 ................................................................................................. x

UL Cautions, Warnings and Instructions .............................................................................. xiii

Circuit Breaker and Fuse Sizes ................................................................................................ xv

Table of Contents

Revisions ............................................................................................................................... xviii

Contact Information ............................................................................................................... xix

Chapter 1: Getting Started

Introduction ............................................................................................................................ 1-2

WJ200 Inverter Specifications .............................................................................................. 1-4

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 ...................................................................................................... 2-4

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

Powerup Test ........................................................................................................................ 2-23

Using the Front Panel Keypad ........................................................................................... 2-25

Chapter 3: Configuring Drive Parameters

Choosing a Programmable Device ........................................................................................ 3-2

Using the Keypad Devices ..................................................................................................... 3-3

“D” Group: Monitoring Functions ......................................................................................... 3-7

“F” Group: Main Profile Parameters ................................................................................... 3-11

“A” Group: Standard Functions .......................................................................................... 3-12

“B” Group: Fine Tuning Functions ..................................................................................... 3-44

“C” Group: Intelligent Terminal Functions ........................................................................ 3-83

“H” Group: Motor Constants Functions ........................................................................... 3-104

“P” Group: Other Parameters ............................................................................................ 3-111

xvii

Chapter 4: Operations and Monitoring

Introduction ............................................................................................................................ 4-2

Connecting to PLCs and Other Devices ............................................................................... 4-4

Control Logic Signal Specifications ...................................................................................... 4-6

Intelligent Terminal Listing ................................................................................................ 4-10

Using Intelligent Input Terminals ...................................................................................... 4-12

Using Intelligent Output Terminals ................................................................................... 4-51

Analog Input Operation ....................................................................................................... 4-87

Pulse Train Input Operation ............................................................................................... 4-89

Analog Output Operation ...................................................................................................... 4-90

Chapter 5: Inverter System Accessories

Introduction ............................................................................................................................ 5-2

Component Description ......................................................................................................... 5-3

Chapter 6: Troubleshooting and Maintenance

Troubleshooting ...................................................................................................................... 6-2

Monitoring Trip Events, History, & Conditions ................................................................... 6-8

Restoring Factory Default Settings .................................................................................... 6-14

Maintenance and Inspection ............................................................................................... 6-15

Warranty ............................................................................................................................... 6-22

Appendix A: Glossary and Bibliography

Glossary .................................................................................................................................. A-2

Bibliography ........................................................................................................................... A-8

Appendix B: ModBus Network Communications

Introduction ............................................................................................................................ B-2

Connecting the Inverter to ModBus ..................................................................................... B-3

Network Protocol Reference .................................................................................................. B-5

ModBus Data Listing ........................................................................................................... B-24

Appendix C: Drive parameter Setting Tables

Introduction ............................................................................................................................ C-2

Parameter Settings for Keypad Entry .................................................................................. C-2

Appendix D: EMC installation guidance Appendix E: Safety

xviii

Revisions

Revision History Table

No. Revision Comments

Date of

Issue

Operation

Manual No.

xix

Contact Information

Hitachi Australia Ltd.

Hitachi America, Ltd.

Level 3, 82 Waterloo Road

Power and Industrial Division

North Ryde, N.S.W. 2113

50 Prospect Avenue

Australia

Tarrytown, NY 10591

Phone: +61-2-9888-4100

U.S.A.

Fax: +61-2-9888-4188

Phone: +1-914-631-0600 Fax: +1-914-631-3672

Hitachi Industrial Equipment Systems Co., Ltd.

Hitachi Europe GmbH

AKS Building, 3, kanda Neribei-cho

Am Seestern 18

Chiyoda-ku, Tokyo, 101-0022

D-40547 Dusseldorf

Japan

Germany

Phone: +81-3-4345-6910

Phone: +49-211-5283-0

Fax: +81-3-4345-6067

Fax: +49-211-5283-649

Hitachi Industrial Equipment Systems Co., Ltd.

Hitachi Asia Ltd.

Narashino Division

16 Collyer Quay

1-1, Higashi-Narashino 7-chome

#20-00 hitachi Tower, Singapore 049318

Narashino-shi, Chiba 275-8611

Singapore

Japan

Phone: +65-538-6511

Phone: +81-47-474-9921

Fax: +65-538-9011

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.

1−1

Getting Started

In This Chapter… page

- Introduction ...................................................................................... 2

- WJ200 Inverter Specifications ........................................................ 4

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

- Frequently Asked Questions ........................................................ 23

1−2

Introduction

Main Features

Congratulation on your purchase of an WJ200 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 WJ200 product line includes more than a dozen inverter models to cover motor sizes from 1/8 horsepower to 20 horsepower, in either 240VAC or 480VAC power input versions. The main features are:

• 200V and 400V class, 0.1 to 15kW inverters having dual rating

• US or EU versions available

• EzSQ (simple programming function) integrated

• Built-in RS485 MODBUS RTU as standard, other FieldBus optional

• New current suppressing function

• Sixteen programmable speed levels

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

• Password protection to avoid unexpected parameter change

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% at 0.5Hz

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

without motor derating.

• Fan has ON/OFF selection to provide longer life for cooling fan.

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

• Integrated USB port for PC communication

• Digital remote operator keypad

• Integrated brake chopper

• EMC filter (footprint type C1) optional

1−3

Inverter Specification Label

The Hitachi WJ200 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, and application safety requirements.

Inverter Specification Label

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

WJ200

001 S F

Series name

Configuration type

F=with keypad

Input voltage:

S=Single-phase 200V class L=Three-phase 200V class H=Three-phase 400V class

pplicable motor capacity in kW

001=0.1kW 037=3.7kW 002=0.2kW 040=4.0kW 004=0.4kW 055=5.5kW 007=0.75kW 075=7.5kW 015=1.5kW 110=11kW 022=2.2kW 150=15kW 030=3.0kW

200 -240

200

-240

2.0/1.3

1.2 /1. 0 1005

05A _T1 2345

A _

-001

-001SF

Model name

Input ratings

Output ratings

Ver:2.0

MFG number

1−4

WJ200 Inverter Specifications

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

The following tables are specific to WJ200 inverters for the 200V and 400V class model groups. Note that “General Specifications” on page in this chapter

apply to both voltage

class groups. Footnotes for all specification tables follow the table below.

Item Single-phase 200V class Specifications

WJ200 inverters, 200V models 001SF 002SF 004SF 007SF 015SF 022SF Applicable motor size *2

kW VT 0.2 0.4 0.55 1.1 2.2 3.0

CT 0.1 0.2 0.4 0.75 1.5 2.2

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

CT 1/8 1/4 1/2 1 2 3

Rated capacity (kVA) 200V VT 0.4 0.6 1.2 2.0 3.3 4.1

CT 0.2 0.5 1.0 1.7 2.7 3.8

240V VT 0.4 0.7 1.4 2.4 3.9 4.9

CT 0.3 0.6 1.2 2.0 3.3 4.5

Rated input voltage

Single-phase: 200V-15% to 240V +10%, 50/60Hz ±5%

Rated output voltage *3 3-phase: 200 to 240V (proportional to input voltage) Rated output current (A) VT 1.2 1.9 3.5 6.0 9.6 12.0

CT 1.0 1.6 3.0 5.0 8.0 11.0 Starting torque *6 200% at 0.5Hz Braking Without resistor

100%:

≤

50Hz

50%:

≤

60Hz

70%: 50Hz

≤

50%: 60Hz

≤

20%: 50Hz

≤

20%:

≤

60Hz

With resistor 150% 100% DC braking Variable operating frequency, time, and braking force Weight kg 1.0 1.0 1.1 1.6 1.8 1.8

lb 2.2 2.2 2.4 3.1 4.0 4.0

1−5

Footnotes for the preceding table and the tables that follow:

Note1: The protection method conforms to JEM 1030.

Note2: The applicable motor refers to Hitachi standard 3-phase motor (4p). When

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

Note3: 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.

Note4: To operate the motor beyond 50/60Hz, consult the motor manufacturer for

the maximum allowable rotation speed.

Note5: For achieving approved input voltage rating categories:

• 460 to 480VAC – Over-voltage category 2

• 380 to 460VAC – Over-voltage category 3

To meet the Over-voltage category 3, insert an EN or IEC standard compliant isolation transformer that is earth grounded and star connected (for Low Voltage Directive).

Note6: At the rated voltage when using a Hitachi standard 3-phase, 4-pole motor.

Note7: The braking torque via capacitive feedback is the average deceleration

torque at the shortest deceleration (stopping from 50/60Hz as indicated). It is not continuous regenerative braking torque. The average deceleration torque varies with motor loss. This value decreases when operating beyond 50Hz. If a large regenerative torque is required, the optional regenerative braking unit and a resistor should be used.

Note8: The frequency command is the maximum frequency at 9.8V for input voltage

0 to 10VDC, or at 19.6mA for input current 4 to 20mA. If this characteristic is not satisfactory for your application, contact your Hitachi representative.

Note9: If the inverter is operated outside the region shown in the graph in the

derating curve, the inverter may be damaged or its service life may be shortened. Set Β083 Carrier Frequency Adjustment in accordance with the expected output current level. See derating curve section for the detailed information of the inverter operating range.

Note10: The storage temperature refers to the short-term temperature during

transportation.

Note11: Conforms to the test method specified in JIS JIS C 60068-2-6 :2010(IEC

60068-2-6:2007). For the model types excluded in the standard specifications, contact your Hitachi sales representative.

Note12: Watt losses are calculated values based on specification of main

semi-conductors. You must take suitable margin when designing cabinet based on these values. Otherwise there is a possibility of heating trouble.

1−6

WJ200 Inverter Specifications, continued…

Item Three-phase 200V class Specifications

WJ200 inverters, 200V models

001LF 002LF 004LF 007LF 015LF 022LF Applicable motor size *2

kW V T 0.2 0.4 0.75 1.1 2.2 3.0

CT 0.1 0.2 0.4 0.75 1.5 2.2

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

CT 1/8 1/4 1/2 1 2 3

Rated capacity (kVA) 200V VT 0.4 0.6 1.2 2.0 3.3 4.1

CT 0.2 0.5 1.0 1.7 2.7 3.8

240V VT 0.4 0.7 1.4 2.4 3.9 4.9

CT 0.3 0.6 1.2 2.0 3.3 4.5

Rated input voltage

Three-phase: 200V-15% to 240V +10%, 50/60Hz ±5%

Rated output voltage *3 Three-phase: 200 to 240V (proportional to input voltage) Rate d o utput c u rr ent (A) VT 1.2 1.9 3.5 6.0 9.6 12.0

CT 1.0 1.6 3.0 5.0 8.0 11.0 Starting torque *6 200% at 0.5Hz Braking Without resistor

100%:

≤

50Hz

50%:

≤

60Hz

70%: 50Hz

≤

50%: 60Hz

≤

With resistor 150% DC braking Variable operating frequency, time, and braking force Weight kg 1.0 1.0 1.1 1.2 1.6 1.8

lb 2.2 2.2 2.4 2.6 3.5 4.0

Item Three-phase 200V class Specifications

WJ200 inverters, 200V models

037LF 055LF 075LF 110LF 150LF Applicable motor size *2

kW VT 5.5 7.5 11 15 18.5

CT 3.7 5.5 7.5 11 15

HP VT 7.5 10 15 20 25

CT 5 7.5 10 15 20

Rated capacity (kVA) 200V VT 6.7 10.3 13.8 19.3 20.7

CT 6.0 8.6 11.4 16.2 20.7

240V VT 8.1 12.4 16.6 23.2 24.9

CT 7.2 10.3 13.7 19.5 24.9

Rated input voltage

Three-phase: 200V-15% to 240V +10%, 50/60Hz ±5%

Rated output voltage *3 Three-phase: 200 to 240V (proportional to input voltage) Rated output current (A) VT 19.6 30.0 40.0 56.0 69.0

CT 17.5 25.0 33.0 47.0 60.0 Starting torque *6 200% at 0.5Hz Braking Without resistor

100%:

≤

50Hz

50%:

≤

60Hz

70%: 50Hz

≤

50%: 60Hz

≤

With resistor 150% DC braking Variable operating frequency, time, and braking force Weight Kg 2.0 3.3 3.4 5.1 7.4

lb 4.4 7.3 7.5 11.2 16.3

1−7

WJ200 Inverter Specifications, continued…

Item Three-phase 400V class Specifications

WJ200 inverters, 400V models

004HF 007HF 015HF 022HF 030HF 040HF Applicable motor size *2

kW V T 0.75 1.5 2.2 3.0 4.0 5.5

CT 0.4 0.75 1.5 2.2 3.0 4.0

HP VT 1 2 3 4 5 7.5

CT 1/2 1 2 3 4 5

Rated capacity (kVA) 380V VT 1.3 2.6 3.5 4.5 5.7 7.3

CT 1.1 2.2 3.1 3.6 4.7 6.0

480V VT 1.7 3.4 4.4 5.7 7.3 9.2

CT 1.4 2.8 3.9 4.5 5.9 7.6

Rated input voltage

Three-phase: 400V-15% to 480V +10%, 50/60Hz ±5%

Rated output voltage *3 Three-phase: 400 to 480V (proportional to input voltage) Rate d o utput c u rr ent (A) VT 2.1 4.1 5.4 6.9 8.8 11.1

CT 1.8 3.4 4.8 5.5 7.2 9.2 Starting torque *6 200% at 0.5Hz Braking Without resistor

100%:

≤

50Hz

50%:

≤

60Hz

70%: 50Hz

≤

50%: 60Hz

≤

With resistor 150% DC braking Variable operating frequency, time, and braking force Weight kg 1.5 1.6 1.8 1.9 1.9 2.1

lb 3.3 3.5 4.0 4.2 4.2 4.6

Item Three-phase 400V class Specifications

WJ200 inverters, 400V models

055HF 075HF 110HF 150HF Applicable motor size *2

kW V T 7.5 11 15 18.5

CT 5.5 7.5 11 15

HP VT 10 15 20 25

CT 7.5 10 15 20

Rated capacity (kVA) 380V VT 11.5 15.1 20.4 25.0

CT 9.7 11.8 15.7 20.4

480V VT 14.5 19.1 25.7 31.5

CT 12.3 14.9 19.9 25.7

Rated input voltage

Three-phase: 400V-15% to 480V +10%, 50/60Hz ±5%

Rated output voltage *3 Three-phase: 400 to 480V (proportional to input voltage) Rated output current (A) VT

17.5 23.0 31.0 38.0

14.8 18.0 24.0 31.0

Starting torque *6 200% at 0.5Hz Braking Without resistor

100%:

≤

50Hz

50%:

≤

60Hz

With resistor 150% DC braking Variable operating frequency, time, and braking force Weight kg 3.5 3.5 4.7 5.2

lb 7.7 7.7 10.4 11.5

1−8

General Specifications

The following table applies to all WJ200 inverters.

Item General Specifications

Protective housing *1

IP20

Control method

Sinusoidal Pulse Width Modulation (PWM) control

Carrier frequency

2kHz to 15kHz (derating required depending on the model)

Output frequency range *4

0.1 to 400Hz

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: 0.01Hz; Analog: max. frequency/1000

Volt./Freq. characteristic

V/f control (constant torque, reduced torque, free-V/F): base freq. 30Hz~400Hz adjustable, Sensorless vector control, Closed loop control with motor encoder feedback

Overload capacity

Dual rating: CT(Heavy duty) : 60 sec. @150% VT(Normal duty) : 60 sec. @120%

Acceleration/deceleration time

0.01 to 3600 seconds, linear and S-curve accel/decel, second accel/decel setting available

Starting torque

200% @0.5Hz (sensorless vector control)

Input

signal

Freq.

setting

Operator panel

Up and Down keys / Value settings

External signal *8

0 to 10 VDC (input impedance 10k Ohms), 4 to 20mA (input impedance 100 Ohms), Potentiometer (1k to 2k Ohms, 2W)

Via network

RS485 ModBus RTU, other network option

FWD/

REV run

Operator panel

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

External signal

Forward run/stop, Reverse run/stop

Via network

RS485 ModBus RTU, other network option

Intelligent input terminal

Seven terminals, sink/source changeable by a short bar

68 functions assignable

FW (forward run command), RV (reverse run command), CF1~CF4 (multi-stage speed setting), JG (jog command), DB (external braking), SET (set second motor), 2CH (2-stage accel./decel. command), FRS (free run stop command), EXT (external trip), USP (startup function), CS (commercial power switchover), SFT (soft lock), AT (analog input selection), RS (reset), PTC (thermistor thermal protection), STA (start), STP (stop), F/R (forward/reverse), PID (PID disable), PIDC (PID reset), UP (remote control up function), DWN (remote control down function), UDC (remote control data clear), OPE (operator control), SF1~SF7 (multi-stage speed setting; bit operation), OLR (overload restriction), TL (torque limit enable), TRQ1 (torque limit changeover1), TRQ2 (torque limit changeover2), BOK (Braking confirmation), LAC (LAD cancellation), PCLR (position deviation clear), ADD (add frequency enable), F-TM (force terminal mode), ATR (permission of torque command input), KHC (Cumulative power clear), MI1~MI7 (general purpose inputs for EzSQ), AHD (analog command hold), CP1~CP3 (multistage-position switches), ORL (limit signal of zero-return), ORC (trigger signal of zero-return), SPD (speed/position changeover), GS1,GS2 (STO inputs, safety related signals), 485 (Starting communication signal), PRG (executing EzSQ program), HLD (retain output frequency), ROK (permission of run command), EB (rotation direction detection of B-phase), DISP (display limitation), NO (no function)

1−9

Item General Specifications

Output

signal

Intelligent output terminal

48 functions assignable

RUN (run signal), FA1~FA5 (frequency arrival signal), OL,OL2 (overload advance notice signal), OD (PID deviation error signal), AL (alarm signal), OTQ (over/under torque threshold), UV (under-voltage), TRQ (torque limit signal), RNT (run time expired), ONT (power ON time expired), THM (thermal warning), BRK (brake release), BER (brake error), ZS (0Hz detection), DSE (speed deviation excessive), POK (positioning completion), ODc (analog voltage input disconnection), OIDc (analog current input disconnection), FBV (PID second stage output), NDc (network disconnect detection), LOG1~LOG3 (Logic output signals), WAC (capacitor life warning), WA F (cooling fan warning), FR (starting contact), OHF (heat sink overheat warning), LOC (Low load), MO1~MO3 (general outputs for EzSQ), IRDY (inverter ready), FWR (forward operation), RVR (reverse operation), MJA (major failure), WCO (window comparator O), WCOI (window comparator OI), FREF (frequency command source), REF (run command source), SETM (second motor in operation), EDM (STO (safe torque off) performance monitor), OP (option control signal), NO (no function)

Monitor output (analog)

Output freq., output current, output torque, output voltage, input power, thermal load ratio, LAD freq., heat sink temperature, general output (EzSQ)

Pulse train output (0~10Vdc, 32kHz max.)

[PWM output] Output freq., output current, output torque, output voltage, input power, thermal load ratio, LAD freq., heat sink temperature, general output (EzSQ) [Pulse train output] Output frequency, output current, pulse train input monitor

Alarm output contact

ON for inverter alarm (1c contacts, both normally open or closed available.)

Other functions

Free-V/f, manual/automatic torque boost, output voltage gain adjustment, AVR function, reduced voltage start, motor data selection, auto-tuning, motor stabilization control, reverse running protection, simple position control, simple torque control, torque limiting, automatic carrier frequency reduction, energy saving operation, PID function, non-stop operation at instantaneous power failure, brake control, DC injection braking, dynamic braking (BRD), frequency upper and lower limiters, jump frequencies, curve accel and decel (S, U, inversed U,EL-S), 16-stage speed profile, fine adjustment of start frequency, accel and decel stop, process jogging, frequency calculation, frequency addition, 2-stage accel/decel, stop mode selection, start/end freq., analog input filter, window comparators, input terminal response time, output signal delay/hold function, rotation direction restriction, stop key selection, software lock, safe stop function, scaling function, display restriction, password function, user parameter, initialization, initial display selection, cooling fan control, warning, trip retry, frequency pull-in restart, frequency matching, overload restriction, over current restriction, DC bus voltage AVR

Protective function

Over-current, over-voltage, under-voltage, overload, brake resistor overload, CPU error, memory error, external trip, USP error, ground fault detection at power on, temperature error, internal communication error, driver error, thermistor error, brake error, safe stop, overload at low speed, modbus communication error, option error, encoder disconnection, speed excessive, EzSQ command error, EzSQ nesting error, EzSQ execution error, EzSQ user trip

Operating environment

Temperature

Operating (ambient): -10 to 40°C(*10), / Storage: -20 to 65°C(*11)

Humidity

20 to 90% humidity (non-condensing)

Vibration *11

5.9m/s2 (0.6G), 10 to 55 Hz

Location

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

Coating color

Black

Options

Remote operator unit, cables for the units, braking unit, braking resistor, AC reactor, DC reactor, EMC filter, fieldbus

1−10

Signal Ratings

Detailed ratings are in “Control Logic Signal Specifications” in chapter 4.

Signal / Contact Ratings

Built-in power for inputs 24VDC, 100mA maximum Discrete logic inputs 27VDC maximum Discrete logic outputs 50mA maximum ON state current, 27 VDC maximum OFF state voltage Analog output 10bit / 0 to 10VDC, 2mA Analog input, current 4 to 19.6 mA range, 20mA nominal Analog input, voltage

0 to 9.8 VDC range, 10VDC nominal, input impedance 10kΩ

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

1−11

Derating Curves

The maximum available inverter current output is limited by the carrier frequency and ambient temperature.. Choosing a higher carrier frequency tends to decrease audible noise, but it also increases the internal heating of the inverter, thus decreasing (derating) the maximum current output capability. Ambient temperature is the temperature just outside the inverter housing⎯such as inside the control cabinet where the inverter is mounted. A higher ambient temperature decreases (derates) the inverter’s maximum current output capacity.

Individual mounting

An inverter may be mounted individually in an enclosure or side-by-side with other inverter(s) as shown below. Side-by-side mounting causes greater derating than mounting inverters separately. Graphs for either mounting methods are included in this section. Refer to “Ensure Adequate Ventilation” on page 2-10 for minimum clearance dimensions for both mounting configurations.

Enclosure

Side-by-side mounting

Enclosure

1−12

The following table shows which models need derating.

1-ph 200V class Need

derating

3-ph 200V class Need

derating

3-ph 400V class Need

derating

WJ200-001S

－－

WJ200-001L

WJ200-004H

WJ200-002S

－

WJ200-002L

WJ200-007H

WJ200-004S

WJ200-004L

WJ200-015H

－

WJ200-007S

WJ200-007L

－－

WJ200-022H

WJ200-015S

－－－

WJ200-015L

WJ200-030H

WJ200-022S

－－

WJ200-022L

WJ200-040H

－－－

WJ200-037L

WJ200-055H

－－－

WJ200-055L

WJ200-075H

－－

WJ200-075L

WJ200-110H

－－

WJ200-110L

WJ200-150H

－－－－

WJ200-150L

9：need derating

－：need no derating

Use the following derating curves to help determine the optimal carrier frequency setting for your inverter and find the output current derating. Be sure to use the proper curve for your particular WJ200 inverter model number.

Legend for Graphs:

Ambient temperature 40℃ max., individual mounting

Ambient temperature 50℃ max., individual mounting

Ambient temperature 40℃ max., side-by-side mounting

Derating curves:

Models need no derating

2 4 6 8 10 12 16kH140

100%

80% 60% 40% 20%

Carrier frequency

2 4 6 8 10 12 0

100%

80% 60% 40% 20%

14kH

Carrier frequency

% of rated

output current

1−13

Derating curves, continued... Models need derating

WJ200-002L

WJ200-004L

246 81012 16 140

HD（1.6A）

Carrier frequency (kHz)

1.5

2.0

1.0

2 4 6 8 10 12 14 0

Carrier frequency (kHz)

1.5

1.0

2.0

40℃ individual 40℃

side-by-side

40℃ individual 40℃

side-by-side

ND（1.9A）

Output current (A)

WJ200-004S

246 81012 16 140

1.0

HD（3.0A）

Carrier frequency (kHz)

2.0

2 4 6 8 10 12 14 0

ND（3.5A）

Carrier frequency (kHz)

3.0

1.0

2.0

3.6

Output current (A)

246 81012 16 140

1.0

HD（3.0A）

Carrier frequency (kHz)

2.0

2 4 6 8 10 12 14 0

ND（3.5A）

Carrier frequency (kHz)

3.0

1.0

2.0

3.6

40℃ indivi 40℃

side-by-side

dual

40℃ individual 40℃

side-by-side

50℃ individual

Output current (A)

1−14

Derating curves, continued...

WJ200-004H

246 81012 16 140

HD（1.8A）

2 4 6 8 10 12 14 0

1.5

1.0

2.0

2.2

ND（2.1A）

40℃ individual 40℃

side-by-side

50℃ individual

40℃

individual

40℃

side-by-side

2.2

2.0

Output current (A)

1.5

1.0

Carrier frequency (kHz)

246 81012 16

4.0

140

4.0

HD（5.0A）

5.0

6.0 40℃ individual

40℃

side-by-side

6.6

ND（6.0A）

WJ200-007S

2 4 6 8 10 12 14 0

40℃ individual 40℃

side-by-side

Carrier frequency (kHz)

6.6

6.0

Output current (A)

5.0

Carrier frequency (kHz)

246 8101216140

2.0

（3.4A）

Carrier frequency (kHz)

3.0

2 4 6 8 10 12 14 0

ND 4.1A）

Carrier fre

（

uency (kHz)

4.0

WJ200 H-007

4.4

2.0

3.0

4.0

Output current (A)

40℃ individual 40℃

side-by-side

1−15

Derating curves, continued...

rrier frequency (kHCa

Carrier frequency (kHz)

246 81012 16 140

HD（17.5A）

2 4 6 8 10 12 14 0

ND（19.6A）

WJ200-037L

20 19

18 17

16 15 14

19 18

17 16 15 14

Output current (A)

46 81012 16 140

HD（9.2A）

Carrier frequency (kHz)

2 4 6 8 10 12 14 0

ND（11.1A）

Carrier frequency (kHz)

WJ200-040H

9 8

7 6

9 8 7

40℃ individual 40℃

side-by-side

40℃ individual 40℃

side-by-side

Output current (A)

WJ200

246 81012 16 140

HD（33.0A）

Carrier frequency (kHz)

2468 10 12 14 0

ND（40.0A）

Carrier frequency (kHz)

-075L

42 40

38 36 34

32 30

40 38

36 34 32 30

40℃ individual 40℃

side-by-side

Output current (A)

40℃ individual 40℃

side-by-side

50℃ individual

1−16

Derating curves, continued...

WJ200-110L

WJ200-075H

246 81012 16140

HD（18.0A）

Carrier fre

uency (kHz)

2468 10 12 14 0

ND（23.0A）

Carrier frequency (kHz)

26 24

22 20 18

16 14

24 22

20 18 16 14

40℃ indivi 50℃

indivi

Output current

dual dual

(A)

40℃ individual 40℃

side-by-side

50℃ individual

J200-110H

246 81012 16 140

HD（24.0A）

Carrier frequency (kHz)

2 4 6 8 10 12 14 0

ND（31.0A）

Carrier frequency (kHz)

32 30

28 26 24

22 20

30 28

26 24 22 20

50℃ individual 40℃

side-by-side

Output current (A)

40℃ individual 40℃

side-by-side

50℃ individual

246 81012 16 140

HD（47.0A）

Carrier frequency (kHz)

2468 10 12 14 0

ND（56.0A）

Carrier frequency (kHz)

60 55

50 45 40 35 30

55 50

45 40 35 30

40℃ individual 40℃

side-by-side

Output current (A)

1−17

Derating curves, continued...

WJ200-150L

WJ200-150H

2 4 6 8 10 12 16kH140

HD（60.0A）

Carrier frequency (kHz)

2 4 6 8 10 12 14 0

ND（69.0A）

Carrier frequency (kHz)

75 70

65 60 55 50 45

70 65

60 55 50 45

50℃ individual 40℃

side-by-side

50℃ individual 40℃

side-by-side

Output current (A)

246 81012 16 140

HD（31.0A）

Carrier frequency (kHz)

2 4 6 8 10 12 14 0

ND（38.0A）

Carrier frequency (kHz)

40 35

30 25 20

15 10

35 30

25 20 15 10

50℃ individual 40℃

side-by-side

Output current (A)

50℃ individual 40℃

side-by-side

1−18

Introduction to Variable-Frequency Drives

The Purpose of Motor Speed Control for Industry

Hitachi inverters provide speed control for 3-phase AC induction motors. You connect AC power to the inverter, and connect the inverter to the motor. Many applications benefit from a motor with variable speed, in several ways:

• Energy savings – HVAC

• Need to coordinate speed with an adjacent process – textile and printing presses

• Need to control acceleration and deceleration (torque)

• Sensitive loads – elevators, food processing, pharmaceuticals

What is an Inverter

The term

inverter

and

variable-frequency drive

are related and somewhat interchangeable. 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.

An inverter, in general, is a device that converts DC power to AC power. The figure below shows how the variable-frequency drive employs an internal inverter. The drive first converts incoming AC power to DC through a rectifier bridge, creating an internal DC bus voltage. Then the inverter circuit converts the DC back to AC again to power the motor. The special inverter can vary its output frequency and voltage according to the desired motor speed.

Rectifier

Motor

Inverter Converter Internal

DC Bus

Power

Input

R/L1

S/L2

T/L3

U/T1 V/T2 W/T3

Variable-frequency Drive

The simplified drawing of the inverter shows three double-throw switches. In Hitachi inverters, the switches are actually IGBTs (insulated gate bipolar transistors). Using a commutation algorithm, the microprocessor in the drive switches the IGBTs on and off at a very high speed to create the desired output waveforms. The inductance of the motor windings helps smooth out the pulses.

1−19

Torque and Constant Volts/Hertz Operation

Output voltage

In the past, AC variable speed drives used an open loop (scalar) technique to control speed. The constant-volts-hertz operation maintains a constant ratio between the applied voltage and the applied frequency. With these conditions, AC induction motors inherently delivered constant torque across the operating speed range. For some applications, this scalar technique was adequate.

Today, with the advent of sophisticated microprocessors and digital signal processors (DSPs), it is possible to control the speed and torque of AC induction motors with unprecedented accuracy. The WJ200 utilizes these devices to perform complex mathematical calculations required to achieve superior performance. You can choose various torque curves to fit the needs of your application. Constant torque applies the same torque level across the frequency (speed) range.

Variab l e torque

, also called

reduced torque

, lowers the torque delivered at mid-level frequencies. A torque boost setting will add additional torque in the lower half of the frequency range for the constant and variable torque curves. With the

free-setting torque

curve feature, you can specify a series of data points that will define a custom torque curve to fit your application.

Inverter Input and Three-phase Power

The Hitachi WJ200 Series of inverters includes two sub-groups: the 200V class and the 400V class inverters. The drive 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 inverter requires (nominal) 200 to 240VAC, and 400V class inverter requires from 380 to 480VAC. The 200V class inverters having a suffix of –SF accept single-phase 200V class input voltage, those with a suffix –LF three-phase power only. All 400V class inverters require three-phase power supply.

TIP: If your application only has single phase power available, refer to WJ200 inverter of 3HP or less (European version with a suffix of -SFE); they can accept single phase input power. Note: Larger models may be able to accept single-phase with derating. Contact your Hitachi distributor for assistance.

The common terminology for single phase power is line (L) and Neutral (N). Three-phase power connections are usually labeled Line 1 [R/L1], Line 2 [S/L2] and Line 3 [T/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 (see “Wire the Inverter Output to Motor” on page 2-21).

Output frequency

100%

Constant torque

1−20

Inverter Output to the Motor

3-phase AC motor

The AC motor must be connected only to the inverter’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 often not necessary to connect 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. In applications where reversed rotation could cause equipment damage or personnel injury, be sure to verify direction of rotation before attempting full-speed operation.

U/T1

V/T2

W/T3

Earth GND

For safety to personnel, 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 controlling 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 disconnect switches in the wiring from the inverter to the motor (except thermal disconnect). Of course, safety-related devices such as fuses must be in the design to break power during a malfunction, as required by NEC and local codes.

1−21

Intelligent Functions and Parameters

Much of this manual is devoted to describing how to use inverter functions and how to configure inverter parameters. The inverter is micro-processor-controlled, and has many independent functions. The microprocessor has an on-board EEPROM for parameter storage. The inverter’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, integrated operator,

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 (overhauling). If you need the motor and load to decelerate quicker than their natural deceleration during coasting, we recommend installing a braking resistor. The dynamic braking unit (built into WJ200) sends excess motor energy into a resistor to slow the motor and load (See “Introduction” on page 5-2 and “Dynamic Braking” on page 5-5 for more information). For loads that continuously overhaul the motor for extended periods of time, the WJ200 may not be suitable (contact your Hitachi distributor).

The inverter parameters include acceleration and deceleration, which you can set 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.

1−22

Velocity Profiles

The WJ200 inverter is capable of sophisticated speed control. A graphical representation of that capability will help you understand and configure the associated parameters. This manual makes use of the velocity profile graph used in industry (shown at right). In the example,

acceleration

is a ramp to a set speed,

and

deceleration

is a decline to a stop.

Speed

Acceleration and deceleration settings specify the time required to go from a stop to maximum frequency (or vise versa). The resulting slope (speed change divided by time) is the acceleration or deceleration. An increase in output frequency uses the acceleration slope, while a decrease uses the deceleration slope. The accel or decel time a particular speed change depends on the starting and ending frequencies. However, the slope is constant, corresponding to the full-scale accel or decel time setting. For example, the full-scale acceleration setting (time) may be 10 seconds – the time required to go from 0 to 60Hz.

The WJ200 inverter can store up to 16 preset speeds. And, it can apply separate acceleration and deceleration transitions from any preset to any other preset speed. A multi-speed profile (shown at right) uses two or more preset speeds, which you can select via intelligent input terminals. This external control can apply any preset speed at any time. Alternatively, the selected speed is infinitely variable across the speed range. You can use the potentiometer control on the keypad for manual control. The drive accepts analog 0-10VDC signals and 4-20 mA control signals as well.

The inverter can drive the motor in either direction. Separate FW and RV 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.

NOTE: The WJ200 can move loads in both directions. However, it is not designed for use in servo-type applications that use a bipolar velocity signal that determines direction.

Velocity Profile

ccel Decel

Set speed

Speed

Maximum speed

Acceleration

(time setting)

Speed

Multi-speed Profile

Speed 1

Speed 2

Speed

Bi-directional Profile

Forward move

Reverse move

1−23

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 very little loss of efficiency, 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 term

inverter, drive,

and

amplifier

are used somewhat interchangeably in

industry. Nowadays, the term

drive, variable-frequency drive, variable-speed

drive

, and

inverter

are generally used to describe electronic,

microprocessor-based motor speed controllers. In the past,

variable-speed

drive

also referred to various mechanical means to vary speed.

Amplifier

is a

term almost exclusively used to describe drives for servo or stepper motors.

Q. Although the WJ200 inverter is a variable speed drive, can I use it in a fixed-speed

application?

A. Yes, sometimes an inverter can be used simply as a “soft-start” device,

providing controlled acceleration and deceleration to a fixed speed. Other functions of the WJ200 may be useful in such applications, as well. However, using a variable speed drive can benefit many types 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 must

turn and still deliver torque. The WJ200 inverter will deliver full torque while turning the motor at 6Hz (180RPM). DO NOT use an inverter 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. Can the inverter be controlled and monitored via a network?

A. Yes. WJ200 inverters have built-in ModBus communications. See Appendix B

for more information on network communications.

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 specific 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.

NOTE: The European 200V class inverter is for single phase input (-SFE), while the USA 200V class inverter is for 3 phase input (-LFU).

1−24

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

A. The 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 alternatively serve as input or return on alternate half-cycle.

Q. Does the motor need a chassis ground connection?

A. Yes, for several reasons. Most importantly, this provides protection in the

event of a short in the motor that puts a hazardous voltage on its housing. Secondly, motors exhibit leakage current that increase with aging. Lastly, a grounded chassis generally emits less electrical noise than an ungrounded one.

Q. What type of motor is compatible with the Hitachi inverters?

A. Motor type – It must be a three-phase AC induction motor. Use an

inverter-grade motor that has at least 800V insulation for 200V class inverters, or 1600V insulation for 400V class. Motor size – In practice, it’s better to find the right size motor for your application; then look for the inverter to match the motor.

NOTE: There may be other factors that will affect motor selection, including heat dissipation, motor operating speed profile, enclosure type, and cooling method.

Q. How many poles should the motor have?

A. Hitachi inverters can be configured to operate motors with 2, 4, 6, or 8 poles.

The greater the number of the poles, the slower the top motor speed will be, but it will have higher torque at the base speed.

Q. Will I be able to add dynamic (resistive) braking to my Hitachi WJ200 drive after

the initial installation?

A. Yes, the WJ200 inverter already has a dynamic braking circuit built in. Just

add the resistor sized to meet the braking requirements. For more information, contact your nearest Hitachi representative.

1−25

Q. How will I know if my application will require resistive braking?

A. For new applications, it may be difficult to tell before you actually test a

motor/drive solution. In general, some application can rely on system losses such as friction to serve as the deceleration force, or otherwise can tolerate a long decel time. These applications will not need dynamic braking. However, applications with a combination of a high-inertia load and a required short decel time will need dynamic braking. This is a physics question that may be answered either empirically or through extensive calculations.

Q. Several options related to electrical noise suppression are available for the Hitachi

inverters. How can I know if my application require any of these options?

A. The purpose of these noise filters is to reduce the inverter electrical noise so

the operation of nearby electrical devices is not affected. Some applications are governed by particular regulatory agencies, and noise suppression is mandatory . in those cases, the inverter must have the corresponding noise filter installed. Other applications may not need noise suppression, unless you notice electrical interference with the operation of other devices.

Q. The WJ200 features a PID control. PID loops are usually associated with chemical

processes, heating, or process industries in general. How could the PID loop feature be useful in my application?

A. You will need to determine the particular main variable in your application

the motor affects. That is the process variable (PV) for the motor. Over time, a faster motor speed will cause a faster change in the PV than a slow motor speed will. By using the PID loop feature, the inverter commands the motor to run at the optimal speed required to maintain the PV at the desired value for current conditions. Using the PID loop feature will require an additional sensor and other wiring, and is considered an advanced application.

2−1

Inverter Mounting and Installation

In This Chapter… page

- Orientation to Inverter Features ..................................................... 2

- Basic System Description ............................................................... 4

- Step-by-Step Basic Installation ...................................................... 6

- Powerup Test .................................................................................. 23

- Using the Front Panel Keypad ...................................................... 25

2−2

Orientation to Inverter Features

Unpacking and Inspection

Please take a few moments to unpack your new WJ200 inverter and perform these steps:

1. Look for any damage that may have occurred during transportation.

2. Verify the contents of the box include:

a. One WJ200 inverter b. One instruction Manual c. One WJ200 Quick Reference Guide

3. Inspect the specifications label on the side of the inverter. Make sure it matches

the product part number you ordered.

Main Physical Features

The WJ200 Series inverters vary in size according to the current output rating and motor size for each model number. All feature the same basic Keypad and connector interface for consistent ease of use. The inverter construction has a heat sink at the back of the housing. The larger models include a fan to enhance heat sink performance. The mounting holes are predrilled in the heat sink for your convenience. Smaller models have two mounting holes, while larger ones have four. Be sure to use all the mounting holes provided.

Never touch the heat sink during or just after operation; it can be very hot.

The electronics housing and front panel are built onto the front of the heat sink.

Inverter Keypad – The inverter uses a digital operator interface, or keypad. The four-digit display can show a variety of performance parameters. LEDs indicate whether the display units are Hertz or Amperes. Other LEDs indicate Power (external), and Run/Stop mode and Program/Monitor Mode status. Membrane keys Run and Stop/Reset control monitor operation. The ESC, SET, U and V keys allow an operator to navigate to the inverter’s functions and parameter values. The SET key is used when changing a parameter.

2−3

Power Wiring Access – First, ensure no power source is connected to the inverter. If

power has been connected, verify that the Power LED is OFF and then wait five minutes after power down to proceed. After removing the terminal cover and front housing cover, the housing partitions that cover the power and motor wiring exits will be able to slide upward as shown below.

Notice the four wire exit slots in the housing partition. This helps keep the power and motor wiring (to the left) separated from the signal-level logic or analog wiring (to the right).

Remove the housing partition and as shown as set them aside in a secure place while wiring. Be sure to replace them afterward. Never operate the inverter with the partition removed or the front housing cover removed.

The power input and motor 3-phase wiring connect to the lower row of the terminals. The upper row of power terminals connect to optional braking units or DC link choke.

The following section in this chapter will describe system design and guide you through a step-by-step installation process. After the section on wiring, this chapter will show how to use the front panel keys to access functions and edit parameters.

Terminal cover

Front cover

Housing partition

NOTE: The h

ousing partition can be removed without removing the front cover in

the following models.

Single-phase 200V: 0.7 to 2.2kW Three-phase 200V: 1.5 to 15kW Three-phase 400V: All size

2−4

Basic System Description

A motor control system will obviously include a motor and inverter, as well as a circuit breaker or fuses for safety. If you are connecting a motor to the inverter on a test bench just to get started, that’s all you may need for now. But a system can also have a variety of additional components. Some can be for noise suppression, while others may enhance the inverter’s braking performance. The figure and table below show a system with all the optional components you might need in your finished application.

Name Function

Breaker / disconnect

A molded-case circuit breaker (MCCB), ground fault interrupter (GFI), or a fused disconnect device. NOTE: The installer must refer to the NEC and local codes to ensure safety and compliance.

Input-side AC Reactor

This is useful in suppressing harmonics induced on the power supply lines and for improving the power factor. WARNIN G: Some applications must use an input-side AC Reactor to prevent inverter damage. See Warning on next page.

Radio noise filter

Electrical noise interference may occur on nearby equipment such as a radio receiver. This magnetic choke filter helps reduce radiated noise (can also be used on output).

EMC filter (for CE applications, see Appendix D)

Reduces the conducted noise on the power supply wiring between the inverter and the power distribution system. Connect to the inverter primary (input) side.

Radio noise filter (use in non-CE applications)

This capacitive filter reduces radiated noise from the main power wires in the inverter input side.

DC link choke

Suppress harmonics generated by the inverter. However, it will not protect the input diode bridge rectifier.

Radio noise filter

Electrical noise interference may occur on nearby equipment such as a radio receiver. This magnetic choke filter helps reduce radiated noise (can also be used on input).

Output-side AC Reactor

This reactor reduces the vibration in the motor caused by the inverter’s switching waveforms, by smoothing the waveform to approximate commercial power quality. It is also useful to reduce harmonics when wiring from the inverter to the motor is more than 10m in length.

LCR filter

Sine wave shaping filter for output side.

NOTE: Note that some components are required for regulatory agency compliance (see chapter 5 and Appendix D).

Breaker, MCCB or GFI

From power supply

L1 L2 L3

T1 T2 T3

Inverter

GND

Motor

Thermal switch

2−5

WARNING: 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 500kVA 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.

2−6

Step-by-S tep Basic Installation

This section will guide you through the following basic steps of installation:

Step Activity Page

1 Choose a mounting location in compliance with the Warnings and Cautions.

See NOTE below. 2 Check the mounting location for adequate ventilation 3 Cover the inverter’s ventilation openings to prevent debris from entering. 4 Check the inverter dimensions for footprint and mounting hole locations. 5 Study the Cautions, Warnings, wire and fuse sizes, and terminal torque

specifications before wiring the inverter. 6 Connect wiring for the inverter power input. 7 Wire the inverter output to the motor. 8 Uncover the inverter’s ventilation openings applied in Step 3. 9 Perform the Powerup Test. (This step includes several sub steps.)

10 Make observations and check your installation.

NOTE: If the installation is in an EU country, study the EMC installation guidelines in Appendix D.

2−7

Choosing a Mounting Location

Step 1: Study the following caution messages associated with mounting the inverter. This is the time when mistakes are most likely to occur that will result in expensive rework, equipment damage, or personal injury.

CAUTION: Be sure to install the unit on flame-resistant material such as 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 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.

2−8

Ensure Adequate Ventilation

Step 2: To summarize the caution messages – you will need to find a solid, non-flammable, vertical surface that is in a relatively clean and dry environment. In order to ensure enough room for air circulation around the inverter to aid in cooling, it is recommended to maintain the specified clearance and the inverter specified in the below diagram.

10 cm (3.94”)

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.

Keep Debris Out of Inverter Vents

Step 3: Before proceeding to the wiring section, it’s a good time to

temporarily

covers the inverter’s ventilation openings. Paper and masking tape are all that is needed. This will prevent harmful debris such as wire clippings and metal shavings from entering the inverter during installation.

Please observe this checklist while mounting the inverter:

1. The ambient temperature must be in the range

of −10 to 40°C.

2. Keep any other heat-producing equipment as

far away from the inverter as possible.

3. When installing the inverter in an enclosure, maintain the clearance around the

inverter and verify that its ambient is within specification when the enclosure door is closed.

4. Do not remove the front housing at any time during operation.

ir flow

minimum

10 cm (3.94”)

minimum

5 cm (1.97”)

minimum

5 cm (1.97”)

minimum

Clear area

WJ200

inverter

Ventilation holes (top)

Ventilation holes

(both sides)

2−9

Check Inverter Dimensions

Step 4: Locate the applicable drawing on the following pages for your inverter. Dimensions are given in millimeters (inches) format.

Power Type W (mm) H (mm) D (mm) D1 (mm) Single-phase 200V WJ200-001SF

WJ200-002SF

68 128

109 13.5

WJ200-004SF 122.5 27

3-phase 200V WJ200-001LF

WJ200-002LF

109 13.5

WJ200-004LF 122.5 27 WJ200-007LF 145.5 50

NOTE: Some inverter housing require two mounting screws, while other requires four. Be sure to use lock washers or other means to ensure screws do not loosen due to vibration.

2−10

Dimensional drawings, continued…

Power Type W (mm) H (mm) D (mm) D1 (mm) Single-phase 200V WJ200-007SF

108 128

170.5 55

WJ200-015SF WJ200-022SF

3-phase 200V WJ200-015LF

WJ200-022LF

3-phase 400V WJ200-004HF

143.5 28

WJ200-007HF WJ200-015HF WJ200-022HF WJ200-030HF

170.5 55

2−11

Dimensional drawings, continued…

Power Type W (mm) H (mm) D (mm) D1 (mm) 3-phase 200V WJ200-037LF

140 128 170.5 55

3-phase 400V WJ200-040HF

2−12

Dimensional drawings, continued…

Power Type W (mm) H (mm) D (mm) D1 (mm) 3-phase 200V WJ200-055LF

WJ200-075LF

140 260 155 73.3

3-phase 400V WJ200-055HF

WJ200-075HF

2−13

Dimensional drawings, continued…

Power Type W (mm) H (mm) D (mm) D1 (mm) 3-phase 200V WJ200-110LF

180 296 175 97

3-phase 400V WJ200-110HF

WJ200-150HF

2−14

Dimensional drawings, continued…

Power Type W (mm) H (mm) D (mm) D1 (mm) 3-phase 200V WJ200-150LF 220 350 175 84

2−15

Prepare for Wiring

Step 5: It is very important to perform the wiring steps carefully and correctly. Before proceeding, please study the caution and warning message herebelow.

WARNING: Use 60/75°C Cu wire only. (for models: WJ200-001L, -002L, -004L, -007L,

-015S, -022S, -004H, -007H, -015H, -022H and -030H)

WARNING: Use 75°C Cu wire only. (for models: WJ200-001S, -002S, -004S, -007S,

-015L, -022L, -037L, -055L, -075L, -110L, -150L, -040H, -055H, -075H,

-110H and -150H)

WARNING: “USE 60°C Cu wire only” or equivalent. For models WJ200-004H, -007H,

and –015H.

WARNING: “Open Type Equipment.”

WARNING: “Suitable for use on a circuit capable of delivering not more than 100k rms symmetrical amperes, 240V maximum.” For models with suffix S or L.

WARNING: “Suitable for use on a circuit capable of delivering not more than 100k rms symmetrical amperes, 480V 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 to the instructions given in this manual. Otherwise, there is a danger of electric shock and/or injury to personnel.

2−16

Determining Wire and Fuse Sizes

The maximum motor currents in your application determines the recommended wore size. The following table gives the wire size in AWG. The “Power Lines” column applies to the inverter input power, output wires to the motor, the earth ground connection, and any other components shown in the “Basic System Description” on page 2-4. The “Signal Lines” column applies to any wire connecting to the two green connectors just inside the front cover panel.

Motor Output

Inverter Model

Wiring

pplicable

equipment

kW HP

Power Lines

Signal

Lines

Fuse (UL-rated,

class J, 600V)

T CT VT CT

0.2 0.1 ¼ 1/8

WJ200-001SF

AWG16 / 1.3mm

(75°C only)

18 to 28

AWG / 0.14

to 0.75 mm

shielded wire

(see Note 4)

10A

0.4 0.2 ½ ¼

WJ200-002SF

0.55

0.4 ¾ ½

WJ200-004SF

1.1

0.75

1.5 1

WJ200-007SF

AWG12 / 3.3mm

(75°C only)

15A

2.2 1.5 3 2

WJ200-015SF

AWG10 / 5.3mm

30A

3.0 2.2 4 3

WJ200-022SF

0.2 0.1 ¼ 1/8

WJ200-001LF

AWG16 / 1.3mm

10A

0.4 0.2 ½ ¼

WJ200-002LF

0.75

0.4 1 ½

WJ200-004LF

1.1

0.75

1.5 1

WJ200-007LF

15A

2.2 1.5 3 2

WJ200-015LF

AWG14 / 2.1mm

(75°C only)

3.0 2.2 4 3

WJ200-022LF

AWG12 / 3.3mm

(75°C only)

20A

5.5 3.7 7.5 5

WJ200-037LF

AWG10 / 5.3mm

(75°C only)

30A

7.5 5.5 10 7.5

WJ200-055LF

AWG6 / 13mm

(75°C only)

40A

11 7.5 15 10

WJ200-075LF

15 11 20 15

WJ200-110LF

AWG4 / 21mm

(75°C only)

80A

18.5

15 25 20

WJ200-150LF

AWG2 / 34mm

(75°C only)

80A

0.75

0.4 1 ½

WJ200-004HF

AWG16 / 1.3mm

10A

1.5

0.75

2 1

WJ200-007HF

2.2 1.5 3 2

WJ200-015HF

3.0 2.2 4 3

WJ200-022HF

AWG14 / 2.1mm2

4.0 3.0 5 4

WJ200-030HF

15A

5.5 4.0 7.5 5

WJ200-040HF

AWG12 / 3.3mm

(75°C only)

7.5 5.5 10 7.5

WJ200-055HF

AWG10 / 5.3mm

(75°C only)

20A

11 7.5 15 10

WJ200-075HF

15 11 20 15

WJ200-110HF

AWG6 / 13mm

(75°C only)

40A

18.5

15 25 20

WJ200-150HF

AWG6 / 13mm

(75°C only)

40A

Note 1: Field wiring must be made by a UL-Listed and CSA-certified closed-loop

terminal connector sized for the wire gauge involved. Connector must be fixed

by using the crimping tool specified by the connector manufacturer. Note 2: Be sure to consider the capacity of the circuit breaker to be used. Note 3: Be sure to use a larger wire gauge if power line length exceeds 66ft. (20m). Note 4: Use 18 AWG / 0.75mm

wire for the alarm signal wire ([AL0], [AL1], [AL2]

terminals).

2−17

Terminal Dimensions and Torque Specs

The terminal screw dimensions for all WJ200 inverters are listed in table below. This information is useful in sizing spade lug or ring lug connectors for wire terminations.

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

Types

Screw

Diameter

Width

(mm)

Tightening Torque

(N•m)

WJ200 - 001S,002S,004S WJ200 - 001L,002L,004L,007L

M3.5 7.6 1.0

WJ200 - 007S,015S,022S WJ200 - 015L,022L,037L WJ200 - 004H,007H,015H,022H,030H,040H

M4 10 1.4

WJ200 - 055L,075L WJ200 – 055H,075H

M5 13 3.0

WJ200 - 110L WJ200 - 110H,150H

M6 17.5 3.9 to 5.1

WJ200 - 150L M8 23 5.9 to 8.8

2−18

Wire the Inverter Input to a Supply

Step 6: In this step, you will connect wiring to the input of the inverter. First, you must determine whether the inverter model you have required three-phase power only, or single-phase power only. All models have the same power connection terminals [R/L1], [S/L2], and [T/L3]. So you must refer to the specifications label (on the side of the inverter) for the acceptable power source types! For inverters that can accept single-phase power and are connected that way, terminal [S/L2] will remain unconnected.

Note the use of ring lug connectors for a secure connection.

Single-phase 200V 0.1 to 0.4kW Three-phase 200V 0.1 to 0.75kW

Single-phase Three-phase

Single-phase 200V 0.75 to 2.2kW Three-phase 200V 1.5, 2.2kW Three-phase 400V 0.4 to 3.0kW

Chassis Ground (M4)

Power input Output to Motor

N U/T1 V/T2 W/T3

R/L1

Power input Output to Motor

S/L2 T/L3 U/T1 V/T2 W/T3

PD/+1

P/+ N/-

Single-phase Three-phase

Chassis Ground (M4)

Power input Output to Motor

N U/T1 V/T2 W/T3

R/L1

Power input Output to Motor

S/L2 T/L3 U/T1 V/T2 W/T3

PD/+1

P/+ N/-

2−19

Three-phase 200V 3.7kW Three-phase 400V 4.0kW

Three-phase 200V 5.5, 7.5kW Three-phase 400V 5.5, 7.5kW

W/T3 V/T2 U/T1 N L1

Chassis Ground (M4)

Power input Output to Motor

G G RB

N/-

P/+

PD/+1

W/T3 V/T2 U/T1

R/L1 S/L2 T/L3

Power input Output to Motor

2−20

Three-phase 200V 11kW Three-phase 400V 11, 15kW

Three-phase 200V 15kW

NOTE: An inverter powered by a portable power generator may receive a distorted power waveform, overheating the generator. In general, the generator capacity should be five times that of the inverter (kVA).

G G RB

N/-

P/+

PD/+1

W/T3 V/T2 U/T1

R/L1 S/L2 T/L3

Power input Output to Motor

G G RB

N/-

P/+

PD/+1

W/T3 V/T2 U/T1

R/L1 S/L2 T/L3

Power input Output to Motor

2−21

CAUTION: Be sure that the input voltage matches the inverter specifications:

• Single-phase 200 to 240 V 50/60 Hz (0.1kW~2.2kW) for SF models

• Three-phase 200 to 240 V 50/60 Hz (0.1kW~15kW) for LF models

• Three-phase 380 to 480 V 50/60Hz (0.4kW~15kW) for HF models

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

Output to Motor

WJ200 Inverter

• 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.

2−22

Wire the Inverter Output to Motor

Step 7: The process of motor selection is beyond the scope of this manual. However, it must be an AC induction motor with three phases. It should also come with a chassis ground lug. If the motor does not have three power input leads, stop the installation and verify the motor type. Other guidelines for wiring the motor include:

• Use an inverter-grade motor for maximum motor life (1600V insulation).

• For standard motors, use the AC reactor accessory if the wiring between the

inverter and motor exceeds 10 meters in length.

Simply connect the motor to the terminals [U/T1], [V/T2], and [W/T3] as shown in page 2-17 to 2-19. This is a good time to connect the chassis ground lug on the drive as well. The motor chassis ground must also connect to the same point. Use a star ground (single-point) arrangement, and never daisy-chain the grounds (point-to-point).

• Check the mechanical integrity of each wire crimp and terminal connection.

• Replace the housing partition that covers access to the power connections.

CAUTION: Power terminal assignment is different compared to old models such as L100, L200 series, etc,. Pay attention when wiring the power cable

Logic Control Wiring

After completing the initial installation and powerup test in this chapter, you may need to wire the logic signal connector for your application. For new inverter users/applications, we highly recommend that you first complete the powerup test in this chapter without adding any logic control wiring. Then you will be ready to set the required parameters for logic control as covered in Chapter 4, Operations and Monitoring.

2−23

Uncover the Inverter Vents

Step 8: After mounting and wiring the inverter, remove any covers from the inverter housing. This includes material over the side ventilation ports.

Ventilation holes (top)

Ventilation holes

(both sides)

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.

Powerup Test

9 Step 9: After wiring the inverter and motor, you’re ready to do a powerup test. The

procedure that follows is designed for the first-time use of the drive. Please verify the following conditions before conducting the powerup test:

• You have followed all the steps in this chapter up to this step.

• The inverter is new, and is securely mounted to a non-flammable vertical surface.

• The inverter is connected to a power source and a motor.

• No additional wiring of the inverter connectors or terminals has been done.

• The power supply is reliable, and the motor is a known working unit, and the motor

nameplate ratings match the inverter ratings.

• The motor is securely mounted, and is not connected to any load.

Goals for the Powerup Test

If there are any exceptions to the above conditions at this step, please take a moment to take any measures necessary to reach this basic starting point. The specific goals of this powerup test are:

1. Verify that the wiring to the power supply and motor is correct.

2. Demonstrate that the inverter and motor are generally compatible.

3. Get an introduction to the use of the built-in operator keypad.

The powerup test gives you an important starting to ensure a safe and successful application of the Hitachi inverter. We highly recommend performing this test before proceeding to the other chapters in this manual.

2−24

Pre-test and Operational Precautions

The following instructions apply to the powerup test, or to any time the inverter is powered and operating. Please study the following instructions and messages before proceeding with the powerup test.

1. The power supply must have fusing suitable for the load. Check the fuse size chart

presented in Step 5, if necessary.

2. Be sure you have access to a disconnect switch for the drive input power if

necessary. However, do not turn OFF power during inverter operation unless it is an emergency.

3. Turn the keypad potentiometer to the minimum position (full counter-clockwise).

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: 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 vibration or noise?

Powering the Inverter

If you have followed all the steps, cautions and warnings up to this point, you’re ready to apply power. After doing so, the following events should occur:

• The

POWER

LED will illuminate.

• The numeric (7-segment) LEDs will display a test pattern, then stop at

0.0

• The

LED will be ON.

If the motor starts running unexpectedly or any other problem occurs, press the STOP key. Only if necessary should you remove power to the inverter as a remedy.

NOTE: If the inverter has been previously powered and programmed, the LEDs (other than the POWER LED) may illuminate differently than as indicated above. If necessary, you can initialize all parameters to the factory default settings. See “Restoring Factory Default Settings

” on page 6-14.

2−25

Using the Front Panel Keypad

Please take a moment to familiarize yourself with the keypad layout shown in the figure below. The display is used in programming the inverter’s parameters, as well as monitoring specific parameter values during operation.

Key and Indicator Legend

Items Contents

(1) POWER LED Turns ON (Green) while the inverter is powered up. (2) ALARM LED Turns ON (Red) when the inverter trips.

(3) Program LED

¾ Turns ON (Green) when the display shows changeable parameter. ¾ Blinks when there is a mismatch in setting.

(4) RUN LED Turns ON (Green) when the inverter is driving the motor. (5) Monitor LED [Hz] Turns ON (Green) when the displayed data is frequency related. (6) Monitor LED [A] Turns ON (Green) when the displayed data is current related. (7) Run command LED Turns ON (Green) when a Run command is set to the operator. (Run key is effective.) (8) 7-seg LED Shows each parameter, monitors etc. (9) Run key Makes inverter run.

(10) Stop/reset key

¾ Makes inverter decelerates to a stop. ¾ Reset the inverter when it is in trip situation

(11) ESC key

¾ Go to the top of next function group, when a function mode is shown ¾ Cancel the setting and return to the function code, when a data is shown ¾ Moves the cursor to a digit left, when it is in digit-to-digit setting mode ¾ Pressing for 1 second leads to display data of d001, regardless of current display.

(12) Up key (13) Down key

¾ Increase or decrease the data. ¾ Pressing the both keys at the same time gives you the digit-to-digit edit.

(14) SET key

¾ Go to the data display mode when a function code is shown ¾ Stores the data and go back to show the function code, when data is shown. ¾ Moves the cursor to a digit right, when it is in digit-to-digit display mode

(15) USB connector Connect USB connector (mini-B) for using PC communication (16) RJ45 connector Connect RJ45 jack for remote operator. (RS422 only)

1 2

RUN

ESC

STOP/

RESET

SET

8888

RUN

PWR

ALM

PRG

(1) POWER LED

(2) ALARM LED

(8) 7-seg LED

(4) RUN LED

(10) Stop/reset key

(15) USB connector

(3) Program LED

(16) RJ45 connector (RS422 only)

(14) Set key

(13) Down key(12) Up key

(11) Escape key

(9) RUN key

(7) Run command LED

(5) Monitor LED [Hz]

(6) Monitor LED [A]

2−26

Keys, Modes, and Parameters

The purpose of the keypad is to provide a way to change modes and parameters. The term function applies to both monitoring modes and parameters. These are all accessible through function codes that are primary 4-character codes. The various functions are separated into related groups identifiable by the left-most character, as the table shows.

RUN

ESC

STOP/

RESET

SET

Function

Group

Type (Category) of Function Mode to Access

PRG LED

Indicator

“D” Monitoring functions Monitor



“F” Main profile parameters

Program

“A” Standard functions

Program

“B” Fine tuning functions

Program

“C” Intellig ent terminal functions

Program

“H” Motor constant related functi ons

Program

“P” Pulse train input, torque, EzSQ, and

communication related functions

Program

“U” User selected parameters

Program

“E” Error codes

−

You can see from the following page how to monitor and/or program the parameters.

Keypad Navigation Map

The WJ200 Series inverter drives have many programmable functions and parameters. Chapter 3 will cover these in detail, but you need to access just a few items to perform the powerup test. The menu structure makes use of function codes and parameter codes to allow programming and monitoring with only a 4-digit display and keys and LEDs. So, it is important to become familiar with the basic navigation map of parameters and functions in the diagram below. You may later use this map as a reference.

8888

RUN PWR

Hz A

ALM

PRG

2−27

d001

V U

ESC

SET

Group "d"

Func. code display

0.00

d002

d104

F001

V U

Group "F"

Func. code display

F002

F004

50.00

50.01

SET

SET ESC

Save

Data display (F001 to F003)

Data does not blink because of real time synchronizing

: Saves the data in EEPROM and returns to func. code display. : Returns to func. code display without saving data.

SET ESC

A001

V U

ESC

Func. code display

: Jumps to the next group

ESC

SET

ESC

: Moves to data display

Func. code display

Group "A"

Func. code display

A002

Group "b"

b001

ESC

Group "C"

C001

ESC

Group "H"

H001

ESC

Group "P"

P001

ESC

Group "U"

U001

ESC

A165

ESC

SET

Data display

When data is changed, the display starts blinking, which means that new data has not been activated yet.

ESC

SET

: Cancels the data change and returns to func. code display.

: Saves the data in EEPROM and returns to func. code display.

ESC

Refer to 2-34 for further information.

Press the both up and down key at the same time in func. code or data display, then single-digit edit mode will be enabled.

NOTE: Pressing the [ESC] key will make the display go to the top of next function

group, regardless the display contents. (e.g. A021 Æ [ESC] Æ b001)

2−28

[Setting example] After power ON, changing from 0.00 display to change the b083 (carrier frequency) data.

Function code dxxx are for monitor and not possible to change. Function codes Fxxx other than F004 are reflected on the performance just after changing the data (before pressing SET key), and there will be no blinking.

When a function code is shown… When a data is shown…

ESC key

Move on to the next function group

Cancels the change and moves back to the function code

SET key Move on to the data display

Fix and stores the data and moves back to the function code

U key Increase function code Increase data value V key Decrease function code Decrease data value

 Note Keep pressing for more than 1 second leads to d001 display, regardless the display situation. But note that the display will circulates while keep pressing the [ESC] key because of the original function of the key. (e.g. F001 Æ A001 Æ b001 Æ C001 Æ …Æ displays 50.00 after 1 second)

b001

b083 5.0

Display is solid lighting.

12.0

F001

d001

0.00

c Data of will be shown on the

display after the first power ON

d Press [ESC] key to show

the function code

e Press [ESC] key to move on to the function group

f Press [ESC] key twice to move on to the function group

g Press Up key to change increase function code ( Æ

h Press SET key to display the data of

d001

F001

b001.

b001 b083)

b083

ESC

i Press up key to increase the

data ( Æ

i Press SET key to set

5.0 12.0)

SET

ESC

SET

ESC

and save the data

When data is changed, the display starts blinking, which means that new data has not been activated yet.

:Fix and stores the data and moves back to the function code :Cancels the change and moves back to the function code

SET

ESC

2−29

Selecting Functions and Editing Parameters

To prepare to run the motor in the powerup test, this section will show how to configure the necessary parameters:

1. Select the digital operator as the source of motor speed command (A001=02).

2. Select the digital operator as the source of the RUN command (A002=02).

3. Set the motor base frequency (A003) and AVR voltage of the motor (A082).

4. Set the motor current for proper thermal protection (b012).

5. Set the number of poles for the motor (H004).

The following series of programming tables are designed for successive use. Each table uses the previous table’s final state as the starting point. Therefore, start with the first and continue programming until the last one. If you get lost or concerned that some of the other parameters setting may be incorrect, refer to “Restoring Factory Default Settings” on page 6-8.

Prepare to Edit Parameters – This sequence begins with powering ON the inverter,

then it shows how to navigate to the “A” Group parameters for subsequent settings. You can also refer to the “Keypad Navigation Map

” on page 2-26 for orientation

throughout the steps.

Action Display Func./Parameter

Turn ON the inverter

0.0

Inverter output frequency displayed (0Hz in stop mode)

Press the ESC key.

d001

“d” group selected

Press the ESC key 2 times.

A001

“A” group selected

1. Select the digital operator for Speed Command – The inverter output frequency

can be set from several sources, including an analog input, memory setting, or the network, for example. The powerup test uses the keypad as the speed control source for your convenience. Note that the default setting depends on the country.

Action Display Func./Parameter

(Starting point)

A001

“A” Group selected Speed command source setting

Press the SET key

00…Potentiometer of ext. operator 01…Control terminals 02…Digital operator (F001) 03…ModBus network

etc.

Press the U / V key to select

02…Digital operator (selected)

Press the SET key to store

A001

Stores parameter, returns to “A001”

2−30

2. Select the digital operator for RUN Command –

To RUN command causes the inverter to accelerate the motor to the selected speed. The Run command can arrive from various sources, including the control terminals, the Run key on the keypad or the network. In the figure to the right, notice the Run Key Enable LED, just above the Run key. If the LED is ON, the Run key is already selected as the source, and you may skip this step. Note that the default setting depends on the country.

Run Key Enable LED

RUN

ESC

STOP/

RESET

SET

If the Potentiometer Enable LED is OFF, follow these steps below (the table resumes action from the end of the previous table).

Action Display Func./Parameter

(Starting point)

A001

Speed command source setting

Press the U key

A002

Run command source setting

Press the SET key

01…Control terminal 02…Digital operator 03…ModBus network input

etc.

Press the U / V key to select

02… Digital operator (selected)

Press the SET key to store

A002

Stores parameter, returns to “A002”

NOTE: After completing the steps above, the Run Key Enable LED will be ON. This does not mean the motor is trying to run; it means that the RUN key is now enabled. DO NOT press the RUN key at this time – complete the parameter setup first.

8888

RUN PWR

Hz A

ALM

PRG

2−31

3. Set the Motor Base Frequency and AVR voltage of the motor – The motor is

designed to operate at a specific AC frequency. Most commercial motors are designed for 50/60 Hz operation. First, check the motor specifications. Then follow the steps below to verify the setting or correct it for your motor. DO NOT set it greater than 50/60 Hz unless the motor manufacturer specifically approves operation at the higher frequency.

Action Display Func./Parameter

(Starting point)

A002

Run command source setting

Press the U key once.

A003

Base frequency setting

Press the SET key.

60.0.

50.0

Default value for the base frequency. US = 60 Hz, Europe = 50 Hz

Press the U / V key to select

60.0

Set to your motor specs (your display may be different)

Press the SET key.

A003

Store parameter, returns to “A003”

Set the AVR Voltage Setting – The inverter has an Automatic Voltage Regulation (AVR) function. It adjusts the output voltage to match the motor’s nameplate voltage rating. The AVR smoothes out fluctuation in the input power source, but note that it does not boost the voltage in the event of a brown-out. Use the AVR setting (A082) that most closely matches the one for your motor.

• 200V class: 200 / 215 / 220 / 230 / 240 VAC

• 400V class: 380 / 400 / 415 / 440 / 460 / 480 VAC

To set the motor voltage, follow the steps on the following table.

Action Display Func./Parameter

(Starting point)

A003

Base frequency setting

Press the U key and hold until Æ

A082

AVR voltage select

Press the SET key.

A230

A400

Default value for AVR voltage: 200V class = 230VAC 400V class = 400VAC (HFE) = 460VAC (HFU)

Press the U / V key to select

A215

Set to your motor specs (your display may be different)

Press the SET key.

A082

Store parameter, returns to “A082”

2−32

4. Set the Motor Current – The inverter has thermal overload protection that is

designed to protect the inverter and motor from overheating due to an excessive load. The inverter’s uses the motor’s current rating to calculate the time-based heating effect. This protection depends on using correct current rating for your motor. The level of electronic thermal setting, parameter B012, is adjustable from 20% to 100% of the inverter’s rated current. A proper configuration will also help prevent unnecessary inverter trip events.

Read the motor’s current rating on its manufacturer’s nameplate. Then follow the steps below to configure the inverter’s overload protection setting.

Action Display Func./Parameter

(Starting point)

A082

AVR voltage select

Press the ESC key.

b001

First “B” Group parameter selected

Press the U key and hold until Æ

b012

Level of electronic thermal setting

Press the SET key.

b160

Default value will be 100% of inverter rated current

Press the U / V key to select

b140

Set to your motor specs (your display may be different)

Press the SET key.

b012

Store parameter, returns to “b012”

2−33

5. Set the Number of Motor Poles – The motor’s internal winding arrangement

determines its number of magnetic poles. The specification label on the motor usually indicates the number of poles. For proper operation, verify the parameter setting matches the motor poles. Many industrial motors have four poles, corresponding to the default setting in the inverter (H004).

Follow the steps in the table below to verify the motor poles setting and change if necessary (the table resumes action from the end of the previous table.)

Action Display Func./Parameter

(Starting point)

b012

Level of electronic thermal setting

Press the ESC key two times

H001

“H” Group selected

Press the U key three times

H004

Motor poles parameter

Press the SET key.

H004

2 = 2 poles 4 = 4 poles (default) 6 = 6 poles 8 = 8 poles 10 = 10 poles

Press the U / V key to select

H004

Set to your motor specs (your display may be different)

Press the SET key.

H004

Store parameter, returns to “H004”

This step concludes the parameter setups for the inverter. You are almost ready to run the motor for the first time!

TIP: If you became lost during any of these steps, first observe the state of the PRG LED. Then study the “Keypad Navigation Map on page 2-26 to determine the current state of the keypad controls and display. As long as you do not press the SET key, no parameter will be changed by keypad entry errors. Note that power cycling the inverter causes it to power up Monitor Mode, displaying the value for D001 (output frequency).

The next section will show you how to monitor a particular parameter from the display. Then you will be ready to run the motor.

2−34

Monitoring Parameters with the Display

After using the keypad for parameter editing, it’s a good idea to switch the inverter from Program Mode to Monitor Mode. The PRG LED will be OFF, and the Hertz or Ampere LED indicates the display units.

For the powerup test, monitor the motor speed indirectly by viewing the inverter’s output frequency. The output frequency must not be confused with base frequency (50/60 Hz) of the motor, or the carrier frequency (switching frequency of the inverter, in the kHz range). The monitoring functions are in the “D” list, located near the top left of the “Keypad Navigation Map”on page 2-26.

Output frequency (speed) set – Resuming keypad operation from the previous table,

follow the steps below.

Action Display Func./Parameter

(Starting point)

H004

Motor poles parameter

Press the ESC key four times

F001

F001 is selected

Press the SET key.

b100

Set frequency displayed

Running the Motor

If you have programmed all the parameters up to this point, you’re ready to run the motor! First, review this checklist:

1. Verify the power LED is ON. If not, check the power connections.

2. Verify the Run Key Enable LED is ON. If it is OFF, check the A002 setting.

3. Verify the PRG LED is OFF. If it is ON, review the instructions above.

4. Make sure the motor is disconnected from any mechanical load.

5. Now, press the RUN key on the keypad. The RUN LED will turn ON.

6. Press the [U] key for a few seconds. The motor should start turning.

7. Press the STOP key to stop the motor rotation.

RUN

ESC

STOP/

RESET

SET

8888

RUN PWR

Hz ALM A

PRG

d.0.0.1.

2 35−

Single-Digit Edit Mode

If a target function code or data is far from current data, using the single-digit edit mode makes it quicker. Pressing the up key and down key at the same time leads you to go into the digit-to-digit changing mode.

(Note) When pressing [ESC] with cursor on the highest digit, the cursor will jump to the lowest digit. ((A) and (B) in above figure.)

(Note) When pressing up key and down key at the same time in single-digit edit mode, the single-digit edit mode is disabled and goes back to normal mode.

F001

1st digit will be blinking. Use up/down keys to change the value of the digit.

F0 01

A001 F 101

F001

F011

F001

F002

50.00

50.00 50.00 50.0 0

50.00

60.00 51.00 50.1 0

50.01

If not existing codes are selected, the data sill not move to the function code but blinking digit will move again to the left end digit.

(A)

△ ▽

(A)

(B)

: Move cursor to left.

: Move cursor to right or set the func.code/data (lowest digit only)

While in Single-digit edit mode (single digit is blinking):

SET

ESC

2nd digit will be blinking. Use up/down keys to change the value of the digit.

3rd digit will be blinking. Use up/down keys to change the value of the digit.

4th digit will be blinking. Use up/down keys to change the value of the digit.

1st digit will be blinking. Use up/down keys to change the value of the digit.

2nd digit will be blinking. Use up/down keys to change the value of the digit.

3rd digit will be blinking. Use up/down keys to change the value of the digit.

4th digit will be blinking. Use up/down keys to change the value of the digit.

ESC

SET

ESC

V U

SET

ESC

V U V U

SET

ESC

SET

ESC

V U

SET

ESC

U V

SET

ESC

U V

2−36

Powerup Test Observations and Summary

Step 10: Reading this section will help you make some useful observations when first running the motor.

Error Codes – If the inverter displays an error code (format is “E xx”), see “Monitoring Trip Events, History, & Conditions” on page 6-5 to interpret and clear the error.

Acceleration and Deceleration – The WJ200 inverter has programmable acceleration and deceleration value. The test procedure left these at the default value, 10 seconds. You can observe this by setting the frequency F001 at about half speed before running the motor. Then press RUN, and the motor will take 5 seconds to reach a steady speed. Press the STOP key to see a 5 second deceleration to a STOP.

State of Inverter at Stop – If you adjust the motor’s speed to zero, the motor will slow to a near stop, and the inverter turns the outputs OFF. The high-performance WJ200 can rotate at a very slow speed with high torque output, but not zero (must use servo systems with position feedback for that feature). This characteristic means you must use a mechanical brake for some applications.

Interpreting the Display – First, refer to the output frequency display readout. The maximum frequency setting (parameter A044) defaults to 50 Hz or 60 Hz (Europe and United States, respectively) for your application.

Example: Suppose a 4-pole motor is rated for 60 Hz operation, so the inverter is configured to output 60 Hz at full scale. Use the following formula to calculate the rpm.

Speed in RPM

RPM

polesof

Frequency

polesofPairs

Frequency

1800

12060

×=×=×

The theoretical speed for the motor is 1800 RPM (speed of torque vector rotation). However, the motor cannot generate torque unless its shaft turns at a slightly different speed. This difference is called slip. So it’s common to see a rated speed of approximately 1750 RPM on a 60 Hz, 4-pole motor. Using a tachometer to measure shaft speed, you can see the difference between the inverter output frequency and the actual motor speed. The slip increases slightly as the motor’s load increases. This is why the inverter output value is called “frequency”, since it is not exactly equal to motor speed.

Run/Stop Versus Monitor/Program Modes – The Run LED on the inverter is ON in Run Mode, and OFF in Stop Mode. The Program LED is ON when the inverter is in Program Mode, and OFF for Monitor Mode. All four mode combinations are possible. The diagram to the right depicts the modes and the mode transitions via keypad.

NOTE: Some factory automation devices such as PLCs have alternative Run/Program

modes; the device is in either one mode or the other. In the Hitachi inverter, however, Run Mode alternates with Stop Mode, and Program Mode alternates with Monitor Mode. This arrangement lets you program some value while the inverter is operating – providing flexibility for maintenance personnel.

Run

STOP/

RESET

Stop

Monitor

RUN

ESC SET

Program

3−1

Configuring Drive Parameters

In This Chapter… page

- Choosing a Programming Device ................................................... 2

- Using the Keypad Devices .............................................................. 3

- “D” Group: Monitoring Functions .................................................. 7

- “F” Group: Main Profile Parameters ............................................. 11

- “A” Group: Standard Functions ................................................... 12

- “B” Group: Fine Tuning Functions ............................................... 44

- “C” Group: Intelligent Terminal Functions .................................. 83

- “H” Group: Motor Constants Functions .................................... 104

: Sensorless Vector Control ...................................... 107

: Auto-tuning Function .............................................. 108

- “P” Group: Other Parameters ...................................................... 111

: Simple Positioning ................................................... 114

3−2

Choosing a Programming Device

Introduction

Hitachi variable frequency drives (inverters) use the latest electronics technology for getting the right AC waveform to the motor at the right time. The benefits are many, including energy savings and higher machine output or productivity. The flexibility required to handle a broad range of applications has required ever more configurable options and parameters – inverter are now a complex industrial automation component. And this can make a product seem difficult to use, but the goal of this chapter is to make this easier for you.

As the powerup test in Chapter 2 demonstrated, you do not have to program very many parameters to run the motor. In fact, most applications would benefit only from programming just a few, specific parameters. This chapter will explain the purpose of each set of parameters, and help you choose the ones that are important to your application.

If you are developing a new application for the inverter and a motor, finding the right parameters to change is mostly an exercise in optimization. Therefore, it is okay to begin running the motor with a loosely tuned system. By making specific, individual changes and observing their effects, you can achieve a finely tuned system.

Introduction of Inverter Programming

The front panel keypad is the first and best way to get to know the inverter’s capabilities. Every function or programmable parameter is accessible from the keypad.

3−3

Using the Keypad Devices

The WJ200 Series inverter front keypad contains all the elements for both monitoring and programming parameters. The keypad layout is pictured below. All other programming devices for the inverter have a similar key arrangement and function.

Key and Indicator Legend

• Run LED – ON when the inverter output is ON and the motor is developing torque

(Run Mode), and OFF when the inverter output is OFF (Stop Mode).

• Program LED – This LED is ON when the inverter is ready for parameter editing

(Program Mode). It is OFF when the parameter display is monitoring data (Monitor Mode).

• Run Key Enable LED – This LED is ON when the inverter is ready to respond to the

Run key, OFF when the Run key is disabled.

• Run Key – Press this key to run the motor (the Run Enable LED must be ON first).

Parameter F004, Keypad Run Key Routing, determines whether the Run key generates a Run FWD or Run REV command.

• Stop/Reset Key – Press this key to stop the motor when it is running (uses the

programmed deceleration rate). This key will also reset an alarm that has tripped.

• Parameter Display – A 4-digit, 7-segment display for parameters and function codes.

• Display Units, Hertz/Amperes – One of these LEDs will be ON to indicate the units

associated with the parameter display.

• Power LED – This is ON when the power input to the inverter is ON.

• Alarm LED – ON when an inverter trip is active (alarm relay contact will be closed).

• Escape Key – This key is used to escape from the current situation.

• Up/Down keys – Use these keys alternatively to move up or down the lists of

parameter and functions shown in the display, and increment/decrement values.

• Set key – This key is used to navigate through the lists of parameters and functions

for setting and monitoring parameter values. When the unit is in Program Mode and you have edited a parameter value, press the Set key to write the new value to the EEPROM.

Display Units (Hertz / Amperes) LEDs

Parameter Display

Run key Enable LED Run key

Escape key

Power LED

larm LED

Program LED

Remote operator Connector (RJ45 ) (RS422 only)

USB port (Mini B connector)

RUN

ESC

STOP/

RESET

SET

8888

RUN

Hz A

PWR

ALM

PRG

Stop/Reset key

Up/Down keys

Set key

Run LED

3−4

Operational Modes

The RUN and PRG LEDs tell just part of the story; Run Mode and Program Modes are independent modes, not opposite modes. In the state diagram to the right, Run alternates with Stop, and Program Mode alternates with Monitor Mode. This is a very important ability, for it shows that a technician can approach a running machine and change some parameters without shutting down the machine.

The occurrence of a fault during operation will cause the inverter to enter Trip Mode as shown. An event such as an output overload will cause the inverter to exit the Run Mode and turn OFF its output to the motor. In the Trip Mode, any request to run the motor is ignored. You must clear the error by pressing the Stop/Reset switch. See “Monitoring Trip Events, History, & Conditions” on page 6-8.

Run Mode Edit

The inverter can be in Run Mode (inverter output is controlling motor) and still allow you to edit certain parameters. This is useful in applications that must run continuously, you need some inverter parameter adjustment.

The parameter tables in this chapter have a column titled “Run Mode Edit”. An Ex mark

U means the parameter cannot be

edited; a Check mark

 means the parameter can be edited.

The Software Lock Setting (parameter B031) determines when the Run Mode access permission is in effect and access permission in other conditions, as well. It is the responsibility of the user to choose a useful and safe software lock setting for the inverter operating conditions and personnel. Please refer to “Software Lock Mode” on page 3-53 for more information.

Control Algorithms

The motor control program in the WJ200 inverter has two sinusoidal PWM switching algorithms. The intent is that you select the best algorithm for the motor and load characteristics of your application. Both algorithms generate the frequency output in a unique way. Once configured, the algorithm is the basis for other parameter settings as well (see “Torque Control Algorithms

” on page 3-22). Therefore, choose the best algorithm early in your application design process.

Run Stop

RUN

STOP RESET

Monitor Program

FUNC

Run Stop

RUN

STOP RESET

Trip

STOP RESET

Fault

Run

Mode

Edit



V/F control

constant torque (V/F-VC)

Output

Inverter Control Algorithms

V/F control,

variable (1.7) torque

V/F control,

Free V/f

Sensorless vector

Control (SLV)

3−5

Dual Rating Selection

The WJ200 series inverter has Dual Rating, so that it can work in two different types of load condition, Constant torque application and Variable torque application. Select parameter b049 depending on your application.

“b” Function

Run

Mode

Edit

Defaults

Func.

Code

Name Description Lnitial data Units

b049

Dual Rating Selection

00… (CT mode) / 01… (VT mode)

−

When changed, the rated output current and related items are changed automatically. Differences between HD and ND are described below.

HD ND

Usage For heavy load with high torque required at start,

acceleration or deceleration

For normal load without high torque required.

Applications Elevators, cranes, conveyers, etc. fans, pumps,

air-conditionings Rated current (example)

1.0A (3-phase 200V 0.1kW) 1.2A (3-phase 200V

0.1kW)

Overload current 150% 60 sec. 120% 60 sec.

Initial values of HD and ND are different shown as below table. Be sure to note that when the dual rating selection b049 is changed except H003/H203, those initial values are also changed. (Even if currently set value is within the range of both HD and ND, data is initialized when b049 is changed.)

Name

Func.

code

HD ND

Range initial data Range initial data

V/f characteristic curve

A044 A244

00: Const. torque 01: Reduced torque 02: Free V/F 03: SLV

00: Const. tq. 00: Const. torque

01: Reduced tq. 02: Free V/F

00: Const. tq.

DC braking force for deceleration

A054 0 to 100 (%) 0 (%) 0 to 70 % 0 (%)

DC braking force at start

A057 0 to 100 (%) 0 (%) 0 to 70 % 0 (%)

Carrier frequency during DC braking

A059

2.0 to 15.0(kHz) 5.0(kHz) 2.0 to 10.0(kHz) 2.0(kHz)

Overload restriction level

b022 b222

(0.20 to 2.00) × Rated current (A)

1.50× Rated current (A)

(0.20 to 1.50) × Rated current (A)

1.20× Rated

current (A) Overload restriction level 2

b025

Carrier frequency

b083 2.0 to 15.0(kHz) 5.0(kHz) 2.0 to 10.0(kHz) 2.0(kHz)

Motor capacity

H003 H203

0.1 to 15(kW)

Depends on type

0.2 to 18.5(kW)

One size up

to HD

3−6

When HD is selected, following parameters are not displayed.

Func.

code

Name

Func.

code

Name

d009 Torque command monitor C058 Over/under-torque level (FW,RG) d010 Torque bias monitor C059 Output mode of Over/under-torque d012 Torque monitor H001 Auto-tuning selection b040 Torque limit selection H002/H202 Motor constant selection b041 Torque limit (1) H005/H205 Motor speed response constant b042 Torque limit (2) H020/H220 Motor constant R1 b043 Torque limit (3) H021/H221 Motor constant R2 b044 Torque limit (4) H022/H222 Motor constant L b045 Torque LAD STOP selection H023/H223 Motor constant Io b046 Reverse run protection H024/H224 Motor constant J C054 Over-torque/under-torque selection P037 Torque bias value C055 Over/under-torque level (FW,PW) P038 Torque bias polar selection C056 Over/under-torque level (RV,RG) P039 Speed limit of Torque control (FW) C057 Over/under-torque level (RV,PW) P040 Speed limit of Torque control (RV)

When ND is selected, following functions are not displayed in intelligent terminals.

Intelligent input terminals Intelligent output terminals

40:TL Torque Limit Selection 07:OTQ Over/under Torque Signal 41:TRQ1 Torque limit switch 1 10:TRQ Torque Limited Signal 42:TRQ1 Torque limit switch 2 - 52:ATR Enable torque command input - -

3−7

“D” Group: Monitoring Functions

You can access important parameter values with the “D” Group monitoring functions, whether the inverter is in Run Mode or Stop Mode. After selecting the function code number for the parameter you want to monitor, press the Function key once to show the value on the display. In functions D005 and D006, the intelligent terminals use individual segments of the display to show ON/OFF status.

If the inverter display is set to monitor a parameter and powerdown occurs, the inverter stores the present monitor function setting. For your convenience, the display automatically returns to the previously monitored parameter upon the next powerup.

“d” Function

Run

Mode

Edit

Units

Func.

Code

Name Description

D001

Output frequency monitor Real time display of output

frequency to motor from

0.0 to 400.0Hz If b163 is set high, output frequency (F001) can be changed by up/down key with d001 monitoring.

−

D002

Output current monitor Filtered display of output current to

motor, range is 0 to 655.3 ampere (~99.9 ampere for

1.5kW and less)

−

D003

Rotation direction monitor Three different indications:

“F” …Forward “o” …Stop “r” …Reverse

− −

D004

Process variable (PV), PID feedback monitor

Displays the scaled PID process variable (feedback) value (A075 is scale factor),

0.00 to 10000

−

% times

constant

D005

Intelligent input terminal status

Displays the state of the intelligent input terminals:

− −

D006

Intelligent output terminal status

Displays the state of the intelligent output terminals:

− −

OFF

Relay

12 11

OFF

7 6 5 4

2 1

Terminal numbers

3−8

“d” Function

Run

Mode

Edit

Units

Func.

Code

Name Description

D007

Scaled output frequency monitor

Displays the output frequency scaled by the constant in B086. Decimal point indicates range: 0 to 3999

−

Hz times

constant

d008

Actual frequency monitor Displays the actual frequency,

range is -400 to 400 Hz

−

d009

Torque command monitor Displays the torque command,

range is -200 to 200 %

−

d010

Torque bias monitor Displays the torque bias value,

range is -200 to 200 %

−

d012

Output torque monitor Displays the output torque, range is

-200 to 200 %

−

D013

Output voltage monitor Voltage of output to motor,

Range is 0.0 to 600.0V

−

d014

Input power monitor Displays the input power, range is 0

to 999.9 kW

−

d015

Watt-hour monitor Displays watt-hour of the inverter,

range is 0 to 9999000

−

D016

Elapsed RUN time monitor Displays total time the inverter has

been in RUN mode in hours. Range is 0 to 9999 / 1000 to 9999 /

⎡100 to ⎡999 (10,000 to 99,900)

−

hours

D017

Elapsed power-on time monitor

Displays total time the inverter has been powered up in hours. Range is 0 to 9999 / 1000 to 9999 /

⎡100 to ⎡999 (10,000 to 99,900)

−

hours

D018

Heat sink temperature monitor

Temperature of the cooling fin, range is -20~150

− °C

d022

Life check monitor Displays the state of lifetime of

electrolytic capacitors on the PWB and cooling fan.

− −

d023

Program counter monitor [EzSQ]

Range is 0 to 1024

− −

d024

Program number monitor [EzSQ]

Range is 0 to 9999

− −

d025

User monitor 0 [EzSQ]

Result of EzSQ execution, range is –2147483647~2147483647

− −

d026

User monitor 1 [EzSQ]

Result of EzSQ execution, range is –2147483647~2147483647

− −

d027

User monitor 2 [EzSQ]

Result of EzSQ execution, range is –2147483647~2147483647

− −

d029

Positioning command monitor

Displays the positioning command, range is –268435455~+268435455

− −

d030

Current position monitor Displays the current position, range

is –268435455~+268435455

− −

d050

Dual monitor Displays two different data

configured in b160 and b161.

− −

d060

Inverter mode monitor Displays currently selected inverter

mode : I-C:IM CT mode/I-v:IM VT mode/ P:PM

− −

Lifetime expired

Normal

Electrolytic caps

Cooling fan

3−9

“d” Function

Run

Mode

Edit

Units

Func.

Code

Name Description

D102

DC bus voltage monitor Voltage of inverter internal DC bus,

Range is 0.0 to 999.9

−

d103

BRD load ratio monitor Usage ratio of integrated brake

chopper, range is 0.0~100.0%

−

D104

Electronic thermal monitor Accumulated value of electronic

thermal detection, range is from

0.0~100.0%

−

Trip Event and History Monitoring

The trip event and history monitoring feature lets you cycle through related information using the keypad. See “Monitoring Trip Events, History, & Conditions

” on page 6-5 for

more details.

“d” Function

Run

Mode

Edit

Units

Func.

Code

Name Description

D080

Trip counter Number of trip events,

Range is 0. to 65530

−

events

D081

Trip monitor 1 Displays trip event information:

• Error code

• Output frequency at trip point

• Motor current at trip point

• DC bus voltage at trip point

• Cumulative inverter operation

time at trip point

• Cumulative power-ON time at

trip point

− −

D082

Trip monitor 2

− −

D083

Trip monitor 3

− −

d084

Trip monitor 4

− −

d085

Trip monitor 5

− −

d086

Trip monitor 6

− −

d090

Warning monitor Displays the warning code

− −

3−10

Local Monitoring with keypad connected

The WJ200 inverter’s serial port may be connected to an external digital operator. During those times, the inverter keypad keys will not function (except for the Stop key). However, the inverter’s 4-digit display still provides the Monitor Mode function, displaying any of the parameters D001 to D060. Function B150, Monitor Display Select for Networked Inverter, determines the particular D00x parameter displayed. Refer to the previous table.

When monitoring the inverter with external keypad connected, please note the following:

• The inverter display will monitor D00x functions according to B150 setting when a

device is already connected to the inverter’s serial port at inverter powerup.

• When external keypad is connected, the inverter keypad will also display error codes

for inverter trip events. Use the Stop key or inverter Reset function to clear the error. Refer to “Error Codes

” on page 6-8 to interpret the error codes.

• The Stop key can be disabled, if you prefer, by using function B087.

3−11

“F” Group: Main Profile Parameters

The basic frequency (speed) profile is defined by parameters contained in the “F” Group as shown to the right. The set running frequency is in Hz, but acceleration and deceleration are specified in the time duration of the ramp (from zero to maximum frequency, or from maximum frequency to zero). The motor direction parameter determines whether the keypad Run key produces a FWD or REV command. This parameter does not affect the intelligent terminal [FW] and [REV] functions, which you configure separately.

Acceleration 1 and Deceleration 1 are the standard default accel and decel values for the main profile. Accel and decel values for an alternative profile are specified by using parameters Ax92 through Ax93. The motor direction selection (F004) determines the direction of rotation as commanded only from the keypad. This setting applies to any motor profile (1st or 2nd) in use at t particular time.

“F” Function

Run

Mode

Edit

Defaults

Func.

Code

Name Description Lnitial data Units

F001

Output frequency setting Standard default target

frequency that determines constant motor speed, range is

0.0 / start frequency to maximum frequency (A004)



0.0 Hz

F002

Acceleration time (1) Standard default acceleration,

range is 0.01 to 3600 sec.



10.0 sec.

F202

Acceleration time (1), 2nd motor



10.0 sec.

F003

Deceleration time (1) Standard default deceleration,

range is 0.01 to 3600 sec.



10.0 sec.

F203

Deceleration time (1), 2nd motor



10.0 sec.

F004

Keypad RUN key routing Two options; select codes:

00 …Forward 01 …Reverse

−

Acceleration and deceleration can be set via EzSQ as well via the following parameter.

“P” Function

Run

Mode

Edit

Defaults

Func.

Code

Name Description Lnitial data Units

P031

Acceleration/Deceleration setting source selection

Two options; select codes:

00 …Via operator 01 …Via EzSQ

Output frequency

A004

F002

F003

F001

ctual accel. time

b082

ctual decel. time

3−12

“A” Group: Standard Functions

The inverter provides flexibility in how you control Run/Stop operation and set the output frequency (motor speed). It has other control sources that can override the A001 / A002 settings. Parameter A001 sets the source selection for the inverter’s output frequency. Parameter A002 selects the Run command source (for FW or RV Run commands). The default settings use the input terminals for –FE (European) models, and the keypad for –FU (USA) models.

“A” Function

Run

Mode

Edit

Defaults

Func.

Code

Name Description Lnitial data Units

A001

Frequency source Eight options; select codes:

00 …POT on ext. operator 01 …Control terminal 02 …Function F001 setting 03 …ModBus network input 04 …Option 06 …Pulse train input 07 …via EzSQ 10 …Calculate function output

−

A201

Frequency source, 2

motor

−

A002

Run command source Five options; select codes:

01 …Control terminal 02 …Run key on keypad,

or digital operator

03 …ModBus network input 04 …Option

−

A202

Run command source, 2

motor

−

Frequency Source Setting – For parameter A001, the following table provides a further description of each option, and a reference to other page(s) for more information.

Code Frequency Source Refer to page(s)…

POT on ext. operator – The range of rotation of the knob matches the range defined by b082 (start frequency) to A004

(max. frequency), when external operator is used

Control terminal – The active analog input signal on analog terminals [O] or [OI] sets the output frequency

4-70, 3-16, 3-40,

3.83

Function F001 setting – T he value in F001 is a constant, used for the output frequency

3-11

ModBus network input – The network has a dedicated register for inverter output frequency

B-24

Option – Select when an option card is connected and use the frequency source from the option

(manual of each

option)

Pulse train input – The pulse train given to EA terminal. The pulse train must be 10Vdc, 32kHz max.

3-113

Via EzSQ – The frequency source can be given by the EzSQ function, when it is used

(EzSQ manual)

Calculate function output – The Calculated function has user-selectable analog input sources (A and B). The output can be the sum, difference, or product (+, -, x) of the two outputs.

3-41

3−13

Run Command Source Setting – For parameter A002, the following table provides a

further description of each option, and a reference to other page(s) for more information.

Code Run Command Source Refer to page(s)…

Control terminal – The [FW] or [RV] input terminals control Run/Stop operation

4-16

Keypad Run key – The Run and Stop keys provide control 2-23

ModBus network input – The network has a dedicated coil for Run/Stop command and a coil for FW/RV

B-24

Option – Select when an option card is connected and use the frequency source from the option

(manual of each

option)

A001/A002 Override Sources – The inverter allows some sources to override the setting for output frequency and Run command in A001 and A002. This provides flexibility for applications that occasionally need to use a different source, leaving the standard settings in A001/A002.

The inverter has other control sources that can temporarily override the parameter A001 setting, forcing a different output frequency source. The following table lists all frequency source setting methods and their relative priority (“1” is the highest priority).

Priority

A001 Frequency Source Setting Method

Refer to page…

1 [CF1] to [CF4] Multi-speed terminals 4-17 2 [OPE] Operator Control intelligent input 4-35 3 [F-TM] intelligent input 4-42 4 [AT] terminal 4-28 5

A001 Frequency source setting

3-10

The inverter also has other control sources that can temporarily override the parameter A002 setting, forcing a different Run command source. The following table lists all Run command setting methods and their relative priority (“1” is the highest priority).

Priority

A002 Run Command Setting Method

Refer to page…

1 [OPE] Operator Control intelligent input 4-35 2 [F-TM] intelligent input 4-42 3

A002 Run command source setting

3-10

3−14

The figure below shows the correlation diagram of all frequency source setting methods and their relative priority.

Note 1: You can set the inverter output frequency with function F001 only when you have specified “02” for the frequency source setting

A001. If the setting of function A001 is other than “02”, function F001

operates as the frequency command monitoring function. And by setting the frequency set in monitoring active (

b163=01), you can change the inverter output frequency with function d001 or d007.

[AT]

terminal

[AT]selection

A005

Multi-speed

inputs

CF1-4,SF1-7

Frequency

source setting

A001/A201

[AT]

terminal

is active

OFF

[O]+[OI]

yes

00 03 04

OFF

Force

terminal

mode

OFF

Operator

control

Frequency

setting

OFF

Multi-speed

A021-A035

Analog voltage

input [O]

OPE-SR/

OPE-SR mini

[VR]

Digital operator

A020/A220=F001

Modbu s

communication

Pulse train

input [EA]

EzSQ

equency calculate functio

00 02 03

OFF

B input select for

calculate function

A142

A Input select for

calculate function

A141

Calculation

symbol

A143

(＋) (－) (×)

Option PCB

Analog current

input [OI]

∗

[AT]

terminal

[AT]selection

A005

Multi-speed

inputs

CF1-4,SF1-7

Frequency

source setting

A001/A201

[AT]

terminal

is active

OFF

[O]+[OI]

yes

00 03 04

OFF

Force

terminal

mode

OFF

Operator

control

Frequency

setting

OFF

Multi-speed

A021-A035

Analog voltage

input [O]

OPE-SR/

OPE-SR mini

[VR]

Digital operator

A020/A220=F001

Modbu s

communication

Pulse train

input [EA]

EzSQ

equency calculate functio

00 02 03

OFF

B input select for

calculate function

A142

A Input select for

calculate function

A141

Calculation

symbol

A143

(＋) (－) (×)

Option PCB

Analog current

input [OI]

[AT]

terminal

[AT]selection

A005

Multi-speed

inputs

CF1-4,SF1-7

Frequency

source setting

A001/A201

[AT]

terminal

is active

OFF

[O]+[OI]

yes

00 03 04

OFF

Force

terminal

mode

OFF

Operator

control

Frequency

setting

OFF

Multi-speed

A021-A035

Analog voltage

input [O]

OPE-SR/

OPE-SR mini

[VR]

Digital operator

A020/A220=F001

Modbu s

communication

Pulse train

input [EA]

EzSQ

equency calculate functio

00 02 03

OFF

B input select for

calculate function

A142

A Input select for

calculate function

A141

Calculation

symbol

A143

(＋) (－) (×)

Option PCB

Analog current

input [OI]

∗

3−15

Basic Parameter Settings

These settings affect the most fundamental behavior of the inverter – the outputs to the motor. The frequency of the inverter’s AC output determines the motor speed. You may select from three different sources for the reference speed. During application development you may prefer using the potentiometer, but you may switch to an external source (control terminal setting) in the finished application, for example.

The base frequency and maximum frequency settings interact according to the graph below (left). The inverter output operation follows the constant V/f curve until it reaches the full-scale output voltage at the base frequency. This initial straight line is the constant-torque part of the operating characteristic. The horizontal line over to the maximum frequency serves to let the motor run faster, but at a reduced torque. This is the constant-power operating range. If you want the motor to output constant torque over its entire operating range (limited to the motor nameplate voltage and frequency rating), then set the base frequency and maximum frequency equal as shown (below right).

NOTE: The “2nd motor” settings in the table in this chapter store an alternate set of parameters for a second motor. The inverter can use the 1st set or 2nd set of parameters to generate the output frequency to the motor.

“A” Function

Run

Mode

Edit

Defaults

Func.

Code

Name Description Lnitial data Units

A003

Base frequency Settable from 30 Hz to the

maximum frequency(A004) Settable from 30 Hz to the 2

maximum frequency(A204)

60.0 Hz

A203

Base frequency, 2nd motor

60.0 Hz

A004

Maximum frequency Settable from the base

frequency to 400 Hz Settable from the 2nd base frequency to 400 Hz

60.0 Hz

A204

Maximum frequency, 2

motor

60.0 Hz

100%

A003

A004

Base

Frequency

Maximum

Frequency

100%

A003

A004

Base Frequency =

Maximum Frequency

3−16

Analog Input Settings

The inverter has the capability to accept an external analog input that can command the output frequency to the motor. Voltage input (0-10 V) and current input (4-20mA) are available on separate terminals ([O] and [OI] respectively). Terminal [L] serves as signal ground for the two analog inputs. The analog input settings adjust the curve characteristics between the analog input and the frequency output.

Adjusting [O-L] characteristics – In the graph to the right, A013 and A014 select the active portion of the input voltage range. Parameters A011 and A012 select the start and end frequency of the converted output frequency range, respectively. Together, these four parameters define the major line segment as shown. When the line does not begin at the origin (A011 and A013 > 0), then A015 defines whether the inverter outputs 0Hz or the A011-specified frequency when the analog input value is less than the A013 setting. When the input voltage is greater than the A014 ending value, the inverter outputs the ending frequency specified by A012.

Adjusting [OI-L] characteristics – In the graph to the right, A103 and A104 select the active portion of the input current range. Parameters A101 and A102 select the start and end frequency of the converted output frequency range, respectively. Together, these four parameters define the major line segment as shown. When the line does not begin at the origin (A101 and A103 > 0), then A105 defines whether the inverter outputs 0Hz or the A101-specified frequency when the analog input value is less than the A103 setting. When the input voltage is greater than the A104 ending value, the inverter outputs the ending frequency specified by A102.

If [AT] is not assigned to any of the intelligent input terminal, inverter recognizes the input [O]+[OI].

Adjusting [VR-L] characteristics – This is used when an optional operator is used. Refer to parameters A161 ~ A165 for the details.

Max frequency

A012

A011

A014

100%

10V

A013

A015=00

A015=01

Input scale

Max frequency

A102

A101

A104

100%

20mA

A103

A105=00

A105=01

Input scale

3−17

“A” Function

Run

Mode

Edit

Defaults

Func.

Code

Name Description Lnitial data Units

A005

[AT] selection Three options; select codes:

00...Select between [O] and [OI] at [AT] (ON=OI, OFF=O)

02...Select between [O] and external POT at [AT] (ON=POT, OFF=O)

03...Select between [OI] and external POT at [AT] (ON=POT, OFF=OI)

The output frequency corresponding to the analog input range starting point,

range is 0.00 to 400.0

−

A011

[O] input active range start frequency

0.00 Hz

A012

[O] input active range end frequency

The output frequency corresponding to the analog input range ending point, range is 0.0 to 400.0 The starting point (offset) for the active analog input range, range is 0. to 100.

0.00 Hz

A013

[O] input active range start voltage

0. %

A014

[O] input active range end voltage

The ending point (offset) for the active analog input range, range is 0. to 100.

100. %

A015

[O] input start frequency enable

Two options; select codes:

00…Use offset (A011 value) 01…Use 0Hz

−

A016

Analog input filter Range n = 1 to 31,

1 to 30 : ×2ms filter 31: 500ms fixed filter with ±

0.1kHz hys.

8. Spl.

A016: External Frequency Filter Time Constant – This filter smoothes the analog input signal for the inverter’s output frequency reference.

・ A016 sets the filter range from n=1 to 30. This is a simple moving average calculation,

where n (number of samples) is variable.

・ A016=31 is a special value. It configures the inverter to use a movable deadband

feature. Initially the inverter uses the 500ms of filter time constant. Then, the deadband is employed for each subsequent average of 16 samples. The deadband works by ignoring small fluctuations in each new average: less than ±0.1Hz change. When a 30-sample average exceeds this deadband, then the inverter applies that average to the output frequency reference, and it also becomes the new deadband comparison point for subsequent sample averages.

The example graph below shoes a typical analog input waveform. The filter removes the noise spikes. When a speed change (such as level increase) occurs, the filter naturally has a delayed response. Due to the deadband feature (A016=31), the final output changes only when the 30-sample average moves past the deadband threshold.

3−18

TIP: The deadband feature is useful in applications that requires a very stable output frequency but use an analog input for the speed reference. Example application: A grinding machine uses a remote potmeter for operator speed input. After a setting change, the grinder maintains a very stable speed to deliver a uniform finished surface.

EzSQ Related Settings

The WJ200 series inverter has capability to execute EzSQ program like SJ700 series inverters. Parameters A017 is for the EzSQ performance. Please refer to the EzSQ section for the detailed explanation.

Noise spikes

Speed increase given

nalog input

16-sample avg.

+0.1

-0.1

Threshold exceeded

Deadband

New deadband

+0.1

-0.1

Output freq. reference

Small step change

A016=31

3−19

Multi-speed and Jog Frequency Setting

Multi-speed – The WJ200 inverter has the capability to store and output up to 16 preset

frequencies to the motor (A020 to A035). As in traditional motion terminology, we call this

multi-speed profile

capability. These preset frequencies are selected by means of digital inputs to the inverter. The inverter applies the current acceleration or deceleration setting to change from the current output frequency to the new one. The first multi-speed setting is duplicated for the second motor settings (the remaining 15 multi-speeds apply only to the first motor).

“A” Function

Run

Mode

Edit

Defaults

Func.

Code

Name Description Lnitial data Units

a019

Multi-speed operation selection

Select codes:

00...Binary operation (16 speeds selectable with 4 terminals)

01...Bit operation (8 speeds

selectable with 7

terminals) Defines the first speed of a multi-speed profile, range is 0.0 / start frequency to 400Hz A020 = Speed 0 (1st motor)

00 -

A020

Multi-speed freq. 0



0.0 Hz

A220

Multi-speed freq. 0, 2

motor

Defines the first speed of a multi-speed profile or a 2nd motor, range is 0.0 / start frequency to 400Hz A220 = Speed 0 (2nd motor) Defines 15 more speeds, range is 0.0 / start frequency to 400 Hz. A021=Speed 1 ~ A035=Speed15



0.0 Hz

A021

A035

Multi-speed freq. 1 to 15 (for both motors)



See next

row

C169

Multistage speed/position determination time

Set range is 0. to 200. (x 10ms)

0. ms

There are two ways for speed selection, that are “binary operation” and “bit operation”.

For binary operation (

A019=00), you can select 16 speeds by combination of 4 digital

inputs. And for bit operation (

A019=01), you can select 8 speeds by using 7 digital inputs.

Please refer to the following figures for detailed explanation.

Hitachi WJ200-007L, WJ200-001L, WJ200-015S, WJ200-022S, WJ200-004H Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual