Hitachi X200-022S, X200-005S, X200-007N, X200-015N, X200-015L Instruction Manual

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X200 Series Inverter Instruction Manual

x Single-phase Input 200V class x Three-phase Input 200V class x Three-phase Input 400V class

Hitachi Industrial Equipment Systems Co., Ltd.

Manual Number: NT301XC

Sep 2007

After read this manual,

Keep it handy for future reference.

Safety Messages

For the best results with the X200 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:

IGH 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.

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

AUTION: 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 C

AUTION 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.

tep 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.

OTE: Notes indicates an area or subject of special merit, emphasizing either the

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

IP: 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.

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 X200 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 X200 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.

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 2-9. 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 2-17).

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

iii

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.

IGH 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.

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 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.

AUTION: Be sure to install the unit on flame-resistant material such as a steel plate.

Otherwise, there is the danger of fire.

AUTION: Be sure not to place any flammable materials near the inverter. Otherwise,

there is the danger of fire.

AUTION: 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.

AUTION: 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.

AUTION: 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.

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

AUTION: 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.

AUTION: 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.

…2-3

…2-4

…2-8

…2-9

…2-10

Wiring – Warnings for Electrical Practice and Wire Specifications

WARNING: “USE 60/75qC Cu wire only” or equivalent. For models X200-005S, -007S,

-011S, -022S, -007N, -015N, -015L, -022L, -037L, -055L, -075L.

WARNING: “USE 75qC Cu wire only” or equivalent. For models X200-002S, -004S, 002N, -004N, -002L, -004L, -007L, -022H, -030H, -037H, -040H, -055H, -075H.

WARNING: “USE 60qC Cu wire only” or equivalent. For models X200-004H, -007H, and –015H.

ARNING: “Open Type Equipment.”

ARNING: “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.

ARNING: “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.

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

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

IGH VOLTAGE: Implement wiring after checking that the power supply is OFF. Otherwise, you may incur electric shock and/or fire.

IGH 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.

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

AUTION: 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;

x Single phase 200V to 240V 50/60Hz (up to 2.2kW) for SFEF model

x Single/Three phase 200V to 240V 50/60Hz (up to 2.2kW) for NFU model

x Three phase 200V to 240V 50/60Hz (7.5kW) for LFU model

x 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

X200 Inverter

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:

x Use only short time-invariant and pulse current-sensitive ground fault

interrupters with higher trigger current.

x Other components should be secured with separate ground fault interrupters.

x 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.

x Is the shorting bar between the [+1] and [+] terminals installed? DO NOT power

or operate the inverter if the jumper is removed.

x Is the direction of the motor rotation correct?

x Did the inverter trip during acceleration or deceleration?

x Were the rpm and frequency meter readings as expected?

x Were there any abnormal motor vibration or noise?

… 2-23

vii

Warnings for Configuring Drive Parameters

WARNING: 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

WARNING: Be sure to turn ON the input power supply only after closing the front

case. While the inverter is energized, be sure not to open the front case. Otherwise,

there is the danger of electric shock.

… 4-3

WARNING: Be sure not to operate electrical equipment with wet hands. Otherwise,

there is the danger of electric shock.

… 4-3

WARNING: While the inverter is energized, be sure not to touch the inverter

terminals even when the motor is stopped. Otherwise, there is the danger of electric

shock.

… 4-3

WARNING: If the retry mode is selected, the motor may suddenly restart after a

trip stop. Be sure to stop the inverter before approaching the machine (be sure to

design the machine so that safety for personnel is secure even if it restarts.)

Otherwise, it may cause injury to personnel.

… 4-3

WARNING: 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

WARNING: The Stop Key is effective only when the stop function is enabled. Be

sure to enable the Stop Key separately from the emergency stop. Otherwise, it may

cause injury to personnel.

… 4-3

WARNING: During a trip event, if the alarm reset is applied and the Run command

is present, the inverter will automatically restart. Be sure to apply the alarm reset

only after verifying the Run command is OFF. Otherwise, it may cause injury to

personnel.

… 4-3

viii

WARNING: Be sure not to touch the inside of the energized inverter or to put any

conductive object into it. Otherwise, there is a danger of electric shock and/or fire.

… 4-3

WARNING: If power is turned ON when the Run command is already active, the

motor will automatically start and injury may result. Before turning ON the power,

confirm that the RUN command is not present.

… 4-3

WARNING: When the Stop key function is disabled, pressing the Stop key does not

stop the inverter, nor will it reset a trip alarm.

WARNING: Be sure to provide a separate, hard-wired emergency stop switch when

the application warrants it.

… 4-3

WARNING: If the power is turned ON and the Run command is already active, the

motor starts rotation and is dangerous! Before turning power ON, confirm that the

Run command is not active.

… 4-11

WARNING: After the Reset command is given and the alarm reset occurs, the

motor will restart suddenly if the Run command is already active. Be sure to set the

alarm reset after verifying that the Run command is OFF to prevent injury to

personnel.

… 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: 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, it may cause injury to personnel.

… 4-2

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.

… 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

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.

… 4-31

HIGH VOLTAGE: Dangerous voltage exists even after the Emergency Stop is

activated. It does

NOT

mean that the main power has been removed.

… 4-32

Warnings and Cautions for Troubleshooting and Maintenance

WARNING: Wait at least five (5) minutes after turning OFF the input power supply

before performing maintenance or an inspection. Otherwise, there is the danger of

electric shock.

… 6-2

WARNING: Make sure that only qualified personnel will perform maintenance,

inspection, and part replacement. Before starting to work, remove any metallic

objects from your person (wristwatch, bracelet, etc.). Be sure to use tools with

insulated handles. Otherwise, there is a danger of electric shock and/or injury to

personnel.

… 6-2

WARNING: Never remove connectors by pulling on its wire leads (wires for cooling

fan and logic P.C.board). Otherwise, there is a danger of fire due to wire breakage

and/or injury to personnel.

… 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

WARNING: 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.

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

Ground fault

interrupter

L1, L2, L3

Inverter

U, V, W

Motor

PCS

Power

Input

Ground fault

interrupter

L1, L2, L3

Inverter

U, V, W

Motor

Surge absorber

Leading power factor capacitor

GND lug

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.

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

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 C015) 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.

EMI Filter

Inverter

Motor

EMI Filter Inverter

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

xii

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.

ARNING: “USE 60/75qC Cu wire only” or equivalent. For models X200-005S, -007S,

-011S, -022S, -007N, -015N, -015L, -022L, -037L, -055L, -075L.

WARNING: “USE 75qC Cu wire only” or equivalent. For models X200-002S, -004S, -002N, -004N,

-002L, -004L, -007L, -022H, -030H, -037H, -040H, -055H, 075H.

WARNING: “USE 60qC Cu wire only” or equivalent. For models X200-004H, -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 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.

WARNING: “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.

WARNING: “Install device inn pollution degree 2 environment.”

WARNING: “Maximum Surrounding Air Temperature 50qC”. or equivalent.

WARNING: “Caution-Risk of electric shockcapacitor discharge time is at least 5 minutes.”

WARNING: “Solid state motor overload protection is provided in each model”.

WARNING: “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” or equivalent.

xiii

Terminal Tightening Torque and Wire Size

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

Motor Output Torque

Input

Voltage

kW HP

Inverter Model

Power Terminal

Wiring Size

Range (AWG)

Ft-lbs (N-m)

0.2 1/4 X200-002SFEF/NFU

0.4 1/2 X200-004SFEF/NFU

0.6 0.8

0.55 3/4 X200-005SFEF

0.75 1 X200-007SFEF/NFU

(75qC only)

1.1 1 1/2 X200-011SFEF

1.5 2 X200-015SFEF/NFU

2.2 3 X200-022SFEF/NFU 10

0.9 1.2

3.7 5 X200-037LFU 12 0.9 1.2

5.5 7 1/2 X200-055LFU

200V

Class

7.5 10 X200-075LFU

8 1.5 2.0

0.4 1/2 X200-004HFEF/HFU

0.75 1 X200-007HFEF/HFU

1.5 2 X200-015HFEF/HFU

(60qC only)

2.2 3 X200-022HFEF/HFU

3.0 4 X200-030HFEF

4.0 5 X200-040HFEF/HFU

(75qC only)

0.9 1.2

5.5 7 1/2 X200-055HFEF/HFU

400V

Class

7.5 10 X200-075HFEF/HFU

10 1.5 2.0

Torque

Terminal Connector

Wiring Size

Range (AWG)

Ft-lbs (N-m)

Logic and Analog connectors 30 – 16 0.16 – 0.19 0.22 – 0.25 Relay connector 30 – 14 0.37 – 0.44 0.5 – 0.6

Wire Connectors

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

Terminal (ring lug)

Cable support

Cable

xiv

Circuit Breaker and Fuse Sizes

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

Input

Voltage

Inverter Model Circuit Breaker / Fuse Ratings (A)

X200-002SFEF/NFU X200-004SFEF/NFU X200-005SFEF

X200-007SFEF/NFU X200-011SFEF

X200-015SFEF/NFU 20 X200-022SFEF/NFU X200-037LFU

X200-055LFU 40

Single/

Three-

Phase

200V

X200-075LFU

Inverse time circuit Breaker

50 X200-004HFEF/HFU 3 X200-007HFEF/HFU 6

X200-015HFEF/HFU X200-022HFEF/HFU

X200-030HFEF X200-040HFEF/HFU

X200-055HFEF/HFU 20

Three-

Phase

400V

X200-075HFEF/HFU

Distribution Fuse (Class J)

Motor Overload Protection

Hitachi X200 inverters provide solid state motor overload protection, which depends on the proper setting of the following parameters:

x B012 “electronic overload protection” x B212 “electronic overload protection, 2nd motor”

Set the rated current [Amperes] of the motor(s) with the above parameters. The setting range is 0.2 * rated current to 1.0 * rated current.

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

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

X200 Inverter Specifications .................................................................................................. 1-5

Introduction to Variable-Frequency Drives ........................................................................ 1-19

Frequently Asked Questions ................................................................................................ 1-24

Chapter 2: Inverter Mounting and Installation

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

Basic System Description .......................................................................................................2-7

Step-by-Step Basic Installation ............................................................................................. 2-8

Powerup Test ......................................................................................................................... 2-24

Using the Front Panel Keypad ............................................................................................ 2-26

Chapter 3: Configuring Drive Parameters

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

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

“D” Group: Monitoring Functions .......................................................................................... 3-6

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

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

“B” Group: Fine Tuning Functions ...................................................................................... 3-32

“C” Group: Intelligent Terminal Functions ......................................................................... 3-49

“H” Group: Motor Constants Functions .............................................................................. 3-65

xvi

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 ...................................................................................................4-7

Using Intelligent Input Terminals ........................................................................................ 4-8

Using Intelligent Output Terminals .................................................................................... 4-36

Analog Input Operation ....................................................................................................... 4-55

Analog Output Operation ..................................................................................................... 4-57

PID Loop Operation .............................................................................................................. 4-58

Configuring the Inverter for Multiple Motors .................................................................... 4-60

Chapter 5: Inverter System Accessories

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

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

Dynamic Braking .................................................................................................................... 5-5

Chapter 6: Troubleshooting and Maintenance

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

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

Restoring Factory Default Settings ....................................................................................... 6-8

Maintenance and Inspection .................................................................................................. 6-9

Warranty ............................................................................................................................... 6-16

Appendix A: Glossary and Bibliography

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

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

Appendix B: ModBus Network Communications

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

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

Network Protocol Reference ...................................................................................................B-6

ModBus Data Listing ...........................................................................................................B-19

Appendix C: Drive parameter Setting Tables

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

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

Appendix D: CE-EMC Installation Guidelines

CE-EMC Installation Guidelines ...........................................................................................D-2

Hitachi EMC Recommendations ............................................................................................D-5

Index

xvii

Revisions

Revision History Table

No. Revision Comments

Date of

Issue

Operation

Manual No.

Initial release of manual NT301X

This manual is valid with QRG (NT3011X) and Caution (NTZ301X)

March

2007

NT301X

Description was reviewed.

March

2007

NT301XA

Page xiii: Corrected UL warning description Pages 1-5 to 1-9: corrected watt loss values Page 1-9: Added torque characteristics Pages 1-12 to 1-17: Added derating curves Page 3-16: Corrected manual torque boost explanation Page 3-34: Corrected electronic thermal explanation Page 3-39: Corrected parameter range of b050 Page 3-46 and C-6: Corrected run mode edit of b055 and b056 Pages 4-5 to 4-11: Corrected terminal name of PCS Pages 4-32 to 4-35: Added explanation and certificate Pages 4-40 to 4-41: Corrected the timing chart of FA2 Page 4-61: Removed H007 (no H007 on X200 inverter) Page 6-6: Corrected thermistor connected terminal number (#6Æ#5) of E21 description Page 6-16: Corrected warranty period Page D-4: Corrected EMC installation condition Other minor corrections throughout. Added 5.5kW and 7.5kW information. Pages xiii, xiv, xv, 1-7, 1-9, 1-15, 1-18, 3-65, 5-6, 5-7, 6-11

Sept

2007

NT301XC

xviii

Contact Information

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

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

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

Hitachi 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

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

Hitachi Industrial Equipment Systems Co., Ltd. AKS Building, 3, kanda Neribei-cho Chiyoda-ku, Tokyo, 101-0022 Japan Phone: +81-3-4345-6910 Fax: +81-3-4345-6067

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

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.

xix

Getting Started

In This Chapter… page

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

- X200 Inverter Specifications ........................................................... 5

- Introduction to Variable-Frequency Drives.................................. 19

- Frequently Asked Questions ........................................................ 24

11

Getting started

−

Getting started

Introduction

Main Features

Congratulation on your purchase of an X200 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 X200 product line includes more than a dozen inverter models to cover motor sizes from 1/4 horsepower to 10 horsepower, in either 240VAC or 480VAC power input versions. The main features are:

x 200V and 400V class inverters x US or EU versions available (country-specific input voltage range and default values) x Built-in RS485 MODBUS RTU as standard x New current suppressing function x Sixteen programmable speed levels x PID control adjusts motor speed automatically to maintain a process variable value x Integrated CE filter for SFE and HFE versions

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

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

without motor derating.

x 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:

x Digital remote operator keypad x Panel-mount keypad bezel kit and DIN rail mounting adapter (35mm rail size) x Dynamic braking unit with resistors x Radio noise filters

12

Getting started

X200-037LFU

X200-004LFU

−

Getting started

Operator Interface Options

The X200 inverter can utilize a remote keypads, such as the OPE-SRmini (right) or SRW-0EX (below). This allows the keypad to operate the inverter remotely, as shown (below, left). A cable (part no. ICS-1 or ICS-3, 1m or 3m) connects the modular connectors of the keypad and inverter.

Hitachi offers a panel mount keypad kit for the OPE-SRmini (below, right). It includes the mounting flange, gasket, keypad, and other hardware. You can mount the keypad with the potentiometer for a NEMA1 rating. The kit also provides for removing the potentiometer knob to meet NEMA4X requirements, as shown (part no. 4X-KITmini).

igital Operator Copy Unit – The optional digital operator / copy unit (part no.SRW-0EX) is shown to the right. It has a 2-line display that shows parameters by function code and by name. It has the additional capability of reading (uploading) the parameter settings in the inverter into its memory. Then you can connect the copy unit on another inverter and write (download) the parameter settings into that inverter. OEMs will find this unit particularly useful, as one can use a single copy unit to transfer parameter settings from one inverter to many.

OTE: Copy is possible between X200 series. It is not

possible to copy between X200 series and other models.

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

OTE: Never turn power OFF while copying (display “Copy CMD!!”). Otherwise the

inverter may lose functionality at next power ON.

13

Getting started

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Getting started

Inverter Specification Label

The Hitachi X200 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:

14

X200 007 S F E

Series name

Restricted distribution

E=Europe, U=USA, R=Japan

Configuration type

F=with keypad

Input voltage:

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

pplicable motor capacity in kW

002=0.2kW 022=2.2kW 004=0.4kW 030=3.0kW 005=0.55kW 037=3.7kW 007=0.75kW 040=4.0kW 011=1.1kW 055=5.5kW 015=1.5kW 075=7.5kW

Integrated Filter

F= With EMC filter No mark = No integrated filter

Getting started

Specifications label

Regulatory agency approval labels (opposite side)

Inverter model number

Motor capacity for this model

Power Input Rating: Frequency, voltage, current

Output Rating: Frequency, voltage, current

Manufacturing codes: Lot number, date, etc.

−

Getting started

X200 Inverter Specifications

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

The following tables are specific to X200 inverters for the 200V and 400V class model groups. Note that “General Specifications” on page 1

-10 apply to both voltage class

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

Item 200V class Specifications

EU version 002SFEF 004SFEF 005SFEF 007SFEF 011SFEFX200 inverters,

200V models

USA version 002NFU 004NFU – 007NFU –

kW 0.2 0.4 0.55 0.75 0.11Applicable motor size *2 H

P 1/4 1/2 3/4 1 1.5

230V 0.5 1.0 1.1 1.5 1.9Rated capacity

(kVA)

240V 0.5 1.0 1.2 1.6 2.0

Rated input voltage - SFEF type: 1-phase input only

- NFU type: 1-phase or 3-phase input 1-phase: 200V-15% to 240V +10%, 50/60Hz r5% 3-phase: 200V-15% to 240V r10%, 50/60Hz r5%

EU version SFEF series : EN61800-3 category C1 filterIntegrated EMC

filter

USA version – EU version 3.1 5.8 6.7 9.0 11.2Rated input

current (A)

USA version 1.8 3.4 - 5.2 Rated output voltage *3 3-phase: 200 to 240V (proportional to input voltage) Rated output current (A) 1.4 2.6 3.0 4.0 5.0 Efficiency at 100% rated output 89.0% 92.3% 93.2% 94.1% 94.7%

at 70% output 18 24 26 33 42

Watt loss (fc=3kHz) Approximate (W)

at 100% output 22 31 34 44 58 Starting torque *7 100% at 6Hz

100%: d 50Hz

50%:

d 60Hz

Dynamic braking,

approx. % torque

(short time stop

from 50/60Hz) *8

Capacitive feedback type, dynamic braking unit and

braking resistor optional, individually installed

Braking

DC braking Variable operating frequency, time, and braking force

Kg 0.8 1.0 1.5 1.5 2.4EU version

(-SFEF)

lb 1.77 2.21 3.31 3.31 5.30 Kg 0.8 0.9 – 1.5 –

Weight

USA version

(-NFU)

lb 1.77 1.99 – 3.31 –

15

Getting started

−

Getting started

Footnotes for the preceding table and the tables that follow:

ote1: The protection method conforms to JEM 1030.

ote2: 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.

ote3: 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.

ote4: To operate the motor beyond 50/60Hz, consult the motor manufacturer for the

maximum allowable rotation speed.

ote5: EU version inverters (-SFE and -HFE) have integrated EMC filter.

ote6: For achieving approved input voltage rating categories:

x 460 to 480VAC – Over-voltage category 2 x 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).

ote7: At the rated voltage when using a Hitachi standard 3-phase, 4-pole motor.

ote8: 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.

ote9: 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.

ote10: 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 B083 Carrier Frequency Adjustment in accordance with the expected output current level. See derating curve section for the detailed information of the inverter operating range.

ote11: The storage temperature refers to the short-term temperature during

transportation.

ote12: Conforms to the test method specified in JIS C0040 (1999). For the model

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

16

Getting started

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Getting started

X200 Inverter Specifications, continued…

Item 200V class Specifications

EU version 015SFEF 022SFEF – – –X200 inverters, 200V models

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

kW 1.5 2.2 3.7 5.5 7.5Applicable motor size *2 H

P 2 3 5 7.5 10

230V 2.8 3.9 6.3 9.5 12.7Rated capacity (kVA)

240V 2.9 4.1 6.6 9.9 13.3 Rated input voltage - SFEF type: 1-phase input only

- NFU type: 1-phase or 3-phase input

- LFU type: 3-phase input only 1-phase: 200V-15% to 240V +10%, 50/60Hz r5% 3-phase: 200V-15% to 240V r10%, 50/60Hz r5%

EU version SFE series : EN61800-3 category C1 filterIntegrated EMC filter

USA version –

EU version 16.0 22.5 – – –Rated input current (A)

USA version 9.3 13.0 20.0 30.0 40.0 Rated output voltage *3 3-phase: 200 to 240V (proportional to input voltage) Rated output current (A) 7.1 10.0 15.9 24 32 Efficiency at 100% rated output 94.5% 96.0% 96.4% 96.1% 96.1%

at 70% output 58 61 91 138 186

Watt loss (fc=3kHz) Approximate (W)

at 100% output 83 87 133 215 295

Starting torque *7 100% at 6Hz

50%: d 60Hz 20%: d 60Hz

Dynamic braking,

approx. % torque

(short time stop

from 50/60Hz) *8

Capacitive feedback type, dynamic braking unit and

braking resistor optional, individually installed

Braking

DC braking Variable operating frequency, time, and braking force

Kg 2.4 2.5 – – –EU version

(-SFEF)

lb 5.30 5.52 – – – Kg 2.3 2.4 2.3 4.2 4.2

Weight

USA version

(-N/LFU)

lb 5.08 5.30 5.08 9.27 9.27

17

Getting started

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Getting started

Item 400V class Specifications

EU version 004HFEF 007HFEF 015HFEF 022HFEFX200 inverters,

400V models

USA version 004HFU 007HFU 015HFU 022HFU

kW 0.4 0.75 1.5 2.2Applicable motor size *2 H

P 1/2 1 2 3

380V 0.9 1.6 2.5 3.6Rated capacity

(kVA)

480V 1.2 2.0 3.1 4.5

Rated input voltage *6

3-phase: 380V-15% to 480V r10%, 50/60Hz r5%

EU version SFE series : EN61800-3 category C2 filterIntegrated EMC

filter

USA version – Rated input current (A) 2.0 3.3 5.0 7.0 Rated output voltage *3 3-phase: 380 to 480V (proportional to input voltage) Rated output current (A) 1.5 2.5 3.8 5.5 Efficiency at 100% rated output 93.8% 94.9% 96.4% 96.9%

at 70% output 20 29 40 49

Watt loss (fc=3kHz) Approximate (W)

at 100% output 25 38 54 68 Starting torque *7 100% at 6Hz

50%: d 60Hz 20%: d 60Hz

Dynamic braking,

approx. % torque

(short time stop

from 50/60Hz) *8

Capacitive feedback type, dynamic braking unit and braking

resistor optional, individually installed

Braking

DC braking Variable operating frequency, time, and braking force

Kg 1.5 2.3 2.4 2.4EU version

(-HFEF)

lb 3.31 5.08 5.30 5.30 Kg 1.4 2.2 2.3 2.3

Weight

USA version

(-HFU)

lb 3.09 4.86 5.08 5.08

18

Getting started

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Getting started

Item 400V class Specifications

EU version 030HFEF 040HFEF 055HFEF 075HFEFX200 inverters, 400V models

USA version – 040HFU 055HFU 075HFU

kW 3.0 4.0 5.5 7.5Applicable motor size *2 H

P 4 5 7.5 10

380V 5.1 5.6 8.5 10.5Rated capacity (kVA)

480V 6.4 7.1 10.8 13.3 Rated input voltage *6

3-phase: 380V-15% to 480V r10%, 50/60Hz r5%

EU version SFE series : EN61800-3 category C2 filterIntegrated EMC filter

USA version – Rated input current (A) 10.0 11.0 16.5 20.0 Rated output voltage *3 3-phase: 380 to 480V (proportional to input voltage) Rated output current (A) 7.8 8.6 13 16 Efficiency at 100% rated output 96.8% 97.3% 97.3% 98.3%

at 70% output 68 74 101 127

Watt loss (fc=3kHz) Approximate (W)

at 100% output 96 107 150 189

Starting torque *7 100% at 6Hz

20%: d 60Hz

Dynamic braking,

approx. % torque

(short time stop

from 50/60Hz) *8

Capacitive feedback type, dynamic braking unit and braking

resistor optional, individually installed

Braking

DC braking Variable operating frequency, time, and braking force

Kg 2.4 2.4 4.2 4.2EU version

(-HFEF)

lb 5.30 5.30 9.27 9.27 Kg – 2.3 4.2 4.2

Weight

USA version

(-HFU)

lb – 5.08 9.27 9.27

Torque characteristics

NOTE: The data are based on the Hitachi standard induction motor (4p). The torque performance depends on the characteristics of the motor to be used.

19

Getting started

Output frequency (Hz)

Output torque (%)

100

130

150

106 20 60 120

Continuous performance

Short time performance

Base frequency = 60Hz

Output frequency (Hz)

Output torque (%)

100

130

150

105 16.7 50 120

Continuous performance

Short time performance

Base frequency = 50Hz

0.2~4kW

5.5, 7.5kW

0.2~4kW

5.5, 7.5kW

0.2~4kW

5.5, 7.5kW

0.2~4kW

5.5, 7.5kW

−

Getting started

General Specifications

The following table applies to all X200 inverters.

Item General Specifications

Protective housing *1 IP00 Control method Sinusoidal Pulse Width Modulation (PWM) control Carrier frequency 2kHz to 12kHz (default setting: 3kHz) Output frequency range *4 0.5 to 400Hz Frequency accuracy Digital command: 0.01% of the maximum frequency

Analog command: 0.4% of the maximum frequency (25qC r 10qC)

Frequency setting resolution Digital: 0.1Hz; Analog: max. frequency/1000 Volt./Freq. characteristic V/f control (constant torque, reduced torque) Overload capacity 150% rated current for 1 minute Acceleration/deceleration time 0.01 to 3000 seconds, linear and S-curve accel/decel, second

accel/decel setting available Operator panel Up and Down keys / Value settings Potentiometer Analog setting

Freq.

setting

External signal*90 to 10 VDC (input impedance 10k Ohms), 4 to 20mA (input

impedance 250 Ohms), Potentiometer (1k to 2k Ohms, 2W) Operator panel Run/Stop (Forward/Reverse run change by command)

FWD/

REV run

External signal Forward run/stop, Reverse run/stop

Input

signal

Intelligent input terminal

W (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), F

RS (free run stop command), EXT (external trip), USP (startup function), SFT (soft lock), AT (analog current input select signal), R

S (reset), PTC (thermistor thermal protection), STA (start), STP (stop), F/R (forward/reverse), PID (PID disable), PIDC (PID reset), U

P (remote control up function), DWN (remote control down function), UDC (remote control data clearing), OPE (operator control), ADD (add frequency enable), F-TM (force terminal mode), RDY (Run ready), SP-SET (Special set) , EMR (Emergency Stop)

Intelligent output terminal

RUN (run status signal), FA1,FA2 (frequency arrival signal), OL (overload advance notice signal), OD (PID error deviation signal), AL (alarm signal), Dc (analog input disconnect detect), FBV (PID two-stage control output), NDc (network detection signal), LOG (Logic output), ODc (comm. watchdog error), LOC (Low load)

Output

signal

Frequency monitor Analog output; Select output frequency or output current monitor

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

avail.)

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

16-stage speed profile, fine adjustment of start frequency, carrier frequency change (2 to 12kHz) *10, frequency jump, gain and bias setting, process jogging, electronic thermal level adjustment, retry func., trip history monitor, 2nd setting select, fan ON/OFF selection.

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

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

Temperature

Operating (ambient): -10 to 40qC(*10), / Storage: -25 to 70qC(*11)

Humidity 20 to 90% humidity (non-condensing) Vibration *12 5.9m/s2 (0.6G), 10 to 55 Hz

Operating environment

Location Altitude 1,000m or less, indoors (no corrosive gasses or dust) Coating color Blue Options Remote operator unit, copy unit, cables for the units, braking unit,

braking resistor, AC reactor, DC reactor, noise filter

110

Getting started

−

Getting started

Signal Ratings

Detailed ratings are in “Control Logic Signal Specifications” on page 4-6.

Signal / Contact Ratings

Built-in power for inputs 24VDC, 30mA maximum Discrete logic inputs 27VDC maximum Discrete logic outputs 50mA maximum ON state current, 27 VDC maximum OFF state voltage Analog output 0 to 10VDC, 1mA Analog input, current 4 to 19.6 mA range, 20mA nominal Analog input, voltage

0 to 9.8 VDC range, 10VDC nominal, input impedance 10k:

+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

Getting started

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Getting started

Derating Curves

The maximum available inverter current output is limited by the carrier frequency and ambient temperature. The carrier frequency is the inverter’s internal power switching frequency, settable from 2kHz to 12kHz. 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.

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.

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 X200 inverter model number.

Legend for Graphs:

Ambient temperature 40qC max., individual mounting Ambient temperature 50qC max., individual mounting Ambient temperature 40qC max., side-by-side mounting

112

Enclosure

Individual mounting

Enclosure

Side-by-side mounting

−

Getting started

Derating curves:

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-002SFEF/NFU

% of rated

output current

Carrier frequency

kHz

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-004SFEF/NFU

% of rated

output current

Carrier frequency

kHz

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-005SFEF

% of rated

output current

Carrier frequency

kHz

113

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Getting started

Derating curves, continued…

114

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-007SFEF/NFU

% of rated

output current

Carrier frequency

kHz

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-011SFEF

% of rated

output current

Carrier frequency

kHz

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-015SFEF/NFU

% of rated

output current

Carrier frequency

kHz

−

Getting started

Derating curves, continued…

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-022SFEF/NFU

% of rated

output current

Carrier frequency

kHz

115

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-037LFU

% of rated

output current

Carrier frequency

kHz

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-055LFU

% of rated

output current

Carrier frequency

kHz

−

Getting started

Derating curves, continued…

116

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-007HFEF/HFU

% of rated

output current

Carrier frequency

kHz

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-004HFEF/HFU

% of rated

output current

Carrier frequency

kHz

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-075LFU

% of rated

output current

Carrier frequency

kHz

−

Getting started

Derating curves, continued…

117

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-030HFEF

% of rated

output current

Carrier frequency

kHz

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-015HFEF/HFU

% of rated

output current

Carrier frequency

kHz

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-022HFEF/HFU

% of rated

output current

Carrier frequency

kHz

−

Getting started

Derating curves, continued…

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-040HFEF/HFU

% of rated

output current

Carrier frequency

kHz

118

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-055HFEF/HFU

% of rated

output current

Carrier frequency

kHz

30%

40%

50%

60%

70%

80%

90%

100%

4 6 8 10 12

X200-075HFEF/HFU

% of rated

output current

Carrier frequency

kHz

−

Getting started

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:

x Energy savings – HVAC x Need to coordinate speed with an adjacent process – textile and printing presses x Need to control acceleration and deceleration (torque) x 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.

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.

Rectifier

Motor

InverterConverter

Internal DC Bus

Power

Input

U/T1

V/T2

W/T3

Variable-frequency Drive

119

Getting started

−

Getting started

Torque and Constant Volts/Hertz Operation

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 X200 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.

Variable 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 X200 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 –SFE accept single-phase 200V class input voltage, those with a –NFU suffix single- or three-phase power, and those with a suffix –LFU three-phase power only. All 400V class inverters require three-phase power supply.

IP: If your application only has single phase power available, refer to X200 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). Threephase 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 voltage

Output frequency

100%

Constant torque

120

Getting started

−

Getting started

Inverter Output to the 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. 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.

3-phase AC motor

U/T1

V/T2

W/T3

Earth GND

121

Getting started

−

Getting started

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 an optional dynamic braking unit. See “Introduction” on page 5-2 and “Dynamic Braking” on page 5-5 for more information on the BRD-E3 and BRD-EZ3 braking units. The X200 inverter sends excess motor energy into a resistor in the dynamic braking unit to slow the motor and load. For loads that continuously overhaul the motor for extended periods of time, the X200 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

Getting started

−

Getting started

Velocity Profiles

The X200 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.

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 X200 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.

OTE: The X200 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.

Speed

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

Getting started

−

Getting started

Frequently Asked Questions

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

alternative solutions?

. 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.

. 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?

. 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.

. Although the X200 inverter is a variable speed drive, can I use it in a fixed-speed

application?

. 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 X200 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.

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

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

turn and still deliver torque. The X200 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).

. Can the inverter be controlled and monitored via a network?

. Yes. X200 inverters have built-in ModBus communications. See Appendix B for

more information on network communications.

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

instead of naming the actual voltage, such as “230 VAC”

. 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.

OTE: The European 200V class inverter is for single phase input (-SFE), while the USA 200V class inverter is for 3/single phase input (-NFU up to 2.2kW) and 3-phase input (-LFU) 3.7kW.

124

Getting started

−

Getting started

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

. 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.

. Does the motor need a chassis ground connection?

. 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.

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

. 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. M

otor size – In practice, it’s better to find the right size motor for your

application; then look for the inverter to match the motor.

OTE: 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?

. 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.

125

Getting started

−

Getting started

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

. 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.

. 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?

. 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.

. The X200 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?

. 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.

126

Getting started

−

Getting started

Inverter Mounting and Installation

In This Chapter… page

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

- Basic System Description............................................................... 7

- Step-by-Step Basic Installation ...................................................... 8

- Powerup Test.................................................................................. 24

- Using the Front Panel Keypad...................................................... 26

2121

Inverter Mounting

and installation

−

Inverter Mountingand

installation

Orientation to Inverter Features

Unpacking and Inspection

Please take a few moments to unpack your new X200 inverter and perform these steps:

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

. Verify the contents of the box include:

. One X200 inverter

. One instruction Manual

. One X200 Quick Reference Guide

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

product part number you ordered.

Main Physical Features

The X200 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.

nverter 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, and an output frequency potentiometer (speed setting knob) control monitor operation. The FUNC., 1 and 2 keys allow an operator to navigate to the inverter’s functions and parameter values. The Store key is used when changing a setting.

22

Inverter Mounting

and installation

PRG

RUN

POWER

LARM

STOP

RESET

FUNC STR

−

Inverter Mountingand

installation

Front Housing Cover

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

Housing Cover Removal – The front housing cover is held in place by a screw and two pairs of tabs. Since these tabs are hidden from view, it is good to become familiar with their locations

before

attempting to remove the cover. The figure below shows a typical housing cover in an upside-down position to reveal the tabs. The two locking tabs are the ones which you will need to press to remove the cover. The two hinging tabs will allow the cover to tilt open after the locking tabs are released.

OTE: Use care when removing the knock-out for the communication connector (indicated by A in above figure). After removal of the knock-out, some burrs may remain. Carefully file them smooth, if necessary.

The figure below shows the procedure for removing the housing cover. First, unscrew the screw, squeeze the side locking tabs, and then lift up the housing cover. DO NOT force the cover open; it is possible to break a tab in this way.

23

Inverter Mounting

and installation

Hinging tabs

Locking tabs

1. Unscrew the screw 2. Lift up the bottom side of the cover

−

Inverter Mountingand

installation

Logic Connector Introduction

After removing the front housing cover, take a moment to become familiar with the connectors, as shown below.

IGH VOLTAGE: Hazard of electrical shock. Never touch the exposed PCB conductors while the unit is powered up. Also, the inverter must be powered OFF before you change any of the DIP switch settings.

24

Inverter Mounting

and installation

Relay output contacts

Logic and analog signal connections

Danger! Do not touch!

Serial communication port

−

Inverter Mountingand

installation

DIP Switch Introduction

The inverter has internal DIP switches, located near the middle of the logic connectors as shown below. This section provides an introduction. Refer to later chapters that discuss the DIP switch operation in more detail.

The 485/OPE (RS485/Operator) DIP switch configures the inverter’s RJ45 serial port. You can use either the inverter’s integrated keypad or the OPE-SRmini connected via a cable to the serial port. In this case, SW7 should be set OPE (default setting). The port is configured for RS422 in this setting. Inverter control via a ModBus network communication requires the “485” setting. See “Connecting the Inverter to ModBus” on

page B-3 for more details.

DIP switch SW8 controls the Emergency stop signal input. Turning this DIP switch ON will enable the inverter to receive a Emergency stop signal from the dedicated safe stop terminal (#3). The inverter will shut off its output by means of direct hardware control (bypassing the internal microprocessor normal program execution) when a signal is given to this terminal. Additionally, the intelligent input terminal assignment will be changed automatically when SW8 is ON. See “Safe Stop” on

page 4-32 for more details.

25

Inverter Mounting

and installation

SW7

SW8

485

OPE

OFF

SW7

485

OPE

SW8

OFF

−

Inverter Mountingand

installation

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 front housing cover, the two housing partitions that cover the power and motor wiring exits will be able to slide upward as shown to the right. The upper cover is for main power input wiring, and the lower one is for the motor output wiring.

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 partitions 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 mains connect to the terminals at the top of the inverter, and the motor 3-phase leads connect to the lower row of the terminals at the bottom of the inverter. The upper row of the bottom 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.

26

Inverter Mounting

and installation

Inverter Mounting

and installation

Power input terminals

Motor connecting terminals and terminals for other options (DC link choke, Braking unit)

−

Inverter Mountingand

installation

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 o

ptional 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. W

ARNING: 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).

EMI 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. EU version (with a suffix of -FEF have integrated EMC Filter, which is category C1 for 200V class and C2 for 400V class.)

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

Motor

Thermal switch

L1 L2 L3

T1 T2 T3

Inverter

GND

27

Inverter Mounting

and installation

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Inverter Mountingand

installation

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.

Step-by-Step 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.

2-9

2 Check the mounting location for adequate ventilation 2-10 3 Cover the inverter’s ventilation openings to prevent debris from entering. 2-10 4 Check the inverter dimensions for footprint and mounting hole locations. 2-11 5 Study the Cautions, Warnings, wire and fuse sizes, and terminal torque

specifications before wiring the inverter.

2-16

6 Connect wiring for the inverter power input. 2-17 7 Wire the inverter output to the motor. 2-21 8 Uncover the inverter’s ventilation openings applied in Step 3. 2-22 9 Perform the Powerup Test. (This step includes several sub steps.) 2-22

10 Make observations and check your installation. 2-33

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

Appendix D.

28

Inverter Mounting

and installation

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Inverter Mountingand

installation

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.

AUTION: 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 not to let the foreign matter enter vent openings in the inverter housing, such as wire clippings, spatter from welding, metal shavings, dust, etc. Otherwise, there is the danger of fire.

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

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

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

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

Inverter Mounting

and installation

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Inverter Mountingand

installation

Ensure Adequate Ventilation

Step 2: To summarize the caution messages – you will need to find a solid, nonflammable, 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, maintain the specified clearance and the inverter specified in the diagram.

AUTION: 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 40qC.

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.

210

Inverter Mounting

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Ventilation holes

(top)

Ventilation holes

(both sides)

ir flow

10 cm (3.94”)

minimum

10 cm (3.94”)

minimum

5 cm (1.97”)

minimum

5 cm (1.97”)

minimum

Clear area

X200

inverter

−

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Check Inverter Dimensions

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

X200-002SFEF, -004SFEF, -002NFU, -004NFU

D [mm] D1 [mm] Applied model

93 13 -002NFU, -002SFEF

107 27 -004NFU, -004SFEF

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.

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

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211

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Dimensional drawings, continued…

X200-005SFEF,007SFEF, -007NFU

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

212

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Dimensional drawings, continued…

X200-011SFEF~022SFEF, -015NFU~022NFU, -037LFU

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

Inverter Mounting

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213

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Dimensional drawings, continued…

X200-004HFEF, -004HFU

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

Inverter Mounting

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214

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Dimensional drawings, continued…

X200-007HFEF, -007HFU

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

215

Inverter Mounting

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Inverter Mountingand

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Dimensional drawings, continued…

X200-015HFEF~040HFEF, -015HFU~040HFU

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

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216

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Dimensional drawings, continued…

X200-055LFU, -075LFU, -055HFU, -075HFU, -055HFEF, -075HFEF

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

Inverter Mounting

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217

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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.

ARNING: “USE 60/75qC Cu wire only” or equivalent. For models X200-005S, -007S,

-011S, -022S, 007N, -015N, 015L, -022L, -037L.

WARNING: “USE 75qC Cu wire only” or equivalent. For models X200-002S, -004S,

002N, -004N, 002L, -004L, -007L, -022H, -030H, 037H and X200-040H.

WARNING: “USE 60qC Cu wire only” or equivalent. For models X200-004H, -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, N 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.

Inverter Mounting

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218

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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 2-7. The “Signal Lines” column applies to any wire connecting to the two green connectors just inside the front cover panel.

Motor Output Wiring

Applicable

equipment

kW HP

Inverter Model

Power Lines Signal Lines

Fuse (UL-rated,

class J, 600V)

0.2 1/4 X200-002SFEF/NFU 10A

0.4 1/2 X200-004SFEF/NFU 10A

0.55 3/4 X200-005SFEF 10A

0.75 1 X200-007SFEF/NFU

AWG14 / 2.1mm

15A

1.1 1 1/2 X200-011SFEF 15A

1.5 2 X200-015SFEF/NFU 20A

2.2 3 X200-022SFEF/NFU

AWG10 / 5.3mm

30A

3.7 5 X200-037LFU AWG12 / 3.3mm

30A

5.5 7 1/2 X200-055LFU AWG10 / 5.3mm

40A

7.5 10 X200-075LFU AWG8 / 8.4mm

50A

0.4 1/2 X200-004HFEF/HFU 3A

0.75 1 X200-007HFEF/HFU 6A

1.5 2 X200-015HFEF/HFU

AWG16 / 1.3mm

2.2 3 X200-022HFEF/HFU

10A

3.0 4 X200-030HFEF

4.0 5 X200-040HFEF/HFU

AWG14 / 2.1mm

(60qC only)

15A

5.5 7 1/2 X200-055HFEF/HFU 20A

7.5 10 X200-075HFEF/HFU

AWG12 / 3.3mm

(60qC only)

18 to 28 AWG /

0.14 to 0.75 mm

shielded wire (see Note 4)

25A

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.

ote 2: Be sure to consider the capacity of the circuit breaker to be used.

ote 3: Be sure to use a larger wire gauge if power line length exceeds 66ft. (20m).

ote 4: Use 18 AWG / 0.75mm2 wire for the alarm signal wire ([AL0], [AL1], [AL2]

terminals).

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Terminal Dimensions and Torque Specs

The terminal screw dimensions for all X200 inverters are listed in table below. This information is useful in sizing spade lug or ring lug connectors for wire terminations.

ARNING: 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.

Models 002S~004S,

002N~004N

Models 007S~022S,

007N~022N,037L,

004H~040H

Models 055~075L/H

Connector

Number

of Screw

Ter mi na ls

Screw

Diameter

Width

(mm)

Screw

Diameter

Width

(mm)

Screw

Diameter

Width

(mm)

Power Terminals (Top side)

5 M3.5 7.1 M4 9.2 M5 12

8(dual in row)

M3.5 7.1



Power Terminals (Bottom side)



M4 9.2 M5 12

Control Signal

15 M2



Alarm Signal

3M3



When connecting wiring, use the tightening torque listed in the following table to safely attach wiring to the connectors.

Screw Tightening Torque Screw Tightening Torque Screw Tightening Torque

0.2Nxm (max. 0.25 Nxm)

M3.5

0.8Nxm (max. 0.9 Nxm)

2.0Nxm (max. 2.2 Nxm)

0.5Nxm (max. 0.6 Nxm)

1.2Nxm (max. 1.3 Nxm) 

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 conn

ected that way, terminal [S/L2] will remain unconnected. The wiring example to the right shows an X200 inverter wired for 3-phase input. Note the use of ring lug connectors for a secure connection.

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

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220

Input wiring for 3-phase input (models -NFU, -LFU, -HFEF, -HFU)

Input wiring for single-phase input (-SFEF and -NFU models)

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Inverter Mountingand

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Please use the terminal arrangement below corresponding to your inverter model.

Inverter models X200-002SFEF~004SFEF, X200-005SFEF~022SFEF,

X200-002NFU~004NFU X200-007NFU~022NFU,037LFU

X200-004HFEF~040HFEF X200-004HFU~040HFU X200-055LFU~075LFU X200-055HFU~075HFU X200-055HFEF~075HFEF

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

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).

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221

U/T1 V/T2 W/T3

- + +1

Jumper

U/T1 V/T2 W/T3

+1+-

Jumper

L1 /

L1 L2

L3/N

SFEF

NFU, LFU

Jumper

L1 /

L1 L2

L3/N

SFEF

NFU,LFU

Jumper

R/L1 S/L2 T/L3

HFEF, HFU

Jumper

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Inverter Mountingand

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

x Single-phase 200 to 240 V 50/60 Hz (0.2kW~2.2kW) for SFEF models x Single/Three-phase 200 to 240 V 50/60 Hz (0.2kW~2.2kW) for NFU models x Three-phase 200 to 240 V 50/60 Hz (3.7kW~7.5kW) for LFU models x Three-phase 380 to 480 V 50/60Hz (0.4kW~7.5kW) for HFEF and HFU 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.

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: x Use only short time-invariant and pulse current-sensitive ground fault interrupters

with higher trigger current.

x Other components should be secured with separate ground fault interrupters. x Ground fault interrupters in the power input wiring of an inverter are not an absolute

protection against electric shock.

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

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

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222

Power Input

Output to Motor

X200 Inverter

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Inverter Mountingand

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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:

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

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

inverter and motor exceeds 10 meters in length.

Simply connect the mot or to the terminals [U/T1], [V/T2], and [W/T3] as shown to the right. 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 (singlepoint) arrangement, and never daisy-chain the grounds (point-to-point).

x Check the mechanical integrity of each

wire crimp and terminal connection.

x 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.

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223

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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.

ARNING: 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

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:

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

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

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

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

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

nameplate ratings match the inverter ratings.

x 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:

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

. Demonstrate that the inverter and motor are generally compatible.

. 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

Inverter Mounting

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Ventilation holes

(top)

Ventilation holes

(both sides)

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Inverter Mountingand

installation

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.

. 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.

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

AUTION: The heat sink fins will have a high temperature. Be careful not to touch

them. Otherwise, there is the danger of getting burned.

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

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

CAUTION: Check the following before and during the Powerup test. Otherwise, there is the danger of equipment damage. x Is the shorting bar between the [+1] and [+] terminals installed? DO NOT power or

operate the inverter if the jumper is removed.

x Is the direction of the motor rotation correct? x Did the inverter trip during acceleration or deceleration? x Were the rpm and frequency meter readings as expected? x 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: x The

POWER

LED will illuminate.

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

0.0

x 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.

OTE: 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 6-8.

225

Inverter Mounting

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Inverter Mountingand

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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

x Run/Stop 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).

rogram/Monitor 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).

un Key Enable LED – is ON when the inverter is ready to respond to the Run key, OFF when the Run key is disabled.

un 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.

top/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.

otentiometer – Allows an operator to directly set the motor speed when the potentiometer is enabled for output frequency control.

otentiometer Enable LED – ON when the potentiometer is enabled for value entry.

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

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

associated with the parameter display.

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

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

unction Key – This key is used to navigate through the lists of parameters and functions for setting and monitoring parameter values.

p/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.

tore key – When the unit is in Program Mode and you have edited a parameter value, press the Store key to write the new value to the EEPROM.

226

Inverter Mounting

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Display Units (Hertz / Amperes) LEDs

Parameter Display

Run key Enable LED

Run key

Stop/Reset key

PRG

RUN

POWER

LARM

STOP

RESET

Function key

Up/Down keys Store key

Power LED

larm LED

Run/Stop LED

Program/Monitor LED

Potentiometer Enable LED

Potentiometer

FUNC STR

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Inverter Mountingand

installation

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.

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” Intelligent terminal functions

Program

“H” Motor constant functions

Program

“P” DeviceNet functions

Program

“E” Error codes



For example, function “A004” is the

base frequency setting

for the motor, typically 50Hz or 60Hz. To edit the parameter, the inverter must be in Program Mode (PRG LED will be ON). You use the front panel keys to first select the function code “A004”. After displaying the value for “A004”, use the Up/Down keys ( or ) to edit it.

OTE: The inverter 7-segment display shows lower case “b” and “d”, meaning the same

as the upper case letters “B” and “D” used in this manual (for uniformity “A” to “F”).

The inverter automatically switches into Monitor Mode when you access “D” Group functions. It switches into Program Mode when you access any other group, because they all have editable parameters. Error codes use the “E” Group, and appear automatically when a fault event occurs. “P” group appears when DeviceNet communication is available. Refer to “Monitoring Trip Events,

History, & Conditions” on page 6-5 for error code

details.

IP: Pressing FUNC key continuously for 3 seconds makes the display back to d001.

FUNC FUNC

MONITOR

“D” Group

PROGRAM

“A” Group

“B” Group “C” Group “F” Group “H” Group “P” Group

227

Inverter Mounting

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PRG

RUN

POWER

LARM

STOP

RESET

FUNC STR

PRG

RUN

POWER

LARM

STOP

RESET

FUNC STR

PRG

RUN

POWER

LARM

STOP

RESET

FUNC STR

PRG

RUN

POWER

LARM

STOP

RESET

FUNC STR

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Inverter Mountingand

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Keypad Navigation Map

The X200 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 a 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.

The navigation map shows the relationship of all resources of the inverter in one view. In general, use the key to move left and right, and the (arrow) keys to move up and down.

FUNC

228

Inverter Mounting

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STR

Monitor Mode

PRG LED=OFF

Program Mode

PRG LED=ON

Display Data

FUNC

Select Function or Grou

Power down

FUNC FUNC

Store as powerup

default

Increment/ decrement

value

Edit

FUNC

Write

data to

EEPROM

Return to

parameter

list

Select parameter Edit parameter

−

Inverter Mountingand

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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:

. Select the keypad potentiometer as the source of motor speed command (A001).

. Select the keypad as the source of the RUN command (A002).

. Set the inverters maximum output frequency to the motor (A003).

. Set the motor current for proper thermal protection (B012).

. Set the inverter’s Automatic Voltage Regulation for the motor (A082).

. 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 key.

d001

“D” Group selected

Press the key four times. A- - - “A” Group selected

Select the Potentiometer 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 potentiometer as the speed control source for your convenience. In the figure to the right, notice the Potentiometer Enable LED, just above the knob. It the LED is ON, the potentiometer is already selected as the source, and you may skip this step. Note that the default setting depends on the country.

FUNC

229

Inverter Mounting

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Potentiometer Enable LED

PRG

RUN

POWER

LARM

STOP

RESET

FUNC STR

−

Inverter Mountingand

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If the Potentiometer Enable LED is OFF, follow these steps below.

Action Display Func./Parameter

(Starting point)

A- - -

“A” Group selected

Press the key. A001 Speed command source setting

Press the key again. 01

00 = Keypad potentiometer 01 = Control terminals 02 = Function F001 setting 03 = ModBus network 04 = Calculate function output

Press the key. 00 00 = Potentiometer (selected)

Press the key. A001

Store parameter, returns to “A” Group list

Select the Keypad 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.

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 key once.

A002

Run command source setting

Press the key.

01 = Control terminals 02 = Run key on keypad 03 = ModBus network

Press the key. 02 02 = Run key on keypad (selected)

Press the key.

A002

Store parameter, returns to “A” Group list

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.

FUNC

STR

FUNC

STR

230

Inverter Mounting

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Run Key Enable LED

PRG

RUN

POWER

LARM

STOP

RESET

FUNC STR

−

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Set the Motor Base Frequency – 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 key once.

A003

Base frequency setting

Press the key.

60.0

50.0

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

Press the or key as needed. 60.0

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

Press the key. A003

Store parameter, returns to “A” Group list

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.

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

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

IP: If you need to scroll through a function or parameter list, press and hold the or

key to auto-increment through the list.

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

FUNC

STR

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Action Display Func./Parameter

(Starting point)

A003

Base frequency setting

Press the key and hold until Æ

A082

AVR voltage select

Press the key.

230

400

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

= 460VAC (HFU)

Press the or key as needed. 215

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

Press the key. A082

Store parameter, returns to “A” Group list

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 120% 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 key.

A- - -

“A” Group selected

Press the key. b- - - “B” Group selected

Press the key.

b001

First “B” Group parameter selected

Press the key and hold until Æ

b012

Level of electronic thermal setting

Press the key. 1.60

Default value will be 100% of inverter rated current

Press the or key as needed. 1.80

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

Press the key. b012

Store parameter, returns to “B” Group list

FUNC

STR

FUNC

STR

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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 key. b- - - “B” Group selected

Press the key two times.

H- - -

“H” Group selected

Press the key.

H003

First “H” Group parameter

Press the key once H004 Motor poles parameter

Press the key. 4

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

Press the or key as needed.

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

Press the key.

H004

Store parameter, returns to “H” Group list

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

IP: 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 STR 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.

FUNC

STR

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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.

utput frequency (speed) monitor – Resuming keypad operation from the previous table, follow the steps below. Or instead, you can simply power cycle the inverter, which automatically sets the display to D001 (output frequency value).

Action Display Func./Parameter

(Starting point)

H004

Motor poles parameter

Press the key.

H- - -

“H” Group selected

Press the key.

d001

Output frequency selected

Press the key. 0.0 Output frequency displayed

When the inverter displays a monitor value, the PRG LED is OFF. This confirms the inverter is not in programming mode, even while you are selecting the particular monitoring parameter. The display shows the current speed (is zero at this point). The Hz LED will be ON, indicating the display units. For current, the Amperes LED will be ON.

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:

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

. Verify the Potentiometer Enable LED is ON. If it is OFF, check the A001 setting.

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

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

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

. Turn the potentiometer to the minimum position (completely counter clock-wise).

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

. Slowly increase the potentiometer setting in clockwise fashion. The motor should

start turning.

. Press the STOP key to stop the motor rotation.

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PRG

RUN

POWER

LARM

STOP

RESET

FUNC STR

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Powerup Test Observations and Summary

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

rror 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 X200 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 potentiometer 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.

tate 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 X200 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.

nterpreting 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.

un/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.

OTE: 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

RUN

STOP RESET

Monitor Program

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Configuring

Drive Parameters

In This Chapter… page

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

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

- “D” Group: Monitoring Functions .................................................. 6

- “F” Group: Main Profile Parameters .............................................. 9

- “A” Group: Standard Functions ................................................... 10

- “B” Group: Fine Tuning Functions............................................... 32

- “C” Group: Intelligent Terminal Functions .................................. 49

- “H” Group: Motor Constants Functions ...................................... 65

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Parameters

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. The other devices simply imitate the keypad’s layout and inverter access, while adding another valuable aspect to the system. For example, the Digital Operator/Copy Unit can transfer one inverter’s parameter settings to another inverter, while still providing standard operator keypad control. In this way, you can use a variety of programming devices with basically the same keypad skills. The following table shows various programming options, the features unique to each device, and the cables required.

Cables (choose one)

Device

Part

Number

Parameter

Access

Parameter

setting

storage

Part number Length

ICS-1 1 meter

External inverter keypad

OPE-SRmini

Monitor and Program

EEPROM in inverter

ICS-3 3 meters ICS-1 1 meter

Digital Operator/ Copy Unit

SRW-0EX

Monitor and Program

EEPROM in operator panel

ICS-3 3 meters

NOTE: When an external digital operator device such as an OPE-SRmini or SRW-0EX is connected to the inverter, the inverter’s keypad is automatically disabled (except for the Stop Key).

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Parameters

Using the Keypad Devices

The X200 Series inverter front keypad contains all the elements for both monitoring and programming parameters. The keypad is layout is pictured below. All other programming devices for the inverter have a similar key arrangement and function.