Hitachi Sj7002 Owners Manual
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Introduction Motor ControlAccessories 5–2 Introduction A motor speed control system will obviously incl ude a motor and inverter, as well as 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 fully developed sy stem can also have a variety of additional components. Some can be for noise suppressi on, while others may enhance the inverter’s braking performance. The figure below shows a system with several possible optional compo- nents, and the table gives part number information. AC reactor, or LCR filterRF noise filter DC link choke AC reactor EMI filter Capacitive filter Braking resistor Braking unit RF noise filter Thermal switch NOTE: The Hitachi part number series for accessories includes different sizes of each part type, specified by the –x suffix. Hitachi product lite rature can help match size and rating of your inverter to the proper accessory size. Each inverter accessory comes with its own printed instruction manual. Please refer to those manuals for complete installation details. This chapter gives only an overview of these optional system devices. For more infor- mation on Hitachi inverter system accessories, please contact your Hitachi sales office or distributor. Name Part No. SeriesSee pageEurope, JapanUSA AC reactor, input side ALI–xxx HRL–x 5–3 RF noise filter, input sideZCL–x ZCL–x 5–4 EMI filter (EMC Class A)NF–CEHx NF–CEHxx 5–4 EMI filter (EMC Class B)NF–CEHx, with FC–Hx NF–CEHxx, with FC–Hx 5–4 Capacitive filter CFI–x CFI–x 5–4 DC link choke—HDC–xxx5–4 Braking resistor JRB–xxx–x, SRB–xxx–xJRB–xxx, SRB–xxx — Braking resistor, NEMA-rated DCL-x-xx HRB1-x, HRB2-x HRB3-x— Resistance braking unit BRD–xxx BRD–xxx — RF noise filter, output side ZCL–xxx ZCL–xxx 5–4 AC reactor, output sideALI–xxx HRL–xxx 5–3 LCR filter—HRL–xxxC5–3 Encoder feed-back expansion SJ-FB 5–5 Digital input expansion card SJ-DG 5–5 Inverter Encoder input expansion card Digital input expansion card AB Switch Breaker, MCCB or GFI Ferrite core Expansion bay L1 L2 L3 T1 T2 T3 Motor Encoder RS T +1 + RB GND UVW – From power supply Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
SJ7002 Inverter Motor ControlAccessories 5–3 Component Descriptions AC Reactors, Input SideThis is useful in suppressing harmonics induced on the power su pply lines, or when the main power voltage imbalance exceeds 3% (and power s ource capacity is more than 500 kVA), or to smooth out line fluctu ations. It also improves the power factor. In the following cases for a general-purpose inve rter, a large peak current flows on the main power supply side, and is able to destroy the inverter module: If the unbalanced factor of the power supply is 3% or higher If the power supply capacity is at least 10 time s greater than the inverter capacity (the power supply capacity is 500 kVA or more) If abrupt power supply changes are expected Examples of these situations include: 1. Several inverters are connected in parallel, sharing the same power bus 2. A thyristor converter and an inverter are conn ected in parallel, sharing the same power bus 3. An installed phase-advance (power factor correction) capacitor opens and closes Where these conditions exist or when the connecte d equipment must be highly reliable, install an AC reactor between the power supply and the inverter. Also, where the effects of an indirect lightning strike is possible, install a lightning conductor. Example calculation: V RS = 205V, VST = 203V, VTR = 197V, where V RS is R-S line voltage, VST is S-T line voltage, VTR is T-R line voltage Please refer to the documentation that comes with the AC reactor for installation instructions. AC Reactor or LCR Filter, Output SideThis reactor reduces the vibrations in the motor caused by the inverter’s switching waveforms, by smoothing the waveforms to approximate commer cial power quality. It is also useful to reduce the reflected voltage wa ve phenomenon when wiring from the inverter to the motor is more than 10m in length. Please refer to the doc umentation that comes with the AC reactor for installation instructions. Unbalance factor of voltage Max. line volta ge (min.) Mean line voltage– Meanline voltage ----------------------------------------------------------------------------------------------------------- 100 × = V RS V RS V ST V TR ++ () 3 ⁄ – V RS V ST V TR ++ () 3 ⁄ ------------------------------------------------------------------------- - 100 × = 205 202 – 202 ----------------------- - 100 × 1.5% == Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
Component Descriptions Motor ControlAccessories 5–4 Zero-phase Reactor (RF Noise Filter)Electrical noise interference may occur on nearby equipment such as a radio receiver. The zero-phase reactor helps reduce radiated noise from the inverter wiring. It can be used on the input or output side of the inverter. The example zero-phase reactor shown to the right comes with a mounting bracket. The wiring must go through the opening to reduce the RF component of the electri- cal noise. Loop the wires three times (four turns) to attain the full RF filtering effect. For larger wire sizes, place multiple zero-phase reactors (up to four) side-by-side for a greater filtering effect. EMI FilterThe EMI filter reduces the conducted noise on the power supply wiring generated by the inverter. Connect the EMI filter to the invert er primary (input side). The NF–CEH–x series filter is required for compliance to the EMC Cl ass A directive (Europe) and C-TICK (Austra- lia). See “ CE–EMC Installation Guidelines” on page D–2. WARNING: The EMI filter has high internal leakage current from power wiring to the chassis. Therefore, connect the chassis ground of the EMI filter before making the power connections to avoid danger of shock or injury. Ferrite CoreTo meet EMC Class B limit an optional ferrite core (FC–Hx) must be inserted between the NF–CEHx filter (above) and the inverter. RF Noise Filter (Capacitive)This capacitive filter reduces radiated noise from the main power wires in the inverter input side. This filter is not for achieving CE compliance and is applicable only to the input side only of the inverter. It comes in two versions—for 200V class inverters or 400V class inverters. Please refer to the documentation that comes with the radio noise filter for installation instruc- tions. DC Link ChokeThe DC choke (reactor) suppresse s harmonics generated by the inverter. It attenuates the high- frequency components on the inverter ’s internal DC bus (link). However, note that it does not protect the diode rectifiers in the inverter input circuit. ZCL–x NF–CEHxx Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
SJ7002 Inverter Motor ControlAccessories 5–5 Expansion CardsThe SJ–FB Encoder Feedback Board installs in the inverter’s expansion bay, which can accept up to two expansion cards. The encoder card accepts two-channel incremental encoder signals. Position feedback is essential for certain torque-control algorithms, and is useful for improving low-speed performance. The card can also generate linear acceleration/deceleration ramps for velocity control. All wiring associated with this card connects to its PWB connectors as shown. Some related signals may be assigned to the intelligent I/O terminals, as described in Chapter 4. For more information, refer to the SJ–FB manual. The SJ–DG Digital Input Card installs in the inverter’s expansion bay. This card accepts up to eight digital input signals, in addition to the intel- ligent inputs on the inverter’s control terminal connector. All wiring associated with card connects to its PWB connectors as shown. The SJ–DN DeviceNet Interface Card (not shown) installs in the inverter’s expansion bay. It connects directly to a DeviceNet network. Invert er parameters P044 to P049 configure the card. Only one DeviceNet card may be installed in an inverter. For more information, please refer to the DeviceNet Expansion Card Instruction Manual.PWB connector to external wiring SJ–FB Encoder Feedback Card PWB connector to external wiring SJ–DG Digital Input Card Phone: 800.894.0412
Dynamic Braking Motor ControlAccessories 5–6 Dynamic Braking IntroductionThe purpose of dynamic braking is to improve the ability of the inverter to stop (decelerate) the motor and load. This becomes necessary when an application has some or all of the following characteristics: High load inertia compared to the available motor torque The application requi res frequent or sudden changes in speed System losses are not great enough to slow the motor as needed When the inverter reduces its output frequency to decelerate the load, the motor can temporarily become a generator. This occurs when the motor rotation frequency is higher than the inverter output frequency. This condition can cause the inverter DC bu s voltage to rise, resulting in an over-voltage trip. In many applications, the over-voltage condition serves as a warning signal that we have exceeded the deceleration capabilities of the system. SJ700 2 inverters rated 15hp (11kW) and below have a built-in braking unit that sends the regenerative energy from the motor during deceleration to the optional braking resistor(s). External braking units may also be us ed if higher braking torques and/or duty cycles are required. The dynamic braking resistor serves as a load, developing heat to stop the motor just as brakes on an automobile develop heat during braking. The braking resistor is the main co mponent of a braking resistor assem- bly, which includes an integral th ermal fuse and thermally activated alarm relay for safety. However, be car eful to avoid overheating its resis- tor. The thermal fuse and thermal relay are safeguards for extreme condi- tions, but the inverter can mainta in braking usage in a safe zone. Dynamic Braking Usage RatioThe inverter controls braking via a duty cycle method (percent of the time braking is ON versus total time). Parameter B090 sets the dynamic braking usage ratio. In the graph to the right, the example shows three uses of dynamic braking in a 100-second period. The inverter calculates the average percentage usage in that time (duty cycle %). The percentage of usage is proportional to the heat dissipated. If the duty cycle is greater than the B090 parameter setting, the inverter enters the Trip Mode and turns OFF the frequency output. Please note the foll owing (for SJ700–055xFU2 to SJ700–220xFU2). When B090 is set for 0%, dynamic braking is not performed. When the duty cycle value exceeds the limit set by B090, the inverter will trip (ending the dynamic braking). The cable from the external resistor to the in verter must not exceed 5 m (16 ft.) length. The wires from the DB resistor to the inverter must not be bundled together with control or signal wires. NOTE: Inverters rated 40hp (30kW) and above (SJ700–300xFU2 and larger models) do not include an internal braking unit. Parameters B090, B095, and B096 do not apply to these models. Braking Resistor B90 BRD Duty cyclet1 t2 t3 ... +++ () 100 seconds ------------------------------------------ 100 × = t t1 t2 t3 ON OFF 100s Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
SJ7002 Inverter Motor ControlAccessories 5–7 Dynamic Braking Selection TablesThe SJ7002 Series 200V and 400V class inverter models in the 1/2 to 30 HP range have internal braking units. Additional stopping torque is avai lable by adding external resistors. The required braking torque depends on your part icular application. Other tables in this section will help you choose the prop er resistor. NOTE: For inverters larger than 30 HP (22kW), an external braking unit will be required. Contact your distributor or Hitachi for assistance. 1/2 to 30 HP (0.4 to 22 kW)Without External ResistorUsing Optional External ResistorPerformance @ Minimum ResistanceMinimum Resistance @ 100% Braking Duty Cycle, Ohms Voltage ClassModel NumberMotor HPBraking Unit Braking To r q u e @ 60Hz, %External Resistance, OhmsBraking To r q u e @60Hz, %Minimum Resistance, Ohms Max. Braking Duty Cycle, % 200V SJ700–004LFUF2 0.5 Built-in 20 48 150 48 10 150 SJ700–007LFUF2 1 Built-in 20 48 150 48 10 150 SJ700–015LFUF2 2 Built-in 20 32 150 32 10 110 SJ700–022LFUF2 3 Built-in 20 32 150 32 10 110 SJ700–037LFUF2 5 Built-in 20 32 110 32 10 110 SJ700–055LFUF2 7.5 Built-in 20 16 140 16 10 50 SJ700–075LFUF2 10 Built-in 20 10 150 10 10 50 SJ700–110LFUF2 15 Built-in 10 10 110 10 10 50 SJ700–150LFUF2 20 Built-in 10 7.5 110 7.5 10 35 SJ700–185LFU2 25 Built- in 10 7.5 90 7.5 10 35 SJ700–220LFU2 30 Bu ilt-in 10 5 110 5 10 35 400V SJ700–007HFUF2 SJ700–007HFEF2 1 Built-in 20 100 150 70 10 300 SJ700–015HFUF2 SJ700–015HFEF2 2 Built-in 20 100 150 70 10 300 SJ700–022HFUF2 SJ700–022HFEF2 3 Built-in 20 70 150 70 10 300 SJ700–040HFUF2 SJ700–040HFEF2 5 Built-in 20 70 150 70 10 200 SJ700–055HFUF2 SJ700–055HFEF2 7.5 Built-in 20 70 130 70 10 200 SJ700–075HFUF2 SJ700–075HFEF2 10 Built-in 20 70 150 35 10 150 SJ700–110HFUF2 SJ700–110HFEF2 15 Built-in 10 50 130 35 10 150 SJ700–150HFUF2 SJ700–150HFEF2 20 Built-in 10 35 140 24 10 100 SJ700–185HFU2/E 25 Built-in 10 35 140 24 10 100 SJ700–220HFU2/E 30 Built-in 10 35 110 20 10 100 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
Troubleshooting and Maintenance In This Chapter....page — Troubleshooting................................................................................ 2 — Monitoring Trip Events, History, & Conditions................................... 5 — Restoring Factory Default Settings................................................. 16 — Maintenance and Inspection........................................................... 17 — Warranty......................................................................................... 29 6 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
Troubleshooting Troubleshooting and Maintenance 6–2 Troubleshooting Safety MessagesPlease read the following safety messages be fore troubleshooting or performing maintenance on the inverter and motor system. WARNING: Wait at least ten (10) minutes after turning OFF the input power supply before performing mainte nance or an inspection. Otherwise, th ere is the danger of electric shock. WARNING: Make sure that only qualified personnel will perform maintenance, inspection, and part replacement. Before st arting to work, remove any meta llic objects from your person (wristwatch, bracelet, etc.). Be sure to use to ols with insulated handles. Otherwise, there is a danger of electric shock and/or injury to personnel. WARNING: Never remove connectors by pulling on it s wire leads (wires for cooling fan and logic P.C. board). Otherwise, there is danger of fire due to wire breakage and/or injury to personnel. General Precau- tions and Notes Always keep the unit clean so that dust or ot her foreign matter does not enter the inverter. Take special care to av oid breaking wires or maki ng connection mistakes. Firmly connect terminals and connectors. Keep electronic equipment away from moisture an d oil. Dust, steel filings and other foreign matter can damage the inverter, causing une xpected accidents, so take special care. Inspection ItemsThis chapter provides instructions or checklists for these inspection items: Daily inspection Periodic inspection (approximately once a year) Insulation resistance test Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]
SJ7002 Inverter Troubleshooting and Maintenance 6–3 Troubleshooting TipsThe table below lists typical symptoms and the corresponding solution(s). Symptom/conditionProbable CauseSolution The motor will not run. The inverter outputs U, V, W are not supplying voltage. • Is the frequency command source A001 parameter setting correct? • Is the Run command source A002 parameter setting correct? • Make sure the parameter setting A001 is correct. • Make sure the parameter setting A002 is correct. • Is power being supplied to terminals [R], [S], and [T] ([L1], [L2], and [L3])? If so, the POWER lamp should be ON. • Check terminals [R], [S], and [T] ([L1], [L2], and [L3]), then [U], [V], and [W] ([T1], [T2], and [T3]). • Turn ON the power supply or check fuses. • Is there an error code E--.- displayed? • Press the FUNC. key and determine the error type. Eliminate the error cause, then clear the error (Reset). • Are the signals to the intelligent input terminals correct? • Is the Run Command active? • Is the [FW] terminal (or [RV]) connected to P24 (via switch, etc.) • Verify the terminal functions for C001 - C008 are correct. • Turn ON Run command enable. • Supply 24V to [FW] or [RV] termi- nal, if configured. • Has the frequency setting for F001 been set greater than zero? • Are the control circuit terminals [H], [O], and [L] connec ted to the potenti- ometer? • Set the parameter for F001 to a safe, non-zero value. • If the potentiometer is the frequency setting source, verify voltage at [O] > 0V. • Is the RS (reset) function or FRS (free- run stop) function ON? • Turn OFF the command(s). Inverter outputs U, V, W are supplying voltage. • Is the motor load too heavy? •Reduce load or test the motor independently of the load. The direction of the motor is reversed. • Are the connections of output termi- nals [U/T1], [V/T2], and [W/T3] correct? • Is the phase sequence of the motor forward or reverse with respect to [U/T1],[V/T2], and [W/T3]? • Make connections according to the phase sequence of the motor. In general: FWD = U-V-W, and REV=U-W-V. • Are the control terminals [FW] and [RV] wired correctly? • Is parameter F004 properly set? • Use terminal [FW] for forward, and [RV] for reverse. • Set motor direction in F004. Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]