Hitachi Sj7002 Owners Manual

							Monitoring Trip Events, History, & Conditions
Troubleshooting
and Maintenance
6–14
Easy Sequence 
Error CodesUse the following table to diagnose errors re lated to Easy Sequence programming. The error 
code will appear when  the related program runs.
DeviceNet Expansion Card Errors
Error Code: OPE / SRWNameProbable Cause(s)
E43.-Invalid instruction A program c ontains an invalid instruction
PRG.CMDThe [PRG] terminal was turn ON but a 
program was not loaded
E44.-Nesting count error Subroutines with FOR and NEXT 
instructions are nest ed more than eight 
levels
PRG.NST
E45.-Execution error 1A FOR (or another) instruction to begin 
nesting is not found at the jump destina-
tion of a GO TO instruction, and the 
NEXT (or another) instruction to end 
nesting precedes the beginning of nesting
PRG.ERR1 An arithmetic operation resulted in overflow 
or underflow, or a divide-by-zero was 
attempted
A CHG PARAM or MON PARAM instruc-
tion attempts to:

 e range for a parameter

during inverter operation
E50.- ... E59.-User trip event A TRIP instruction was executed in a  program
PRG-0 ... PRG-9

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							SJ7002 Inverter
Troubleshooting
and Maintenance
6–15
Trip History and 
Inverter StatusWe recommend that you first find the cause of th e fault before attempting clearing it. When a 
fault occurs, the inverter stores important performance data at the moment of the fault. To 
access the data, use the monitor functions (Dxxx)  and select D081 for details about the present 
fault (E
n). The previous five faults are stored in D081 to D086, with D (En-1 to En-5). Each error 
shifts D081–D085 to D082–D086, and writes the new error to D081.
The following Monitor Menu map shows how to acc ess the error codes. When fault(s) exist, 
you can review their details by first selecting  the proper function: D081 is most recent, and 
D086 is the oldest.
1
Error Code
Error
exists?
Output frequency at 
trip point
Motor current at  trip point
DC bus voltage at  trip pointNo error
Ye s
No
212
2
1
1
1
1
1
Cumulative inverter 
operation time
at trip point
Cumulative power-
ON time at trip point
1
2
Current Trip  Conditions Trip History
Monitor Menu
FUNC.
FUNC.
FUNC.
d08 1
d086
d082
E07.2
60.00
4.0 0
270.0
15
18

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							Restoring Factory Default Settings
Troubleshooting
and Maintenance
6–16
Restoring Factory Default Settings
You can restore all inverter parame ters to the original factory (default) settings for the intended 
country of use. After initializing the inverter, us e the powerup test in Chapter 2 to get the motor 
running again. To initialize the inverter, follow the steps below.
No.ActionDisplayFunc./Parameter
1 Use the , , and   keys to 
navigate to the “B” Group. “B” Group selected
2 Press the 
 key. First “B” parameter selected
3 Press and hold the   key until -> Country code fo
r initializa-
tion selected
4 Press the 
 key. 00 = Japan, 01 = Europe,
02 = U.S. 
5 Confirm the country code is correct. Do not  change it unless you are absolutely sure 
the power input voltage ra nge and frequency match th e country code setting.
To change the country code, press   or   to set;   to store.
6 Press the   key. Country code fo
r initializa-
tion selected
7 Press the   key. Initialization function selected
8 Press the 
 key. 00 = initialization disabled, 
clear trip history only
9 Press the   key. 01 = enable initialization
10 Press the   key. Initialization now enabled to 
restore all defaults
11 Press and hold the
  and  
keys together, and immediately 
press and hold the   key. Do not 
release these keys yet. First part of special key 
sequence, the “B” in the 
display begins flashing
12 Holding the keys above, press and  hold the 
 (STOP) key for 3 sec. Entire “B084” display will 
begin flashing
13 When the
 b084 display begins 
flashing, release the   key.  
or
 Default parameter country 
code shown duri ng initializa-
tion process (left-most charac-
ter displays alternating 
pattern)
14 Release the 
, , and  
keys together. Final part of key sequence, 
function code for output 
frequency monitor shown after 
initialization is complete
FUNC.12b---
FUNC.b00 1
1d 104
FUNC.02
12STR
FUNC.b085
2b084
FUNC.00
10 1
STRb084
12
FUNC.
b084
STOPRESETb084
STOPRESET0  EU
0USA
12FUNC.d001

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							SJ7002 Inverter
Troubleshooting
and Maintenance
6–17
Maintenance and Inspection
Monthly and 
Yearly Inspection 
Chart
Item InspectedCheck for...
Inspection  Cycle
Inspection MethodCriteria
MonthYe a r
General Ambient  environment Extreme
temperatures
& humidity ✔
Thermometer, 
hygrometer Ambient temperature 
between -10 to 50°C, 
non-condensing
Major devices Abnormal  vibration, 
noise ✔
Visual and aural Stable environment for 
electronic controls
Power supply 
voltage Vo l t a g e  
tolerance ✔
Digital volt meter, 
measure between 
inverter terminals 
[L1], [L2], [L3] 200V class:
200 to 240V 50/60 Hz
400V class:
380 to 460V 50/60 Hz
Main 
circuits Ground
Insulation Adequate 
resistance ✔
Megger test 500VDC, reading of 5M 
ohms or greater, see next 
section for test details
Mounting No loose  screws ✔
Torque wrench M3: 0.5 – 0.6 Nm
M4: 0.98 – 1.3 Nm
M5: 1.5 – 2.0 Nm
Components Overheating ✔Thermal trip events No trip events
Housing Dirt, dust ✔Visual Vacuum dust and dirt
Terminal block Secure  connections ✔
Visual No abnormalities
Smoothing 
capacitor Leaking, 
swelling ✔
Visual No abnormalities
Relay(s) Chattering ✔Aural Single click when 
switching ON or OFF
Resistors Cracks or  discoloring ✔
Visual Use Ohm meter to check 
braking resistors
Cooling 
system Cooling fan Noise
✔Power down, 
manually rotate Rotation must be smooth
Heat sink Dust ✔Visual Vacuum to clean
Control 
circuit General No odor, 
discoloring, 
corrosion ✔
Visual No abnormalities
Capacitor No leaks or  deformation ✔
Visual Undistorted appearance
Display LEDs Legibility ✔Visual All LED segments work

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							Maintenance and Inspection
Troubleshooting
and Maintenance
6–18
Note 1: The life of a capacitor is affected by the ambient temperature. See  “Capacitor Life 
Curve” on page 6–20.
Note 2: The inverter must be cleaned periodically. If dust accumulates on the fan and heat 
sink, it can cause overheating of the inverter .
Motor General Vibration
✔Visual, touch Ordinary range
Unusual odor ✔Look for signs of 
overheating Normal appearance
Insulation 
resistance Isolation 
boundary 
fault ✔
Disconnect motor 
from inverter, do 
megger test on 
motor 500V class megger test 
must pass
Item InspectedCheck for...
Inspection 
Cycle
Inspection MethodCriteria
MonthYe a r

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							SJ7002 Inverter
Troubleshooting
and Maintenance
6–19
Megger TestThe  megger  is a piece of test equipment that uses a  high voltage to determine if an insulation 
degradation has occurred. For inverters, it is im portant that the power terminals be isolated 
from the Earth GND terminal via  the proper amount of insulation.
The circuit diagram below shows the inverter wiri ng for performing the megger test. Just follow 
the steps to perform the test:
1. Remove power from the inverter and wait at least 10 minutes  before proceeding.
2. Open the front housing pane l to access the power wiring.
3. Remove all wires to terminals [R, S, T, PD, P,  N, RB, U, V, and W]. Most importantly, the 
input power and motor wires will be  disconnected from the inverter.
4. Remove the jumper at connector J61. It is lo cated on the main circuit board beside the 
power terminals.
5. Use a bare wire and short terminals [R, S, T, PD, P, N, RB, U, V, and W] together as shown 
in the diagram.
6. Connect the megger to the inve rter Earth GND and to the shorted power terminals as shown. 
Then perform the megger test at 500 VDC and verify 5M Ω or greater resistance.
7. After completing the test, disconne ct the megger from the inverter.
8. Reconnect the jumper at  connector J61 as before.
9. Reconnect the original wires to terminals  [R, S, T, PD, P, N, RB, U, V, and W].
CAUTION: Do not connect the megger to any control circuit terminals such as intelligent I/O, 
analog terminals, etc. Doing so co uld cause damage to the inverter.
CAUTION: Never test the withstand voltage (HIPOT) on the inverter. The inverter has a surge 
protector between the main circuit te rminals above and the chassis ground.
U
V
W
Motor
R
S
T
Disconnect 
power source
P
PD
RB N
J61 SJ700
2Disconnect 
motor wires
Earth  GND
Megger, 500VDC
Add test
jumper wire
Disconnect jumper at 
J61 before performing  the megger test
L1
L2
L3

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							Maintenance and Inspection
Troubleshooting
and Maintenance
6–20
Spare partsWe recommend that you stock spare parts to reduce down time, including parts listed below:
Capacitor
Life CurveThe DC bus inside the inverter uses a large  capacitor as shown in the diagram below. The 
capacitor handles high  voltage and current as it smooths the power for use by the inverter. So, 
any degradation of the capacitor will affect th e performance of the inverter. The capacitor bank 
in SJ700
2 series inverters is replaceable. This sect ion will show you how to replace it in the 
field.
Capacitor life is reduce d in higher ambient temperatures, as  the graph below demonstrates. Be 
sure to keep the ambient temper ature at acceptable levels, and perform maintenance inspections 
on the fan, heat sink, and other co mponents. If the inverter is installed on a cabinet, the ambient 
temperature is the temper ature inside the cabinet.
Part descriptionSymbol
Quantity
Notes
UsedSpare
Cooling  fan FAN 1, 2, 3... (depends 
on model) 1 or 2 Fan unit at top of housing 
in all models
Auxiliary cooling fan FAN 0 or 1... (depends  on model)0 or 1 –150Lxx, –185Lxx, and  
–220Lxx models
Capacitor bank CB 11 All models
Power 
Input Inverter
L1/R
Motor
L2/S
L3/T
Rectifier
Variable-frequency Drive
Internal DC Bus
+
+
– U/T1
V/T2
W/T3
Converter
Ambient
temperature, °C
Ye a r s
Capacitor Life Curve
24 hrs / day operation
12 345678 910
-10 0
30 50
10
20
40

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							SJ7002 Inverter
Troubleshooting
and Maintenance
6–21
Capacitor 
ReplacementThe DC section of the inverter main circuit uses  high-capacity aluminum electrolytic capacitors 
as smoothing filter components. Since chemical  reactions occur inside the capacitors, the 
service life of these parts depends mainly on th e ambient temperature and operating conditions, 
Capacitors used in a standard operating environm ent must be replaced after about 10 years. 
However, each capacitor must me immediately repl aced if it fails a visual inspection or if 
periodic inspections shows the  capacity to be 80% or less of the component rating.
WARNING: The screws that retain the capacitor bank assembly are part of the electrical 
circuit of the high-voltage internal DC bus. Be  sure that all power has been disconnected from 
the inverter, and that you have waited at leas t 10 minutes before accessing the terminals or 
screws. Be sure the charge lamp is extinguished.  Otherwise, there is the danger of electrocution 
to personnel.
CAUTION: Do not operate the inverter unless you have  replaced the two screws that connect 
the capacitor bank assembly to the internal DC  bus. Otherwise, damage to the inverter may 
occur.
For inverters above 11kW output with molded plastic housings...
1.Loosen the two screws that secure the  lower front panel. Remove  the panel from the 
inverter.
2. Turn OFF power to the inverter and confir m that the Charge Indicator LED is OFF.
3. Remove the wiring entry/exit plate from the inverter.
4. Remove the screws that connect the capacito r unit to the main circuit terminal block.
5. Remove the screws that secure the capacitor mounting plate to the inverter casing.
6. Pull down the capacitor mounting plate.
7. Remove the capacitor unit from the capacitor mounting plate.
To install the new capacitor unit:
1. Place the capacitor unit on the mounting plate.
2. Slide the capacitor mounting plate into the guides in the inverter housing. Push the capacitor 
unit until the metal plate is flush with the housing.
3. Connect the capacitor unit to the main circuit terminal block by using the two (2) terminal 
screws.
4. Secure the capacitor mounting plate to th e inverter housing by using the screws.
5. Replace the wire/entry plate.
6. Replace the lower front panel cove r and secure it with screws.

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							Maintenance and Inspection
Troubleshooting
and Maintenance
6–22
For inverters with sheet metal housings...
1. Loosen the two screws that secure the  lower front panel. Remove the panel from the 
inverter.
2. Turn OFF power to the inverter and confirm that the Charge Indicator LED is OFF.
3. Remove the lower screws from term inal block terminals [P] and [N].
4. Remove the screws that secure  the capacitor mounting plate.
5. Pull down the capacitor mounting plate.
6. Remove the bus bar and resistors. Then remove the capacitor unit from the capacitor 
mounting plate.
To install the new capacitor unit:
1. Place the capacitor unit on  the mounting plate and secure the unit with screws.
2. Mount the bus bar and resistors  in the original positions and secure them with screws.
3. Slide the capacitor mounting plat e into the inverter housing.
4. Secure the capacitor mounting plate to th e inverter housing by using the screws.
5. Install the lower screws in the te rminal block terminals [P] and [N].
6. Mount the terminal block cover.
Capacitor mounting plate
Lower screws, terminals [P] and [N]
Capacitor unit

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							SJ7002 Inverter
Troubleshooting
and Maintenance
6–23
For inverters 11kW output and belo w with molded plastic housings...
The inverters in this category do not have separate  capacitor units. It is necessary to replace the 
main circuit board, accessible by following the steps below.
1. Loosen the two screws that secure the  lower front panel. Remove  the panel from the 
inverter.
2. Turn OFF power to the inverter and confir m that the Charge Indicator LED is OFF.
3. Loosen the two screws that secure the  upper front panel. Remove the panel from the 
inverter.
4. Press the tabs inward on each  side of the cooling fan unit and lift the unit away from the top 
of the inverter housing.
5. Disconnect the fan unit wiring on the circuit board at the top of the inverter.
6. Disconnect the ribbon cable that connects the control board and main board.
7. Remove the wiring entry/exit plate and the ju mper between terminal [P] and [PD] on the 
main board.
8. Remove the two (2) screws in the plastic housing, and remove the top half of the housing. 
Be careful not to damage the plastic tabs at the top corners of the housing.
Fan Assembly 
ReplacementThe SJ7002 Series inverters have field -replaceable fan units. The serv ice life of the cooling fan 
bearings is approximately 100,000 hours. However, actual results vary with the inverter 
operating environment. Inverters running contin uously usually need fan unit replacement at 
10-year intervals. In addition,  fan unit replacement is require d immediately if the fan has 
abnormal sound or vibration. The fan replacem ent procedure depends according to the model 
(housing type).
For inverters with molded plastic housings...
1. Loosen the two screws that secure the  lower front panel. 
Remove the panel from the inverter.
2. Turn OFF power to the inverter and confirm that the Charge 
Indicator LED is OFF.
3. Loosen the two screws that secure the  upper front panel. 
Remove the panel from the inverter.
4. Press the tabs inward on each side of the cooling fan unit and 
lift the unit away from the top of the inverter housing.
5. Disconnect the fan unit wiring  on the circuit board at the top 
of the inverter.
6. Remove the defective fan(s) from the cooling fan mounting 
plate.

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