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    J300 Service Manual

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    Iprahim Zaki

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    © All Rights Reserved
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    HITACHI INVERTER J300 SERIES SERVICE MANUAL (ADJUSTMENT AND MAINTENANCE) Model: J300-055LFU to J300-550LFU J300-055LF to J300-550LF J300-055HFE to J300-550HFE J300-055HFU to J300-550HFU J300-055HF to J300-550HF After reading this manual, keep it at hand for future reference, . NBS481BX Hitachi, Ltd. Tokyo Japan TABLE OF CONTENTS PRE-OPERATION CHECK... 1.1 Check of the Inverter Model Name and Manufacturing No. 1.2 Check of Inverter end Motor Specifications FUNCTION OF CHECK TERMINALS TROUBLE SHOOTING PROCEDURE 3.1 Failure Messages and Diagnoses 3.2 Description of the Codes A, B and C under the Tabulated Column Heading " Method to reset”, 3.3. Troubleshooting Procedure Based on Diagnoses by the Remote Operator (1) Flowchart when the motor will not rotate (2) Flowchart when the motor will not accelerate G) Flowchart when the motor speed is too high (4) When inverter operation can not be done. {5) Trouble shooting based on displayed trip (6) Other MEASUREMENT AND ADJUSTMENT OF CONTROL CHARACTERISTICS 4.1 Controlled Power Supply Voltage 42 — Overvoltage Detection Characteristics {Without motor] 4.3. Overcurtent (Overload) Detection Characteristics 44 Undervoliage Detection Characteristics 4.5 Forced Resetting Characteristics 46 — Extemal Frequency Indicator (Analog Meter) Adjustment Characteristics (Monitor Mode M-ADJ) 4.7 Returning to the initialization (State set at factory before shipment) 4.8 Howto Delete Trip History Data (F10, and F11) OPERATIONAL ADJUSTMENT 5.1 Motor Without Load, Forward and Reverse Run 5.2 Motor Operation with Load (100% Load) ACTIONS TO TAKE IN AN OCCURRENCE OF ABNORMALITIES... 6.1 Howto Check the Converter Module 6.2 How to Check the PM Module and Transistors Used with BRD 63 How to Check the Printed-Circuit Board 6.4 Howto Check the Digital operator 65 How to Check Conmol Signals 7. MAINTENANCE AND INSPECTION PROCEDURE 7.1 Maintenance andInspection Precautions 7.2 Measurement of InpuyOutput voltage, Current and Power 7.3 Method co Measure Insulation Resistance and Test Withstand Voltage 7.4 Maintenance of parts Appendix] Plural Motor Operation and Precautions on Operation Appendix2 5300 Series Logic, Main Circuit, and Power Circuit Connection Diagram... Appendix3 300 Series Structural Drawing ~ BL . &1 “He PERATION CHECK ) Before starting adjustment and maintenance, be sure to check the following specifications of the inverter and motor. LL Check of the Inverter Model Name and Manufacturing No. Inverter model ‘This information is writen on the name plate on the ‘MFG. NO. side cover of the inverter Example of contents of specification label + The example is for the J300-055HFE. inverter model] HITACHI Eos]. _O5SHFE 15 [Sate [=O 1. x | Fak, [Oe [Wore espcrvaasl sr Puase [2 [aera iach Ue tensees SEE] L Production J mrumber Description of Inverter Model — Version number 3300-055 H F Ef e:dsopanvesion cC_] U: USA version None: Japanese (JPN) version L_. seucmuze rype (F: with digital operatar) Gemi-osed,open ype) (055 :5.5 kW 075.75 aw L_____trput vluge 110: iw Series mime (Thee phate 00 V etase | 130: 152 K: Thvse phase 400 V clas) | 220: 222 oS EW Acplicable motor capacity : ew) See iss ew Description of Mfg. Number J300-055H 3JA LL main bady revision No Praduction menth (10 3,5; Oetoter,: November, Ki Desembars Production yer (The unit digit of the year of grace) Tres cloae ce phe 03 V chsh Agplieabte motor expacily 11 12 Check of Inverter and Motor Specifications (2) Inverter specifications Monitor mode and function mode Screen display Ty " Remarks WPT Cadedispley | Europe} usa | sen 1 | Qutput frequency monitor | Monitor ao - - - 2 | Motor revolution speed Moniioe ai - - - moniae 3 Qutpat current monitor Monitor a2 = - - 4 | Trip Monitor woaiar | 410 -{- 7 - 5 | Tap history monitor Motor | alt -|-{- 6 Output frequency seuing Set value, F2 O00 0.00 0.00 7 | Running direction setting | savne| F4 Fl FF 8 | ¥/f pater setting ‘Set value FS 00 2 a 9 Acceleration time setting } ‘Sec valve. Fé 300 30.0 30.0 10 | Deceisrationtime soning i | suvke] F7 30.0 | 300 | 300 Ti | Manval torque boost sauing | savane| 8 af [| a NOTE | NOTE | NOTE 12 | Runnoommand, frequency | Setvabe F9 o | o | o command sexing 13. | Analog meter adjustment | Savaice} FIO n|nin 14 | Motor receiving voltage Servalue Fil 380. | 230/460) 2001400) 15 | Extension function voting | Suvske| Fd ao] ao] ao NOTE; The initial value over 300LF and HF is 11. Extention function mode va Screen dteplay ction name 5 i ‘ Tf Code display jaiealvatee 1 | Conwol meld seting AO 0 Q 0 2 ‘Matot capacity seuing Al NOTE 1 3 | Moor poi sexing az + 4 a [Speed cond response canst sting aS To0_[ 100 [100 3_| Sut teqiency adusment aa 050] _O30_| 050 | Main Feeney ier sing aS a o 7 7 [Mini fequenay linier sang aS a 7 T Tump frequency sexing T AT 7 o o | Tag Trequeney satng 7 x Tv e T TO | Jump freqnency sing 3 aD a a t T_| Carer frequency ving AIO 16.0 | 16.0 | 160 [NOTE 2 12 _| Muispeed fc sped sexing Ai2, ° a @ 13 _| Multispeed second speed setting ESE 0 a 0 14 _| Mullspeed third speed sexing ‘Als 0 0 0 13 Eiearunic drecwal levet adjusunent AQ3 100 100 100 16 Elearoni¢ taeemal characteristic selection A24 o I I 17 1 Beemal frequency sewing start 26 0 0 0 18 _| Exiemal (quency seg end AzT a o a Ig Instantaneous resize seleaion AR o a oO 2 ‘Dynamic baking usage sitio ASB Ls 15 Ls ‘Z| Optional arial frequency for acveleraron Aa 0 a o 22_| Optnnal anival quency for deletion | _A&O. o @ a 23 _| Monitor signal selection Aas a a 5 2a [Analog inpat stlecion AS T T 7 35 _| Frequency erival ignal output method AD 0 0 0 26 | Autouming seating AS4 o | « [ w# at ‘Running mode selection ASD 0 o oO 28 _ | Topging freguency seaing ‘ASI 100 | 100 | 1.00 29_ | Basefrequency seting 482 o | HT 30" | Manian frequency senng ABS so | 60 | wo 3 Preset dala program AGS oO Q a 32 ‘Anpat terminal seuing 1 co 18 18 1g 35 | pat treed soning 2 cr % [| 6 | 16 $4 pu emntal seung 3 C2 3 3 3 35 Tnput terminal setting 4 ci i u u 36 Inpattemnial suing ca 9 3 9 ‘FF _ | lnpudtenminal sexing 6 co z B z 38 _ | taputteninal setting 7 Cé 1 T T 39 {Tope cena sein & C7 a o a FO | Outpt terminal seaing 1 Cid a o 0 | Ouputrersinal sexing 7 on v 1 i $2_| lnpaeminal a and b corte sein C0 ox [0 | 0 “T3_[ Oupt terminal and b conc ing cu “ale | oo NOTE 1: The most applicable motor capacity of the inverter is set NOTE 2: Carrier frequency initial value 055 to 1SOLE, HF: 16 kHz, 220LF, HF: 12 kHz, 300 to 370LF, HF: 10 kHz 450 to SSOLF, HF: 6 kHz 1-3 (2) Motor specifications v Ey s $ g 2. 3 6 ‘urpur frequency He He Motor MFG, number Motor output kw Rated current A Number of motor poles P Rated voltage v Motor rated rpm mint Rated frequency Hz Starting current A (3) Mating equipment specifications Equipment name Torque characteristics Acceleration time Sec Required torque Nem peceleration time Sec (kgfem) Load inertia-J kgem? Variable speed range Hz Hz CHECK TERMINALS Table 2-1 below shows the functions of the cleck round on the printed-circuit board. Refer to Sub-section 4.1 for the check round location and address. Addresses are described on the control circuit vertically (figures) and horizontally (alpha- bets). Fable 2-1 Functions of Check Terminals : Observation Function waveform PVS [Check round PS | Digital circuit power supply > Address (2B) PY5e— Control circuit terminal L: C power supply 431052 P12 Check round P12 CT/Remote operator Address (3B) power supply DC power supply NZ [Check round NI2 ] P12 Controtcircuit terminal L: Note: When the remote Address (3B) 1170 43 V operator is connected Ni2<-Conwol circuit terminal L: -11.70-143V VDC | Check round Main cireuit DC voltage PVDC dereetion signal: DC power supply Address (1B) VPN = 300 VDC(200 V class) vince victim ey | et PYDC+-conool circuit terminal L: 351040, L Conmol circuit Common eleciric potential for terminal L the power supply above U |[Checkround PU [ PWM waveform logic signal; Pe Conve cv ein Address (3A) Period during which the main PP stra 5 Vv [Check round PV | circuit wansistoris ON and OFF |=; 14 Address GA) is shown, Measurement of — Ww Check round PW | nonlapped period is possible by Ltn weer On Address (34) observing waveforms by the aine weed XK — |Checkround PX | pairs, je., U and X phase, Min unider OFF Address (2A) Vand Y phase, and ering thie pod ¥ — |Check round PY | Wand Z phase pus Con Address (34) Allowable nonlapped period sie Zz Check round PZ range: 11, 2=3 ta Spi sec. Court Address (3A) PR aa ft NOTE: Geil, Nonlapped period—dead time| Nentapped period wy [Checkround PUF | eotor current detection signal: | PIUF, PIWF+— Cony circuit Address (2B) 2.2¥ peak (approx.) with the Dav w \twe os inverter at rated load w JAddress (1B) During iaverter trip: approx. 4 V peak -2.2N 24 Function Observation ss S waveform TRIP [Check round PU | IPM module protect detection Address (3A) signal (approx. 9 V) , PUscontrol circuit terminal L. DC voltage 3V (approx.) When IPM is uipped, “ee PV24_ Control circuit Power supply to Fan and Power terminal P24 relay, interface Control circuit terminal P24 DC voltage control circuit terminal CM1: 22.5 0 27.5 CMi |Convol circuit Common electric potential for jterminasl CM1 PV24 power supply 22 3.1 Failure Messages and Diagnoses TROUBLE SHOOTING PROCEDURE: Table 3-1 Failure Messages and Diagnoses ‘When the inverter is out of order, be sure to take the actions indicated on Table 3-1, Find and correct the cause of the trouble and then reuse. Bees 2 3 GLE wR Digital operator || probable cause] 8 =| i E (Contents of |2 Check for: Correction 5 5 [Remote operator |3 message] [SB a BEE = = rercurentduring/ [Rapid changesin | Eliminate rapid oO} pertion of mage, oad changes in load. tor detection Short-circuits or [Check output wiring ferounds of output and motor for shorts (Check with a megodm meer} |or grounds. Overcurrent | [Rapiddeceleration _ [Increase the decelera during motor O} deceleration tion time, \Short-circuies or Check output wiring during motor JO} ecceleration by ACCT lgrounds of output —_| and motor for shorts detection (Check with amegohm mees} | or grounds. Rapid acceleration | Increase the decelers tion time. Short-circuits or Check output wiring Jgrounds of ouput and motor for shorts Overcurrent Check with a megohm meter) | or grounds. [Too high starting frequency Decrease starting stop by ACCT detection byACCT | |ewhenzeiecing tte ‘| frequency. detection Vit mode) [Too high torque [Decrease torque boost looose lLocked motor Check motor or load. [Overcurrent | fdvring motor 14 [Faulty CT Replace CT. 3} z ah 2| Probable cause| ® iS ‘ g [Coments.of |2 Check for: Correction E [S|message] |B i 1 2 Ea eh F Inver over- | [Excessive load Decrease load factor lo} loaded {Opes AlElecuonic thermal | Adjust to proper overload) level. (F not changed) level. Regenerative + Increase the decel- brake applica- eration time. [Dynamic braking Olexcceding | [usage ratio, + Increase operating exceeding Eecatan duty cycle. (OL. BRD) | |theBRD%ED + Raise BRDGED value setting sewing Rapid deceleration | Irereasethe decelera. tion time. £ 1} DCsmoott- | [Motor forced to _| Impossibte to apply } ingeireut | Abonteby the toad [CORAMUOUS (Over. V) overvoltage regenerative load. (Grounding Check output wiring (Check vita megotm mete) | a motor for grounds, [Large noise sources | Keep noise souzces in proximity away. £ 8 lol E} PROM rf Decreace the arbi- Ezror lAmbient tempecacure | ent rermperature. (EEPROM) (Too tigh) Replace the cooling fan ES (Under. V) Power failure (undervoltage) 1A. [Decrease in voliage [Evaluate power supply system. [Faulty contact of IMCB or Mg Replace MCB or Mg. Repeated occurrence lof momentary power | pyatnan failure of 100msee or | supply system, less by 10 times or lmore in 10 minutes. EID (cT) CT Error A Faulty CT Replace CT. Tal z ©) Probable cause} & ch S {8 [[Comtearsof [2+ Check for: ~Comection . ! S| message] ig 2 3 3 Large noise sources | Keep noise sources Ol CPU Ewer — | Alin proximity away. Faulty inverter Repair faulty external device |Eiminace extemal equipment (When {device and equip- E i2 O} External rip aca trip function |ment faulty condi- (EXTERNAL) fis selected) tions. Ef power is nov Eliminate external lurned on with " device and equip- E {9 O] USP Error — | Ajinverter ia RUN ment faulty condi- (USP) stare (When USPS function is selected) (Grounding of wiring Grounds at between inverter and nded inverter ouput) |motor and motor (COTTECt Broa E ff J) cwhen power |*lrsetr (Check with «Portion. istumedon) | fnegohm meter) (GND. Ft) Rapid acceleration or | INerease the acceleration deceleration and deceleration time. * Decrease fine voltage. + Minimize the [High incoming] 4] Check forhigh line | fluctuation of E iS line voltage voltage except incoming line (ov. SRC) during deceleration. | voltage. + Enter the AC reactor into the > input. Power failure Voltage drop Recovery of the E iB (mstantaneous power supply (Inst. P-F) ‘| power failure) | 4/Fauhy comactof | Replace MCB or MCB or Mg. Mg. Tncomect Check for conection] Repair EVD eee] option 1 PCB {NG. OP1} 2) 3 Probable cause| & Elicomemsot [8] Check for: Correction Blmessagel 8 | S AE = Tacomrect E ia | connection of | a| (NG. OP) option 2 PCB | | Faulty contact Repair Abnormality Refer to each [n- E ig o[ofoption 1 | 4} struction Manual, (OP1) PCB Abuormality |” [Refer to each In- Feb clef option 2 | [struction Manual. PCB (oP2) (OTE) Rapid changes in | Bliminate rapid Abnormality | [load. changes in load. with the detec-/ [Shorts-circuit or Check output wiring tor in IPM grounds of ourput and motor for shorts a }O] during opera- | Al (Check with a om grounds. tion of metor megohin meter) (PM. Drive) | | set speed cand high temperature in the inverter (NOTE Inclease the decel- Abnormality | |Rapid deceleration | eration time. with the detec- tor in IPM Check ourput wiring CaP O} during decel AlShoris-circuit or ‘and motor for shors eration of (PM. Dece!) note and grounds of ourpur or grounds. . (Check with a high tempera- megohm meter) ture in the inverer NOTE 1: Malfunction detections in IPM are overcurrent detection, thermal detection of main element, undervoltage detection of the gate circuit power supply. TET eS re |Protiable cause) & EliConrenis of | 2) Check for: Tes ineasage] 8 pS = 3 iE iz (OTE 1) Rapid acceleration —_| Increase the accel- Abnormality eration time. with the detec-} [Rapid changes in | Eliminate rapid tor in PM load changes in load. during accel- Shoris-circuit or ‘Check output wiring eration of grounds of outpyt —_ [and moter for shorts E95 freee | een eaten [eran (PM Acca) o| nah erperae Too high starting | Decrease starting : ‘ frequency frequency, javerier Toohightorque [Decrease torque boost(When select. j boost. ing the V/f mode} Rocked motor Check moror or load. Vertical installation (NOTE 1} ‘of the motor and Tastallation check Abnormality aonflammable with the detec-/ [installating wall. tor in IPM ‘Cooling fan and high | Replace the cooling during the ambient temperature. | fan. EY olmoorstop, | AHmematponer Repel (PMeRA) | [chee | |sopply. temperature in| [Main element. Replace the main the inverter element. NOTE 1: Malfunction detections in IPM are overcurrent detection, thermal detection of main element, undervoltage detection of the gate circuit power supply. | e 8 fal 2 | Probable cause| # IS E (Contents of 2 ‘Check for: Correction ie ps|message} |B é = = a 2 = fOverload Decrease load factor. | —— | ¢]limproper thermal [Reset to the proper relay set value value. [Grounds and shorts off Correct shorted or Jpower supply grounded portion, Undercapacity of | Increase MCB te) -| —~ |p|McB capacity. [Damaged inverier module or converter | Repair module Power failure Correct the power supply ~| Power failure |B[Faulty contact of MCB or Mg Replace MCB or Mg, 3.2 Description of the Codes 4, B and C under the Tabulated Column Heading" Method to reset’ A; After the motor has stopped, close between the terminals RS and P24 (CMI) on the priated- circuit board, or press the stop/teset key of the digital operator on the front cover. B; Operate the breaker and electromagnetic contactor. C: Reset the thermal relay after the motor has stopped. Resetting by the terminals RS yy «RS) 9 t ¢ CMI {| PLC Pu » 1 M1 | PLC P24 )) 1 ue OO So} Reset signal Reset signal SOURCE TYPE wiring * SUNK TYPE wiring Factory seitiag for European version) (Factory setting for USA & JPN version) 3.3 Troubleshooting Procedure Based on Diagnoses by the Remote Operator (2) Flowchart when the motor will not rotate ‘Was frequency crnmand mode PSELe ‘terminal mode ‘Mexte doe not rata. sereea and chagge lamp Some wpa oe Spl oe emp displayed? Kee digg ‘simed on? Valageinps No pr] Ten te enor ose Soi wanda ma ate not Tr oR asa fc roaizor spa S000, RDO OH NOTE: Do not mount or dismount the digital operator or remote opera tor during the power supply. NOTE: When FO9 of the function mode(parameter sctiing method) is set to OP! or OP 2option | or option 2), other date except for some monitor modes can not be set with a digital operator or a remote operator. Movor fsture No Yer Cheech wiring reaker and lecresmagnede eontneior arpa apy syne played ip information. Bap openticn cominard ig eereainal cnc ren ‘eiput operation coremand, Release PRS oe RS. input opestion exeninand, Inverter fature lxpit operation commend Invener faire Invenee fare "Tamm power supply off nee, ben increase ivener Vi, “Reduce load vorgue (Disconnect loed}- ‘ Trereaee verter and solor espucty (2) Flowchart when the movor will not accelerate pees One item Of the monitor mode. (Press the [FUN] key once, then press the [MON] ey) Display=18000.0% Mulistage speed com- 10 65000.0~.? ‘mand is inputted, Release 1,3,3-F24 (CMI"), NOTE Inverter failure Properly reselect F-SET-SELECT Operator failure Inverer failure Property weset LIMIT (frequency upper limiter sexing) Fusion mode LIMIT: He Target frequency ? Properly reset IN EXE (external frequency end| setting) ‘Punsion mode INEXE Taget quency + Raise the inverter (motor) capacity, + Raise overload Limit level. + For low speed range, changing the torque boost value may result in decrease in ouput current (Wher using the V/f contro!) + Recommend Ue customer tw reduce load, + Increase the acceleration time. + Raise the inverter (motor) capacity. NO Inverter failure NOTE: * Symbols are indicated for Sink ype wiring, Factory settings for USA & JPN version. @) Flowchart when the motor speed is too high | No tha funetion mode VE-YC sat propety ? = Comect setting “the numberof moter poles " Request the customer to select the motor anew. Inverter failure NOTE: When vector coatrol(SLV, V2 mode) is used, the speed of the motor may increase more than the synchronous speed because of slip frequency compen- sation. ol f ‘Output frequency setting value (a) ah L ‘Actual ouput frequency with a digital operator and indicated value of ouput { frequency with a digital Slip frequency compersation. operator. (4) When inverter operation can not be done. Check item Correction 1s the [STOP] key on the digital operation panel not pressed while in the TRM (terminale) mode > Stop the operation command from the TRM (terminale) mode once, then reinput the opera- tion command. Is the DB command not inputted ? ‘After cutting the DB command off, input the operation command. Is the RS/FRS command not inputted ? ‘After cutting the RS/FRS command off, input the operation command, Ts the frequency setting nor0 ? Correct the frequency setting to a desired frequency. Is the display on the remote operator not the function mode 7 Go wo the monitor mode by pressing the [MON key. Is nip not effected 7 Reset If the frequency setting command mode (F SET-SELECT) is "TRM (terminal)”, does the speed command exist between terminals O and L, or Olland L on primed board? Evaluate the speed command circuit, “There is input on the printed bowrd ar multistage speed input terminals intelligent input terminals; but is the setting of "“SPEED1” to "SPBED7" not made OHz ? Set "SPEED 107" to a desired frequency or cutoff the command to terminals intelligent input terminals. Ts the command input aot made externally by selecting the internal command [REM (remote) OPi, OP2 (option 1, option 2)] mode or is the command input not made from the digital operation panel by selecting the external com- mand TRM (terminal) mode ? ‘Check the operation mode. (Input the operation command with the mode currently set} ‘Are the external command TRM (terminal) mode and the FW and RV terminals on the printed board not inputted simultancously ? Be sure to allow either forward o7 reverse operation to function. Minimom frequency > Frequency set value ? Set the frequency to minimum Frequency or above. Does communication error occur? (The display of the dijital operation pane! is displayed as [-[-—] .) ® Release the RS command. (NOTE) ® Replace the dijital operation panel. ® Replace the control PCB. NOTE: 1a J300 series, be sure to check which of the 1 to 8 terminals is the RS terminal because. that the selection of the terminal is allowed. (The initial setting value of the terminal | is the RS command.) . For terminal input specification, when the terminal is selected from N.O. (normal open) to N.C.(aormal close) (refer to the extended function [EJ 77]), the inverter can be operated vhen the PV24 (CM1*) terminal and RS terminal are short-circuited. (When pressing a key on the digital operation panel, the display will recover.) * Factory settings for USA & JPN version 3-11 (6) Trouble shooting based on displayed tip (a) Overcurrent trip (PM. Accel) is actuated Grousd fait happens ? Ts the inverter ouput volage balanced ? ‘EVE onan ave de saving Ts nt ying to st the ‘mote runing fee” TE the aecelerstion time sera short ngains wo the load 2 Bors te lead change repay ant ieeurtent fokow exit Correct showed portion, Correct ground fault portion. Inverter failure Inverter faiture ‘Decrease the starting frequency and torque boost. Operate the motor after it has stopped The load and GD? Gnersa) are too heavy. @ increase the acceleration time. @ Request the customer to reduce the load or raise the motor and inveriex capacity. Increase the acceleration time. + Decrease the setting value of the function mode F-24 OLOAD [OLOAD CONST X.XX. + Request the customer to ease a shack of the loads or to raise che capacity of die motor and inverter, Inverter failure 3-12 {b) Overcurrent trip (PM. Decel) is actuated ie i Ct) Ve) aad WETS) Correct shorted portion. ter abon creed | Correct ground fault ponion. Inverter failure laventer failure Decrease the 1orque boos. The load and GD? (inertia) are 100 heavy. @ loceease the deceleration time, ® Request the customer 9 reduce the load ‘or raise the motor and inverter capacity. Increase the deceleration time. + Lower the setting value of the fonction mode F-24 OLOAD {OLOAD CONST X.XX} + Request the customer to mitigate load shocks or raise te motor and inverter capacity. 3-13 (©) Overcurrent trip (PM. Decel) is actuated. ut, vor sad WO) Correct shorted portion. pot ahort-euited? Correct ground fault portion. ‘Ground fault happens ? Inverter failure * Lower the setting value of the function mode 24 OLOAD [OLOAD CONST X XX] + Request the customer to mitigate load shocks or raise the motor and inverter capacity. Inverter failure (d) Overload (OverL) is actuated Comect the senting Request the customer to reduce the load or raise the motor and inverter capacity. Ts the fou nto feayy? Inverter failure 3-14 (©) Overvoltage tip (Over) is zctuated : Inverter failure, + Increase the deceleration ime. + Request the eustemer 1 install a braking resistor or raise the invener capacity, Aller the wiring system between the leading phase. capacitor. (f) Undervoltage tip UnderV) is actuated tage (ROT Trt OS ee Tos rector eguingelege suting acer come 28 pow: applyryuem) ‘id commercial power voluge rerio exterely Inverter failure: Evaluaie the power system. Seto the function mode F-22 {IPS POWER RST] Reset and restart operation. Reset and restart operation. Replace the magnetic switches. Allow 30 soconds or more before turning the power ‘on next time. (The 30 seconds is the time for the inverter to be set wher the power is turned off, This time is between 3 and 30 seconds depending on a load current relating to the equipment type. ‘The larger the capacity, the longer is the ume to be allowed.) 3-15 (6) Other (A) Phase failure European and USA version inverter are provided with the phase failure protection on the power supply. . But JPN version inverter is not provided with the phase failure protection on the power supply; hence the following are expected to happen when the phase failure hes occurred. (a) When the R phase is an phase failure An instantaneous power failure will occur indicating the following display and then the inverter wil! stop. Digital operator: [=] Remote operator: [POWER OFF (©) When the S phase or T phase is an phase failure The resistor RS overheats because that the relay 84 does not close(ON), and the lines will break down. (B) Be careful of the following conditions because the converter module may be damaged. + When the power supply voltage unbalance ratio is 3% or above + When the power supply capacity is ten times that of the inverver, and ic is 500 KVA OT greater. + When a severe voltage transients occur Examples: When multiple inverters are connected to a short bus. ‘When a leading phase capacitor is mmed on/off. In the cases above, it is recommended that a reactor of about 3 percent of the power supply voltage (voltage drop at the rated current) be inserted on the power supply. 3-16 44 IEA‘ UREMENT AND ADJUSTMENT OF CONTROL CHARACTERISTICS ’) Controlled Power Supply Voltage “Allowable Measurement location ; voltage range (V) + = PY5 (for+5'V) power supply | 4.9%05.2 [Check round PS | Conwol croult emmilnal L (Address 2B) [PV12(for +12 V) power supply | 11.710 143 Check round P12 | Conmol circuit erminal (Address 3B) NV12 (for -12 V) Power supply | -11.7 0-143 | Check round Ni2__| Control circuit iemminal L (Address 3B) [PV24 (for +24 V) power supply | 22.5t0 27.5 | Conuol circuit Control cucuit terminal terminal P24 Mi VDC voltage 35040 | Check round Control circuit ierminal L ‘(for detection of P to N voltage) PYDC (Address 1B) [¥on=DOVDCHOOVDC (200 ¥ clsu400V class) Blind cover Frontcover Set screw (ur front.cover termi S : Main circuit terminal Appearance of J300(example: 055 to 075 LF and 085 to 075 HF) 4a 4.2 Overvoltage Detection Characteristics [Without motor} Make detections of the following by varying the main circuit voltage (R (L1), $ (L2) and T (L3)} which have been adjusted with the variable transformer. When checking the BRD function, connect a resistance of hundreds kQ between P and RB. ABRD circuit is supplied to the inverters 055 to 075 LF and 055 to075 HF as standard, A resistor is an option. (European version 055 to O7SHFE are provided with a internal dis- charge resistor as standard.) etected Voliage (between, and.N on main circuit) Criteria vote: | ON | DC AYR set value + 138 VDC BRD of mote (200 V class) Connect ant oscilloscope from RB to P (+). The DC AVR set value +276 VDC _| voltage waveform must become "L". or more (400 V class) OFF |DC AVR set value + 138 VDC or less (200 V class) Connect an oscilloscope from RB to P (4). The DC AVR set value +276 VDC | voltage waveform must become “H”. or less (400 V class) note? 369 to 404 V (200 V class) + The output power turned off: Logic PCB: OV-TRP | 756 to 827 V (400 V class) Control circuit: check round PU < control circuit terminal L must be “H" LEVEL + ALARM OUTPUT: ALO-AL1 ON OFF + Overvoltage trip display: “PERROR Over. V" (Remote operator display) NOTE 1: When detecting BRD, set the usage ratio to 10.0 using the dynamic braking. Afler detecting, reset to the setting value before change. NOTE 2: When detecting OV-TRIP, set the usage ratio 10 0.0 using the dynamic braking. This operation should be done within 100 seconds because incoming voltage protection is effective. NOTE 3: Be careful of high voltage to check BRD operation 42 43 Overcurrent (Overload) Detection Characteristics ‘With the motor running, gradually increase the load and then make the following measure- ment, ~» OFF) + Overcurrent tip display: (TERROR OC. Drive" (Remote operator display) Method to test Criteria Remarks Overload limit | © F-24 LM.CONS | Ourput frequency must start Possible to change level 50% O1.0 setting: — / decreasing. LM.CON setting Apply a load of 4¢ to with the remote 60 percent of the operator connected inverter rated cur- rent. @ F-24 LM.CONS 150% 01.0 setting: Apply a load of 140 to 160 percent of the inverter rated cur- Tent. Overload trip | Apply aload of 180 |+ Overload tip must occurin | LM.CONS 150% percent of the in- about 10 to 20 seconds (Use the remote verter rated current. |+ The output power tured of. operator.) (Check round PU Control circuit terminal L:"H” level) + Alarm output (ALO-ALI ON 3 OFF). + Overload trip display: ("ERROR Over. L” (Remote operator display) Overcurrent | Apply a load of 170 |~ The output power tumed off | LMCONS 150% wip to 180 percent of the | Check round PU < Control | (Use the remote invener rated cur- curevit werminal L: "E tevel) | operator.) tent. + Alarm output (ALO-AL] ON 43 44 Undervoltage Detection Characteristics Operate the inverter at the maximum output frequency As the main circuit power supply voltage (R (Ll), S (L2) and T (L3)} is gradually decreased through the variable transformer, the output has to be turned off or Undervoliage trip must ‘occur (this operation to be carried out at the rated load), Criteria 140 to 160 V_| * The output power tumed off. Check round PU (Address 3A) (200 V class) |< Control circuit terminal L: “H” level) Undervoltage | 28010 320 V | * Alarm ouput: ALO-ALI, ON > OFF (400 Velass)_| + Undervoltage display: ("7ERROR Under V") Following the detective operation, execute latching. After resetting (by short-circuiting RS to L, or pressing the [STOP] key,) release the latching. 45 Forced Resetting Characteristics ‘Description Operation Criteria Fored resetiing | Short circuit RS 1 P24 (CMI*) The abnonnal mode must be resi. on the printed board *: Factory settings for USA & JPN version. 4.6 External Frequeney Indicator (Analog Meter) Adjustment Characteristics (Monitor Mode M-ADJ) Connect the remote operator. Select { F-10 (when the dijital operator is used)] with the Function mode. In this state, an output (VT) which is proportional to the output frequency is available between FM- control circuit terminal L. Adjust the constant on the monitor mode so the meter reading becomes maximum at the maximum frequency. FM | CMI 4 t = Wis variable T 4-4 47 4.8 lization (State set at factory before shipment) Returning to the i When retuming the equipment to the initial sate set at factory before shipment for some reason, follow the following procedure, @® Allocate STN (set value []_ J] to one of the input intelligent terminals. (Use [Eto [in the extension function mode to set the intelligent terminals.) (However, can [E[_{f not be used since resetting RS is initially set.) ® Short-circuit the STN terminal and P24 (CM1*), then tam power off and on. (When the power is turned off, do not tum it on again until the CHARGE lamp of the logic PCB goes off) ® Keep the STN terminal open for more than 6 seconds. (When keying, resetting, or turning power off is performed within 6 seconds, the equipment may not be initialized.) @ Tum the power off after more than 6 seconds. (When the power is tamed off within 6 seconds, the equipment may not be initialized.) How to Delete Trip History Data (F10, and F11) To delete mip hisory data for some reason, follow the instractions shown below using the remote operator (DOP or HOP) or copy unit (DRW or HRW) 1. Using the remote operator (DOP-OA) or copy unit (DRW-OA) ® Display [INIT TCNT] (wip history count clear) or the function mode initial setting CES INIT). ® Move the cursor to beneath the initial set values. Select CLR and store it ® Tum the power off once and then tum it on, or close the reset terminal RS- P24 (CM1*) for approx. a second. By this, trip history data is deleted. ® When wip history is deteted, data of [F-381]is set to [CNT]. Trip counting restars, 2, Using high-performance remote operator (HOP-OJ) or high-performance copy unit (ERW-OJ) ® Display [TCNT 0: CNT] (wip history count clear) or the function mode initial setting (2-2 INIT}. ® Enter a count clearing valuc {0: CLR] from the 10-key pad. ® Tum the power off once and then turn it on. or close the reset terminal RS- P24 (CMI1*) for approx. a second. By this, trip history data is deleted. © When mip history is deleted, data of [2-2 INET] is set to [CNT]. ‘Trip counting re- starts. NOTE: * Symbols are indicated for Sink type wiring, Factory settings for USA & JPN version. 45 5A 32 TONAL ADJUSTMENT Motor Without Load, Forward and Reverse Run The motor must accelerate without allowing the OC-TRIP to occur, when the motor is run forward first, and then with the use of the selection switch, the speed is decreased and the operation is switched over to the reverse mun, OFF SOURCE TYPE wiring (Fociory settings for European version) alewnlpudez[rw] 2 [-- 6&3 yh Lay’ ye eon oe SINK TYPE wiring, Forward aX fit (Wien decelerated) Frequency ‘Gactory settings for USA & JPN version) Reverse run Adjasable (Fs1op-T) reifemfeuqpres|rw] 3 | Oto ee a3 ay 9E Motor Operation with Load (100% Load) Operation Criteria jescription. Balance of ouiput voltage and current Make measurements of the voltage and current at the in- verter output (U, V and W). Gee Section 7.) + Free from open phase, etc. + Balanced output voltage and current + Motor operation free from abnormal noises ‘Current monitor ‘Check the ouspur current values on the operation monitor (42). 90 to 110% of the inverter rated current (approx.) Voltage monitor (NOTE) Check the DC voltages(Vpa). The value depends on input voltages: 270 V {approx.) against the 200VAC input 540 V (approx.) against the 400 VAC input NOTE: Be sure to check the voltage monitor display using the remote operator(DOP, HOP) ‘or copy unit(DRW, HRW) according to the following procedures: 1. When seating with the remote operator(DOP-OD of copy unit(DRW-OD ® Display the function mode[F—38_ INIT DEBG. @® Move the cursor to the position to be set, then enter ON to store. @ Press the monitor key once and the YW _key seven times to display PN-V_ 000.0V. This displayed value is the voltage monitor value. i When setting with the high performance remote operator(HOP-OG) or high performance copy unit(HRW-OJ) @ Display the function mode (2-2 INIT] and initial setting [DEBG 0: OFF] @ Set and store the debug ON setting value (1: ON] using the ten key, @ Press the monitor key and VJ key to display OPN-V O00.0V. This displayed value is the voltage monitor value. 5-2 EIN AN OCCURRENCE OF ABNORMALITIES J C 61 How to Check the Converter Module Possible to check the module with the tester P) GR (2) § (3) T NOQ) Circuit diagram of the converter module Tum the power off and start the work after the voltage between P (+) and N () has become 15 volts or below. Use the @ range when making measurements with the tester. (A simple way to check the module as assembled) Bi ‘ester terminal Resistance value Three different ways for ~~ (corresponding to R-S, $-T and R-T) 50kQorabove | ~ + AC terminal {RL1), PG) Each of R, S and T SOK or above S 2) and THL3)} Each of R, $ and T>P(+) 500 or below NG) Each of R, S and T 500 or below Each of R, § and T >N(-) ‘S0KQ or above Replace the converter module if any of the measurements is out of the values shown above. + Trouble to occur when the converter module fails: MCB ip (Short-cireuit of the power supply) 6-1 6.2, How to Check the PM Module and Transistors Used with BRD Check the module with the tester (PM Inverter module circuit diagram (example: 055 to 075LF and 055 to O7SHF) Tum the power off and start the work after the voltage between P (+) and N (—} has become 15 volts or below. Use the 10 range when making measurements with the tester. (A simple way to check the module as assembled) NOTE: There is a possibility thet the module is out of order even when judged to be up to standards. Resistance value Location to check U phase arm Piv 50k or below 'V phase ann POW W phase arm NU U phase arm Nov 502 orabove V phase arm Now W phase arm USP U phase arm VP 502 or below V phase arm WP Wophasearm USN TF phase arm VN 50kQ. or above V phase arm WoN W phase arm 6-2 6.3 6.4 Troubles to occur: When the IPM module fails: + The OC tip occurs even when the motor is nor connected. When the BRD transistors (BRD transistors within 1PM) fail: + BRD discharge resistor heats up How to Check the Printed-Circuit Board Visually check the mounted printed-circuit board for damaged resistor and thick-film mod- ule (called PSM), short-circuited IC lead due to ceposited foreign matter and abnormal or disconnected connector. How to Check the Digital operator Select “01” for F9 with | A |key and[A] [P] key on the digital operator, and connect the frequency setter betweenthe terminals O and L on the priated-circuit board, Set the frequency to a maximum, select F1 with the] ;ane [Key on the operation panel and press the | ify |key. (In the case of the remote operator, select “Terminal” for F-SET-SE- LECT) Be sure to check if the frequency can be set (0 amaximum setting value. (Example) Tey (clan on CHL 6-3 65 How to Check Control Signals While operating the inverter, PWM waveforms appear between the check round PU or PX and control circuit terminal L. Note that these PWM waveforms are different depending on the frequency setting. ‘When the PWM waveform is incorrect, replace the control substrate. = 5v “Ww PMW wave form {approx.) + Check ronnd PU © Conrol circuit terminal L Check round PX < Conrol circuit terminal L + Check round PV © Conroi circuit terminal L Check round PY + Conrol cireuit terminal L. + Check round PW < Conrol circuit tennina! L Check round PZ < Conrol circuit terminal L 64 NANCE AND INSPECTION PROCEDURE 7.1 Maintenance and Inspection Precautions (1) Precautions before starting maintenance and inspection ‘Be sure to confinn the following before starting maintenance and inspection because there is a danger of receiving a electric shock. > The display oa the digital operation panel has wrned off and the charge lamp on the PCE has gone out. + The voltage between P(+) and NC) is 15V or below when measured with the tester. + A discharge resistor (30 W300 Q: 200 V class, 60 W 1 &2:400 V class) has been con- nected between P(+) and N(-) for 15 seconds or longer after the power was curned off. (2) General precautions Always keep ihe unit clean so that dust or other foreign matter does not enter the inverter. Use special care with respect to broken lines and faulty connections. Firmly connect terminals and connectors, Keep electronic equipment away from moisiure and oil. Dust, steel filings and other foreign matier can damage insulation, causing unexpected ucci- dents, so take special care. 7.2 Measurement of Input/Output Voltage, Current and Power General measuring instruments for inpuourput voltage, current and power are shown in Figure 7-3 and Table 7-1. “The voltage to be measured is the fundamental wave effective value and the power to be measure is the total effective value. (1) Measurement of output voltage ‘The moving-iron type instrument does not give accurate readings for measurement of the output voltage. Make measurements according to the method shown in Figure 7-3 (Table 7-1) or using the circuits indicated in Figures 7-1 and 7-2. Diote Ov 0.14 or above (200¥ class) 1OO8V O°1A or mere (40¥ class) Fundamental wave, effective calue ¢ Vac 11x Voc ‘Moving cod type meter 500 (200¥ clase) o0v (aon alae) Figure 7-1 Output Voltage Measurement Circuit TA ‘When a load is not connected to the output terminals U(T1), V(T2) and W(T3), a voltage is present at them because of the leakage current of semiconductors (about 2mA) even whea the output frequency command is made naught. ‘When connecting the voltmeter to the output terminals under the conditions mentioned above, make connections as indicated in Figure 7-2 to prevent the indication exor of the meter, Diese, Ov 0A oF above (200V class) NQGBY 0.1 or more {O0Y dae) rags Y resister 5k. a” BOW (abo clas) 7 1OOW (400¥ class) Tindng cad ype mee gov iooy ala S20 (400 eat) Figure 7-2 Output Voltage Measurement Circuit (2) Mezsurement of input voltege and input/output current Make measurements of the input voltage and input/output current for all of the three phases with the moving-iron type metor (Scc Figure 7-3 and Table 7-1), (3) Measurement of inpuvourput power ‘Make measurements of the inpuvoutput power with the clectrodynami¢ type watuncter for single phase use. Make measurements for all of the three phases in cases where there is an unbalance in voltages and currents. ay mee Power Supply s—GO) s 3 Ev ay Fe & hb To ow Figure 7-3 Parts to be Measured 7-2 Table 7-1 Measuring Instruments ad ” Migasuring instronieiit: irks <2 ‘Supply volage Bt Berween Rand S, and, | a" Moving-ton ipe voluneter or [Fundamenta wave Tand R (ERSXEST) rectifier type volumecer effective value Err) aa ‘Supply current 11 Amperage R,S andT | ‘Moving-iron type ammeter Total effective ‘RXIsyIT) value ‘Supply power Wi Beoween Rand §, and S a Electrodynamic type watuneter | Toial effective and TOW11) CW 22) value Supply power factor Pf | Calculate the supply power factor from the measured supply voltage, El, supply curent and supply power Wi ‘Ontput voltage ED ‘Between Uand Y, ¥ and ‘Refer to Figure 7-2 or reciitier | Toul effective. W, W and U uv) moving-iton type ameter: |vae (vw) wu) ‘Output current Io ‘Amparage a U,V anaW [ge Moving-rontypeanmes: — [Toateectve awavyaw value ‘Output power Wo Between Uand V, V and eR Electrodynamic type wattmerer | Toual elfective Ww (WO1)(WOZ) value ‘Quipet power factor Pf | Calculate the output power factor from the ouiput vollage Ed, output current Toand output power Wo Wo Pf =" _ x 100(%) ¥3+Eo*To NOTE 1: Use a meter indicating a fundamental wave effective value for voltage, and meters indi- cating total effective values for current and power. NOTE 2: Since the inverter output waveform isa distorted wave, the measuring instruments shown in the table above are liable to cause errors at low frequencies. The measuring method and instruments indicated above provides comparatively accurate values. Some testers (general-purpose products) are not applicable to the distomed wave. NOTE power meter, e.g., YEW 2503 and 2504. 7-3 : For the input and output current, measurements of the power are made with the digital 7.3. Method to Measure Insulation Resistance and Withstand Voltage ‘Make these measurements and tests by short-circuiting the terminals as shown in Figure 7-4, and by following the conditions described. (Conditions) a) Make insulation resistance measurements between the terminals and grounding with the S500DCV megaohm-meter, and make sure that 5 M-ohms or greater is indicated, b) Withstand voltage test Make withstand voltage tests by supplying 1S00VAC (200V class) , and 2000 VAC (400 V class) to between the terminals and grounding for one minute, and make sure that there are no abnommulities. + Do not conduct withstand voltage tests for terminals other than those indicated in Figure 7-4, Arrlied vlage Granta) Thayer i RS TRB RN UY W % RRR AL RP Sune ime tot mer a Mersin Oieer atecor Sow hose Figure 7-4 Insulation Resistance Tests and Withstand Voltage Tests 7.4 Maintenance of parts (1) Printed-cireuit boards ate maintenance-free under normal applications. However, in cases in which maintenance and inspection are necessary, pay attention to the preven- tion of damage caused by static electricity as shown below, and be sure to follow the instructions in Section 4. MEASUREMENT AND ADIUSTMENT OF CONTROL CHARACTERISTICS and Section 5. OPERATIONAL ADJUSTMENT. * Prevent damage caused by static electricity The MCUs and LSIs on a printed-cireuit board can be destroyed by static electricity, so be sure to ground work benches, soldering irons, and yourself before working on a printed-circuit board. (2) Maintenance of smoothing capacitor and cooling fan We recommend that smoothing capacitors CB and cooling fans be regularly replaced every three years taking their lives into account. Note that their lives shorten when they are used, in particular, under high temperatures and heavy loads. 7-4 Appendix1 — Plural Motor Operation and Precautions on Operation Appendix 2 — J300 Series Logic, Mais cuit, and Power Circuit Connection Diagram r LogicPCB | Mamcircuit | Power PCB PM : drawing érawing | _drauingNo. -| pcB'arawing No 3300-055,07SLE STBIS164 3300-110LF 37813165 jaOOLE wrei2s13 | 3T812883 SE 3300-220LF 31813167 1300-300, 370LF T300-450LF 77300873 | 31812884 sees 27800885 7300-330LF 27800874 u ZEBOORES 3300-055, O7SHE 2T800875 3T813164 378125514 1300-110,150HF wsr8tosrae | 37812883. [Freisi66 T300-220HF 31813167 3300-300, 370HF 37812885 27800884 27800885 1300-450, S350HE * 37812885E | 3781286 | 2Ta008E6 *: Symbols are indicated for European version Appendix 3 J300 Series Structural Drawing o ‘Structural drawing No. Structural drawing. 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