Hitachi CONVENTION 14 Troubleshooting and Maintenance

Troubleshootingand Maintenance

In This Chapter… page

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

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

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

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

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

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Troubleshooting and

Maintenance

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Troubleshooting and

Maintenance

Contents

Main Safety Messages i i Definitions and Symbols Hazardous High Voltage i ii ii General Precautions Read These First! iii iii iv iv Index to Warnings and Cautions in This Manual iv Cautions and Warnings for Orientation and Mounting Procedures a. b. c. v v Wiring Warnings for Electrical Practice and Wire Specifications vi Wiring Cautions for Electrical Practice vi vii vii Powerup Test Caution Messages viii viii Warnings for Configuring Drive Parameters Cautions for Configuring Drive Parameters Warnings for Operations and Monitoring ix ix Cautions for Operations and Monitoring NOT x x Warnings and Cautions for Troubleshooting and Maintenance General Warnings and Cautions iv xi xi xii xii normally closed when the external system is powered OFF or disconnected from the inverter! xiii xiii xiv xiv Terminal Tightening Torque and Wire Size Wire Connectors xv xv Circuit Breaker and Fuse Sizes Motor Overload Protection Table of Contents xvi xvi Safety Messages Table of Contents xvii xvii xviii xviii Revisions xix xix Contact Information Page Getting Started 11 1 1 Main Features 12 1 2 Operator Interface Options 13 1 3 Inverter Specification Label Inverter Specification Label 14 X200 007 S F E 1 4 X200 Inverter Specifications Model-specific tables for 200V and 400V class inverters 15 1 5 16 1 6 X200 Inverter Specifications, continued 17 1 7 18 1 8 Torque characteristics 19 1 9 General Specifications The following table applies to all X200 inverters. 110 1 10 Signal Ratings Detailed ratings are in Control Logic Signal Specifications on page 4-6. 111 Derating Curves 112 1 12 113 Derating curves: 1 13 114 1 14 115 1 15 116 1 16 117 1 17 118 1 18 Introduction to Variable-Frequency Drives The Purpose of Motor Speed Control for Industry varying the frequency variable-frequency drive 1 19 Torque and Constant Volts/Hertz Operation Variable torque free-setting torque reduced torque 1 20 Inverter Output to the Motor while the motor is running 121 1 21 Intelligent Functions and Parameters digital operator, integrated operator, digital operator panel Braking 1 22 Velocity Profiles acceleration deceleration 123 1 23 Frequently Asked Questions amplifier Amplifier variable-speed drive 1 24 125 1 25 126 1 26 Inverter Mounting and Installation 2121 2 1 Orientation to Inverter Features Unpacking and Inspection 2 2 Front Housing Cover before 23 A 2 3 Logic Connector Introduction 24 2 4 DIP Switch Introduction 25 2 5 26 2 6 Basic System Description must 27 2 7 Step-by-Step Basic Installation 28 2 8 Choosing a Mounting Location 29 2 9 Ensure Adequate Ventilation Keep Debris Out of Inverter Vents temporarily 210 2 10 Check Inverter Dimensions 211 212 2 12 213 2 13 214 2 14 215 2 15 216 2 16 217 2 17 218 Prepare for Wiring 2 18 219 Determining Wire and Fuse Sizes 2 19 Terminal Dimensions and Torque Specs Wire the Inverter Input to a Supply 220 2 20 221 2 21 222 2 22 223 Wire the Inverter Output to Motor Logic Control Wiring 2 23 Uncover the Inverter Vents Powerup Test Goals for the Powerup Test 224 2 24 Pre-test and Operational Precautions Powering the Inverter Hz 0.0 2 25 Using the Front Panel Keypad Key and Indicator Legend 226 2 26 Keys, Modes, and Parameters function base frequency setting function codes 2 27 Keypad Navigation Map 228 2 28 Selecting Functions and Editing Parameters 229 2 29 230 2 30 231 2 31 232 2 32 233 2 33 Monitoring Parameters with the Display output frequency base frequency carrier frequency 2 34 235 2 35 Page Configuring Drive Parameters 31 3 1 Choosing a Programming Device Introduction of Inverter Programming 3 2 Using the Keypad Devices Key and Indicator Legend 33 3 3 Keypad Navigation Map Download with Store 3 4 Operational Modes Run Mode Edit Control Algorithms 35 3 5 D Group: Monitoring Functions IN-TM LHLHL FB 00000.00% Dir STOP 3 6 F-Cnv 00000.00 Vout 00000V Vpn 0000.0Vdc ERR3 ######## 3 7 Local Monitoring During Network Operation 38 3 8 F Group: Main Profile Parameters VR 0000.0Hz 2DEC 1 010.00s DEC 1 010.00s 3 9 A Group: Standard Functions OPE-Mode REM 2F-COM VR F-COM VR 3 10 311 Basic Parameter Settings Inverter for Multiple Motors F-MAX 00060Hz 2F-BASE 00060Hz 3 12 Analog Input Settings 313 3 13 AT-Slct O/VR O-EXS 0000.0Hz F-SAMP 00008 O-LVL 0Hz 3 14 Multi-speed and Jog Frequency Setting Jog-F 001.00Hz 2SPD00s 0000.0Hz SPD 00s 0000.0Hz 3 15 Torque Control Algorithms torque boost 316 3 16 317 V-Bst Slct MN U V-Gain 00100% 3 17 DC Braking (DB) Settings 318 3 18 DCB Mode OFF DCB F 0000.5Hz DCB T 0000.0s DCB V 00000% 3 19 Frequency-related Functions Lim L 0000.0Hz 2Lim H 0000.0Hz Lim H 0000.0Hz 3 20 jump frequencies JUMP F2 0000.0Hz JUMP F3 0000.0Hz U JUMP W2 0000.5Hz JUMP W3 0000.5Hz 3 21 PID Control PID Vari 0000.0% PID MINUS OFF PID INP OI 3 22 Automatic Voltage Regulation (AVR) Function AVR AC 00230V AVR Mode ON U 3 23 Energy Savings Mode / Optional Accel/Decel RUN MODE NOR and ECO Adj 0050.0% 3 24 Second Acceleration and Deceleration Functions ACC CHG TM 2DEC2 0015.00s DEC 2 0015.00s 3 25 ACC CHfr 0000.0Hz 2ACCCHfr 0000.0Hz 2DECCHfr 0000.0Hz DEC CHfr 0000.0Hz 3 26 Accel/Decel DEC LINE L ACC LINE L 327 3 27 Additional Analog Input Settings OI-LVL 0Hz OI-EX%E 00000% OI-EX%S 00000% 3 28 CALC Slct1 POT CALC Slct2 OI CALC SMBL 329 3 29 ST-PNT 0000.0Hz ADD DIR PLUS 330 3 30 Potentiometer Settings POT-LVL 0Hz POT-EX%E 00000% POT-EX%S 00000% 3 31 B Group: Fine Tuning Functions Automatic Restart Mode 332 3 32 IPS POWR ALM IPS Time 0001.0s FSch CNS 0000.5s FSch Md CUTOFF 3 33 Electronic Thermal Overload Alarm Setting E-THM LVL 001.60A 2ETHM CHAR CRT E-THM CHAR CRT 3 34 Overload Restriction 2OL L_SLCT PARAM OL L_SLCT PARAM 2OL Cnst 0001.0s 3 35 336 3 36 337 S-Lock MD1 See appendix C for the accessible parameters in this mode. 3 37 Controlled Stop Operation at Power Loss 338 3 38 IPS MODE OFF IPS V 0000.0V IPS F 0000.0Hz IPS DEC 0001.0s 3 39 Miscellaneous Settings start frequency chopper frequency switching frequency 3 40 AM-Adj 00100% 9 Cnv Gain 0001.0 INIT Slct EU 3 41 342 frequency pull-in 3 42 RUN FRS ZST STOP DEC 343 3 43 PANEL d001 9 FAN-CTRL OFF 344 3 44 345 lower not LADST LVL 0 0380V 3 45 346 DC Bus AVR for Deceleration Settings VpnP 0000.2s Vpn LVL 00380V 3 46 Miscellaneous Settings (continued) 347 3 47 I-SUP Mode OFF 9 Cr-DEC OFF RDY-FUNC OFF 3 48 C Group: Intelligent Terminal Functions options function codes Functions and Options The 3 49 O/C-1 NO O/C-2 NO O/C-5 NO O/C-4 NC 3 50 351 3 51 352 3 52 353 3 53 Output Terminal Configuration O/C-11 NO AM-KIND F OUT-TM RY AL 3 54 355 3 55 356 3 56 Low Load Detection Parameters LOC MODE CRT LOC LVL 02.60A U 3 57 Output Function Adjustment Parameters 358 3 58 OV LVL 001.60A 2OV LVL 001.60A PID LtL 0000.0% PID LtU 0100.0% 3 59 Network Communications Settings U COM Wait 00000ms COM ETIM 000.00s 3 60 Analog Signal Calibration Settings AM OFFST 0000.0V OI-ADJ 0100.0% O-ADJ 0100.0% 3 61 Miscellaneous Functions The following table contains miscellaneous functions not in other function groups. RS Slct ON UP/DWN NO-STR 3 62 Output Logic and Timing LogicOut1 RUN LogicOut2 FA1 LogicOPE AND 3 63 DLAY 11 000.0s HOLD 11 000.0s HOLD RY 000.0s DLAY RY 000.0s 3 64 H Group: Motor Constants Functions AUX KCD 100 2AUXP 4p AUX P 4p 3 65 Page Operations and Monitoring 41 4 1 Caution Messages for Operating Procedures 42 4 2 Warning Messages for Operating Procedures 43 4 3 Connecting to PLCs and Other Devices programmable logic controller 44 4 4 Example Wiring Diagram N/- 45 X200 4 5 Control Logic Signal Specifications 46 4 6 Intelligent Terminal Listing Intelligent Inputs Use the following table to locate pages for intelligent input material in this chapter. Intelligent Outputs 4 7 Using Intelligent Input Terminals sourcing sources sinks 4 8 49 4 9 ** 410 4 10 Forward Run/Stop and Reverse Run/Stop Commands: 411 Multi-Speed Select 412 4 12 413 4 13 Jogging Command 414 4 14 External Signal for DC Braking 415 4 15 Set Second Motor, Special Set 416 4 16 Two Stage Acceleration and Deceleration 417 4 17 Free-run Stop 418 4 18 External Trip 419 4 19 Unattended Start Protection will not 420 4 20 Software Lock 421 4 21 Analog Input Current/Voltage Select 422 4 22 Reset Inverter 423 4 23 Thermistor Thermal Protection NOTE: The trip level is hardware wise fixed and cannot be changed. 424 4 24 Three-wire Interface Operation 425 4 25 PID ON/OFF and PID Clear 426 4 26 Remote Control Up and Down Functions 427 4 27 428 4 28 Force Operation from Digital Operator 429 4 29 Add Frequency Enable 430 4 30 Force Terminal Mode Inverter Ready 431 4 31 Emergency Stop 432 4 32 433 NOT 4 33 434 4 34 Page Using Intelligent Output Terminals Sinking Outputs, Open Collector 436 4 36 Internal Relay Output It allows you to determine whether or not an inverter power loss causes the relay to change state. 437 4 37 Output Signal ON/OFF Delay Function 438 4 38 Run Signal . 439 4 39 Frequency Arrival Signals Frequency Arrival frequency arrives The 4 40 Foff early delayed 441 4 41 Overload Advance Notice Signal 442 4 42 Output Deviation for PID Control 443 4 43 Alarm Signal contacts AL and the alarm relay signal 4 44 445 4 45 Analog Input Disconnect Detect 446 4 46 PID Second Stage Output two-stage control, 447 4 47 448 4 48 449 4 49 Network Detection Signal (Integrated ModBus) 450 4 50 Logic Output Function 451 4 51 452 4 52 Network Detection Signal (FieldBus Option) 453 4 53 Low Load Detection Signal 454 4 54 Analog Input Operation sinking sourcing 455 4 55 456 4 56 Analog Output Operation 457 4 57 PID Loop Operation calculate + setpoint 4 58 PID Loop Configuration increasing decreasing 6 4 59 Configuring the Inverter for Multiple Motors Simultaneous Connections Inverter Configuration for Two Motor Types 460 4 60 461 4 61 Page Page Accessories Inverter System 52 5 2 Component Descriptions .)(min. u voltageMeanline voltageLineMeanvoltagelineMax 5 3 Zero-phase Reactor (RF Noise Filter) EMI Filter RF Noise Filter (Capacitive) DC Link Choke 5 4 55 Dynamic Braking Dynamic Braking Usage Selecting Braking Resistors for External Braking Units 5 5 56 Accessories Inverter System 5 6 57 5 7 Page Troubleshooting and Maintenance 61 6 1 Troubleshooting Safety Messages 6 2 Troubleshooting Tips The table below lists typical symptoms and the corresponding solution(s). E X X 63 6 3 64 6 4 Monitoring Trip Events, History, & Conditions Fault Detection and Clearing Error Codes E01 6 5 E13 E14 E15 E21 6 6 Trip History and Inverter Status 67 6 7 Restoring Factory Default Settings EU USA JP d001 NOTE : 68 6 8 Maintenance and Inspection Monthly and Yearly Inspection Chart 9 69 6 9 Megger test megger X200 610 6 10 Spare parts Capacitor Life Curves 611 General Inverter Electrical Measurements uu IE uu 6 12 613 6 13 Inverter Output Voltage Measurement Techniques 614 6 14 IGBT Test Method 615 6 15 Warranty Warranty Terms 616 6 16 A Glossary A2 A 2 A3 A 3 A4 A 4 A5 A 5 A6 A 6 Setpoint(SP) setpoint Trip Rotor A 7 orque ransistor tripping Saturation Voltage A 8 B B2 B 2 Connecting the Inverter to ModBus B3 B 3 B4 B 4 Required must B5 B 5 Network Protocol Reference Transmission procedure Message Configuration: Query B6 B 6 B7 B 7 Message Configuration: Response B8 B 8 B9 B 9 Explanation of function codes B10 B 10 B11 B11 The data set in the response is as follows: B12 B 12 B13 B 13 B14 B 14 B15 B 15 B16 B 16 B17 B 17 Store New Register Data (ENTER command) B18 B 18 ModBus Data Listing ModBus Coil List register address offset B19 B 19 B20 B 20 ModBus Holding Registers register address offset B21 B 21 The following table lists holding registers for the D Group Monitor Functions. Note1: Assume that the inverter current rating is 1000 (for D002). B22 B 22 B23 B 23 Note1: When the value is 10000 (100.0 seconds), a value in the second decimal place is ignored. B24B24 B 24 The following table lists the holding registers for the A Group Standard Functions. B25 B 25 B26 B 26 B27 B 27 B28 B 28 B29 B 29 B30 B 30 The following table lists the holding registers for the B Group Fine Tuning Functions. B31 B 31 B32 B 32 B33 B 33 B34 B 34 Note1: Assume that the inverter current rating is 10000 (for B013/B213). B35 B 35 The following table lists the holding registers for the C Group Intelligent Input Functions. B36 B 36 B37 B 37 B38 B 38 B39 B 39 Page C Parameter Settings for Keypad Entry Main Profile Parameters C2 C 2 Standard Functions C3 C 3 C4 C 4 C5 C 5 Fine Tuning Functions C6 C 6 C7 C 7 Intelligent Terminal Functions C8 C 8 Motor Constants Functions Expansion Card Functions C9 C 9 Page D CE-EMC Installation Guidelines D2 D 2 Integrated EMC Filter D3 D 3 Installation for X200 series (example of SFEF models) D4 D 4 Hitachi EMC Recommendations D5 D 5 Page Index Index2 Index3 Index4 Index5 Index6