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Hitachi L2002 Safety Messages, Inspection Items, General Precautions and Notes, Troubleshooting and Maintenance

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Troubleshooting

Troubleshooting and Maintenance

Troubleshooting

Safety Messages

Please read the following safety messages before troubleshooting or performing maintenance on the inverter and motor system.

WARNING: Wait at least five (5) minutes after turning OFF the input power supply before performing maintenance or an inspection. Otherwise, there is the danger of electric shock.

WARNING: Make sure that only qualified personnel will perform maintenance, inspec- tion, and part replacement. Before starting to work, remove any metallic objects from your person (wristwatch, bracelet, etc.). Be sure to use tools with insulated handles. Otherwise, there is a danger of electric shock and/or injury to personnel.

WARNING: Never remove connectors by pulling on its wire leads (wires for cooling fan and logic P.C.board). Otherwise, there is a danger of fire due to wire breakage and/or injury to personnel.

General Precautions and Notes

•Always keep the unit clean so that dust or other foreign matter does not enter the inverter.

•Take special care in regard to breaking wires or making connection mistakes.

•Firmly connect terminals and connectors.

•Keep electronic equipment away from moisture and oil. Dust, steel filings and other foreign matter can damage insulation, causing unexpected accidents, so take special care.

Inspection Items

This chapter provides instructions or checklists for these inspection items:

•Daily inspection

•Periodic inspection (approximately once a year)

•Insulation resistance test

Contents

400V Class Page Safety Messages Page Page Cautions and Warnings for Orientation and Mounting Procedures Wiring - Warnings for Electrical Practices and Wire Specifications Wiring - Cautions for Electrical Practices Powerup Test Caution Messages Warnings for Configuring Drive Parameters Cautions for Configuring Drive Parameters Warnings for Operations and Monitoring Cautions for Operations and Monitoring Warnings and Cautions for Troubleshooting and Maintenance CAUTION: MOTOR TERMINAL SURGE VOLTAGE SUPPRESSION FILTER (For the 400 V CLASS) CAUTION: EFFECTS OF POWER DISTRIBUTION SYSTEM ON INVERTER CAUTION: SUPPRESSION FOR NOISE INTERFERENCE FROM INVERTER Wiring Warnings for Electrical Practices and Wire Sizes Terminal Tightening Torque and Wire Size Motor Output Power Terminal Torque Inverter Model Fuse and Circuit Breaker Sizes Motor Overload Protection Table of Contents Page Revision History Table 1.Model 2.Date of purchase 3.Manufacturing number (MFG No.) 4.Symptoms of any inverter problem Getting Started Getting Started Main Features Operator Interface Options Started Getting Inverter Specifications Label Specifications label Inverter model number Motor capacity for this model Power Input Rating: frequency, voltage, phase, current Model-specifictables for 200V and 400V class inverters “General Specifications” on page 1–10 Item 200V Class Specifications Note 1: Note 2: Note 3: Note 4: Note 5: L2002 Inverter Specifications, continued 015NFEF2 022NFEF2 015NFE2 022NFE2 400V Class Specifications 1/2 400V Class Specifications, continued General Specifications The following table applies to all L2002 inverters General Specifications Signal Ratings Detailed ratings are in “Control Logic Signal Specifications” on page 4–6 Signal / Contact Ratings Derating Curves Started Getting Derating curves, continued L200–015NFE(F)2/NFU2 L200–022NFE(F)2/NFU2 L200–037LFU2 L200–055LFU2 L200–075LFU2 L200–004HFE(F)2/HFU2 L200–007HFE(F)2/HFU2 L200–015HFE(F)2/HFU2 L200–022HFE(F)2/HFU2 L200–030HFE(F)2 -040HFE(F)/HFU2 100% L200–055HFE(F)2/HFU2 L200–075HFE(F)2/HFU2 The Purpose of Motor Speed Control for Industry What is an Inverter Output frequency Constant torque Torque and Constant Volts/Hertz Operation Output voltage Variable torque Inverter Output to the Motor Intelligent Functions and Parameters Braking Velocity Profiles Page Motor type Motor size Page Page Inverter Mounting and Installation Orientation to Inverter Features Inverter Mounting and Installation Unpacking and Inspection 1.Look for any damage that may have occurred during shipping Front Housing Cover To remove the cover, follow the steps below (applies to all inverter models): Installation and Mounting Inverter To install the cover, follow the steps below (applies to all inverter models): Logic Connector Introduction DIP Switch Introduction Page From power supply Breaker MCCB or GFI L1 L2 L3 Page Choosing a Mounting Location Step 1: Ensure Adequate Ventilation Step 2: Keep Debris Out of Inverter Vents Step 3: Check Inverter Dimensions Step 4: Inverter Mounting and Installation Page Model -007NFU2 130(5.12) -015NFU2 156(6.14) Page Prepare for Wiring Step 5: Determining Wire and Fuse Sizes Terminal Dimensions and Torque Specs Wire the Inverter Input to a Supply Step 6: terminals [R/L1], [S/L2], and [T/L3] So, you must refer to the specifications N/L3 R/L1 S/L2 T/L3 R/L1 Page Wire the Inverter Output to Motor Step 7: Logic Control Wiring Uncover the Inverter Vents Step 8: Step 9: Goals for the Powerup Test Pre-testand Operational Precautions Powering the Inverter Key and Indicator Legend Display Units, Hertz/Amperes Function Key Up/Down Keys Keys, Modes, and Parameters A 0 0 Keypad Navigational Map Monitor Mode Program Mode Selecting Functions and Editing Parameters TM/PRG DIP Switch Setting Prepare to Edit Parameters d 0 0 A – – – If the Potentiometer Enable LED is OFF, follow the steps below A – – – A 0 0 key again Select the Keypad for the RUN Command Set the Motor Base Frequency Set the AVR Voltage Setting key and hold until A 0 8 Set the Motor Current b – – – b 0 0 Set the Number of Motor Poles b – – – H – – – H 0 0 Monitoring Parameters with the Display Output frequency (speed) monitor d 0 0 Running the Motor Powerup Test Observations and Summary Step 10: Error Codes EXX Acceleration and Deceleration Page Configuring 3 Drive Parameters Drive Parameters Introduction to Inverter Programming Parameters Drive Page Operational Modes Run Mode Edits Control Algorithms “D” Group: Monitoring Functions “D” Function Trip Event and History Monitoring using the keypad. See for more details Local Monitoring During Network Operation Page “A” Group: Standard Functions Control Source Settings “A” Function Frequency Source Setting Frequency Source Run Command Source Setting A001/A002 Override Sources Page Basic Parameter Settings Analog Input Settings A016: External Frequency Filter Time Constant – Multi-speedand Jog Frequency Setting Page Torque Control Algorithms Manual Torque Boost – The Constant Voltage Gain – cations The following table shows the methods of torque control selection Page DC Braking Settings Frequency-relatedFunctions Jump Frequencies – PID Control •Proportional, integral, and derivative gains are all adjustable •See “PID Loop Operation” on page 4–56for more information Configuring Parameters Drive Second Acceleration and Deceleration Functions Page Accel/Decel Additional Analog Input Settings Input Range Settings – “Analog Input Settings” on page Analog Input Calculate Function – ADD Frequency – Page Automatic Restart Mode “B” Group: Fine Tuning Functions Instantaneous Power Failure / Under-voltageAlarm “B” Function Electronic Thermal Overload Alarm Setting Page Overload Restriction Page Software Lock Mode See “Software Lock” on page 4–22 Miscellaneous Settings B080: [AM] analog signal gain – B082: Start frequency adjustment – B084, B085: Initialization codes – B086: Frequency display scaling – free-run stop (coast to a stop). When using the frequency matching Page When the L200 “Local Monitoring During Network Operation” on page 3–8 for more details B130/B131: Page B150: Carrier Mode – B151: Quick start enable – Input Terminal Configuration Functions and Options “C” Group: Intelligent Terminal Functions Intelligent Input Terminal Overview Input Function Summary Table – “Using Intelligent Input Terminals” on page Input Function Summary Table Function Name Page Page Page Output Terminal Configuration Output Function Summary Table – “Using Intelligent Output Terminals” on page Output Function Summary Table Analog Function Summary Table – Output Function Adjustment Parameters Page Network Communication Settings “ModBus Network Communications” on page B–1 Analog Signal Calibration Settings Miscellaneous Functions Output Logic and Timing Logic Output Function – Output Signal ON/OFF Delay Function Page “P” Group: Expansion Card Functions “P” Function Operations and Monitoring Operations and Monitoring Caution Messages for Operating Procedures Warning Messages for Operating Procedures Operations Monitoring and Page Example Wiring Diagram N/– Control Logic Signal Specifications Relay contacts AL2 AL1 AL0 Logic inputs AMH O OI L L 5 4 3 2 1 PCS CM2 12 Intelligent Inputs Intelligent INPUTS 4–26 4–29 4–32 Intelligent Terminal Listing Intelligent Outputs Intelligent OUTPUTS 4–45 4–46 Page Sinking Inputs, Internal Supply Sourcing Inputs, Internal Supply Sinking Inputs, External Supply Sourcing Inputs, External Supply SR/SK switch = SR position Forward Run/Stop and Reverse Run/Stop Commands: Valid for inputs: Required settings: Notes: Multi-SpeedSelect Note: Notes: Jogging Command •00 Free-runstop (coasting) •01 Deceleration (normal level) and stop •02 Use DC braking and stop value is 0 Hz External Signal for DC Braking •A053 – DC braking delay time setting. The range is 0.1 to 5.0 seconds •A054 – DC braking force setting. The range is 0 to 100% Scenario 1 – The [FW] or [RV] terminal is ON. When [DB] is ON, DC braking is Set Second Motor and Special-SetSecond Motor Set Second Motor - The inverter can select a different motor only in Stop Mode Special-Set Two-stageAcceleration and Deceleration L 5 4 3 2 1 PCS Free-runStop Resume from motor speed wait time FRS B003, B088, C011 to C015 External Trip Unattended Start Protection Software Lock Analog Input Current/Voltage Select Reset Inverter The [RS] terminal causes the inverter to in Trip Mode, the reset cancels the Trip state When the signal [RS] is turned ON and OFF the inverter executes the reset operation. The Thermistor Thermal Protection MOTOR Three-wireInterface Operation Page PID ON/OFF and PID Clear Remote Control Up and Down Functions Page Force Operation from Digital Operator •A001 - Frequency source setting •A002 - Run command source setting Force Operation Forces the operator interface to override: ADD Frequency Enable Force Terminal Mode •A001 - Frequency source setting (01 = control terminals [FW] and [RV]) •A002 - Run command source setting (01 = control terminals [O] or [OI]) Forces A001=01 (frequency source setting control terminal), and Quick Start Enable Sinking Outputs Open Collector Open Collector with External Relays Internal Relay Output AL0 AL1 AL2 de-energized energized Output Signal ON/OFF Delay Function Original signal ...with ON delay ...with OFF delay ...with ON/OFF delays Run Signal Frequency Arrival Signals Frequency Arrival frequency arrives Page Overload Advance Notice Signal Output Deviation for PID Control Alarm Signal The inverter alarm signal is active when a fault has occurred and it is in the Trip Mode (refer to the diagram at right). When the fault is cleared the alarm signal becomes inactive Trip/Power Loss Alarm – Trip Alarm – Analog Input Disconnect Detect Voltage signal loss at [O] terminal Current signal loss at [OI] terminal PID Second Stage Output Page Page Network Detection Signal Logic Output Function C141, C142, C143 Option Card Detection Signal AMH O OI L Voltage Input Current Input Other Analog Input-relatedtopics: Page Page PID Loop Configuration PID Output Limit Error Inversion Other PID-relatedtopics: Simultaneous Connections Inverter Configuration for Two Motor Types Parameter Codes 1st motor 2nd motor Page Inverter System Accessories Motor Control Accessories AC Reactors, Input Side •If the unbalanced factor of the power supply is 3% or higher •If abrupt power supply changes are expected Examples of these situations include: 1.Several inverters are connected in parallel, sharing the same power bus Zero-phaseReactor (RF Noise Filter) EMI Filter RF Noise Filter (Capacitive) DC Link Choke Dynamic Braking Usage Selecting Braking Resistors for External Braking Units Dynamic Braking Note the column meanings in the tables: •Column “A” = Average braking torque from 60 Hz to 3 Hz •Column “B” = Average braking torque from 120 Hz to 3 Hz Page Page Troubleshooting 6 and Maintenance Troubleshooting and Maintenance Safety Messages General Precautions and Notes Inspection Items Troubleshooting Tips The table below lists typical symptoms and the corresponding solution(s) Symptom/condition Probable Cause Solution Page Fault Detection and Clearing The microprocessor in the inverter detects a variety of fault conditions and captures the event, record ing it in a history table. The inverter output turns OFF, or “trips” similar to the way a circuit breaker Monitoring Trip Events, History, & Conditions Trip History and Inverter Status Monitor Menu Trip 2Conditions Restoring Factory Default Settings No b 0 8 and Monthly and Yearly Inspection Chart Item Inspected Check for Inspection Criteria Megger Test Spare parts Capacitor Life Curve General Inverter Electrical Measurements Circuit location Measuring Reference Value of measurement Single-phaseMeasurement Diagram Inverter Output Voltage Measurement Techniques IGBT Test Method Table Legend – Warranty Terms Glossary and Bibliography Appendix A A Appendix Insulated Gate Bipolar Transistor (IGBT) – A semiconductor Page Page Page Page ModBus Network Communications Specifications User-selectable B Appendix Appendix B Required must Required Settings ...ModBus network input Transmission procedure Message Configuration: Query Slave address: Data: Function code: Error check: Header and trailer (silent interval): Message Configuration: Response Transmission time required: Normal response: Response when an error occurs: •The content of the error is known from the exception code No response occurs: In the cases below, the inverter ignores a query and returns no response •When receiving a broadcasting query •When detecting a transmission error in reception of a query •When the data length of the query is invalid Explanation of function codes Read Coil Status [01h]: Read Holding Register [03h]: The data set in the response is as follows: Response Buffer Write in Coil [05h]: This function writes data in a single coil. Coil status changes are as follows: Coil Status When writing in a selected coil fails, see the exception response Write in Holding Register [06h]: This function writes data in a specified holding register. An example follows: Write “50Hz” as the first Loopback Test [08h]: B Appendix Writing in Holding Registers [10h]: This function writes data in consecutive holding registers. An example follows: Start address (high Start address (low Exception Response: Function Code Exception Code Store New Register Data (ENTER command) Submitting an ENTER Command: ModBus Coil List Coil Number register address offset • Name - The functional name of the coil • Description - The meaning of each of the states of the coils ModBus Data Listing List of Coil Numbers ModBus Holding Registers Function Code Register Range Page Note 1: Assume that the inverter current rating is 1000 (for D002) Holding Registers, “D” Group Monitor Functions Register Page Holding Registers, “F” Group Main Profile Parameters Holding Registers for “A” Group Standard Functions Page Page Page Page Page Page Page Page Page Page Page Note 1: Assume that the inverter current rating is 10000 (for B013/B213) Functions.I “C” Group Intelligent Terminal Functions See “Input Terminal Configuration” on page 3– See “Output Terminal Communication Settings” on page 3–58 See “Output Logic and Timing” on page 3–61 Note 1: Assume that the inverter current rating is 10000 (for C041) “H” Group Motor Constants Page Drive Parameter Settings Tables Inverter model L2002 MFG. No Appendix C Main Profile Parameters “F” Group Parameters Standard Functions “A” Group Parameters Page Page Page Fine Tuning Functions “B” Group Parameters Page Intelligent Terminal Functions “C” Group Parameters Page Motor Constants Functions “H” Group Parameters C Appendix Expansion Card Functions “P” Group Parameters CE–EMC Installation Guidelines Appendix D D Appendix L2002 inverter with footprint-typefilter Page Page Index