Hitachi SJ100 Series User manual

SJ100 Inverter i
Safety Messages
For the best results with the SJ100 Series inverter, carefully read this manual and all of
the warning labels attached to the inverter before installing and operating it, and follow
the instructions exactly. Keep this manual handy for quick reference.
Definitions and Symbols
A safety instruction (message) includes a hazard alert symbol and a signal word,
WARNING or CAUTION. Each signal word has the following meaning:
HIGH VOLTAGE: This symbol indicates high voltage. It calls your attention to items
or operations that could be dangerous to you and other persons operation this equipment.
Read the message and follow the instructions carefully.
This symbol is the “Safety Alert Symbol.” It occurs with either of two signal words:
CAUTION or WARNING, as described below.
WARNING: Indicates a potentially hazardous situation which, if not avoided, can result
in serious injury or death.
CAUTION: Indicates a potentially hazardous situation which, if not avoided, can result
in minor to moderate injury, or serious damage to the product. The situation described in
the CAUTION may, if not avoided, lead to serious results. Important safety measures
are described in CAUTION (as well as WARNING), so be sure to observe them.
1 Step 1: Indicates a step in a series of action steps to accomplish a goal.
NOTE: Notes indicate an area or subject of special merit, emphasizing either the
product’s capabilities or common errors in operation or maintenance.
TIP: Tips give a special instruction that can save time or provide other benefits while
installing or using the product. The tip calls attention to an idea that may not be obvious
to first-time users of the product.
Hazardous High Voltage
HIGH VOLTAGE: Motor control equipment and electronic controllers are connected to
hazardous line voltages. When servicing drives and electronic controllers, there may be
exposed components with housings or protrusions at or above line potential. Extreme
care should be taken to protect against shock.
Stand on an insulating pad and make it a habit to use only one hand when checking com-
ponents. Always work with another person in case an emergency occurs. Disconnect
power before checking controllers or performing maintenance. Be sure equipment is
properly grounded. Wear safety glasses whenever working on electronic controllers or
rotating machinery.

ii General Precautions - Read These First!
General Precautions - Read These First!
WARNING: This equipment should be installed, adjusted, and serviced by qualified
electrical maintenance personnel familiar with the construction and operation of the
equipment and the hazards involved. Failure to observe this precaution could result in
bodily injury.
WARNING: The user is responsible for ensuring that all driven machinery, drive train
mechanism not supplied by Hitachi, Ltd., and process line material are capable of safe
operation at an applied frequency of 150% of the maximum selected frequency range to
the AC motor. Failure to do so can result in destruction of equipment and injury to
personnel should a single-point failure occur.
WARNING: For equipment protection, install a ground leakage type breaker with a fast
response circuit capable of handling large currents. The ground fault protection circuit is
not designed to protect against personal injury.
HIGH VOLTAGE: HAZARD OF ELECTRICAL SHOCK. DISCONNECT INCOM-
ING POWER BEFORE WORKING ON THIS CONTROL.
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.
CAUTION: These instructions should be read and clearly understood before working
on SJ100 series equipment.
CAUTION: Proper grounds, disconnecting devices and other safety devices and their
location are the responsibility of the user and are not provided by Hitachi, Ltd.
CAUTION: Be sure to connect a motor thermal cutoff switch or overload device to the
SJ100 series controller to assure that the inverter will shut down in the event of an
overload or an overheated motor.
HIGH VOLTAGE: Dangerous voltage exists until power light is off. Wait at least 5
minutes after input power is disconnected before performing maintenance.
WARNING: This equipment has high leakage current and must be permanently(fixed)
hard-wired to earth via two independent cables.

SJ100 Inverter iii
WARNING: Rotating shafts and above-ground electrical potentials can be hazardous.
Therefore, it is strongly recommended that all electrical work conform to the National
Electrical Codes and local regulations. Installation, alignment and maintenance should
be performed only by qualified personnel.
Factory-recommended test procedures included in the instruction manual should be
followed. Always disconnect electrical power before working on the unit.
CAUTION:
a) Class I motor must be connected to protective earth via low resistive path (< 0.1ohm)
b) Any motor used must be of a suitable rating.
c) Motors may have hazardous moving parts. In this event suitable protection must be
provided.
CAUTION: Alarm connection may contain hazardous live voltage even when inverter is
disconnected. When removing the front cover for maintenance or inspection, confirm
that incoming power for alarm connection is completely disconnected.
CAUTION: Hazardous (main) terminals for any interconnection (motor, contact
breaker, filter, etc.) must be inaccessible in the final installation.
CAUTION: This equipment should be installed in IP54 or equivalent (see EN60529)
enclosure. The end application must be in accordance with BS EN60204-1. Refer to the
section on inverter mounting, starting on page 2–6. The diagram dimensions are to be
suitably amended for your application.
CAUTION: Connection to field wiring terminals must be reliably fixed having two
independent means of mechanical support. Using a termination with cable support
(figure below), or strain relief, cable clamp, etc.
CAUTION: A double-pole disconnection device must be fitted to the incoming mains
supply close to the inverter. Additionally, a protection device meeting IEC947-1/
IEC947-3 must be fitted at this point (protection device data shown in page 2–13).
NOTE: The above instructions, together with any other requirements are highlighted in
this manual, and must be followed for continued LVD (European Low Voltage Directive)
compliance.
Terminal (spade lug) Cable support
Cable

iv Precautions for EMC (Electromagnetic Compatibility)
Precautions for EMC (Electromagnetic Compatibility)
You are required to satisfy the EMC directive (89/336/EEC) when using an SJ100
inverter in a European country. To satisfy the EMC directive and to comply with
standard, follow the checklist below.
WARNING: This equipment should be installed, adjusted, and serviced by qualified
personal familiar with construction and operation of the equipment and the hazards
involved. Failure to observe this precaution could result in bodily injury.
1. The power supply to SJ100 inverter must meet these specifications:
a. Voltage fluctuation+/- 10% or less
b. Voltage imbalance +/- 3% or less
c. Frequency variation +/- 4% or less
d. Voltage distortion THD = 10% or less
2. Installation measure:
a. Use a filter designed for SJ100 inverter
3. Wiring:
a. Shielded wire (screened cable) is required for motor wiring, and the length must
be less than 50 meters.
b. The carrier frequency setting must be less than 5 kHz to satisfy EMC require-
ments.
c. Separate the main circuit from the signal/process circuit wiring.
4. Environmental conditions - when using a filter, follow these guidelines:
a. Ambient temperature: -10 to 40 °C
b. Humidity: 20 to 90% RH (non-condensing)
c. Vibration: 5.9 m/sec2(0.6 G) 10 ~ 55Hz
d. Location: 1000 meters or less altitude, indoors (no corrosive gas or dust)

SJ100 Inverter v
Index to Warnings and Cautions in This Manual
Installation - Cautions for Mounting Procedures
Wiring - Warnings for Electrical Practices and Wire Specifications
CAUTION: Be sure to install the unit on flame-resistant material
such as a steel plate. Otherwise, there is the danger of fire. ........... 2–6
CAUTION: Be sure not to place any flammable materials near the
inverter. Otherwise, there is the danger of fire. ........... 2–6
CAUTION: Be sure not to let the foreign matter enter vent openings
in the inverter housing, such as wire clippings, spatter from welding,
metal shavings, dust, etc. Otherwise, there is the danger of fire.
........... 2–6
CAUTION: Be sure to install the inverter in a place which can bear
the weight according to the specifications in the text (Chapter 1,
Specifications Tables). Otherwise, it may fall and cause injury to per-
sonnel.
........... 2–6
CAUTION: Be sure to install the unit on a perpendicular wall which
is not subject to vibration. Otherwise, it may fall and cause injury to
personnel.
........... 2–6
CAUTION: Be sure not to install or operate an inverter which is
damaged or has missing parts. Otherwise, it may cause injury to per-
sonnel.
........... 2–6
CAUTION: Be sure to install the inverter in a well-ventilated room
which does not have direct exposure to sunlight, a tendency for high
temperature, high humidity or dew condensation, high levels of dust,
corrosive gas, explosive gas, inflammable gas, grinding-fluid mist,
salt damage, etc. Otherwise, there is the danger of fire.
........... 2–6
WARNING: “Use 60/75°C Cu wire only” or equivalent. ......... 2–12
WARNING: “Open Type Equipment.” ......... 2–12
WARNING: “A Class 2 circuit wired with Class 1 wire” or equiva-
lent. ......... 2–12
WARNING: “Suitable for use on a circuit capable of delivering not
more than 5,000 rms symmetrical amperes, 240 V maximum.” For
models with suffix N or L.
......... 2–12

vi Index to Warnings and Cautions in This Manual
Wiring - Cautions for Electrical Practices
WARNING: “Suitable for use on a circuit capable of delivering not
more than 5,000 rms symmetrical amperes, 240 V maximum.” For
models with suffix N or L.
........ 2–12
HIGH VOLTAGE: Be sure to ground the unit. Otherwise, there is a
danger of electric shock and/or fire. ........ 2–12
HIGH VOLTAGE: Wiring work shall be carried out only by quali-
fied personnel. Otherwise, there is a danger of electric shock and/or
fire.
........ 2–12
HIGH VOLTAGE: Implement wiring after checking that the power
supply is off. You may incur electric shock and/or fire. ........ 2–12
HIGH VOLTAGE: Do not connect wiring to an inverter or operate
an inverter that is not mounted according the instructions given in
this manual. Otherwise, there is a danger of electric shock and/or
injury to personnel.
........ 2–12
WARNING: Make sure the input power to the inverter is off. If the
drive has been powered, leave it off for five minutes before continu-
ing.
........ 2–16
CAUTION: Be sure that the input voltage matches the inverter
specifications: • Single/Three phase 200 to 240 V 50/60 Hz (up to
2.2kW) • Three phase 200 to 230V 50/60Hz (above 2.2kW) • Three
phase 380 to 460 V 50/60Hz
........ 2–14
CAUTION: Be sure not to input a single phase to a three-phase-
only type inverter. Otherwise, there is the danger of fire. ........ 2–14
CAUTION: Be sure not to connect an AC power supply to the
output terminals. Otherwise, there is the danger of injury and/or
fire.
........ 2–14
Power Input Power Output
L1 L2 L3
T1 T2 T3
UVW
(L) (N)
NOTE:
L, N:
L1, L2, L3:Single-phase 200 to 240V 50/60 Hz Three-phase 200 to 240V 50/60 Hz
Three-phase 380 to 460V 50/60 Hz

SJ100 Inverter vii
Powerup Test Caution Messages
CAUTION: Fasten the screws with the specified fastening torque
(see the following table). Check for any loosening of screws. Other-
wise, there is the danger of fire.
......... 2–15
CAUTION: Remarks for using earth leakage circuit breakers in the
mains supply: Frequency inverters with CE-filters (RFI-filter) and
shielded (screened) motor cables have a higher leakage current
toward Earth GND. Especially at the moment of switching on this
can cause inadvertent tripping of earth leakage circuit breakers.
Because of the rectifier on the input side of the inverter there is the
possibility to stall the switch-off function through small amounts of
DC current. Please observe the following: • Use only short time-
invariant and pulse current-sensitive earth leakage circuit breakers
with higher trigger current. • Other components should be secured
with separate earth leakage circuit breakers. • Earth leakage circuit
breakers in the power input wiring of an inverter are not an absolute
protection against electric shock by direct touching.
......... 2–15
CAUTION: Be sure to install a fuse in the wire for each phase of
the main power supply to the inverter. Otherwise, there is the
danger of fire.
......... 2–15
CAUTION: For motor leads, earth leakage breakers and electro-
magnetic contactors, be sure to size these components properly
(each must have the capacity for rated current and voltage). Other-
wise, there is the danger of fire.
......... 2–15
CAUTION: The heat sink fins will have a high temperature. Be
careful not to touch them. Otherwise, there is the danger of getting
burned.
......... 2–17
CAUTION: The operation of the inverter can be easily changed
from low speed to high speed. Be sure check the capability and
limitations of the motor and machine before operating the inverter.
Otherwise, there is the danger of injury.
......... 2–17
CAUTION: If you operate a motor at a frequency higher than the
inverter standard default setting (50Hz/60Hz), be sure to check the
motor and machine specifications with the respective manufacturer.
Only operate the motor at elevated frequencies after getting their
approval. Otherwise, there is the danger of equipment damage.
......... 2–18
CAUTION: Check the following before and during the powerup
test. Otherwise, there is the danger of equipment damage. • Is the
shorting bar between the +1 and + terminals installed? DO NOT
power or operate the inverter if the jumper is removed. • Is the
direction of the motor correct? • Did the inverter trip during acceler-
ation or deceleration? • Were the rpm and frequency meter readings
as expected? • Were there any abnormal motor vibrations or noise?
......... 2–18

viii Index to Warnings and Cautions in This Manual
Warnings for Operations and Monitoring
WARNING: Be sure to turn on the input power supply after closing
the front case. While being energized, be sure not to open the front
case. Otherwise, there is the danger of electric shock.
.......... 4–3
WARNING: Be sure not to operate the switches with wet hands.
Otherwise, there is the danger of electric shock. .......... 4–3
WARNING: While the inverter is energized, be sure not to touch
the inverter terminals even when the motor is stopped. Otherwise,
there is the danger of electric shock.
.......... 4–3
WARNING: If the Retry Mode is selected, the motor may suddenly
restart during the trip stop. Do not approach the machine (be sure to
design the machine so that safety for personnel is secure even if it
restarts.) Otherwise, it may cause injury to personnel.
.......... 4–3
WARNING: If the power supply is cut off for a short period of time,
the inverter may restart operation after the power supply recovers if
the command to operate is active. If a restart may pose danger to
personnel, so be sure to use a lock-out circuit so that it will not
restart after power recovery. Otherwise, it may cause injury to
personnel.
.......... 4–3
WARNING: The Stop Key is effective only when the Stop function
is enabled. Be sure to enable the Key separately from the
emergency stop. Otherwise, it may cause injury to personnel.
.......... 4–3
WARNING: After the operation command is given, if the alarm
reset is conducted, it will restart suddenly. Be sure to set the alarm
reset after verifying the operation command is off. Otherwise, it
may cause injury to personnel.
.......... 4–3
WARNING: Be sure not to touch the inside of the energized
inverter or to put any conductive object into it. Otherwise, there is a
danger of electric shock and/or fire.
.......... 4–3
WARNING: When the power is turned on when the running
command is already active, the motor will suddenly start rotation
and is dangerous. Before turning the power on, confirm that the
running command is not enabled.
.......... 4–3
WARNING: When the Stop key function is disabled, pressing the
Stop key does not cancel the stop and trip. .......... 4–3
WARNING: Be sure to provide a separate, hard-wired emergency
stop switch. When the operation command source is a digital opera-
tor, this selection is ineffective.
.......... 4–3
WARNING: If the power is turned on and the Run command is
already active, the motor starts rotation and is dangerous! Before
turning power on, confirm that the Run command is not active.
.......... 4–6

SJ100 Inverter ix
Cautions for Operations and Monitoring
Warnings and Cautions for Troubleshooting and Maintenance
WARNING: After the Reset command is given and the alarm reset
occurs, the motor will restart suddenly if the Run command is
already active. Be sure to set the alarm reset after verifying that the
Run command is off to prevent injury to personnel.
......... 4–18
WARNING: You may need to disconnect the load from the motor
before performing auto-tuning. The inverter runs the motor forward
and backward for several seconds without regard to load movement
limits.
......... 4–30
CAUTION: The heat sink fins will have a high temperature. Be
careful not to touch them. Otherwise, there is the danger of getting
burned.
........... 4–2
CAUTION: The operation of the inverter can be easily changed
from low speed to high speed. Be sure check the capability and
limitations of the motor and machine before operating the inverter.
Otherwise, it may cause injury to personnel.
........... 4–2
CAUTION: If you operate a motor at a frequency higher than the
inverter standard default setting (50Hz/60Hz), be sure to check the
motor and machine specifications with the respective manufacturer.
Only operate the motor at elevated frequencies after getting their
approval. Otherwise, there is the danger of equipment damage.
........... 4–2
CAUTION: It is possible to damage the inverter or other devices in
your application if the maximum current or voltage characteristics
of a connection point are exceeded.
........... 4–4
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.
........... 6–2
WARNING: Make sure that only qualified personnel will perform
maintenance, inspection, 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. Other-
wise, there is a danger of electric shock and/or injury to personnel.
........... 6–2
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 or injury due to wire breakage.
........... 6–2
CAUTION: When removing connectors, never pull the wires (wires
for the cooling fan and logic P.C. board. Otherwise, there is danger
of fire due to wire breakage and/or injury to personnel.
........... 6–2

xGeneral Warnings and Cautions
General Warnings and Cautions
WARNING: Never modify the unit. Otherwise, there is a danger of electric shock and/
or injury.
CAUTION: Withstand voltage tests and insulation resistance tests (HIPOT) are
executed before the units are shipped, so there is no need to conduct these tests before
operation.
CAUTION: Do not attach or remove wiring or connectors when power is applied. Also,
do not check signals during operation.
CAUTION: Do not stop operation by switching off electromagnetic contactors on the
primary or secondary sides of the inverter.
When there has been a sudden power failure while an operation instruction is active, then
the unit may restart operation automatically after the power failure has ended. If there is
a possibility that such an occurrence may harm humans, then install an electromagnetic
contactor (Mgo) on the power supply side, so that the circuit does not allow automatic
restarting after the power supply recovers. If the optional remote operator is used and
the retry function has been selected, this will also cause automatic restarting when an
operation instruction is active. So, please be careful.
CAUTION: Never test the withstand voltage (HIPOT) on the
inverter. The inverter has a surge protector between the main circuit
terminals above and the chassis ground.
........ 6–12
HIGH VOLTAGE: Be careful not to touch wiring or connector
terminals when working with the inverters and taking measure-
ments. Be sure to place the measurement circuitry above in an
insulated housing before using them.
........ 6–13
Power
Input
Inverter
L1, L2, L3
Earth leakage
breaker
U, V, W Motor
P24
FW