Hitachi SJ200 Series User manual

SJ200 Series Inverter
Instruction Manual
• Single-phase Input 200V Class
• Three-phase Input 200V Class
• Three-phase Input 400V Class
After reading this manual,
keep it handy for future reference.
Hitachi Industrial Equipment Systems Co., Ltd.
Manual Number: NB650XA
March 2004
Cover

SJ200 Inverter i
Safety Messages
For the best results with the SJ200 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 “Safety Alert Symbol” and a signal word or
phrase such as 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.
WARNING: Indicates a potentially hazardous situation that, if not avoided, can result in
serious injury or death.
CAUTION: Indicates a potentially hazardous situation that, 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 required to accomplish a goal. The
number of the step will be contained in the step symbol.
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!
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 Industrial Equipment Systems Co., 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.
WARNING: HAZARD OF ELECTRICAL SHOCK. DISCONNECT INCOMING
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 SJ200 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 Industrial
Equipment Systems Co., Ltd.
CAUTION: Be sure to connect a motor thermal disconnect switch or overload device to
the SJ200 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 five
(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 ground via two independent cables.

SJ200 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 earth ground via low resistive path (< 0.1Ω)
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 “Choosing a Mounting Location” on page 2–10. 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. Use 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 main
power 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 “Determining
Wire and Fuse Sizes” on page 2–18).
NOTE: The above instructions, together with any other requirements highlighted in this
manual, must be followed for continued LVD (European Low Voltage Directive)
compliance.
Terminal (ring lug) Cable support
Cable

iv
Index to Warnings and Cautions in This Manual
Cautions and Warnings for Orientation and Mounting Procedures
Wiring - Warnings for Electrical Practices and Wire Specifications
CAUTION: Hazard of electrical shock. Disconnect incoming power
before working on this control. Wait five (5) minutes before removing the
front cover.
....... 2–4
CAUTION: Be sure to install the unit on flame-resistant material such as
a steel plate. Otherwise, there is the danger of fire. ..... 2–10
CAUTION: Be sure not to place any flammable materials near the
inverter. Otherwise, there is the danger of fire. ..... 2–10
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.
..... 2–10
CAUTION: Be sure to install the inverter in a place that can bear the
weight according to the specifications in the text (Chapter 1, Specifica-
tions Tables). Otherwise, it may fall and cause injury to personnel.
..... 2–10
CAUTION: Be sure to install the unit on a perpendicular wall that is not
subject to vibration. Otherwise, it may fall and cause injury to personnel. ..... 2–10
CAUTION: Be sure not to install or operate an inverter that is damaged
or has missing parts. Otherwise, it may cause injury to personnel. ..... 2–10
CAUTION: Be sure to install the inverter in a well-ventilated room that
does not have direct exposure to sunlight, a tendency for high tempera-
ture, 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.
..... 2–10
CAUTION: Be sure to maintain the specified clearance area around the
inverter and to provide adequate ventilation. Otherwise, the inverter may
overheat and cause equipment damage or fire.
..... 2–11
WARNING: “Use 60/75°C Cu wire only” or equivalent. ..... 2–17
WARNING: “Open Type Equipment.” ..... 2–17
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.
..... 2–17

SJ200 Inverter v
Wiring - Cautions for Electrical Practices
WARNING: “Suitable for use on a circuit capable of delivering not more
than 5,000 rms symmetrical amperes, 480 V maximum.” For models with
suffix H.
.... 2–17
HIGH VOLTAGE: Be sure to ground the unit. Otherwise, there is a
danger of electric shock and/or fire. .... 2–17
HIGH VOLTAGE: Wiring work shall be carried out only by qualified
personnel. Otherwise, there is a danger of electric shock and/or fire. .... 2–17
HIGH VOLTAGE: Implement wiring after checking that the power
supply is OFF. Otherwise, you may incur electric shock and/or fire. .... 2–17
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.
.... 2–17
WARNING: Make sure the input power to the inverter is OFF. If the drive
has been powered, leave it OFF for five minutes before continuing. .... 2–23
CAUTION: Fasten the screws with the specified fastening torque in the
table below. Check for any loosening of screws. Otherwise, there is the
danger of fire.
.... 2–19
CAUTION: Be sure that the input voltage matches the inverter specifica-
tions: • Single/Three phase 200 to 240 V 50/60 Hz (up to 2.2kW) for
NFEF/NFU models • Three phase 200 to 240V 50/60Hz (above 2.2kW)
for LFU models • Three phase 380 to 480 V 50/60Hz for HFEF models
.... 2–20
CAUTION: Be sure not to power a three-phase-only inverter with single
phase power. Otherwise, there is the possibility of damage to the inverter
and the danger of fire.
.... 2–20
CAUTION: Be sure not to connect an AC power supply to the output
terminals. Otherwise, there is the possibility of damage to the inverter
and the danger of injury and/or fire.
.... 2–21
Power Input Output to Motor
SJ200 Inverter

vi
Powerup Test Caution Messages
CAUTION: Remarks for using ground fault interrupter breakers in the
main power supply: Adjustable 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 an inadvertent trip of ground fault interrupters. 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
ground fault interrupters with higher trigger current. • Other components
should be secured with separate ground fault interrupters. • Ground fault
interrupters in the power input wiring of an inverter are not an absolute
protection against electric shock.
..... 2–21
CAUTION: Be sure to install a fuse in each phase of the main power
supply to the inverter. Otherwise, there is the danger of fire. ..... 2–21
CAUTION: For motor leads, ground fault interrupter breakers and
electromagnetic contactors, be sure to size these components properly
(each must have the capacity for rated current and voltage). Otherwise,
there is the danger of fire.
..... 2–21
CAUTION: The heat sink fins will have a high temperature. Be careful
not to touch them. Otherwise, there is the danger of getting burned. ..... 2–24
CAUTION: The operation of the inverter can be easily changed from low
speed to high speed. Be sure to check the capability and limitations of the
motor and machine before operating the inverter. Otherwise, there is the
danger of injury.
..... 2–24
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 and/or injury.
.... 2–24,
..... 2–30
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
rotation correct? • Did the inverter trip during acceleration or decelera-
tion? • Were the rpm and frequency meter readings as expected? • Were
there any abnormal motor vibrations or noise?
..... 2–24

SJ200 Inverter vii
Warnings for Configuring Drive Parameters
Cautions for Configuring Drive Parameters
Warnings for Operations and Monitoring
WARNING: When parameter B012, level of electronic thermal setting, is
set to motor FLA rating (Full Load Ampere nameplate rating), the
inverter provides solid state motor overload protection at 115% of motor
FLA or equivalent. If parameter B012 exceeds the motor FLA rating, the
motor may overheat and be damaged. Parameter B012, level of electronic
thermal setting, is a variable parameter.
.... 3–32
CAUTION: Be careful to avoid specifying a braking time that is long
enough to cause motor overheating. If you use DC braking, we recom-
mend using a motor with a built-in thermistor, and wiring it to the
inverter’s thermistor input (see “Thermistor Thermal Protection” on
page 4–25). Also refer to the motor manufacturer’s specifications for
duty-cycle recommendations during DC braking.
.... 3–19
WARNING: Be sure to turn ON the input power supply only after closing
the front case. While the inverter is 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 electrical equipment 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 after a trip stop. Be sure to stop the inverter before approaching 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 Run
command 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 Stop Key separately from the emergency
stop. Otherwise, it may cause injury to personnel.
...... 4–3
WARNING: During a trip event, if the alarm reset is applied and the Run
command is present, the inverter will automatically restart. Be sure to
apply the alarm reset only after verifying the Run command is OFF.
Otherwise, it may cause injury to personnel.
...... 4–3

viii
Cautions for Operations and Monitoring
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: If power is turned ON when the Run command is already
active, the motor will automatically start and injury may result. Before
turning ON the power, confirm that the RUN command is not present.
....... 4–3
WARNING: When the Stop key function is disabled, pressing the Stop
key does not stop the inverter, nor will it reset a trip alarm. ....... 4–3
WARNING: Be sure to provide a separate, hard-wired emergency stop
switch when the application warrants it. ....... 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.
..... 4–12
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.
..... 4–24
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 if your
application exceeds the maximum current or voltage characteristics of a
connection point.
....... 4–4
CAUTION: Be sure to turn OFF power to the inverter before changing
the SR/SK switch position. Otherwise, damage to the inverter circuitry
may occur.
....... 4–9
CAUTION: Be careful not to turn PID Clear ON and reset the integrator
sum when the inverter is in Run Mode (output to motor is ON). Other-
wise, this could cause the motor to decelerate rapidly, resulting in a trip.
..... 4–28

SJ200 Inverter ix
Warnings and Cautions for Troubleshooting and Maintenance
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: Be sure to connect the grounding terminal to earth ground.
CAUTION: When inspecting the unit, be sure to wait five minutes after tuning OFF the
power supply before opening the cover.
WARNING: Wait at least five (5) minutes after turning OFF the input
power supply before performing maintenance or an inspection. Other-
wise, 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. Otherwise, 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
due to wire breakage and/or injury to personnel.
...... 6–2
CAUTION: Do not connect the megger to any control circuit terminals
such as intelligent I/O, analog terminals, etc. Doing so could cause
damage to the inverter.
.... 6–10
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.
.... 6–10
HIGH VOLTAGE: Be careful not to touch wiring or connector terminals
when working with the inverters and taking measurements. Be sure to
place the measurement circuitry components above in an insulated
housing before using them.
.... 6–14