LS Industrial Systems SV-iV5 Series User manual

i
Safety instructions
Thank you for purchasing LS Vector Drives!
SAFETY INSTRUCTIONS
To prevent injury and property damage, follow these instructions.
Incorrect operation due to ignoring instructions will cause harm or damage.
The seriousness of which is indicated by the following symbols.
WARNING
Do not remove the cover while power is applied or the unit is
in operation.
Otherwise, electric shock could occur.
Do not run the inverter with the front cover removed.
CAUTION This symbol indicates the possibility of
in
j
ur
y
or dama
g
e to
p
ro
p
ert
y
WARNING This symbol indicates the possibility of
death or serious injury
■The meanin
g
of each s
y
mbol in this manual and on
y
our equipment
is as follows.
This is the safety alert symbol.
Read and follow instructions carefully to avoid dangerous situation.
This symbol alerts the user to the presence of “dangerous voltage”
inside the product that might cause harm or electric shock.
■After reading this manual, keep it in the place that the user always
can contact easily.
■This manual should be given to the person who actually uses the
products and is responsible for their maintenance.
This symbol indicates the instant death or
serious injury if you don’t follow instructions
DANGER

ii
Safety instructions
Otherwise, you may get an electric shock due to high voltage termi-
nals or charged capacitor exposure.
Do not remove the cover except for periodic inspections or
wiring, even if the input power is not applied.
Otherwise, you may access the charged circuits and get an electric
shock.
Wiring and periodic inspections should be performed at
least 10 minutes after disconnecting the input power and af-
ter checking the DC link voltage is discharged with a meter
(below DC 30V).
Otherwise, you may get an electric shock.
Operate the switches with dry hands.
Otherwise, you may get an electric shock.
Do not use the cable when its insulating tube is damaged.
Otherwise, you may get an electric shock.
Do not subject the cables to scratches, excessive stress,
heavy loads or pinching.
Otherwise, you may get an electric shock.
CAUTION
Install the inverter on a non-flammable surface. Do not
place flammable material nearby.
Otherwise, fire could occur.
Disconnect the input power if the inverter gets damaged.
Otherwise, it could result in a secondary accident and fire.
After the input power is applied or removed, the inverter will
remain hot for a couple of minutes.
Otherwise, you may get bodily injuries such as skin-burn or damage.
Do not apply power to a damaged inverter or to an inverter
with parts missing even if the installation is complete.
Otherwise, electric shock could occur.
Do not allow lint, paper, wood chips, dust, metallic chips or

iii
Safety instructions
other foreign matter into the drive.
Otherwise, fire or accident could occur.
OPERATING PRECAUTIONS
1) Transport and Installation
zBe sure to carry inverter in a proper way suitable for its weight, or it may result
in damage to inverter.
zDo not pile up inverters above allowable limit.
zBe sure to install the inverter as directed in this instruction manual.
zDo not turn off the power supply to the damaged inverter.
zDo not open the front cover while carrying the inverter.
zDo not place the heavy material on the inverter.
zThe direction of installation should be observed properly as criterions specified
in this manual show.
zMake sure that you should not put screw, metal material, water, oil and the in-
flammable something else.
zKeep in mind that inverter is very vulnerable to drop from the mid air and strong
shock.
zBe certain to use the inverter under the following conditions.
Ambient temperature - 10 ~ 40 ℃ (Non-frozen)
Humidity Below 90% RH (Dewdrop should not be
formed)
Storage temperature - 20 ~ 65 ℃
Ambient condition Free of corrosive gas, inflammable gas, oil-
waste and dust
Environment
Altitude/vibration Below 1000m above sea level, Below
5.9m/sec²(=0.6g)
2) Wiring works
zDo not connect phase-leading capacitors, surge filter, radio noise filter to the
output of inverter.
zOutput terminals (terminals named U, V, W respectively) should be connected
in a proper phase sequence.
3) Adjustment before starting trial operation
zBe sure to check relevant parameters for the application before starting trial
operation.
4) Directions
zBe sure not to approach the machine when retry function is selected. The ma-
chine may start working suddenly.
zStop key on the keypad should be set to be in use. For safety, additional emer-
gency stop circuit should be required.
zInverter restarts if alarm condition is cleared while FX/RX signal is on. There-
fore, be sure to operate the alarm reset switch after checking if FX/RX signal is
off.
zNever modify the inverter for inappropriate use.
zMotor may not be protected by electronic thermal protection.

iv
Safety instructions
zDo not start or stop the inverter by the magnetic contactor installed at the in-
put of inverter.
zNoise filter should be used for the minimization of troubles by electro-
magnetic noise. Electronic equipments close to the inverter should be pro-
tected against the damage caused by troubles.
zBe sure to install the AC reactor at the input of inverter in case of input voltage
unbalance. Otherwise, generator or phase-leading capacitors may be destroyed
by the harmonic current from inverter.
zIf 400V class motor is used with the inverter, insulation-enforced motor should
be used or countermeasures against the suppression of micro-surge voltage
generated by the inverter should be carried out. Otherwise, micro-surge volt-
age is generated across input terminal for the motor and this voltage lowers al-
lowable insulation break-down voltage and then, may cause the destruction of
the motor.
zBe sure to set the parameters once more, in case of initialization of parameters,
all values of parameters is set to values of factory setting.
zHigh speed operation can be set easily, therefore be sure to check the perform-
ance of motor or machine before changing parameter value.
zDC braking function cannot produce a zero-servo torque. If required, additional
equipment should be installed.
zWhen inverter trip or emergency stop (BX) occurs without keypad connected,
LED on the control board will blink by the interval of 0.5 sec. But LED will blink
by 1 sec when keypad is connected.
5) Countermeasure against malfunction troubles
zIf inverter is damaged and then gets into uncontrollable situation, the machine
may lead to the dangerous situation, therefore to avoid this situation, be sure
to install the additional equipments such as brake.
6) Maintenance, inspection and parts replacement
zDo not perform the megger (insulation resistance check) test on the control
board.
zPlease refer to Chapter 7 (intervals for parts replacement).
7) Disposal
z Handle the inverter as an industrial waste when disposing of it.
8) General instructions
Many of the diagrams and drawings in this instruction manual show the inverter without
a circuit breaker, a cover or partially open. Never run the inverter like this. Always place
the cover with circuit breakers and follow this instruction manual when operating the
inverter.

v
Table of Contents
Safety Instructions ----------------------------------------------------------------------------------------------------------- i
Chapter
1 Introduction
1.1 Key features --------------------------------------------------------------------------------------------- 1
1.2 Inverter nameplate and model ------------------------------------------------------------------------ 2
Chapter
2 Specifications
2.1 Standard specification ----------------------------------------------------------------------------------- 3
2.2 Common specification ---------------------------------------------------------------------------------- 4
Chapter
3 Installation and wiring
3.1 Wiring precaution --------------------------------------------------------------------------------------- 5
3.2 Basic wiring ---------------------------------------------------------------------------------------------- 7
3.3 Power circuit terminal ---------------------------------------------------------------------------------- 9
3.4 Control circuit terminal --------------------------------------------------------------------------------- 14
3.4.1 Control terminal layout ---------------------------------------------------------------------------- 14
3.4.2 Control terminal description ---------------------------------------------------------------------- 14
3.4.3 Wiring Control terminal --------------------------------------------------------------------------- 16
3.4.4 Caution on Encoder wiring ----------------------------------------------------------------------- 16
3.4.5 Wiring and jumper setting for Complementary or Open Collector -------------------------- 17
3.4.6 Wiring and jumper setting for Line Drive ------------------------------------------------------- 17
3.4.7 Jumper setting for Analog Input ---------------------------------------------------------------- 18
Chapter
4 Trial Operation
4.1 Keypad description -------------------------------------------------------------------------------------- 19
4.2 Keypad display description ---------------------------------------------------------------------------- 20
4.3 Setting of Parameter values --------------------------------------------------------------------------- 21
4.4 Parameter group ---------------------------------------------------------------------------------------- 22
4.5 Auto-Tuning ---------------------------------------------------------------------------------------------- 24
4.5.1 Motor and Encoder parameter setting ---------------------------------------------------------- 24
4.5.2 Rotational Auto-tuning ---------------------------------------------------------------------------- 25
4.5.3 Standstill Auto-tuning ----------------------------------------------------------------------------- 27
4.6 Pulse encoder check ------------------------------------------------------------------------------------ 28
4.7 Operation by Keypad ----------------------------------------------------------------------------------- 29
4.8 Operation by Terminal ---------------------------------------------------------------------------------- 30
Chapter
5 Parameter List
5.1 Display group (DIS_[][]) ------------------------------------------------------------------------------- 33
5.2 Input/output group (I/O_[][]) ------------------------------------------------------------------------ 34
5.3 Parameter group (PAR_[][]) --------------------------------------------------------------------------- 37
5.4 Function group (FUN_[][]) ---------------------------------------------------------------------------- 38
5.5 Control group (CON_[][]) ------------------------------------------------------------------------------ 39
5.6 User group (USR_[][]) --------------------------------------------------------------------------------- 40
5.7 2nd function group (2nd_[][]) ------------------------------------------------------------------------- 41
Chapter
6 Parameter description
6.1 Display group (DIS_[][]) ------------------------------------------------------------------------------- 42
6.1.1 DIS_00(Motor control status monitoring) ------------------------------------------------------ 42
6.1.2 DIS_01 ~ 03(user display 1, 2, 3) -------------------------------------------------------------- 42
6.1.3 DIS_04(Process PID Controller) ----------------------------------------------------------------- 44
6.1.4 DIS_05(Fault display) ----------------------------------------------------------------------------- 44
6.1.5 DIS_06(User group display selection) ---------------------------------------------------------- 45

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Table of Contents
6.2 Input/output group (I/O_[][]) ------------------------------------------------------------------------ 46
6.2.1 Jump code (I/O_00) ------------------------------------------------------------------------------- 46
6.2.2 Multi-function Input Terminal -------------------------------------------------------------------- 46
1) I/O_01 ~ 07(Multi-function input terminal P1 ~ P7 define) ------------------------------- 46
2) I/O_08(Reversal of Multi-function input terminal) ------------------------------------------ 57
3) I/O_09(Low Pass Filter Time Constant for the Terminals) --------------------------------- 57
4) I/O_10Inversion of Multi-function aux contact output ------------------------------------- 57
6.2.3 Multi-function analog input ----------------------------------------------------------------------- 58
1) I/O_11 ~ 25
(Definition of Multi-function analog input terminal, Gain, Bias, LPF time constant) ------ 58
2) Adjusting Gain and Bias by Keypad ----------------------------------------------------------- 60
6.2.4 Multi Function Outputs (MFO) ------------------------------------------------------------------- 61
1) I/O_41 ~ 43
(Multi-function aux contact output (AX1 ~ AX2) and Open collector (OC1) output setting----- 61
2) I/O_46(Fault Output Relay (30A, 30B, 30C)) ----------------------------------------------- 66
3) I/O_59 ~ 61(Overload trip enable, level, time) --------------------------------------------- 66
6.2.5 Analog output -------------------------------------------------------------------------------------- 66
6.3 3 Parameter group (PAR_[][]) ------------------------------------------------------------------------ 68
6.3.1 Jump code (PAR_00) ------------------------------------------------------------------------------ 68
6.3.2 Parameter group function ------------------------------------------------------------------------ 68
1) PAR_01(Parameter initialize) ------------------------------------------------------------------ 68
2) PAR_02 ~ 03(All Parameter Read/Write) ----------------------------------------------------- 68
3) PAR_04(Parameter Lock) ----------------------------------------------------------------------- 69
4) PAR_05(Password) ------------------------------------------------------------------------------- 69
6.3.3 Motor parameters setting ------------------------------------------------------------------------- 70
1) PAR_07(Motor rating setting), PAR_08(Motor cap. Selection of user) ------------------- 70
2) PAR_09(Motor Cooling method) --------------------------------------------------------------- 70
3) PAR_10 ~ 13(pulse number of Encoder, direction, Error detection, LPF) ------------------ 70
6.3.4 PAR_14, PAR_15(Encoder error detection time, encoder error reference speed) -------- 71
6.3.5 Auto-tuning ----------------------------------------------------------------------------------------- 73
1) Motor and Encoder parameters setting for Auto-tuning ------------------------------------ 73
2) Rotational Auto-tuning -------------------------------------------------------------------------- 74
3) Standstill Auto-tuning --------------------------------------------------------------------------- 76
4) Motor parameters -------------------------------------------------------------------------------- 78
5) Auto tuning error message --------------------------------------------------------------------- 79
6.4 Function group (FUN_[][]) ---------------------------------------------------------------------------- 81
6.4.1 Jump code (FUN_00) ------------------------------------------------------------------------------ 81
6.4.2 Operating method select -------------------------------------------------------------------------- 81
1) FUN_01(RUN/STOP source select) ----------------------------------------------------------- 81
2) FUN_02(Speed setting method) --------------------------------------------------------------- 82
3) FUN_03(Stop method) ------------------------------------------------------------------------- 82
6.4.3 FUN_04(Motor Max Speed Reference) ---------------------------------------------------------- 82
6.4.4 Multi-step speed and Dwell Speed setting methods ------------------------------------------ 82
1) FUN_12 ~ 19(Multi-step speed 0 ~ 7) -------------------------------------------------------- 82
2) FUN_20(JOG speed command) ---------------------------------------------------------------- 82
3) FUN_21 ~ FUN_22(Dwell Speed, Time) ------------------------------------------------------ 83
6.4.5 Accel/Decel pattern and time selection --------------------------------------------------------- 84
1) FUN_33(Accel/Decel reference speed) -------------------------------------------------------- 84
2) FUN_40 ~ 47(Accel/Decel time 1 ~ 4) ------------------------------------------------------- 84
3) FUN_36 ~ 39(S curve ratio during Accel/Decel 1 ~ 2) ------------------------------------- 85
4) FUN_48(Deceleration time for zero speed selection) --------------------------------------- 87
5) FUN_49(Zero speed deceleration time) ------------------------------------------------------- 87
6) FUN_51(Decel time when BX is ON) ---------------------------------------------------------- 88
7) FUN_52(Pre-excitation) ------------------------------------------------------------------------- 88
8) FUN_53(Hold Time) ---------------------------------------------------------------------------- 88
6.4.6 Electronic Thermal (Motor
I
T
2) Selection ---------------------------------------------------- 89

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Table of Contents
6.4.7 Inverter switching frequency select ------------------------------------------------------------- 90
1) FUN_57(Inverter switching frequency select) ----------------------------------------------- 90
2) Setting range and factory setting of switching frequency --------------------------------- 90
6.4.8 Power ON Start Selection (FUN_58) ------------------------------------------------------------ 91
6.4.9 Restart after fault reset (FUN_59) ------------------------------------------- ------------------- 91
6.4.10 Restart After Fault Reset ------------------------------------------------------------------------ 92
1) FUN_60(Number of auto restart try) ---------------------------------------------------------- 92
2) FUN_61(Delay time before Auto restart) ----------------------------------------------------- 92
6.4.11 Wait time for restart upon stop ---------------------------------------------------------------- 93
6.4.12 Overspeed error detection (FUN_63,FUN_64) ----------------------------------------------- 93
6.5 Control group (CON_[][]) ------------------------------------------------------------------------------ 94
6.5.1 Jump code (CON_00) ----------------------------------------------------------------------------- 94
6.5.2 Control mode select (CON_01) ------------------------------------------------------------------ 94
6.5.3 Application mode (CON_02) ---------------------------------------------------------------------- 94
6.5.4 Automatic Speed Regulator : ASR --------------------------------------------------------------- 94
1) CON_05(ASR LPF Time Constant 1) -------------------------------------------------------- 94
2) CON_08(ASR LPF Time Constant 2) -------------------------------------------------------- 94
3) CON_03 ~ 04(ASR PI Gain 1) ------------------------------------------------------------------ 95
4) CON_06 ~ 07(ASR PI Gain 2) ------------------------------------------------------------------ 95
5) CON_09(Ramp time for ASR gain Transfer) ------------------------------------------------- 95
6) CON_10(Motor Speed at the time of ASR Gain Transfer) ---------------------------------- 95
6.5.5 Process PID Control ------------------------------------------------------------------------------- 97
6.5.6 Draw Control ---------------------------------------------------------------------------------------- 99
6.5.7 Droop Control --------------------------------------------------------------------------------------- 101
6.5.8 Torque Control -------------------------------------------------------------------------------------- 103
1) CON_26(Torque Reference Source Selection) ----------------------------------------------- 103
2) CON_32(Torque Bias Source select) ---------------------------------------------------------- 103
3) CON_35(Torque Balance) ---------------------------------------------------------------------- 104
4) Torque Bias Enable/Disable --------------------------------------------------------------------- 104
5) CON_34(Torque Bias F/F) ---------------------------------------------------------------------- 104
6) CON_28 ~ 31
(Torque Limit Define, Torque Limit during FWD RUN /REV RUN/Regenerating) ----------- 104
7) Torque Current reference ----------------------------------------------------------------------- 105
6.5.9 Speed Search (CON_49) -------------------------------------------------------------------------- 106
6.6 User group (USR_[][]) --------------------------------------------------------------------------------- 107
6.6.1 Jump code (USR_00) ------------------------------------------------------------------------------ 107
6.6.2 Macro ------------------------------------------------------------------------------------------------ 107
1) USR_01(Macro Init) ------------------------------------------------------------------------------ 107
2) USR_02(User Save) ------------------------------------------------------------------------------ 107
3) USR_03(User Recall) ---------------------------------------------------------------------------- 107
6.6.3 User code define (USR_04 ~ 67) -------------------------------------------------------------- 107
6.7 2nd group (2nd_[][]) ----------------------------------------------------------------------------------- 109
6.7.1 Jump code (2nd_00) ------------------------------------------------------------------------------- 109
6.7.2 2nd motor control mode selection (2nd_01) --------------------------------------------------- 109
6.7.3 2nd motor speed setting -------------------------------------------------------------------------- 109
6.7.4 2nd motor parameters related to acceleration and deceleration ---------------------------- 110
6.7.5 2nd motor parameters related to the pulse encoder ----------------------------------------- 110
6.7.6 2nd motor parameters ---------------------------------------------------------------------------- 110
6.7.7 2nd motor miscellaneous parameters ----------------------------------------------------------- 110

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Table of Contents
Chapter
7 Periodic inspection
7.1 Precautions ----------------------------------------------------------------------------------------------- 111
7.2 Check points --------------------------------------------------------------------------------------------- 111
7.3 Parts replacement --------------------------------------------------------------------------------------- 112
Chapter
8 Troubleshooting and maintenance
8.1 Fault display --------------------------------------------------------------------------------------------- 113
8.2 Fault status and history -------------------------------------------------------------------------------- 114
8.3 Fault reset ------------------------------------------------------------------------------------------------ 114
8.4 Troubleshooting ----------------------------------------------------------------------------------------- 115
Appendix
A Accessories ------------------------------------------------------------------------------------------------- 125
B Dimensions ------------------------------------------------------------------------------------------------- 127
C Encoder division option card ---------------------------------------------------------------------------- 132
D Braking resistor and braking unit ----------------------------------------------------------------------- 134
E Control block diagram ------------------------------------------------------------------------------------ 136

1
1. Introduction
Chapter 1 - Introduction
1.1 Key Features
zCurrent Controlled Vector Control Inverter with Speed Sensor using IGBT as Power Semiconductor Device.
zTension/Torque Control and Wide Variety of Process Control
zProcess PI Control, Draw Control, Droop Control etc.
zAuto-tuning of Motor Parameters for Precise Speed/Torque Control: Rotational/Standstill mode
zEncoder error (H/W and S/W) detection function
zInverter Application
Application Applicable Machine/System Features
zSteel Strip Tension Control
zPaper Mill Wide Range of Speed
Control
zTextile
zFilm
zCoater
Process Control
zPrinting Machine
zLifts (Elevators) High Speed Operation
zParking High Starting Torque
Positioning
zStacker Crane Wide Range of Speed
Control
zCrane
Hoisting Control
zHoist
zMachine Tool High Speed Operation
zWire Drawing High Starting Torque
Machine Control
zExtruder Positioning
zConveyor High Speed Operation
Others zIndustrial Washing Machine Positioning
This instruction manual is designed for LS STARVERT-iV5 series Vector Control
Inverters, which have excellent characteristics in speed and torque control with pulse
encoder mounted on the shaft of 3 phase induction motor, and covers installation,
maintenance, wiring and operation for these inverters.