Saftronics VG520P4 User manual

www.saftronics.com
TECHNICAL MANUAL
VG5
REV2 (9/98)
P/N 027-2040
1998

PREFACE
Firmware – S1043
Revision: 2 (9/98) i© Saftronics, Inc.
The VG5 Series of general-purpose Inverters provides V/f Control and Vector Control as standard features along with user-friendly operation.
This manual is designed to ensure correct and suitable application of the VG5 Series Inverters. Read this manual before attempting to install,
operate, maintain, or inspect an Inverter and keep it in a safe, convenient location for future reference. Make sure you understand all
precautions and safety information before attempting any application.
Saftronics, 1998
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, or by any means,
mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of Saftronics. No patent liability is assumed
with respect to the use of the information contained herein. Moreover, because Saftronics is constantly striving to improve its high-quality
products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the preparation of
this manual. Nevertheless, Saftronics assumes no responsibility for errors or omissions. Neither is any liability assumed for damages
resulting from the use of the information contained in this publication.

PREFACE
Firmware – S1043
Revision: 2 (9/98) ii © Saftronics, Inc.
Safety Information
The following conventions are used to indicate precautions in this manual. Failure to follow the precautions provided in this manual can result
in serious or possible even fatal injury or damage to the products or to related equipment and systems.
WARNING Indicates precautions that, if not followed, could possibly result in loss of life or serious injury.
CAUTION Indicates precautions that, if not followed, could result in serious injury, damage to the product,
or faulty operation.
The warning symbols for ISO and JIS standards are different, as shown below.
ISO JIS
The ISO symbol is used in this manual. Both of these symbols appear on warning labels on Saftronics products. Please abide by these
warning labels regardless of which symbol is used.
Visual Aids
The following aids are used to indicate certain types of information for easier reference.
‘‘EXAMPLE•• Indicates application examples.
NOTE: Indicates important information that should be memorized.
General Precautions
•The diagrams in this manual may be indicated without covers or safety shields to show details. Be sure to restore covers or shields
before operating the units and run the units according to the instructions described in this manual.
•Any illustrations, photographs, or examples used in this manual are provided as examples only and may not apply to all products to
which this manual is applicable.
•The products and specifications described in this manual or the content and presentation of the manual may be changed without notice
to improve the product and/or the manual.
•When ordering a new copy of the manual due to damage or loss, contact your Saftronics representatives or the nearest Saftronics sales
office and provide the manual number shown on the front cover.
•If nameplates become warn or damaged, order new ones from your Saftronics representatives or the nearest Saftronics sales office.

PREFACE
Firmware – S1043
Revision: 2 (9/98) iii © Saftronics, Inc.
Safety Precautions
§Confirmations upon Delivery
CAUTION Page
•Never install an Inverter that is damaged or missing components. Doing so can result in injury. 10
§Installation
CAUTION Page
•
Always hold the case when carrying the Inverter. If the Inverter is held by the front cover, the main body of the Inverter
may fall, possibly resulting in injury. 14
•
Attach the Inverter to a metal or other noncombustible material. Fire can result in the Inverter if attached to a
combustible material. 14
•
Install a cooling fan or other cooling device when installing more than one Inverter in the same enclosure so that the
temperature of the air entering the Inverters is below 45°C. Overheating can result in fires or other accidents. 14
§Wiring
WARNING Page
•Always turn OFF the input power supply before wiring terminals. Otherwise, an electric shock or fire can occur. 20
•
Wiring must be performed by an authorized person qualified in electrical work. Otherwise, an electric shock or fire can
occur. 20
•
Be sure to ground the ground terminal. (200 V class: Ground to 100 ×or less, 400 V class: Ground to 10 ×or less)
Otherwise, an electric shock or fire can occur. 20
•
Always check the operation of any emergency stop circuits after they are wired. Otherwise, there is the possibility of
injury. (Wiring is the responsibility of the user.) 20
•
Never touch the output terminals directly with your hands or allow the output lines to come into contact with the Inverter
case. Never short the output circuits. Otherwise, electrical shock or grounding can occur. 20
CAUTION Page
•
Check to be sure that the voltage of the main AC power supply satisfies the rated voltage of the Inverter. Injury or fire
can occur if the voltage is not correct. 20
•
Do not perform voltage withstand tests on the Inverter. Otherwise, semiconductor elements and other devices can be
damaged. 20
•
Connect braking resistors, Braking Resistor Units, and Braking Units as shown in the I/O wiring examples. Otherwise, a
fire can occur. 20
•Tighten all terminal screws to the specified tightening torque. Otherwise, a fire may occur. 20
•
Do not connect AC power to output Terminal T1, T2, and T3 (U, V, and W). The interior parts of the Inverter will be
damaged if voltage is applied to the output terminals. 20

PREFACE
Firmware – S1043
Revision: 2 (9/98) iv © Saftronics, Inc.
CAUTION Page
•
Do not connect Power Factor Correction Capacitors or LC/RC noise filters to the output circuits. The Inverter can be
damaged or internal parts burnt if these devices are connected. 20
•
Do not connect electromagnetic switches or contactors to the output circuits. If a load is connected while the Inverter is
operating, surge current will cause the overcurrent protection circuit inside the Inverter to operate. 20
§Setting User Constants
CAUTION Page
•
Disconnect the load (machine, device) from the motor before Auto-Tuning. The motor may turn, possibly resulting in
injury or damage to equipment. Also, motor constants cannot be correctly set with the motor attached to a load. 81
§Trial Operation
WARNING Page
•
Check to be sure that the front cover is attached before turning ON the power supply. Do not remove the front cover
during operation. An electric shock may occur. 86
•
Do not come close to the machine when the fault reset function is used. If the alarm is cleared, the machine may start
moving suddenly. Also, design the machine so that human safety is ensured even when it is restarted. Injury may
occur. 86
•
Provide a separate emergency stop switch; the Digital Operator STOP key is valid only when the function is set. Injury
may occur. 86
•
Reset alarms only after confirming that the RUN signal is OFF. If an alarm is reset with the RUN signal turned ON, the
machine may suddenly start. Injury may occur. 86
CAUTION Page
•
Do not touch the radiation fins (heat sink), braking resistor, or Braking Resistor Unit. These can become very hot.
Otherwise, a burn injury may occur. 86
•
Be sure that the motor and machine is within the applicable ranges before starting operation. Otherwise, an injury may
occur. 86
•Provide a separate holding brake if necessary. Otherwise, an injury may occur. 86
•Do not check signals while the Inverter is running. Otherwise, the equipment may be damaged. 86
•
Be careful when changing Inverter settings. The Inverter is factory set to suitable settings. Otherwise, the equipment
may be damaged. You must, however, you must set the power supply voltage jumper for 400 V class Inverters of 18.5
kW or higher (See Chapter 5, 5.2.4 Setting Input Voltage). 86

PREFACE
Firmware – S1043
Revision: 2 (9/98) v© Saftronics, Inc.
§Maintenance and Inspection
WARNING Page
•
Do not touch the Inverter terminals. Some of the terminals carry high voltages and are extremely dangerous. Doing so
can result in electric shock. 276
•
Always have the protective cover in place when power is being supplied to the Inverter. When attaching the cover,
always turn OFF power to the Inverter through the MCCB. Doing so can result in electric shock. 276
•
After turning OFF the main circuit power supply, wait until the CHARGE indicator light goes out before performance
maintenance or inspections. The capacitor will remain charged and is dangerous. 276
•
Maintenance, inspection, and replacement of parts must be performed only by authorized personnel. Remove all metal
objects, such as watches and rings, before starting work. Always use grounded tools. Failure to heed these warnings
can result in electric shock. 276
CAUTION Page
•
A CMOS IC is used in the control board. Handle the control board and CMOS IC carefully. The CMOS IC can be
destroyed by static electricity if touched directly. 276
•
Do not change the wiring, or remove connectors or the Digital Operator, during operation. Doing so can result in
personal injury. 276
§Other
WARNING
•Do not attempt to modify or alter the Inverter. Doing so can result in electrical shock or injury.

PREFACE
Firmware – S1043
Revision: 2 (9/98) vi © Saftronics, Inc.
How to Change the Digital Operator Display from Japanese to English
If the Digital Operator displays messages in Japanese, change to the English mode using the following steps. (This manual provides
descriptions for the English mode.)

Firmware – S1043
Revision: 2 (9/98) vii © Saftronics, Inc.
Table of Contents
1Introduction .......................................................................................... 1
1.1 Outline and Functions.................................................................................... 2
1.1.1 VG5 Inverter Models ........................................................................................................... 2
1.1.2 Outline of Control Methods................................................................................................. 3
1.1.3 Functions............................................................................................................................. 3
1.2 Nomenclature ............................................................................................. 6
1.2.1 VG5 Components................................................................................................................ 6
1.2.2 Digital Operator Components ............................................................................................. 7
2Handling Inverters................................................................................ 9
2.1 Confirmations upon Delivery.......................................................................... 10
2.1.1 Nameplate Information........................................................................................................ 10
2.2 Exterior and Mounting Dimensions................................................................. 12
2.3 Checking and Controlling the Installation Site................................................. 14
2.3.1 Installation on Site............................................................................................................... 14
2.3.2 Controlling the Ambient Temperature................................................................................. 14
2.3.3 Protecting the Inverter from Foreign Matter ....................................................................... 14
2.4 Installation Orientation and Space.................................................................. 15
2.5 Removing/Attaching the Digital Operator and Front Cover.............................. 16
2.5.1 Inverters of 15 kW or Less.................................................................................................. 16
2.5.2 Inverters of 18.5 kW or Higher............................................................................................ 17
3Wiring .......................................................................................... 19
3.1 Connections to Peripheral Devices................................................................. 21
3.2 Connection Diagram...................................................................................... 22
3.3 Terminal Block Configuration......................................................................... 23
3.4 Wiring Main Circuit Terminals ........................................................................ 24
3.4.1 Applicable Wire Sizes and Closed-Loop Connectors ........................................................ 24
3.4.2 Main Circuit Terminal Functions......................................................................................... 29
3.4.3 Main Circuit Configurations................................................................................................. 30
3.4.4 Standard Connection Diagrams.......................................................................................... 32
3.4.5 Wiring the Main Circuits...................................................................................................... 33
3.5 Wiring Control Circuit Terminals..................................................................... 39
3.5.1 Wire Sizes and Closed-loop Connectors............................................................................ 39
3.5.2 Control Circuit Terminal Functions ..................................................................................... 40
3.5.3 Control Circuit Terminal Connections (All Models)............................................................ 41
3.5.4 Control Circuit Wiring Precautions...................................................................................... 42
3.6 Wiring Check................................................................................................. 42
3.7 Installing and Wiring PG Speed Option Cards................................................ 43
3.7.1 Installing a PG Speed Option Card..................................................................................... 43
3.7.2 PG Speed Option Card Terminal Blocks............................................................................ 44
3.7.3 Wiring a PG Speed Option Card......................................................................................... 45
3.7.4 Wiring PG Speed Option Card Terminal Blocks ................................................................ 49
3.7.5 Selecting the Number of PG Pulses................................................................................... 51
4Setting User Constants........................................................................ 53
4.1 Using the Digital Operator.............................................................................. 54
4.2 Modes ......................................................................................................... 56
4.2.1 Inverter Modes..................................................................................................................... 56
4.2.2 Switching Modes ................................................................................................................. 57
4.2.3 User Constant Access Levels............................................................................................. 58
4.2.4 Operation Mode................................................................................................................... 63
4.2.5 Initialize Mode...................................................................................................................... 70
4.2.6 Programming Mode............................................................................................................. 77
4.2.7 Auto-Tuning Mode............................................................................................................... 81
4.2.8 Modified Constants Mode ................................................................................................... 83

Firmware – S1043
Revision: 2 (9/98) viii © Saftronics, Inc.
5Trial Operation....................................................................................... 85
5.1 Procedure ...................................................................................................... 57
5.2 Trial Operation Procedures............................................................................. 88
5.2.1 Power ON............................................................................................................................ 88
5.2.2 Checking the Display Status............................................................................................... 88
5.2.3 Initializing Constants........................................................................................................... 88
5.2.4 Setting Input Voltage........................................................................................................... 89
5.2.5 Auto-Tuning......................................................................................................................... 90
5.2.6 No-Load Operation.............................................................................................................. 93
5.2.7 Loaded Operation ............................................................................................................... 94
6Basic Operation..................................................................................... 95
6.1 Common Settings........................................................................................... 96
6.1.1 Setting the Access Level and Control Method: A1-01, A1-02.......................................... 96
6.1.2 Frequency Reference Settings: b1-01, H3-01, H3-08, H3-09.......................................... 98
6.1.3 Frequency reference from Digital Operator: b1-01, o1-03, d1-01, to d1-09 .................... 101
6.1.4 Run Source and Sequence Input Responsiveness: b1-02, b1-06, b1-07 ....................... 103
6.1.5 Acceleration/Deceleration Times: C1-01 through C1-08, C1-09, C1-10 C1-11 .............. 104
6.1.6 Prohibiting Reverse Operation: b1-04................................................................................ 105
6.1.7 Selecting the Stopping Method: b1-03.............................................................................. 106
6.1.8 Multi-Function Input Settings: H1-01 through H1-06........................................................ 107
6.2 Open-Loop Vector Control..............................................................................112
6.2.1 Auto-Tuning......................................................................................................................... 112
6.2.2 Auto-Tuning Faults.............................................................................................................. 113
6.3 V/f Control......................................................................................................114
6.3.1 Setting the Motor Constants: E1-01, E1-02, E2-01.......................................................... 114
6.3.2 V/f Pattern Selection: E1-03.............................................................................................. 115
6.4 Flux Vector Control ........................................................................................121
6.4.1 PG Speed Option Card Settings ........................................................................................ 121
6.4.2 Setting the Zero Speed Operation Constants.................................................................... 124
6.4.3 Auto-Tuning......................................................................................................................... 126
6.4.4 Speed Control (ASR) Structure.......................................................................................... 128
6.4.5 Speed Control (ASR) Gain ................................................................................................. 130
6.5 V/f Control with PG.........................................................................................132
6.5.1 Motor Constants: E1-01, E1-02, E2-01, E2-04................................................................. 132
6.5.2 V/f Pattern Selection: E1-03.............................................................................................. 133
6.5.3 PG Speed Option Card Settings ........................................................................................ 134
6.5.4 Speed Control (ASR) Structure.......................................................................................... 136
6.5.5 Adjusting Speed Control (ASR) Gain................................................................................. 137
7Advanced Operation.............................................................................139
7.1 Open-Loop Vector Control..............................................................................140
7.1.1 Torque Limit Function......................................................................................................... 141
7.1.2 Adjusting Speed Feedback................................................................................................. 143
7.1.3 Setting/Adjusting Motor Constants..................................................................................... 143
7.2 Normal V/f Control..........................................................................................146
7.2.1 Energy Saving Control Function......................................................................................... 147
7.2.2 Hunting Prevention Function .............................................................................................. 148
7.2.3 Setting Motor Constants..................................................................................................... 149
7.3 Flux Vector Control ........................................................................................150
7.3.1 Droop Control Function....................................................................................................... 151
7.3.2 Zero Servo Function ........................................................................................................... 152
7.3.3 Torque Control .................................................................................................................... 153
7.3.4 Speed/Torque Control Switching Function ........................................................................ 159
7.3.5 Torque Limit Function......................................................................................................... 160
7.3.6 Setting/Adjusting Motor Constants..................................................................................... 162
7.4 V/f Control with PG Feedback.........................................................................165
7.4.1 Energy Saving Control Function......................................................................................... 166
7.4.2 Hunting Prevention Function .............................................................................................. 167
7.4.3 Setting Motor Constants..................................................................................................... 168

Firmware – S1043
Revision: 2 (9/98) ix © Saftronics, Inc.
7.5 Common Functions........................................................................................ 169
7.5.1 Application Constants: b .................................................................................................... 170
7.5.2 Tuning Constants: C........................................................................................................... 178
7.5.3 Reference Constants: d ..................................................................................................... 181
7.5.4 Option Constants: F ........................................................................................................... 183
7.5.5 External Terminal Functions: H ......................................................................................... 187
7.5.6 Protective Functions: L....................................................................................................... 204
7.5.7 Operator Constants: o........................................................................................................ 215
8User Constants ............................................................................... 219
8.1 Initialize Mode Constants............................................................................... 221
8.2 Programming Mode Constants....................................................................... 222
8.2.1 Application Constants: b .................................................................................................... 222
8.2.2 Auto-Tuning Constants: C.................................................................................................. 227
8.2.3 Reference Constants: d ..................................................................................................... 233
8.2.4 Motor Constant Constants: E............................................................................................. 236
8.2.5 Options Constants: F.......................................................................................................... 240
8.2.6 Terminal Constants: H ....................................................................................................... 243
8.2.7 Protection Constants: L...................................................................................................... 249
8.2.8 Operator Constants: o........................................................................................................ 255
8.2.9 Factory Settings that Change with the Control Method (A1-02)........................................ 257
8.2.10 Factory Settings that Change with the Inverter Capacity (o2-04)...................................... 258
9Troubleshooting ............................................................................... 261
9.1 Protective and Diagnostic Functions .............................................................. 262
9.1.1 Fault Detection .................................................................................................................... 262
9.1.2 Minor Fault Detection.......................................................................................................... 265
9.1.3 Operation Errors.................................................................................................................. 267
9.2 Troubleshooting............................................................................................. 268
9.2.1 If Constant Constants Cannot Be Set................................................................................. 268
9.2.2 If the Motor Does Not Operate............................................................................................ 268
9.2.3 If the Direction of the Motor Rotation is Reversed............................................................. 270
9.2.4 If the Motor Does Not Put Out Torque or If Acceleration is Slow...................................... 270
9.2.5 If the Motor Does Not Operate According to Reference.................................................... 270
9.2.6 If the Slip Compensation Function Has Low Speed Precision .......................................... 270
9.2.7 If There is Low Speed Control Accuracy at High-speed Rotation in Open-
Loop Vector Control Mode.................................................................................................. 271
9.2.8 If Motor Deceleration is Slow.............................................................................................. 271
9.2.9 If the Motor Overheats ........................................................................................................ 271
9.2.10 If There is Noise When the Inverter is Started or From an AM Radio............................... 272
9.2.11 If the Ground Fault Interrupter Operates When the Inverter is Run.................................. 272
9.2.12 If There is Mechanical Oscillation....................................................................................... 272
9.2.13 If the Motor Rotates Even When Inverter Output is Stopped ............................................ 273
9.2.14 If 0 V is Detected When the Fan is Started, or Fan Stalls ................................................. 273
9.2.15 If Output Frequency Does Not Rise to Frequency Reference........................................... 273
10 Maintenance and Inspection ............................................................... 275
10.1 Maintenance and Inspection .......................................................................... 277
10.1.1 Daily Inspection................................................................................................................... 277
10.1.2 Periodic Inspection.............................................................................................................. 277
10.1.3 Periodic Maintenance of Parts............................................................................................ 277
11 Specifications....................................................................................... 279
11.1 Standard Inverter Specifications..................................................................... 280
11.2 Specifications of Options and Peripheral Devices........................................... 284
12 Appendix............................................................................................... 287
12.1 Inverter Application Precautions..................................................................... 288
12.1.1 Selection ............................................................................................................................. 288
12.1.2 Installation............................................................................................................................ 288
12.1.3 Settings ............................................................................................................................. 288
12.1.4 Handling ............................................................................................................................. 289