Top Gin TG250 User manual

1
Notes：
Upon receipt of the inverter and before any operation, please carefully read this instruction manual
thoroughly, also keep this manual for reference in the future. If you have any question or problem,
please no hesitate to contact your local SHANGCHIN representative. Thanks！
PREFACE
TOP GIN TG-300 is an optimized inverter specifically designed for variable torque applications.
This instruction manual describes installation, maintenance and inspection, troubleshooting, and
specifications of the TG-300 Read this instruction manual thoroughly before operation.
SHANGCHIN ELECTRONICS CORP.
General Precautions
●Some drawings in this manual are shown with the protective cover or shields removed, in order to
describe detail with more clarity. Make sure all covers and shields are replaced before operating this
product.
●This manual may be modified when necessary because of improvement of the product,
modification, or changes in specifications.
Such modifications are denoted by a revised manual
●To order a copy of this manual, if your copy has been damaged or lost, contact your SHANGCHIN
representative.
●SHANGCHIN is not responsible for any modification of the product made by the user, since that
will void your guarantee.

2
CONTENTS
1 RECEIVING ··············································································································4
1.1 INSPECTION CHECKPOINTS ··························································································· 4
1.2 IDENTIFYING THE PARTS································································································ 5
2 INSTALLATION·······································································································6
2.1 LOCATION FOR THE INVERTER ····················································································· 6
2.2 CLEARANCES ···················································································································· 7
3 WIRING······················································································································8
3.1 CONNECTION DIAGRAM ································································································· 9
3.2 WIRING THE MAIN CIRCUIT ··························································································· 10
3.3 WIRING THE CONTROL CIRCUIT ··················································································· 13
3.4 WIRING INSPECTION········································································································ 14
4 OPERATION··············································································································15
4.1 OPERATION MODE SELECTION ····················································································· 16
4.2 TEST RUN CHECKPOINTS································································································ 17
4.3 SETTING THE LINE VOLTAGE USING JUMPER
(FOR 440V CLASS 18.5kW AND ABOVE) ··················································································· 17
4.4 TEST RUN···························································································································· 18
5 SIMPLE DATA SETTING ·······················································································23
5.1 DIGTAL OPERATOR KEY DESCRIPTION ······································································· 23
5.2 LED DESCRIPTION ············································································································ 24
6 PROGRAMMING FEATURES ··············································································26
6.1 CONSTANT SET-UP AND INITALIZATION ····································································· 26
6.2 V/F PATTERN SETTING····································································································· 26
6.3 OPERATION CONDITIONS ······························································································· 29
6.4 STOPPING METHOD·········································································································· 43
6.5 INTERFACE CIRCUITS WITH EXTERNAL DEVICES···················································· 46
6.6 ADJUSTING MOTOR TORQUE························································································· 56
6.7 MOTOR PROTECTION······································································································· 57
6.8 PID CONTROL ···················································································································· 59
6.9 ENERGY SAVING CONTROL···························································································· 61
6.10 MODBUS CONTROL·········································································································· 63

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7 MAINTENANCE AND INSPECTION ··································································64
7.1 PERIODIC INSPECTION ···································································································· 65
7.2 PARTS REPLACEMENT SCHEDULE (GUIDELINES)····················································· 65
8TROBULESHOOTING·····························································································66
8.1 FAULT DIAGNOSIS AND CORRECTIVE ACTIONS ······················································· 66
8.2 ALARM DISPLAY AND EXPLANATION ········································································· 69
8.3 MOTOR FAULTS AND CORRECTIVE ACTIONS ···························································· 70
APPENDIX 1 SPECIFICATIONS ·············································································71
APPENDIX 2 DIMENSIONS (mm)···········································································72
APPENDIX 3 TYPICAL CONNECTION DIAGRAM···········································73
3.1 BRAKING RESISTOR UNIT······························································································· 73
3.2 BRAKING UNIT AND BRAKING RESISTOR UNIT ························································ 74
APPENDIX 4 CONSTANT LIST···············································································75
APPENDIX 5 DIGTAL OPERATOR MONITOR DISPLAY ································81
BRAKING UNIT APPLICATION LIST···································································83
SEPARATELY-INSTALLED TYPE BRAKING RESISTOR ································84

4
1. RECEIVING
CAUTION
●Do not install or operate any inverter which is damaged or has missing parts.
Failure to observe this caution may result in personal injury or equipment damage
This chapter describes how to inspect the inverter after delivery to the user.
1.1 INSPECTION CHECKPOINTS
(1)Receiving Checkpoints
Checkpoints Description
Does the inverter model number correspon
the purchase order？
Check the model number on the nameplate on the
side of the TG-300
Are any parts damaged？Visually check the exterior and verify that there
was no damage during transport.
Is hardware properly seated and securely
tightened？
Remover inverter front cover.
Check all visible hardware with appropriate tools.
Was an instruction manual received？TG-300 instruction manual
If any of the above checkpoints are not satisfactory, contact your SHANGCHIN representative.
(2)Checking the Nameplate Data
(a)Nameplate Date
Example of TG-300
TOP GIN MADE IN TAIWAN
TG 300 -
SOU
R
C
E
V
Hz
CAPACITY kVA
VOLTS V CURRENTS A
SERIAL NO.
Model
Input power supply
Output capacity
Output power supply
Manuf. No.

5
Symbol Enclosure
0 Open shdssis type (IP00)
1 Enclosed wall-mounted type(IP20)
Symbol Specification
T Standard
E CE mark
U UL
Digital Operator
Front Cover
Protective Cover (top/bottom)
4 Mountin
g
Holes
Ventilation Slots
●Model Designation
TG – 300 – L 100 – A 2 T 1
TOP GIN
IGBT Series
1.2 IDENTIFYING THE PARTS
Flg. 4 Configuration of TG-300
Symbol Voltage
L 3φ220V Series
H 3φ440V Series
Max applicable motor
output (10Hp)
A：
Without
Braking
resitstor
B：With
Operator
1 Black
2 Digital with
VR
3 LCD with VR

6
2 . INSTALLATION
CAUTION
●Lift the cabinet by the base. When moving the unit, never lift by the front cover.
Otherwise, the main unit may be dropped causing damage to the unit.
●Mount the inverter on nonflammable material (i.e. metal).
Failure to observe this caution can result in a fire.
●When mounting units in an enclosure, install a fan or other cooling device to keep the intake air
temperature below 45℃.
Overheating may cause a fire or damage to the unit.
This chapter describes configuration, location and clearances when mounting the TG-300.
2.1 LOCATION FOR THE INVERTER
To ensure proper performance and long operating life, follow the recommendations below when
choosing a location for installing the TG-300. Make sure the inverter is protected from the following
conditions：
□ Extreme cold and heat.
□ Use only within ambient temperature range：-10℃to +40℃
□ Rain, moisture. (For enclosed wall-mounted type)
□ Oil sprays, splashes
□ Salt spray
□ Direct sunlight. (Avoid using outdoors.)
□ Corrosive gases or liquids.
□ Dust or metallic particles in the air.(For enclosed wall-mounted type)
□ Physical shock, vibration.
□ Magnetic noise. (Example: welding machines, power devices, etc.)
□ High humidity.
□ Radioactive materials.
□ Combustibles：thinners, solvents, etc.

7
2.2 CLEARANCES
Install the TG-300 vertically and allow sufficient clearances for effective cooling as shown below.
150
150
500
500
+ 100
Door width
For
front/rear
door
+ 100
Door width
Inverter
Front
face
50mm50mm
150mm
100mm
Note：
1.The clearances required at top/bottom and both sides are common in open chassis type (IP00) and
enclosed wall-mounted type (IP20).
2.Remove the top and bottom covers to use the open chassis type of 220V/440V 15Kw or less.
3.For the external dimensions and mounting dimensions, refer to Appendix 2 “DIMENSIONS”.
4.Allowable intake air temperature to the inverter：
●Openchassistype ：-10℃to +45℃
●Enclosed wall-mounted type：-10℃to +40℃
5. Ensure sufficient space for the sections at the upper and lower parts marked with ＊ in order to permit
the flow of intake/exhaust air to/from the inverter.

8
3. WIRING
WA R I N G
●Only commence wiring after verifying that the power supply is turned OFF.
Failure to observe this warning can result in an electrical shock or a fire.
●Wiring should be performed only by qualified personnel.
Failure to observe this warning can result in an electrical shock or a fire.
●When wiring the emergency stop circuit, check the wiring thoroughly before operation.
Failure to observe this warning can result in personal injury.
CAUTION
●Verify that the inverter rated voltage coincides with the AC power supply voltage.
Failure to observe this warning can result in personal injure or a fire.
●Do not perform a withstand voltage test of the inverter.
It may cause semi-conductor elements to be damaged.
●To connect a braking resistor, braking resistor unit or braking unit, follow the procedures described
in APPENDIX 3.
Improper connection may cause a fire.
●Tighten terminal screws to the specified tightening torque.
Failure to observe this caution can result in a fire.
This chapter describes the main circuit wiring and the control circuit wiring of the TG-300.

9
ON OFF
3.1 CONNECTION DIAGRAM
Below is connection diagram of the main circuit and control circuit. Using the digital operator, the
motor can be operated by wiring the main circuit only.
R
3-Phase L1(R)
S
Power Supply L2(S)
200 to 240V
345 to 480V
50/60 HZ TL3(T)
MCCB
Breaking Resistor (Option)
Motor
IM
Ground (100Ωor less)
Forward Run/Stop
Reverse Run/Stop
External Fault
Fault Reset
Multi-step Speed Setting 1
Multi-step Speed Setting 2
Factory
Setting
S1 Forward Run
when CLOSED
S2
SC
S3
S4
S6
S5
Multi-function
Contact input
Sequence Commom
Terminal (0V)
G
FS
FV
FI
FC
0V
12B1 B2
U(T1)
V(T2)
W(T3)
AM
AC
(G)
MA
MB
MC
M1
M2
Analog
Monitor
Shield Sheath
Connection
Terminal
Freq. Setting Power
Supply +15V 20mA
Master Freq. Ref.
0 to 10V (20kΩ)
Master Freq. Ref.
4 to 20mA (250Ω)
[0 to 10V(20kΩ)input available]
FM
-
+
Multi-function Analog Output 0
to +10V
(Output Frequency at Factory
Setting)
Multi-function Contact Output
Contact Capacity：250 VAC 1A or less
30 VDC 1A or less
(Fault Output Signal at Factory Setting)
Multi-function Contact Output
250 VAC 1A or less
30 VDC 1A or less
(Signal during Running at Factory Setting)
TG 250
TG 300
P
P
0V
4 to 20mA
0 to +10V
2kΩ
Master
Frequency
Reference
M4
M3
OPEN COLLECTOR OUTPUT
(ZERO SPEED SIGNAL)
(OPTION)
Connection Diagram
W2
S1 S2 S3 SC SC S4 S5 S6 FV FI FS FC AM AC M1 M2 MA MB MC
VR SET HZ W2 OFF
REMOTE SET HZ W2 ON
Note：
1. indicates shielded wires and
P
indicates twisted-pair shielded wires.
2.Voltage or current input for the master frequency reference can be selected by constant H042.
Voltage reference input is preset at the factory.
3.Control circuit terminal FR of +15 V has a maximum output current capacity of 20 mA.
4.Multi-function analog output should be used for monitoring meters (e.g. output frequency meter)
and should not be used for feedback control system.
G

10
3.2 WIRING THE MAIN CIRCUIT
WA R N I N G
●Make sure to ground the ground terminal
(Ground resistance 220V class：100Ωor less. 440V class：10Ωor less)
Failure to observe this warning can result in an electrical shock or a fire.
CAUTION
●Never connect the AC main circuit power supply to output terminals U,V and W.
The inverter will be damaged and invalidate the guarantee.
(1)Wiring Precautions for Main Circuit Input
(a)Installation of Molded-case Circuit Breaker (MCCB)
Make sure to connect MCCBs of fuses between AC main circuit power supply and TG-300 input
terminals L1, L2 and L3 to protect wiring.
(b)Installation of Ground Fault Interrupter
When connecting a ground fault interrupter to input terminals L1, L2 and L3, select one that is not
affected by high frequency.
(c)Installation of Magnetic Contactor
Inverters can be used without a magnetic contactor (MC) installed at the power supply side. When
the main circuit power supply is shut OFF in the sequence, a magnetic contactor (MC) can be used
instead of a molded-case circuit breaker (MCCB). However, when a magnetic contactor is switched
OFF at the primary side, regenerative braking does not function and the motor coasts to a stop.
●The load can be operated/stopped by opening/closing the magnetic contactor at the primary side.
However, frequent switching may cause the inverter to malfunction.
●When using a braking resistor unit, use a sequencer to break power supply side on overload relay
trip contact. If the inverter malfunctions, the braking resistor unit may be burned out.
(d)Terminal Block Connection Sequence
Input power supply phases can be connected to any terminal regardless of the order of L1, L2 and L3
on the terminal block.
(e)Installation ofAC Reactor
When connecting an inverter (220V/440V 15Kw or less) to a large capacity power supply
transformer (600Kva or more), or when switching a phase advancing capacitor, excessive peak
current flows in the input power supply circuit, which may damage the converter section. In such
cases, install a DC reactor (optional) between inverter 1 and 2terminals or an AC reactor
(optional) on the input side. Installation or a reactor is effective for improvement of power factor on
the power supply side.

11
(f)Installation of Surge Suppressor
For inductive loads (magnetic contactors, magnetic relays, magnetic valves, solenoids, magnetic
brakes, etc.) connected near the inverter, use a surge suppressor simultaneously.
(g)Prohibition of Installation of Phase Advancing Capacitor
If a phase advancing capacitor or surge suppressor is connected in order to improve the power factor,
it may become overheated and damaged by inverter high harmonic components. Also, the inverter
may malfunction because of overcurrent.
(2)Wiring Precautions for Main Circuit Output
(a)Connection of Terminal Block and Load
Connect output terminals U, V and W to motor lead wires U, V and W. Verify that the motor rotates
in the forward direction (CCW：counterclockwise when viewed from the motor load side) with the
forward run command. If the motor rotation is incorrect, exchange any two of output terminals U,V
or W.
(b)Strict Prohibition of Connection of Input Power Supply to Output Terminals
Never connect input power supply to output terminals U, V and W.
(c)Strict Prohibition of Short Circuiting or Grounding of Output Circuit
Never touch the output circuit directly or put the output line in contact with the inverter case.
Otherwise, it may cause an electrical shock or grounding. In addition, never short circuit the output
line.
(d)Prohibition of Connection of Phase Advancing Capacitor or LC/RC Noise Fitter
Never connect a phase advancing capacitor or LC/RC noise, filter to the output circuit.
(e) Avoidance of Installation of Magnetic Starter
Do not connect a magnetic starter or magnetic contactor to the output, circuit.
If the load is connected while the inverter is running, the inverter overcurrent
protective circuit operates because of inrush current.
(f) Installation of Thermal Overload Relay
An electronic overload protective function is incorporated into the inverter.
However, connect a thermal overload relay when driving several motors with one inverter or when
using a multi-pole motor. When using a thermal overload relay, set inverter constant H033 to 0.
Additionally, for thermal overload relay, at 50Hz set the same rated current value as that described
on the motor nameplate, or at 60Hz 1.1 times larger than the rated current value described on the
motor nameplate.

12
(g) Wiring Distance between Inverter and Motor
If the total wiring distance between inverter and motor is excessively long and the inverter carrier
frequency (main transistor switching frequency) is high, harmonic leakage current from the cable
will adversely affect the inverter and peripheral devices.
If the wiring distance between inverter and motor is long, reduce the inverter carrier frequency as
described below. Carrier frequency can be set. by constant H050.
Wiring Distance between Inverter and Motor
Wiring Distance between
Inverter and Motor Up to 50m Up to 100m More than 100m
Carrier Frequency
(Set value of constant H050)
15kHZ or less
(6)
10kHZ or less
(4)
5kHZ or less
(2)
(3)Grounding
●Ground resistance
220 V class：100Ωor less, 440 V class：10Ωor less
●Never ground TG-300 in common with welding machines, motors, or other large-current electrical
equipment. Run all the ground wires in a conduit separate from wires for large-current electrical
equipment.
●Use the ground wires described in tables below and keep the length as short as possible.
●When using several TG-300 units side by side, ground the units as shown below
(c)Not Acceptable
(b)Acceptable(a)Acceptable
Grounding of Three TG-300 Units

13
3.3 WIRING THE CONTROL CIRCUIT
The following table outlines the functions of the control circuit terminals
Wire according to each terminal function.
(1) Functions of Control Circuit Terminate
Control Circuit Terminals
Classification Terminal Signal Function Description Signal Level
S1 Forward run/stop Forward run when closed, stop
when open
S2 Reverse run/stop
Reverse run
when closed,
stop when open
S3 External fault input
Fault when
closed, normal
state when
open
S4 Fault reset input Reset when
closed
S5 Multi-step speed
reference 1
Effective when
closed
S6 Multi-step speed
reference 2
Effective when
closed
Multi-function
contact inputs
(H035 to H039)
Sequence Input Signal
SC Sequence control input
common terminal ---
Photo-coupler
insolation
Input ：+24VD
8mA
FS +15V Power supply
output
For analog command +15V power
supply
+15V
(Allowable
current 20mA
max.)
FV
Frequency reference
input (voltage) 0 to
+10V/100%
0 to +10V
(20 kΩ)
FI Frequency reference
input (current)
4 to
20mA/100%
H042 = 0：FV
effective
H042 = 0：FI
effective 4 to 20mA
(250Ω)
FC Common terminal for
control circuit 0V ---
Analog Input Signal
G Connection to shield
searth of signal lead --- ---
M1
M2
During running
(NO contact)
Closed when
running
Multi-function
contact output
(H041)
Dry contact
Contact
capacity：
250VAC 1 A or
less
30VDC 1 A or
less
MA
MB
Sequence Output Signal
MC
Fault contact output
(NO/NC contact)
Fault when
closed between
terminals MA
and MC
Fault when
open between
terminals MB
and MC
Multi-function
contact output
(H040)
Dry contact
Contact
capacity：
250VAC 1 A or
less
30VDC 1 A or
less
AM Frequency meter output
Analog Output Signal
AC Common
0 to +
10V/100%
Freq.
Multi-function
contact analog
monitor 1
(H048)
0 to +10V 2mA
or less

14
ON
(2) Wiring the Control Circuit Terminals
Screwdriver Blade Width
Insert the wire into the lower part of the terminal block and connect it tightly with a screwdriver.
Wire sheath strip length must be 7 mm.
7mm
(3) Precautions on Control Circuit Wiring
●Separate control circuit wires from main circuit wires and other power cables to prevent erroneous
operation caused by noise interference.
●Use twisted shielded or twisicd-pair shielded wire for the control circuit line and connect the
shielded sheath to the inverter terminal G.
Wiring distance should be less than 50 m.
3.4 WIRING INSPECTION
After completing of installation and wiring, check for the following items. Never use
control circuit buzzer check-
□ Wiring is proper.
□ Wire clippings or screws are not left in the unit.
□ Screws are securely tightened.
□ Bare wire in the terminal does not contact other terminals

15
4 OPERATION
WA R N I N G
●Only turn ON the input power supply after replacing the front cover. Do not remove the cover
while current is flowing.
Failure to observe this warning can result in an electrical shock.
●When the retry function (H057) is selected, do not approach the inverter or the load, since it may
restart suddenly after being stopped.
(Construct machine system, so as to assure safety for personnel, even if the inverter should restart.)
Failure to observe this warning can result in personal injury.
●Since the stop button can be disabled by a function setting, install a separate emergency stop
switch.
Failure to observe this warning can result in personal injury.
CAUTION
●Never touch the heatsink or discharging resistor since the temperature is very high.
Failure to observe this caution can result in harmful burns to the body.
●Since it is easy to change operation speed from low to high speed, verify the safe working range of
the motor and machine before operation.
Failure to observe this caution can result in personal injury and machine damage
●Install a holding brake separately if necessary.
Failure to observe this caution can result in personal injury
●Do not change signals during operation.
The machine or the inverter may be damaged
●Ail the constants of the inverter have been preset at the factory. Do not change the settings
unnecessarily.
The inverter may be damaged. For supply voltage, follow Par. 4.3.
This chapter describes the basic operation procedures of the TG-300.

16
4 .1 OPERATION MODE SELECTION
The TG-300 has two operation modes, LOCAL and REMOTE, as described below. These two
modes can be selected by the digital operator "LOCAL/REMOTE" key only while the operation is
stopped. The selected operation mode can be verified by observing the digital operator SEQ and
REF LEDs as shown below. The operation mode is set to REMOTE (run by control circuit terminals
FV and FI frequency reference and run command from a control circuit terminal) prior to shipment.
Multi-function contact inputs from control circuit terminals S3 to S6 are enabled in both operation
modes LOCAL/REMOTE.
●LOCAL ：Both frequency reference and run command are set by the digital operator. SEQ
and REF LEDs go OFF.
●REMOTE：Master frequency reference and run command can be selected as described below.
Reference Selection in REMOTE Mode (H002: Operation Method Selection)
Setting Operation Method Selection SEQ
LED Reference Selection REF LED
0 Operation by run command from digital
operator OFF Master frequency reference
from digital operator OFF
1
Operation by run command from control
circuit terminal ON
Master frequency reference
from
digital operator
OFF
2
Operation by run command from digital
operator OFF
Master frequency reference
from
control circuit terminals FV
and FI
ON
3
Operation by run command from control
circuit terminal ON
Master frequency reference
from
control circuit terminals FV
and FI
ON
4 Operation by run command from digital
operator OFF Master frequency reference set
by serial communication ON
5 Operation by run command from control
circuit terminal ON Master frequency reference set
by serial communication ON
6 Operation by run command from serial
communication ON Master frequency reference set
by serial communication ON
7
Operation by run command from serial
communication ON
Master frequency reference
from
digital operator
OFF
8
Operation by run command from serial
communication ON
Master frequency reference
from
control circuit terminals FV
and FI
ON

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4.2 TEST RUN CHECKPOINTS
To assure safety, prior to initial operation, disconnect the machine coupling so that the motor is
isolated from the machine. If initial operation must be performed while the motor is still coupled to
the machine, use great care to avoid potentially hazardous conditions. Check the following items
before a test run.
□ Wiring and terminal connections are correct.
□ No short circuit caused by wire clippings.
□ Screw-type terminals are securely tightened.
□ Motor is securely mounted.
□ All items are correctly earthed(grounded).
4.3 SETTING THE LINE VOLTAGE USING JUMPER
(FOR 440V CLASS 55kWAND ABOVE)
Set the line voltage jumper according to the main circuit power supply.
Insert the jumper at the appropriate location corresponding to the input line voltage
It has been preset at the factory to 440V.
Line Voltage Jumper (For 440V Class 55W to 300kW)

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4.4 TEST RUN
(1) Digital Operator Display at Power-up
When the system is ready for operation, turn ON the power supply. Verify that the inverter powers
up properly. If any problems are found, turn OFF the power supply immediately. The digital operator
display illuminates as shown below
DigitalOperatorDisplay DigitalOperatorDisplay
LED LCD

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(2) Operation Check Points
Check the following items during operation
□ Motor rotates smoothly.
□ Motor rotates in the correct direction.
□ Motor does not have abnormal vibration or noise.
□ Acceleration and deceleration are smooth.
□ Current matches the load flow.
□ Status indicator LEDs and digital operator display are correct
(3) Example of Basic Operation
(a) Operation by Digital Operator
The diagram below shows a typical operation pattern using the digital operator
fForward gh
60Hz
cdeForward
25Hz
Reverse
60Hz
Operation Sequence by Digital Operator
Power ON
Frequency Setting
Forward Run
Frequency Reference Change
Reverse Run
Stop

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Typical Operation by Digital Operator