TOYODenki VF66R User manual

PWM Sine Wave Converter
Operating Manual

3
Table of Contents
Preface............................................................................................................................................................................................. 6
Be Sure To Read This Before Use.............................................................................................................................................. 7
Safety Notice.................................................................................................................................................................................. 7
Chapter 1 Checking and Inspecting Package .......................................................................................................... 10
1.1. Checking Package and Inspection on Purchase................................................................................................... 10
Chapter 2 Product Overview................................................................................................................................................ 12
2.1. Features........................................................................................................................................................................ 12
2.2. Configuration .............................................................................................................................................................. 12
Chapter 3 How to Install and Connect Converter .............................................................................................. 14
3.1. Installation Environment and How to Install................................................................................................... 14
3.1.1. Installation Environment................................................................................................................................ 14
3.1.2. How to Install Converter................................................................................................................................ 14
3.2. How to Open and Close Front Cover....................................................................................................................... 16
3.2.1. How to Open Front Cover.................................................................................................................................. 16
3.2.2. How to Close Front Cover................................................................................................................................ 19
3.3. How to Connect Converter ........................................................................................................................................ 21
3.3.1. How to Connect Converter Terminals............................................................................................................ 21
3.4. Terminal Specifications .......................................................................................................................................... 23
3.5. Notes for Wiring and Electrical Wire Size....................................................................................................... 26
3.5.1. Notes for Wiring ............................................................................................................................................... 26
3.5.2. Electrical Wire Size of Input/Output Device and Main Circuit Wires............................................. 27
3.5.3. Electrical Wire Size of Control Board...................................................................................................... 28
3.6. AC Filter...................................................................................................................................................................... 29
3.6.1. AC Reactor ........................................................................................................................................................... 29
3.6.2. AC Filter Capacitor ......................................................................................................................................... 30
Chapter 4 Basic Operating Procedures for Converter....................................................................................... 31
4.1. Checks before Starting Operation......................................................................................................................... 31
4.1.1. About the Control Mode.................................................................................................................................... 31
4.1.2. Minimum Parameter Settings............................................................................................................................ 31
4.1.3. Replacing Control Board <VFC66R-Z> with Spare ...................................................................................... 31
4.2. Basic Operating Procedures from Console........................................................................................................... 32
4.2.1. Explanation of Display and Operation Keys on Console ........................................................................ 32
4.2.2. What Are Displayed at Power-on.................................................................................................................... 38
4.2.3. Changing Parameter Settings.......................................................................................................................... 39
4.2.4. Checking Operating State................................................................................................................................ 42
4.2.5. List of Monitor Items ..................................................................................................................................... 43
4.3. Operations on Console .............................................................................................................................................. 47

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4.4. Start and Stop through External Contact........................................................................................................... 48
Chapter 5 Explanation of Parameters ....................................................................................................................... 51
5.1. List of Parameter Areas .......................................................................................................................................... 51
5.2. List of Parameters .................................................................................................................................................... 52
5.3. Detailed Explanation of Each Parameter............................................................................................................. 57
5.3.1. Basic Setting Area ........................................................................................................................................... 57
5.3.2. Area A (filter constant setting area)...................................................................................................... 59
5.3.3. Area b (operation command related setting area) .................................................................................. 60
5.3.4. Area c (multifunction input/output related setting area) ................................................................ 63
5.3.5. Area d (converter operation setting area).............................................................................................. 68
5.3.6. Area E (control gain setting area)............................................................................................................ 70
5.3.7. Area F (protection function/traceback setting area) .......................................................................... 73
5.3.8. Area G (special adjustment area)................................................................................................................ 77
5.3.9. Area J (setting area for digital communication options) .................................................................. 77
5.3.10. Area L (analog input/output setting area).............................................................................................. 79
5.3.11. Area n (converter mode/model display area) ............................................................................................ 81
5.3.12. Area o (special adjustment area)................................................................................................................ 82
5.3.13. Area P (special adjustment area)................................................................................................................ 82
5.3.14. Area S (converter mode selection and analog input/output adjustment area)............................... 83
5.4. Operation Using S Area Parameters....................................................................................................................... 85
5.4.1. How to Clear Protections................................................................................................................................ 85
5.4.2. Data Transfer from/to External Console Option ...................................................................................... 87
5.4.3. DC Voltage Detection Gain Adjustment........................................................................................................ 95
5.4.4. Analog Input (2) and (3) Gain and Offset Adjustment .......................................................................... 98
5.4.5. Analog Output (2) and (3) Gain and Offset Adjustment ...................................................................... 103
Chapter 6 Tr o ubl e sh o oti n g ....................................................................................................................................... 109
6.1. Protection Messages and Actions......................................................................................................................... 109
6.1.1. Displays and Behaviors in Protection Display Mode ............................................................................109
6.1.2. List of Protection Messages........................................................................................................................ 110
6.1.3. How to Handle Protection Messages............................................................................................................ 115
6.2. How to Check Data in Protection Display Mode...............................................................................................123
6.2.1. How to Display Protection Operation Data..............................................................................................123
6.2.2. List of Data of Protection Operation and Protection History Display......................................... 124
6.3. How to Reset Protection Display Mode...............................................................................................................125
6.4. How to Check Protection History......................................................................................................................... 126
Chapter 7 Maintenance and Inspection........................................................................................................... 128
7.1. Periodic Inspection ................................................................................................................................................128
7.2. Main Circuit Capacitor/Cooling Fan Replacement Timing .............................................................................129
7.3. How to Replace Cooling Fan .................................................................................................................................. 130
7.3.1. How to Remove Cooling Fan............................................................................................................................130
7.3.2. How to Install Cooling Fan..........................................................................................................................133

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7.4. Inspecting and Replacing Main Circuit Capacitor.........................................................................................134
7.5. How to Perform Insulation Resistance Test.....................................................................................................134
7.6. How to Discard Parts .............................................................................................................................................. 135
Chapter 8 Replacing Control Board.......................................................................................................................... 136
8.1. Tasks Required for Replacing Control Board...................................................................................................136
8.2. How to Replace Control Board ..............................................................................................................................136
8.3. How to Initialize Converter Main Unit.............................................................................................................140
Chapter 9 Standard Specifications ...................................................................................................................... 143
9.1. Common Specifications ............................................................................................................................................143
9.2. List of Models ..........................................................................................................................................................144
Chapter 10 Outline Drawing of Converter ......................................................................................................... 145
10.1. Standard Type ............................................................................................................................................................145
10.2. Non-standard Type (Heat Generation Part Protruded Outside) ...................................................................147
Chapter 11 VF64R Parameter Compatibility Chart .............................................................................................. 148
11.1. Basic Setting Area ..................................................................................................................................................148
11.2. Area A (filter constant setting area).............................................................................................................148
11.3. Area b (operation command related setting area).........................................................................................148
11.4. Area c (multifunction input/output related setting area) ....................................................................... 149
11.5. Area E (control gain related setting area)...................................................................................................149
11.6. Area F (protection function/traceback setting area)................................................................................. 150
11.7. Area G (setting area for analog input and output).....................................................................................150
11.8. Area J (communication option setting area)...................................................................................................150
11.9. Area o (special adjustment area).......................................................................................................................151
11.10. Area P (special adjustment area)....................................................................................................................... 151
11.11. Area S (converter capacity/DC voltage detection gain area) ...................................................................151
Chapter 12 Attentions for Contacting Us......................................................................................................... 152
Chapter 13 Industrial Product Warranty.......................................................................................................... 153
13.1. No-charge warranty Period ....................................................................................................................................153
13.2. Warranty Scope ..........................................................................................................................................................153
13.2.1. Problem diagnosis ...........................................................................................................................................153
13.2.2. Repair .................................................................................................................................................................153
13.3. Disclaimers................................................................................................................................................................153
13.4. Repair period after product discontinuation.................................................................................................153
13.5. Delivery Condition ..................................................................................................................................................154

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Preface
Thank you very much for choosing our converter.
This manual describes how to handle a main unit of the converter.
It provides instructions for using the converter, such as how to install, wire, and operate it correctly as
well as handling methods of its protection operation.
Before operating it, be sure to carefully read this manual. Also, keep this manual in an appropriate place so
that operators can always take and read it.
In addition to the standard functions, the converter provides many features. You can build an optimal system
for different applications by using its various functions. In such a case, use the values described in the
dedicated "Operating Instructions" and "Test Report" for the function.
When delivering any of your products with our converter built in, consider that this manual can be distributed
to end users. Also, when changing our factory default initialized data (hereinafter referred to as
Initialize.Val) for setting parameters of the converter, make sure that end users can be informed about the
changed contents of the Initialize.Val.
Product Overview
Connecting VF66R to an inverter causes the regenerative energy from the motor to return to the power supply
efficiently, which results in energy saving. Also, the power supply harmonics generated from an inverter can
be suppressed significantly.
VF66R provides the PWM sine wave mode and 120-degree conduction mode.
The 120-degree conduction mode enables regenerative operation without high-speed switching since it energizes
according to the phase of three-phase power supply voltage in turn so that the energization period of each phase
becomes 120 degrees.

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Be Sure To Read This Before Use
Safety Notice
To use the converter correctly, be sure to completely read this manual and all other attached documents before installation,
operation, maintenance, and inspection.
You need to have a good knowledge of equipment, safety information, and all notices before using the converter.
In this manual, safety notices are ranked as "Danger," "Warning," and "Caution."
Danger
When improper use may cause a dangerous situation, death or serious injury may result, and its danger seems to be very urgent.
Danger
When improper use may cause a dangerous situation, death or serious injury may result, and its danger seems to be very urgent.
Warning
When improper use may cause a dangerous situation, and death or serious injury may result.
Warning
When improper use may cause a dangerous situation, and death or serious injury may result.
Caution
When improper use may cause a dangerous situation, medium-level or minor injury may result, and only physical damage may result.
However, it can cause serious results depending on the situation. Cautions described in this manual are all important. Be sure
to observe them.
Caution
When improper use may cause a dangerous situation, medium-level or minor injury may result, and only physical damage may result.
However, it can cause serious results depending on the situation. Cautions described in this manual are all important. Be sure
to observe them.

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Caution Installation
●Install the converter on non-inflammables such as metal.
Otherwise, a fire may occur.
●Do not put inflammables near the converter.
Otherwise, a fire may occur.
●75 kW and higher grade models are heavy. Do not attempt to raise it alone.
Otherwise, you may be injured.
●Do not hold the front cover when transporting the converter.
It may fall, which can result in injury.
●Install the converter in a place which can support its weight.
It may fall, which can result in injury.
●Do not install and operate the converter which is damaged or has a missing part.
Otherwise, you may be injured.
●Do not install the converter in an atmosphere which contains plasticizer such as halogen and DOP (phthalate ester).
Otherwise, it may be damaged.
Danger Wiring
●Before wiring, ensure that the input power supply is OFF and the system is disconnected from the power supply.
Otherwise, electric shock or a fire may occur.
Warning Wiring
●Be sure to connect a ground wire.
Otherwise, electric shock or a fire may occur.
●Electrical engineering technicians should connect wires.
Otherwise, electric shock or a fire may occur.
●Be sure to install the converter before wiring.
Otherwise, electric shock or a fire may occur.
●Do not directly connect a resistor between DC terminals [+]and [－].
Otherwise, a fire may occur.
Warning Operation
●Be sure to install the front cover before turning on the input power. Do not remove the front cover during energization.
Otherwise, it can result in a risk of electric shock.
●Do not use operation keys by wet hands.
Otherwise, it can result in a risk of electric shock.
●Do not touch terminals such as main circuit terminals and a ground terminal during energization.
Otherwise, it can result in a risk of electric shock.
●The stop button ([STOP/RESET] key) is enabled only when functions have been set. Provide an emergency stop button separately.
Otherwise, you may be injured.
When alarm reset is performed with operation signals input, the converter suddenly restarts. Check that signals are turned off,
and then perform alarm reset.
Otherwise, you may be injured.

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Caution Operation
●Do not touch a heat sink and a discharge resistor because they reach high temperatures.
Otherwise, you may get burned.
WarningMaintenance and inspection, and replacement of parts
●Before inspection, turn off the input power after checking that the operation is stopped, and then wait for over ten minutes.
Also, check that DC voltage between the DC terminals [+] and [-]is less than or equal to 30 V.
Otherwise, electric shock, injury, or a fire may occur.
●Do not perform maintenance and inspection or replace parts by anyone except qualified persons. Use a tool for insulation
for maintenance and inspection.
Otherwise, electric shock or injury may occur.
Warning Others
●Never modify the converter.
Otherwise, electric shock or injury may occur.
Caution General notice
●To provide detailed explanation, all figures described in this manual are sometimes drawn with the cover or a safety shield
removed.
To operate the converter, be sure to return the specified cover or shield to its original position and to follow the procedure
described in this manual.
●When the converter is packed with fumigated wooden materials, its electronic components may be fatally damaged.
Be sure to use ways other than fumigation for sterilization and insect removal. Also, process them before packing.
●These safety notices and specifications in this manual are subject to change without notice.

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Chapter 1 Checking and Inspecting Package
1.1. Checking Package and Inspection on Purchase
After receiving the converter, check the package, and then inspect the product and accessories.
If you have any problem, contact us or the distributor.
(1) Check that the package contains the converter main unit and "Operating Instructions."
(2) Check that the specifications, accessories, spares, and options are delivered as you order.
You can check the converter model by seeing the model label on the surface of the cover.
Model label
Converter main unit
Operating Instructions

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Example of the model label on the cover surface
(3) Check the product for damages and loose or removed screws during transportation.
Caution Safety notice
●To use the converter correctly, read this manual completely.
●Our converter is not designed and produced for the purpose of being used for a device or system under a situation where human
life may be threatened.
●Do not use this converter for special purposes such as riding, medical, aerospace, nuclear power control, and a submarine
repeater or system.
●This converter is produced under the strict quality control. However, when it is applied to an important facility where its
failure might threaten human life or cause expected serious losses, you should install any safety devices to prevent serious
accidents.
●This converter requires electrical work. Electrical engineering technicians should do it.
Applied symbol
Type
Converter series name
(Indicates a sine wave PWM converter)
Model: VF66R-7522-W1
Voltage class
22: 200 V class
44: 400 V class
Input power supply voltage specification
Converter rated output power
Weight
Serial number
7522
7522
69
75

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Chapter 2 Product Overview
2.1. Features
■Equipped with the functions designed specially for power supply
Connecting VF66R to an inverter causes the regenerative energy from the motor to return to the power supply
efficiently, which results in energy saving. Also, the power supply harmonics generated from an inverter can
be suppressed significantly.
VF66R provides the PWM sine wave mode and 120-degree conduction mode.
The 120-degree conduction mode enables regenerative operation without high-speed switching since it energizes
in turn according to the phase of three-phase power supply voltage so that the energization period of each phase
becomes 120 degrees.
■Reduced maintenance cost
Long-life parts are used for components which require replacement.
･Main circuit capacitor: About ten years (life expectancy in design)
･Cooling fan: About five years (life expectancy in design)
You can check the replacement timing with a cumulative operation timer.
2.2. Configuration
■Converter main unit
･Front cover
This is a front cover of the converter. For how to remove it, refer to {3.2.1. How to Open Front Cover}.
･Cooling fan
This is a fan motor for cooling. For how to replace it, refer to {7.3. How to Replace Cooling Fan}.
･Console
It is used for operation from the converter main unit.
It consists of a seven-segment display, a unit LED, a status display LED, and operation keys.
For details, refer to {4.1.1. Explanation of Display and Operation Keys on Console}.
Console
Cooling fan
Front cover

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■Circuit board
･Terminal block
For details of wiring, refer to {3.3.1. How to Connect Converter Terminals} and {3.5. Notes for Wiring and
Electrical Wire Size}. For details of the terminal block, refer to {3.4. Terminal Specifications}.
･Control board <VFC66R-Z>
This is a control part of the converter. A terminal block is located on the left side.
For details of wiring, refer to {3.3.1. How to Connect Converter Terminals} and {3.5.3. Electrical Wire Size
of Control Board}. For details of the terminal block, refer to {3.4. Terminal Specifications}. For how to
replace the control board <VFC66R-Z>, refer to {8.2. How to Replace Control Board}.
･Console board <SET66-Z>
This is a console part of the converter. It has LEDs and operation keys.
･Optional boards
Optional boards are used to add external input/output, etc.
Console
Board
<SET66-Z>
Connector
Support
Control board
<VFC66R-Z>
Optional board

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Chapter 3 How to Install and Connect Converter
3.1. Installation Environment and How to Install
3.1.1. Installation Environment
Install the converter in an environment not exceeding the overvoltage category III or the pollution degree 2
defined by the IEC60664-1.
Overvoltage category
Overvoltage
category
Equipment
Equipment overview
I
Secondary circuit
Equipment connecting to a circuit where any measures are taken to
limit transient overvoltage to a lower level. It includes a
protected electronic circuit.
II
Home electrical appliance
and office machine
Equipment consuming energy supplied from a fixed wiring facility.
III
Electrical facility
Equipment in the fixed wiring facility which especially requires
reliability and effectiveness.
IV
Power receiving
Equipment used for a service entrance.
Pollution degree
Pollution
degree
Overview
Specific example
1
There is no pollution, or only dry and non-conductive pollution
occurs. This type of pollution has no effect.
Clean room and others
2
Typically, only non-conductive pollution occurs. However, when the
system is not running, temporary conductivity can be expected due
to condensation.
Electrical equipment in
an office and a control
panel, and others
3
Conductive pollution, or dry and non-conductive pollution resulting
in conductivity due to expected condensation occurs.
In a general factory and
others
4
Pollution causes continuous conductivity due to conductive dust,
rain, and snow.
Outdoor and others
3.1.2. How to Install Converter
■Requirements of where to install the converter
Installation conditions of the converter will greatly affect its life and reliability. Avoid installing it in
the places listed below. Use it under the environmental conditions described in {Chapter 9 Standard
Specifications}.
(1) In a humid and dusty area or a place where water or oil drips, the insulation of circuits is deteriorated,
which may reduce the life of parts.
(2) Too high ambient temperature will cause the life of the main circuit capacitor or the cooling fan to be
reduced.
(3) In a place containing corrosive gas, connectors may have a loose connection, electrical wires may be
disconnected, and parts may be damaged.

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(4) In a place having many vibrations, connectors may have a loose connection, electrical wires may be
disconnected, and parts may be damaged.
(5) When using the converter in a place where ambient temperature is below 0 ℃, use a heater, etc. to ensure
that it becomes 0 ℃or higher at the start of the converter. After it starts, when the temperature becomes
0 ℃or higher due to its heat generation, there is no problem.
■Action after short-circuit
Dispose of a short-circuited converter in any circumstances without using it.
Caution Installation
●Install the converter on non-inflammables such as metal.
Otherwise, a fire may occur.
●Do not put inflammables near the converter.
Otherwise, a fire may occur.
●22 kW and higher grade models are heavy. Do not attempt to raise it alone.
Otherwise, you may be injured.
●Do not hold the front cover when transporting the converter.
It may fall, which can result in injury.
●Install the converter in a place which can support its weight.
It may fall, which can result in injury.
●Do not install and operate the converter which is damaged or has a missing part.
Otherwise, you may be injured.
●Do not install the converter in an atmosphere which contains plasticizer such as halogen and DOP (phthalate ester).
Otherwise, it may be damaged.
■Converter installation requirements and heat radiation
To use the converter, incorporate it into the control board, etc. to meet the environmental conditions for
installation.
Warning How to install converter
●Install it correctly.
Incorrect installation can result in a risk of electric shock or a fire.
･Installation orientation and intake/exhaust direction
Install the converter vertically with a cooling fan facing up. When it is installed sideways, ventilation is
prevented, which may increase temperature. You should sufficiently consider a path of intake and exhaust.
The cooling fan built in the converter sucks air from the bottom and exhausts it to the top. To prevent a wiring
duct, etc. from blocking up the vent, keep enough space.
･Keeping cooling space
To install the converter, keep a cooling space.
When heat generation devices exist in the surrounding environment, place them so that they do not affect cooling
of the converter and others.
The operating temperatures of the converter are 0 to 50 ℃. To install it in the control board, perform ventilation
to ensure that the temperature in the board is below 50 ℃. High ambient temperature will decrease reliability.

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3.2. How to Open and Close Front Cover
Warning Opening and closing front cover
●Be sure to turn off the converter when opening and closing the front cover.
Otherwise, it can result in a risk of electric shock.
3.2.1. How to Open Front Cover
To work inside the converter (such as connecting or wiring terminals, and maintenance/inspection), follow the
steps below to open the front cover.
■For models using a sheet-metal chassis and front cover
Remove the sheet-metal front cover and the resin control part cover.
1. Use the Phillips screwdriver (M4) to remove the mounting screws at the top of the front cover.
2. Loosen the screws at the bottom of it.
3. Remove the front cover from the main unit.
･The number of mounting screws at the top and bottom of the front cover depends on the model. Refer to the
figure below.
30cmormore
20cmormore
10cmormore
10cmormore
Exhaustair
Intakeair
Converterunit
15 cmormore
15 cmormore
15 cmormore
15 cmormore
20cmormore
ACreactor

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For VF66R-20044，25044，31544
(40044～100044)
Upper cover
For VF66R-7522，9022（15022，18022）
7544，11044，16044
Just loosen the lower screws to
remove the covers
Front cover mounting screw
(Upper cover: 5 pcs)
(Lower cover: 5 pcs)
Lower cover
Just loosen the lower screws to
remove the covers
Front cover mounting screw
(Upper cover: 5 pcs)
(Lower cover: 5 pcs)
4. When the control part cover is vibration resistant, use the
Phillips screwdriver (M4) to remove two mounting screws of the
control part cover.
･When it is not vibration resistant, it does not have mounting
screws.
5. While holding the lock part of the control part cover with
your thumb, pull it and remove it,
using the two claws on the right side as supporting points.
Controlpartcover
mountingscrew(2pcs)
Controlpartcover
Claw
Lockpart
<Vibration-resistantspecificationonly>

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When opening the front cover, check that the serial number described in the front of the front cover matches
the one described inside the main unit.
<Front>
* Check that the serial number specified on the front cover agrees with
that specified inside the inverter.
Front cover
VFC66R-Z
Control board
7522
7522
69
75
Warning Notes for replacing parts
●Do not disassemble the converter unreasonably.
●After disassembling it, check that all parts are assembled correctly.
Incorrect assembly can result in a risk of a fire.
●In particular, if a flat cable is not inserted correctly, the control circuit may not work properly.
●Make sure that screws are tightened.

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3.2.2. How to Close Front Cover
Follow the steps below to close the front cover of the converter.
When closing the front cover, ensure that the serial number described in the main unit matches the one described
on the front cover. For how to check the serial number, refer to {3.2.1. How to Open Front Cover}.
■For models using a sheet-metal chassis and front cover
Install the resin control part cover and the sheet-metal front cover.
1. Insert the two claws on the right side of the control part cover into the sockets of the converter main
unit.
2. Push them until a lock clicks.
3. When the control part cover is vibration resistant, use the
Phillips screwdriver (M4) to tighten the two mounting screws of
the control part cover.
･Tighten it within a tightening torque of 1.4 N･m.
･When it is not vibration resistant, it does not have mounting
screws.
Controlpartcover
mountingscrew(2pcs)
<Vibration-resistantspecificationonly>
Controlpartcover

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4. Use the Phillips screwdriver (M4) to tighten the mounting screws of the front cover.
･Tighten it within a tightening torque of 1.5 N･m.
･The number of mounting screws of the front cover depends on the model. Refer to the figure below.
Upper cover
Lower cover
Mounting screw: Upper cover 5 pcs
Lower cover 5 pcs
VF66R-7522, 9022
7544, 11044, 16044
Mounting screw: Upper cover 4 pcs
Lower cover 4 pcs
VF66R-20044, 25044, 31544
Lower cover
Upper cover