Hitachi L100 Series, Service Manual

Page 1: ...to L100 075HFE US Version L100 002NFU to L100 022NFU L100 004HFU to L100 075HFU L100 037LFU L100 002MFU to L100 007MFU Japanese Version L100 002LFR to L100 037LFR L100 004HFR to L100 075HFR L100 002MFR to L100 007MFR After reading this manual keep it at hand for future reference NBS541X Hitachi Ltd Tokyo Japan L100 SERIES ...

Page 2: ...ge Detection Characteristics 5 2 Output Current Detection Characteristics 5 3 Motor Temperature Detection PTC 5 4 Over Temperature Detection of the Frequency Inverter 6 Measurement Replacement of Subassemblies 6 1 Insulation Measurement 6 2 Power Components Measurements 7 Maintenance and Inspection Procedure 7 1 Precautions 7 2 Measurement of Mains Voltage Current and Power 7 3 Maintenance of Part...

Page 3: ...Revisions Revision history table No Revision contents Date of issue Manual No ⅰⅰ ...

Page 4: ...e side cover of the unit 1 Description of the model name 2 Description of MFG No Inverter model MFG No T112967 0060 H 8 7 Unique number Production code Revision of the inverter Production Month 1 9 0 October J November K December Production year The unit digit of the year of grace 7 1997 8 1998 9 1999 0 2000 1 1 E F 015 H L100 Version number E European version U US version R Japanese version Serie...

Page 5: ...Monitor d05 6 Intelligent output terminal condition monitor Monitor d06 7 Output frequency converted value monitor Monitor d07 8 Trip monitor Monitor d08 9 Trip history monitor Monitor d09 2 Inverter specifications Basic function mode Display Function name Category Screen display Initial Remarks order Code display EU US JPN 1 Output frequency setting set F01 0 0 0 0 0 0 2 Acceleration time 1 set F...

Page 6: ... of DC braking set A51 00 00 00 20 DC braking frequency set A52 0 5 0 5 0 5 21 DC braking waiting time set A53 0 0 0 0 0 0 22 DC braking force set A54 0 0 0 23 DC braking time set A55 0 0 0 0 0 0 24 Frequency upper limiter set A61 0 0 0 0 0 0 25 Frequency lower limiter set A62 0 0 0 0 0 0 26 Jump frequency 1 3 set A63 A65 A67 0 0 0 0 0 0 27 Jump frequency width 1 3 set A64 A66 A68 0 5 0 5 0 5 28 S...

Page 7: ...level set b22 note note note Rated current 1 25 for each inverter 9 Deceleration rate while overload restriction set b23 1 0 1 0 1 0 10 Selection of software lock set b31 01 01 01 11 Reactive current setting set B32 note note Note Rated current 0 58 for each inverter 13 Analog meter adjustment set b81 80 80 80 14 Start frequency adjustment set b82 0 5 0 5 0 5 15 Carrier frequency set b83 5 5 12 16...

Page 8: ...3 condition set C13 00 00 00 9 Input terminal 4 condition set C14 00 01 00 10 Input terminal 5 condition set C15 00 00 00 11 Output terminal 11 assign set C21 01 01 01 12 Output terminal 12 assign set C22 00 00 00 13 FM terminal condition set C23 00 00 00 14 Output terminal 11 condition set C31 00 00 00 15 Output terminal 12 condition set C32 00 00 00 16 AL output terminal condition set C33 01 01 ...

Page 9: ...FG number kW Motor output p Motor poles rpm Motor rated rpm Amps Rated current V Rated voltage Hz Rated frequency Amps Starting current Equipment name Torque characteristics Nm Required torque kgm2 Load inertia J sec Acceleration time sec Deceleration time Hz to Variable speed range Hz 1 6 E ...

Page 10: ...ls Nominal voltage min 21 60Vdc to max 26 40Vdc Check PV24 address 1A L NV12L supply voltage Supplies 12Vdc to remote operator DOP DRW s yellow backlight Nominal voltage max 10 80Vdc to min 17 5Vdc Check NV12 address 3A L H terminal voltage Suppiles 10V to H terminal Nominal voltage min 9 5Vdc to max 11 5Vdc Check H L with VR 1kohm Potentiometer function on the front case Set A01 00 Monitor F01 di...

Page 11: ...ted from the inverter the overcurrent should not be detected anymore Cause A single phase power failure fuse wire can cause a shutdown in certain underload situations Remedy Check all these mains phases and the mains fuses preferably by comparison of the three two in case of single phase inverter mains currents in a steady operating state Cause The motor is switched with a motor contactor during f...

Page 12: ...rapid mains voltage return choke energy leads to voltage increase Remedy Make sure that mains voltage is within tolerance limits Cause In case L100 is used in combination with a regenerative braking unit but the regenerative braking unit does not function Remedy Replace regenerative braking unit Cause In case L100 is used in combination with a raking resistor but the braking resistor cannot absorb...

Page 13: ... EEPROM If this time is too short this storage performance cannot be done and leads to EEPROM error Remedy Keep certain time between power off and re power up Cause You didn t wait 6 seconds or more at FACTORY SETTING Remedy Please try FACTORY SETTING again Cause RS terminal was keeping ON at power off If RS is on INV can not write the correct data to EPROM at power off next power on E08 will come...

Page 14: ... USP function is selected Cause Frequency inverter trips when it is powered up with RUN command is given Remedy Disable RUN command when power up the frequency inverter Or disable USP function if possible to the system Way to Reset A or set RUN command off stop 9 Ground fault error E 14 Phenomena Earth contact in the motor or the motor cable or in the IGBT Frequency inverter detects this earth con...

Page 15: ...ntilation openings in the cabinet Way to Reset A 12 PTC error E 35 Phenomena Resistance of motor thermistor is high This error can occur when you select PTC function Cause Too much load of the motor Remedy Reduce the load use bigger motor Cause Motor thermistor is not connected while PTC function is selected Remedy Disable PTC function when it is not used Cause Characteristics of the motor thermis...

Page 16: ... not increase speed Motor load is too heavy Overload limitation Remove or decrease the motor load External frequency set VR is out of order replace VR Frequency limiter A61 is set Eliminate frequency limiter Acceleration time is too short Set longer acceleration time The inverter cannot be programmed Software lock is selected b31 Make software lock invalid RS or FRS command is given Make them inva...

Page 17: ...e time If front case is not closed by the screw dittcult to press 3keys 4 Additionally press key and release key approximately after one second 5 Keep pressing keys until d 00 will blink Approximately 2 seconds 6 Release all the keys after starts blinking c95 INV kW code 01 0 2kW 02 0 4kW 03 0 75kW 0 5 kW 04 1 5kW 05 2 2kW 06 3 7kW 4 0kW 07 5 5kW 08 7 5kW Initialization end Release after d 00 star...

Page 18: ... other condition than above such as 0Hz injection brake Over L Over load Possible to reset after 10 seconds has passed Over V Over voltage DC bus EEPROM EEPROM error Check the parameters again if this error occurred Under V Under voltage DC bus CPU 1 CPU error CPU 2 External External error USP USP error GND Flt Ground fault at power on OV SRC Over voltage at source DC bus OH FIN Over temperature P...

Page 19: ... as at power on Voltage is within UV level Power OFF During retry mode During initialization as EU settings During initialization as US settings During initialization as Japanese settings Erasing trip histories Copying with DRW DRW 2 When there is no data i g feedback data of PID etc 3 9 E ...

Page 20: ...ency Standard ratings in 40 degree C Top cover removed condition in 50 degree C max Top cover removed condition in 55 degree C max rate of output current L100 002NFE U 100 90 80 70 16 14 12 10 8 6 4 2 0 5 Carrier frequency kHz rate of output current L100 004NFE U 100 90 80 70 16 14 12 10 8 6 4 2 0 5 Carrier frequency kHz L100 015NFE U 100 90 80 70 16 14 12 10 8 6 4 2 0 5 Carrier frequency kHz 16 L...

Page 21: ...8 6 4 2 0 5 Carrier frequency kHz L100 007HFE U 100 80 90 60 70 40 50 16 14 12 10 8 6 4 2 0 5 L100 022HFE U 100 80 90 60 70 40 50 16 14 12 10 8 6 4 2 0 5 Carrier frequency kHz Carrier frequency kHz L100 004HFE U 100 80 90 60 70 40 50 16 14 12 10 8 6 4 2 0 5 16 L100 015HFE U 100 80 60 40 14 12 10 8 6 4 2 0 5 Carrier frequency kHz 90 70 50 4 2 ...

Page 22: ...16 14 12 10 8 6 4 2 0 5 Carrier frequency kHz L100 055HFE U 100 90 80 70 16 14 12 10 8 6 4 2 0 5 Carrier frequency kHz L100 075HFE U 100 90 80 70 16 14 12 10 8 6 4 2 0 5 Carrier frequency kHz L100 002MFU L100 004MFU 100 90 80 70 16 14 12 10 8 6 4 2 0 5 Carrier frequency kHz L100 007MFU 100 90 80 70 16 14 12 10 8 6 4 2 0 5 ...

Page 23: ...e will be as follows 4 Amps 90 95 3 4 Amps Note 1 When the top cover is removed for the high ambient temperature inverter should be installed in an enclosure of IP 4 see EN60529 to comply with LVD directive Note 2 If class B of EMC directive is required carrier frequency must be set to 5kHz 100 90 80 70 1000 2000 3000 4000 Altitude m Carrier frequency derating Altitude frequency derating 4 4 E ...

Page 24: ...followings 1 200V class 5 1 Over voltage level 395V 20V 400 DC bus voltage Vdc Actual DC bus voltage Trip on Display example of monitoring output frequency Under voltage trip or During Under voltage Over voltage trip Waiting for Retry 350 300 250 200 150 100 50 0 Trip Reset Under voltage recovering level 220V 10V Under voltage level 190V 10V on Trip ...

Page 25: ...ctual DC bus voltage Trip Trip Display example of monitoring output frequency Under voltage trip or During Under voltage Over voltage trip Waiting for Retry Under voltage recovering level 440V 20V Under voltage level 380V 20V 700 600 500 400 300 200 100 0 Trip Reset on on ...

Page 26: ...current is 7 1 Arms 200 14 2 Arms 20 1 A peak 2 Over load Electronic thermal protection Frequency inverter shuts off the output when integration value of output current and time exceeds specific value This Electronic thermal level can be changed from 50 to 120 Initial setting is 100 200 150 180s 120s time 150 60s E Thermal Level 100 No over load trip with 115 load 60s 180 10s output current of the...

Page 27: ... 10 the frequency inverter trips with E35 5 4 Over Temperature Detection of the Frequency Inverter Frequency inverter has a temperature detection against power devices of the main circuit Frequency inverter shuts down the output when temperature around IGBT comes up to 120 degree C L100 inverter V L 5 PTC U Motor PTC thermistor W 5 4 E Except Japanese version ...

Page 28: ...universal tester with a diode function Visual check is important for the ISPM check the outlooking such as smoke trace Note In this test the absolute values are not so important since they depend strongly on the test device used The uniformity of the measured value is more important 1 DC BUS Measurement Check voltage Zero Resistance Measurement Allowable Value From To 50kohm or more P1 PD are loca...

Page 29: ... R Ll R Ll S L2 S L2 T L3 T L3 Each R Ll S L2 and T L3 50kohm or more Each R Ll S L2 and T L3 50 ohm or less Each R Ll S L2 and T L3 P1 50 ohm or less P1 Each R Ll S L2 and T L3 50kohm or more To make sure MOV visual check of MOV is necessary on the ISPM If the result is out of its spec replace the unit relative check is important R L1 T L3 S L2 P1 6 2 1 U R Ll W V T L3 S L2 Main circuit of L100 R...

Page 30: ... find the failure while they are not activated 5 Cooling FAN voltage circuit in the ISPM PV 24N Measurement on the ISPM Disconnect the cooling FAN Resistance Measurement Allowable Value From To Pin Red Pin Black 20kohm or more Pin Black Pin Red 50ohm or less relative check is important 6 Cooling FAN Disconnect the cooling FAN and measure impeadance of FAN circuit Resistance Measurement Allowable V...

Page 31: ...way from moisture and oil z Dusts steel filings swarf and other foreign materials can damage insulation and causing unexpected accidents failure Please pay attention to them 7 2 Measurement of Mains Voltage Current and Power General measuring instruments for mains voltage current and power are shown in Table 7 1 The voltage to be measured is the effective value of fundamental wave and the power to...

Page 32: ...type watt meter for single phase use Make measurements for all 3 phases is case there is an unbalance in voltages and currents Fig 7 2 Output voltage measurement circuit without motor U V W Frequency Inverter 2W 220kohm Additional resistor 5kohm 30W 200V class 100W 400V class VDC Fundamental wave effective value VAC VDC 1 1 Moving coil type DC Volt meter 300V 200V class 600V 400V class Diode 600V ...

Page 33: ...er Factor Pf1 Calculate from above measured values E1 I1 and W1 Pf W E I 1 3 100 1 1 1 Output voltage Eo EU V EV W and EW U According to Fig 7 1 and Fig 7 2 Total effective value Output current Io IU IV and IW Moving iron type ammeter Total effective value Output power Wo WO1 and WO2 Electrodynamics wattmeter Total effective value Output power factor Pf2 Calculate from above measured values Eo Io ...

Page 34: ...ery three years taking their lives into account Please note that their life span shorten when they are used in high temperatures and heavy loads 7 4 If you install replacement INV at site If you install replacement units at site please preset the parameter by the panel or copy unit If you used the previous I O board to replacement unit the parameters are not changed Because parameters are memorize...

Page 35: ...er Main circuit Overall Check installation for looseness 9 Tighten Tightening torque except for terminal block M3 0 5 0 6 N m M4 0 98 1 3 N m Check for evidence of over heating in the various components 9 Visual inspection Clean 9 Terminal block No damage 9 Visual inspection No abnormalities DC bus capacitor Check for leaking liquid 9 Visual No abnormalities Check for swelling inspection Relay Che...

Page 36: ... Operate without any trouble Component check including PCB No abnormal odor nor changes in color 9 Visual inspection No abnormalities No significant corrosion 9 Capacitors on I O board No liquid leakage nor deformation 9 Visual inspection No abnormalities Display Digital operation panel No illegible display No lack of character Segment failure of LEDs 9 Visual inspection Normal operation Display i...

Page 37: ...L3 S L2 R L1 INVERTER CONVERTER １ W T3 V T2 U T1 DRIVE CIRCUIT DETECT V I POWER SUPPLY MCU EEPROM COMMUNICATION PORT CORE INVERTER ISPM SERIAL COMMUNICATION HITACHI USER INTERFACE I O BLOCK I O board TERMINALS OPERATION PANEL WITH POTENTIOMETER SUB CONDENCER BOARD RS EMC DIRECTIVE COMPLIANT WITH DEDICATED NOISE FILTER OPTION 9 1 ...

Page 38: ...1 INVERTER CONVERTER １ W T3 V T2 U T1 DRIVE CIRCUIT DETECT V I POWER SUPPLY MCU EEPROM COMMUNICATION PORT CORE INVERTER ISPM SERIAL COMMUNICATION HITACHI USER INTERFACE I O BLOCK I O board TERMINALS OPERATION PANEL WITH POTENTIOMETER SUB CONDENCER BOARD RS EMC DIRECTIVE COMPLIANT WITH DEDICATED NOISE FILTER OPTION 9 2 ...

Page 39: ...ETECT V I MCU EEPROM CORE INVERTER ISPM SERIAL COMMUNICATION RUN FUNC 1 2 STR PRG RUN A Hz STOP RESET MAX MIN POWER HITACHI ISORATION POWER SUPPLY COMMUNICATION PORT USER INTERFACE I O BLOCK I O board SUB CONDENCER BOARD TERMINALS OPERATION PANEL WITH POTENTIOMETER EMC DIRECTIVE COMPLIANT WITH DEDICATED NOISE FILTER OPTION 9 3 E ...

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Page 41: ... 5 D 254872 3T016369 1 Top cover LL L100 055 075LFU HFE HFU 1 10 6 D 254820 2T004371 1 Case S L100 002 004NFE NFU 1 10 6 D 254817 1T001783 1 Case M L100 005 007NFE L100 007NFU L100 004 015HFE HFU L100 002 004MFU 1 10 6 D 254816 1T001782 1 Case L L100 011 022NFE L100 015 022NFU 037LFU L100 022 040HFE HFU L100 007MFU 1 10 6 D 254866 1T001858 1 Case LL L100 055 075LFU HFE HFU 1 10 7 D 254829 4T013417...

Page 42: ...ISPM without PCB2 L100 011 015NFE L100 015NFU 1 1 11 3T015522 3 ISPM without PCB2 L100 022NFE NFU 1 1 11 3T015524 3 ISPM without PCB2 L100 037LFU 1 1 11 3T016566 2 ISPM without PCB2 L100 055LFU 1 1 11 3T016567 2 ISPM without PCB2 L100 075LFU 1 1 11 3T015526 1 ISPM without PCB2 L100 004HFE HFU 1 1 11 3T015527 1 ISPM without PCB2 L100 007HFE HFU 1 1 11 3T015528 1 ISPM without PCB2 L100 015HFE HFU 1 ...

Page 43: ...075LFU L100 055 075HFE HFU 1 1 15 CB470 Capacitor board L100 011 015NFE L100 015NFU L100 037LFU 1 1 15 CB680 Capacitor board L100 022NFE NFU 1 1 15 CB470H Capacitor board L100 030 040HFE L100 040HFU 1 1 15 CB680M Capacitor board L100 007MFU 1 1 15 CB68X4L Capacitor board L100 055LFU 1 1 15 CB68X6L Capacitor board L100 075LFU 1 1 15 CB68X4H Capacitor board L100 055HFE HFU 1 1 15 CB68X6H Capacitor b...

Page 44: ...00B2 PCB2 L100 002MFU 1 1 16 CB1800B2 PCB2 L100 004MFU 1 1 16 CB1800B2T PCB2 L100 007MFU 1 1 Note No 10 4T013337 3 is usable for 4T01337 4 The difference is the length No 13 The copper bar is used between ISPM and heatsink C H version is applied US version except key pad knob cover case etc S 002NFE 004NFE 002NFU 004NFU M 005NFE 007NFE 004HFE 007HFE 015HFE 007NFU 004HFU 007HFU 015HFU L 011NFE 015N...

Page 45: ...s name Quantity 1 Keypad 1 2 Front case L 1 3 Key cover 1 4 Volume knob 1 5 Top cover S 1 6 Case S 1 7 Rear cover S 1 10 ISPM IO cable S 1 11 ISPM 1 12 RS 1 14 I O board 1 16 PCB2 1 L100 002NFE 002NFU 004NFE 004NFU ...

Page 46: ...me Quantity 1 Keypad 1 2 Front case L 1 3 Key cover 1 4 Volume knob 1 5 Top cover L 1 6 Case M 1 7 Rear cover L 1 10 ISPM IO cable L 1 11 ISPM 1 12 RS 1 14 I O board 1 16 PCB2 1 L100 004HFE 004HFU 005NFE 007NFE 007NFU ...

Page 47: ...No Parts name Quantity 1 Keypad 1 2 Front case L 1 3 Key cover 1 4 Volume knob 1 5 Top cover L 1 6 Case M 1 7 Rear cover L 1 10 ISPM IO cable L 1 11 ISPM 1 12 RS 1 14 I O board 1 16 PCB2 1 L100 007HFE 007HFU ...

Page 48: ...name Quantity 1 Keypad 1 2 Front case L 1 3 Key cover 1 4 Volume knob 1 5 Top cover L 1 6 Case M 1 7 Rear cover L 1 8 Cooling fan L 1 10 ISPM IO cable L 1 11 ISPM 1 12 RS 1 14 I O board 1 16 PCB2 1 L100 015HFE 015HFU ...

Page 49: ... Keypad 1 2 Front case L 1 3 Key cover 1 4 Volume knob 1 5 Top cover L 1 6 Case L 1 7 Rear cover L 1 8 Condensor cover 1 10 ISPM IO cable L 1 11 ISPM 1 12 RS 1 14 I O board 1 15 Capacitor board 1 16 PCB2 1 L100 011NFE 015NFE 015NFU ...

Page 50: ...ase L 1 3 Key cover 1 4 Volume knob 1 5 Top cover L 1 6 Case L 1 7 Rear cover L 1 8 Condensor cover 1 9 Cooling fan L 1 10 ISPM IO cable L 1 11 ISPM 1 12 RS 1 14 I O board 1 15 Capacitor board 1 16 PCB2 1 L100 022NFE 022NFU 030HFE 037LFU 040HFE 040HFU ...

Page 51: ...Keypad 1 2 Front case L 1 3 Key cover 1 4 Volume knob 1 5 Top cover L 1 6 Case L 1 7 Rear cover L 1 8 Condensor cover 1 9 Cooling fan L 1 10 ISPM IO cable L 1 11 ISPM 1 12 RS 1 14 I O board 1 16 PCB2 1 L100 022HFE 022HFU 10 11 ...

Page 52: ...1 3 Key cover 1 4 Volume knob 1 5 Top cover LL 1 6 Case LL 1 7 Rear cover LL 1 8 Condensor cover LL 1 9 Cooling fan S 1 10 ISPM IO cable L 1 11 ISPM 1 12 RS 1 14 I O board 1 15 Capacitor board 1 16 PCB2 1 L100 055LFU 055HFU 075HFU 055HFE 075HFE 10 12 ...

Page 53: ... Front case L 1 3 Key cover 1 4 Volume knob 1 5 Top cover LL 1 6 Case LL 1 7 Rear cover LL 1 8 Condensor cover LL 1 9 Cooling fan S 2 10 ISPM IO cable L 1 11 ISPM 1 12 RS 1 14 I O board 1 15 Capacitor board 1 16 PCB2 1 L100 075LFU 10 13 ...

Page 54: ...10 14 No Parts name Quantity 1 Keypad 1 2 Front case L 1 3 Key cover 1 4 Volume knob 1 6 Case M 1 7 Rear cover L 1 10 ISPM IO cable L 1 11 ISPM 1 12 RS 1 14 I O board 1 16 PCB2 1 L100 002MFU 004MFU ...

Page 55: ...name Quantity 1 Keypad 1 2 Front case L 1 3 Key cover 1 4 Volume knob 1 6 Case L 1 7 Rear cover L 1 8 Condensor cover 1 10 ISPM IO cable L 1 11 ISPM 1 12 RS 1 14 I O board 1 15 Capacitor board 1 16 PCB2 1 L100 007MFU ...

Page 56: ...EULH F is available from L100EUL G J K M P I O board Name Revision 002NFE 022NFE 002NFU 022NFU 037LFU 004HFE 040HFE 004HFU 040HFU 002LFR 037LFR 004HFR 037HFR 055HFE 075HFE 055LFU 075LFU 055HFU 075HFU 055LFR075LFR 055HFR 075HFR L100EUL A V L100EUL B C G H K M P V L100EULH F V L100EUL G J K M P V L100L D E G J K M P V L100L G J K M P V L100075EUL L N P V L100075L L N P V 10 16 ...

Page 57: ...et C94 F947 O terminal adjustment constant set C95 xx adjust this data power off and wait Power lamp off and power on and check the freq setting set C91 01 Debug on set C94 F948 OI terminal adjustment constant set C95 xx adjust this data power off and wait Power lamp off and power on and check the freq setting set C91 00 Debug off If the data was added the freq setting will be increased concept is...

Page 58: ...play F 23 E THM LVL B12 s display table kW 200V 400V 002 1 40 004 2 60 1 50 005 007 4 00 2 50 011 015 7 10 3 80 022 10 00 5 50 030 040 15 90 8 60 055 24 0 13 0 075 32 0 16 0 kW code table common L100 SJ100 xx kW 01 002 02 004 03 005 007 04 011 015 05 022 06 030 040 07 055 08 075 In case of L100 SJ100 it automatically detects it s voltage class with hardware in the ISPM voltage class setup is not n...

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