Hitachi SJ100 Series, Service Manual

Page 1: ...0 022NFE SJ100 004HFE to SJ100 075HFE US Version SJ100 002NFU to SJ100 022NFU SJ100 004HFU to SJ100 075HFU SJ100 037LFU Japanese Version SJ100 002LFR to SJ100 037LFR SJ100 004HFR to SJ100 075HFR After reading this manual keep it at hand for future reference NBS585XA Hitachi Ltd Tokyo Japan SJ100 SERIES ...

Page 2: ... 1 DC Bus Voltage 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 Main...

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

Page 4: ...ttached at the 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 SJ100 Version number E European version U US version R Japanese...

Page 5: ...202 10 10 10 3 Deceleration time 1 Set F03 10 10 10 Deceleration time 1 2nd setting Set F203 10 10 10 4 Running direction setting Set F04 00 00 00 5 Extended function A group setting Set A 6 Extended function B group setting Set B 7 Extended function C group setting Set C 8 Extended function H group setting Set H Note means hidden display depends on 2nd setting selection 3 Inverter specifications ...

Page 6: ...ump 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 Selection of PID control Set A71 00 00 00 29 P gain Set A72 1 0 1 0 1 0 30 I gain Set A73 1 0 1 0 1 0 31 D gain Set A74 0 0 0 0 0 0 32 Scale conversion of PID control Set A75 1 0 1 0 1 0 33 Feedback destination Set A76 00 00 00 34 Selection of AVR function Set A81 02 02 02 35 AVR voltage Set A8...

Page 7: ...ration mode Set B21 01 01 01 7 Overload restriction level Set B22 note note note Rated current 1 25 for each inverter 8 Deceleration rate while overload restriction Set B23 1 0 1 0 1 0 9 Selection of software lock Set B31 01 01 01 10 Analog meter adjustment Set B81 80 80 80 11 Start frequency adjustment Set B82 0 5 0 5 0 5 12 Carrier frequency Set B83 5 5 12 13 Data initialization or Trip history ...

Page 8: ...00 00 15 FM terminal condition set C23 00 00 00 16 Function of AL terminal setting Set C24 05 05 05 17 Output terminal 11 condition Set C31 00 00 00 18 Output terminal 12 condition Set C32 00 00 00 19 AL output terminal condition Set C33 01 01 01 20 Level of overload signal Set C41 note note note Rated current of each inverter 21 Arrival frequency while acceleration Set C42 0 0 0 0 0 0 22 Arrival ...

Page 9: ... R2 setting Set H21 2 2 2 Motor constant R2 setting 2nd setting Set H221 2 2 2 8 Motor constant L setting Set H22 2 2 2 Motor constant L setting 2nd setting H220 2 2 2 11 Motor constant Io setting H23 2 2 2 Motor constant Io setting 2nd setting H223 2 2 2 12 Motor constant J setting H24 2 2 2 Motor constant J setting 2nd setting Set H224 2 2 2 13 Motor constant R1 auto tuning data 1 H30 2 2 2 Moto...

Page 10: ...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 7 E ...

Page 11: ...terminals 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 back light 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 Monito...

Page 12: ...ituations 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 frequency inverter operation Remedy Switching over the motor is inhibited Cause Defect in the power component Remedy Check the IGBT portion of ISPM Cause Rapi...

Page 13: ... Reduce the load and or increase thermal level and or use bigger capacity of frequency inverter Cause V Boost value is high Remedy Reduce V Boost value or increase thermal level and or use bigger capacity of frequency inverter Cause Set wrong value for electronic thermal level b12 and or electronic thermal characteristic b13 Remedy Set suitable value Cause Set wrong value for the reactive current ...

Page 14: ...the frequency inverter Cause The mains voltage is not available or not within the tolerance limits Remedy Check all 3 or 2 mains power supply voltage that it is within its specification Cause Thyristor for smooth charging is defect and DC bus voltage drops while operation due to current flows through smooth charging resistor Remedy Change ISPM Cause Period of instantaneous power failure is longer ...

Page 15: ...pec occurs on built in CT Cause Influenced by Electrical Magnetic Interference such as near contactor on off Remedy To Resolve if it s influence use another power line and don t connect motor wires control wires If no error comes out resolve noise causes Cause CT offset level failure Remedy To Resolve if it s failure use another power line and power on and check if E10 comes out at power on If E10...

Page 16: ... 11 Ground fault error E 14 Phenomena Earth contact in the motor or the motor cable or in the IGBT Frequency inverter detects this earth contact only at power up To resolve the causes please power off and disconnect the motor wire at INV UVW terminal Cause Earth contact in the motor or the motor cable Remedy Check the impedance between output portion wire and motor and earth Cause Detection circui...

Page 17: ...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 thermistor is not suitable Frequency inverter gives PTC error when the resistance value becomes more than 3k ohm 10 Remedy Use motor which has suitable thermist...

Page 18: ...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 While INV running Stop the INV RS or FRS command is giv...

Page 19: ... time If front case is not closed by the screw difficult 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 20: ...er L Over load Possible to reset after 10 seconds has passed detected by CT OL BRD Over voltage after the BRD ED was run out DC bus Over V Over voltage DC bus EEPROM EEPROM error Check the parameters again if this error occurred Under V Under voltage DC bus CT CT offset error such as external noise or CT itself CPU 1 CPU error CPU 2 External External error USP USP error GND Flt Ground fault at pow...

Page 21: ...en there is no data i g feedback data of PID etc Auto tuning was done Auto tuning was failed 3 6 Auto tuning under high incoming voltage If Auto tuning is not successful try following procedure 1 Set C91 01 and press STR key to access debug mode 2 Set H01 01 and press STR key to do auto tuning 3 If the SJ100 is 4kW or less set C94 fb82 and press STR key 3 If the SJ100 is 5 5kW or above set C94 fb8...

Page 22: ...cy 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 SJ100 002NFE U 100 90 80 70 16 14 12 10 8 6 4 2 0 5 Carrier frequency kHz rate of output current SJ100 004NFE U 100 90 80 70 16 14 12 10 8 6 4 2 0 5 Carrier frequency kHz SJ100 015NFE U 100 90 80 70 16 14 12 10 8 6 4 2 0 5 Carrier frequency kHz 16 ...

Page 23: ... 6 4 2 0 5 Carrier frequency kHz SJ100 007HFE U 100 80 90 60 70 40 50 16 14 12 10 8 6 4 2 0 5 SJ100 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 SJ100 004HFE U 100 80 90 60 70 40 50 16 14 12 10 8 6 4 2 0 5 16 SJ100 015HFE U 100 80 60 40 14 12 10 8 6 4 2 0 5 Carrier frequency kHz 90 70 50 4 2 ...

Page 24: ...y kHz SJ100 075LFU 100 90 80 70 16 14 12 10 8 6 4 2 0 5 Carrier frequency kHz SJ100 055HFE U 100 90 80 70 16 14 12 10 8 6 4 2 0 5 Carrier frequency kHz SJ100 075HFE U 100 90 80 70 16 14 12 10 8 6 4 2 0 5 4 3 16 SJ100 040HFE U 100 80 60 40 14 12 10 8 6 4 2 0 5 Carrier frequency kHz 90 70 50 ...

Page 25: ...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 26: ...usly 100sec while stop BRD circuit has no hysterisys 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 BRD on off level 37...

Page 27: ...voltage Vdc Actual 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 BRD on off level 740V 40V ...

Page 28: ...rated 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 100 220 190 150 180s 120s time 150 60s E Thermal Level 100 No over load trip with 115 load 60s 180 10s output curr...

Page 29: ... 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 SJ100 inverter V L 5 PTC U Motor PTC thermistor W 5 4 E Except Japanese version ...

Page 30: ...rsal tester with a diode function Visual check is important for the ISPM check the appearance 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 located o...

Page 31: ... 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 MOV ZNR ZNR1 ZNR2 ZNR3 are for phase to phase MOV ZNR ZNR4 ZNR5 ZNR6 are for phase to ground R L1 T L3 S L2 P1 6 2 1 U R Ll W V ...

Page 32: ...Pin down Black 20kohm or more Pin up Black Pin down Red 50ohm or less relative check is important 6 Cooling FAN Disconnect the cooling FAN and measure impedance of FAN circuit Resistance Measurement Allowable Value From To Red wire Black wire 50kohm or less Black wire Red wire 100kohm or more relative check is important 7 BRD RB Disconnect BRD resistor Red wire Black wire mean tester s wires Resis...

Page 33: ...rom moisture and oil 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 be mea...

Page 34: ...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 35: ...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 36: ...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 37: ...n Tester Main circuit Overall Check installation for looseness 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 Visual inspection Clean Terminal block No damage Visual inspection No abnormalities DC bus capacitor Check for leaking liquid Visual No abnormalities Check for swelling inspection Relay Check f...

Page 38: ... Operate without any trouble Component check including PCB No abnormal odor nor changes in color Visual inspection No abnormalities No significant corrosion Capacitors on I O board No liquid leakage nor deformation Visual inspection No abnormalities Display Digital operation panel No illegible display No lack of character Segment failure of LEDs Visual inspection Normal operation Display is readab...

Page 39: ... 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 POTEN TIOMETER SUB CONDENCER BOARD HFx C B RS LFU NFE Tr BR RB BRD resistor option EMC DIRECTIVE COMPLIANT WITH DEDICATED NOISE FILTER OPTION Note Main circuit capacitor CB HFE HFU serial connection LFU NFE single connection 9 1 E ...

Page 40: ......

Page 41: ...l models 1 10 5 D 254863 4T013419 4 Top cover S SJ100 002 007LFR SJ100 002 005NFE SJ100 002 004NFU 1 10 5 D 254865 4T013459 4 Top cover L SJ100 015 037LFR SJ100 007 022NFE SJ100 007 022NFU SJ100 037LFU SJ100 004 037HFR SJ100 004 040HFE HFU 1 10 5 D 3T016369 4 Top cover LL SJ100 055 075LFU HFE HFU LFR HFR 1 10 6 D 254856 2T004371 4 Case S SJ100 002 007LFR SJ100 002 005NFE SJ100 002 004NFU 1 10 6 D ...

Page 42: ...No Class Parts Code DWG No Parts Name Remarks Quantity Lot 9 C 254270 3T012518 2 Cooling fan S SJ100 015 022LFR HFR SJ100 015 022HFE HFU SJ100 055LFR LFU 1 3 9 C 254270 3T012518 2 Cooling fan S SJ100 075LFU LFR 2 3 9 D 254822 3T011924 4 Cooling fan L SJ100 022NFE NFU SJ100 037LFR LFU HFR SJ100 030HFE SJ100 040HFE HFU 1 3 10 D 254827 4T013337 1 ISPM IO Cable S SJ100 002 037LFR SJ100 002 022NFE NFU ...

Page 43: ...HFR HFE HFU 1 1 11 3T017103 2 ISPM without PCB2 SJ100 075HFR HFE HFU 1 1 12 254890 4T013548 1 RS soft charge resistor SJ100 002 022NFE NFU SJ100 037 055LFU SJ100 002 055LFR SJ100 004 055HFE HFU HFR 1 10 12 254890 4T013548 1 RS soft charge resistor SJ100 075HFE HFU LFU LFR HFR 2 10 13 4T013438 1 Copper bar SJ100 002 007LFR SJ100 002 004NFE NFU 005NFE 1 10 13 4T013439 1 Copper bar SJ100 015 037LFR S...

Page 44: ... 16 SJCB2680A PCB2 SJ100 004NFE NFU 005NFE 1 1 16 SJCB560B2 PCB2 SJ100 007NFE NFU 1 1 16 SJCB470B2T PCB2 SJ100 015NFE NFU 037LFR LFU 1 1 16 SJCB680B2T PCB2 SJ100 022NFE NFU 1 1 16 L100SB055L PCB2 SJ100 055LFR LFU 1 1 16 L100SB075L PCB2 SJ100 075LFR LFU 1 1 16 SJCB180B4 PCB2 SJ100 004HFR HFE HFU 1 1 16 SJCB270B4 PCB2 SJ100 007HFR HFE HFU 1 1 16 SJCB470B4 PCB2 SJ100 015HFR HFE HFU 1 1 16 SJCB680B4 P...

Page 45: ...is used between ISPM and heatsink C H version is applied US version except key pad knob cover case etc This spare parts list will be changed without notice To get latest spare parts list please contact to sales office This service manual may not be revised if the spare parts list was revised 10 5 ...

Page 46: ...me 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 SJ100 002NFE 002NFU 004NFE 004NFU 005NFE ...

Page 47: ...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 SJ100 004HFE 004HFU 007NFE 007NFU 011NFE ...

Page 48: ... 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 SJ100 007HFE 007HFU 015HFE 015HFU 022HFE 022HFU ...

Page 49: ...y 1 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 SJ100 015NFE 015NFU ...

Page 50: ...se 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 SJ100 022NFE 022NFU 030HFE 037LFU 040HFE 040HFU ...

Page 51: ...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 SJ100 055LFU 055HFU 075HFU 055HFE 075HFE 055LFE 10 11 ...

Page 52: ...nt 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 SJ100 075LFU 075LFE 10 12 ...

Page 53: ...037HFR 055LFR 075LFR 055HFR 075HFR SJ100EUL C D H V SJ100EUL E F G H V SJ100075EUL A V SJ100L C D H V SJ100075L A V Note SJ100xxxEUx SOURCE type on the control terminal different from SINK SJ100xxxL SINK type on the control terminal different from SOURCE kW setup is not necessary such as J100 J300 series for I O board if I O board was replaced There is no compatibility between L100 series and SJ10...

Page 54: ...ing F01 is not enough max freq increase C81 value and press the STR key and check the result If the freq Setting F01 is not enough continue the above procedure OI terminal adjustment Supply the DC20 mA and if the freq Setting F01 is not enough max freq increase C82 value and press the STR key and check the result If the freq Setting F01 is not enough continue the above procedure If the data was ad...

Page 55: ...heck B12 display 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 se...

Page 56: ......

Page 57: ......

Page 58: ......

Page 59: ......

Page 60: ......

Page 61: ......

Page 62: ......

Page 63: ......

Page 64: ......

Page 65: ......

Page 66: ......

Page 67: ......

Page 68: ......

Page 69: ......

Page 70: ......

Page 71: ......

Page 72: ......

Page 73: ......

Page 74: ......

Page 75: ...End of page ...