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AF-300 Mini - Dealers Electric Motor

1. P99 1 for GE standard motors P99 4 for Other motors For motors from other manufacturers or unknown models set P99 to 4 Other motors H04 HOS Retry Times latency time To automatically exit from the alarm status and restart the drive use the retry functions The drive automatically exits from Alarm mode and restarts without issuing a block alarm even if it has already entered the forced Alarm mode If the drive has entered Alarm mode many times in excess of the number of times specified by function code H04 it issues a block alarm and does not exit Alarm mode for restarting Listed below are the recoverable alarm statuses of the drive Alarm Status LED monitor display Instantaneous overcurrent protection 0C1 0C2 or 0C3 Overvoltage protection 0U1 0U2 or 0U3 The 230 V and 460 V series of motors share the same data listed above P99 Motor Selection In order to perform automatic control features such as the auto torque boost auto energy saving and slip compensation or overload protection for the motor electronic thermal the drive invokes the rated values and properties of the motor To match the drive proper ties of the drive and motor set the motor properties to this code and set function code HO3 Initialize data to 2 to initialize the motor parameter This action automati cally updates the data of function code P03 and the
2. of the two ground terminals Electric Codes specify that i a co all metal frames of electrical equipment must be ground fas baie Sl g 1 i EF DT oy ed to avoid electric shock fire and other disasters 3 P Ground terminals should be wired as follows A a 1 Connect the ground terminal of the drives to a a Util ground in compliance with your applicable local ee a a Electric Codes oy 2 Connect a thick ground wire with a large surface ae area and keep the wiring length as short as pos sible Figure 2 5 Drive Output Terminal Wiring pT Fa t oF 5i a j ft Output Cicuit Filter 7 pial Power Power a T nma j Suppl Suppl iia aT So SO Z Drive Motor SPE pene Max 165 ft 60m Max 1300 ft 400m ef ET EL i i a NOTE Do not connect a power factor improvement ca Fes A pacitors or surge absorber to the drive output terminals Figure 2 4 Ground Terminal Wiring If the wiring length is excessive stray capacitance between the wires will increase resulting in high leakage current This may activate the overcurrent protection increase leakage current or degrade the accuracy of the current display If more than one motor is to be connected to a single drive the allowable wiring length is the combined length of all the wires to the motors NOTE Driving a 460V motor If a thermal relay is installed in the path between the drive and the motor the thermal relay may malfunction even with a wiring length shorter than 165 ft
3. To select To select manual Load type torque boost set pee ee F37 0 Variable torque F09 0 0 to 20 0 F37 1 por Constant torque F09 0 0 to 20 0 If auto energy saving operation is enabled by selecting load properties during acceleration and deceleration general purpose motors and other induction motors is set to 5 minutes by factory default To select Data entry range 0 5 to 75 0 minutes in 0 1 minute L To select manual t oad type torque boost set automatic torque increments babel set REFERENCE Refer to the AF 300 Mini User s Manual Variable torque 37 8 1 Chapter 9 FUNCTION CODES for details of the built in OE RAE NNE F37 5 cooling fan and properties of electronic thermal detection F37 4 Constant torque F09 0 0 to 20 0 F14 Restart after Instantaneous Power Failure F10 to Eec tronie THEnnalOyeroan Selects the action of the drive to be followed when an Property Selection Overload Detection mle Level and Thermal Time Constant Function codes F10 through F12 set the thermal proper ties of the motor including the thermal time constant This imputes motor overload using the embedded electronic thermal detection of the drive which calcu lates motor temperature indirectly based on the drive s internally measured output current F11 is used to determine the overload detection level NOTE Thermal properties of the motor spec
4. Stops the drive by detecting overvoltage 100V 200V series 400 Vdc 400V series 800V in de link circuit Incoming surge Protects the drive from surge voltage entering between main circuit power cable and earth cable Stops the drive by detecting voltage drop 100V 200V series 200V DC 400V series 400V in de link circuit Input phase loss Stops the drive against input phase loss by simply detecting the ripple voltage at a capacitor Output phase loss Stops the drive by detecting output cable s phase loss at the start of operation or during operation Overheating Stop the drive by detecting drive heat sink temperature caused by a failure or overload of the cooling fan Stops the drive and built in braking transistor if discharging capability or allowable loss set for the braking resistor is exceeded more frequency than the set number of times Overload Stops the drive by calculating the IGBT internal temperature from the output current and drive heat sink temperature Electric Stops the drive to protect the motor when the set output current is exceeded thermal Thermal time constant can be adjusted 0 5 to 75 0min PTC thermistor A PTC thermistor stops the drive to protect the motor Protection Warning signal can be output based on the preset level before stopping the drive E 2 3 D 2L 2 2 o 2 Overload early warning Stall Lowers output frequency to prevent overcurrent trip when output cu
5. e Check that the operating environment conforms to Chapter 2 Section Operating Environment e Check that the LED monitor displays normally e Check for abnormal noise odor or excessive vibration e Check for signs of overheating such as discoloration and for other defects 7 2 Periodic Inspection Perform periodic inspection using the list items of Table 7 1 Stop the motor turn the drive off and remove the control and main circuit terminal block covers to perform periodic inspection Table 7 1 List of Periodic Inspections Check part Check item How to inspect Evaluation criteria Environment Check the ambient temperature humidity 1 Check visually or measure 1 Standard specifications vibration and atmosphere dust gas oil mist using suitable test instru must be met or water drops ments Check if tools or other foreign matter or 2 No foreign or dangerous dangerous objects are left around the equip 2 Visual inspection objects present ment Voltage Check if the voltages of the main and control Measure the voltages using a The standard specification circuit are correct multimeter or similar must be satisfied Keypad 1 Check if the display is clear 1 2 1 2 2 Check for missing elements in the display Visual inspection The display can be read characters and there is no fault 7 1 Check part Structure such as frame and cover Table 7 1 List of Periodic Inspections C
6. Data reset 1_Return to factory set value 2_Motor parameter initializing Motor 1 H Auto reset Times 0_Inactive 1 to 10 times Reset interval 0 5 to 20 0s 1_Active 1 5kW and above ACC DEC pattern 0_Inactive linear 1_S curve weak 2_S curve strong 3_Curvilinear H12 Instantaneous overcurrent Select limiting PTC thermistor Select 0_Inactive 1 Active Arbitrary point on Frequency _0 0 cancel to 400 0 Hz polygonal V f line Voltage 0 t0 240V_AVR active 230V class 1 V 0 to 500V_AVR active 460V class H54 ACC DEC time Jogging operation 0 00 to 3600s Hz s imi ba 0 1 c rrent or tordue limiting active 0 0 Depends on F16_Freq limiter Low 0 1 to 60 0Hz Ha Low limiter min freq when Automatic deceleration control Select 0_Inactive Regeneration prevention 1_Active Overload prevention control 0 00 equivalent to DEC time 0 01 to 100 0Hz s 999 cancel 5 6 H80 Current oscillation suppression 0 00 to 0 20 gain H96 STOP key priority Start check Data function STOP key priority function OFF ON OFF ON Start check function OFF OFF ON ON Clear alram data Returns to zero after data clear by H97 setting at 1 Eee a p Protection Select Data 0 1 2 3 4 5 6 Y 3 maintenance function Carrier frequency automatic DEC function OFF ON OFF ON OFF ON OFF ON Input phase loss protection OFF OFF ON ON OFF OFF ON ON Output phase loss protection OFF OFF OFF OFF ON ON ON
7. If you press the or key in any conditions other than those described above the following will appear Frequency command Multistep Sneed eon from communications frequency seals a Displayed using or key link command PID enabled 0 Disabled Disabled Frequency command by keypad Cancelled PID enabled PID output as final frequency command Other than the above Manual speed command currently selected frequency Cancelled command TIP e When setting the frequency and others with the keys the lowest digit on the display will flash Change the setting starting from the lowest digit and the cursor will move to the next digit to be changed e When the data is to be dump changed hold down the key for 1 second or longer and the flashing cursor will move to the next digit where the data can be changed cursor movement 3 Monitor the Running Status In Run mode the seven items listed below can be monitored Immediately after the drive is turned on the monitor item specified by function code E43 is displayed Press the key to switch between monitor items Table 3 3 Monitor Items Display Sample on Monitor Items the LED monitor Meaning of Displayed Value Speed monitor Hz rom m min min Refer to Table 3 4 Output current A Detected value Power kW P An alternative expression for kW Output voltage V Commanded value PID process command Note P Non PI
8. a0 50 90 110 o Overload capabilit 150 of rated current for 1 min 200 of rated current for 0 5 s 50 60 Hz Phase voltage frequenc 3 phase 200 to 240V 50 60 Hz 3 phase 380 to 480V 50 60 Hz Voltage frequency variations Voltage 10 to 15 voltage unbalance 8 2 or less Frequency 5 to 5 Momentary voltage dip As long as input voltage is 165V or more the drive capability 4 continues operation If it drops below 165V the drive operates for 15 ms Output ratings As long as input voltage is 300V or more the drive continues operation If it drops below 300V the drive operates for 15 ms Rated current 9A Required Pen E K fos oa os fit 20 so 4a os ia 20 29 49 Capacity 5 kVA Torque 7 aa 150 150 DC injection braking Starting frequency 0 0 to 60 0 Hz braking time 0 0 to 30 0 s braking level 0 to 100 of rated current Conformity to safety standards UL508C C22 2No 14 EN50178 1997 Conformity to EMC standards __Conductive Radiated disturbance Class 1A EN55011 1998 A1 1999 ity __ Industrial environment second environment EN61800 3 1996 A1 1 2000 Enclosure IEC60529 Cooling method Natural cooling Natural cooling won m efe e Polos os ou os os os os foo N D T z is gt 2 GE 4 pole standard motor Drive output capacity kVA at 230V 460V Output voltage cannot exceed the power supply voltage Tested under standard conditions with 85 nominal m
9. 11 OLU Overload protection Problem Temperature inside drive rises abnormally Possible Causes What to Check and Suggested Measures Temperature around the drive exceeds drive specifications CHECK Measure the temperature around the drive SUGGESTED ACTIONS Lower the temperature e g improve control board ventilation Reduce the load The service life of the cooling fan has expired or the cooling fan malfunctioned CHECK Check the accumulated running time of cooling fan E52 2 Refer to Chapter 3 Section 3 8 Reading Maintenance Information SUGGESTED ACTIONS Replace the cooling fan CHECK Visually check that the cooling fan is turning normally SUGGESTED ACTIONS Replace the cooling fan Air vent blocked CHECK Check if there is sufficient clearance around the drive SUGGESTED ACTIONS Increase the clearance CHECK Check if the heat sink is clogged SUGGESTED ACTIONS Clean the heat sink Excessive load CHECK Measure the output current SUGGESTED ACTIONS Reduce the load e g lighten the load before overload occurs using the overload early warning E34 Decrease the carrier frequency F26 Enable overload protection control H70 Acceleration decelera tion time too short CHECK Recalculate the required acceleration deceleration torque and time using the moment of inertia for the load and the deceleration time SUGGESTED ACTIONS Lengthen
10. 3 54_ 0 foso 10 loos as GKXCIZIF25EG 3 15 80 2 64 67 0 26 6 5 6 67 170 433 110 0 20 3 94 100 3 54 0 0 99 10 0 06 1 5 4 02x0 24 4 6x6 GKXCIZ1FSOEG 3 15_ 0 2 64 67 0 26 6 5 6 67 170 4 33 110 0 20 4 53 115 3 54 0 Joos 25 0 06 1 5 Indicates product revision on To ato RIS e a D gt 2 jojolo ojojo jo njo jojo atla ta lao a Jo To ato RIS ow on a NOTE EMC Filter Built in type H size includes EMC flange for shield cable 8 11 Dimensions inches mm Aa 3 phase 230V 6KXC123002X9 2 52 64 6KXC123003X9 2 52 64 3 phase 460V 6KXC143F50X9 1 57 40 6KXC143001X9 2 52 64 6KXC143002X9 2 52 64 6KXC143003X9 2 52 64 1 phase 230V 6KXC121002X9 2 52 64 6KXC111001X9 1 57 40 6KXC143F50E9 1 57 40 6KXC143001E9 2 52 64 6KXC121001E9 1 57 40 If EMC filter Built in Type is supplied the total height is 7 05 which includes the EMC flange for shielded cable connection Dimensions inches mm Model No 3 phase 230V ekxc123005x9 547 139 295 g5 252 6 6KXC143005X9 295 75 252 64 6KXC121003X9 2 95 75 252 4 6KXC123002E9 ekxc123003E9 747 182 4 aa 2 6KXC123005E9 ekxc143002E9 7147 182 4 118 6KXC143003E9 6KXC143005E9 118 2 6KXC121002E9 18 64 6KXC121003E9 118 64 If EMC filter Buil
11. A command similar to terminal Y1 can be selected for the transistor output signal and use it for signal output Switching of the normal negative logic output is applicable to the following two contact outputs Terminals 30A and 30C are short circuited for ON signal output or the terminals 30B and 30C are short circuited non excite for ON signal output Used to connect the drive with PC or PLC using RS485 port Used to connect the drive with the remote keypad The drive supplies the power to the remote keypad through the extension cable for remote keypad This terminal can be used with standard drives equipped with an RS485 communications card option NOTE Route the wiring of the control terminals as far from the wiring of the main circuit as possible in order to prevent malfunctioning resulting from interference and noise Fix or bind the control cables inside the drive so that they are kept away from the live parts of the main circuit such as the main circuit terminal block 2 12 2 3 7 Switching of SINK SOURCE Jumper Bar Warning Before changing the jumper bar wait for at least five minutes after the power has been turned off then check with a multimeter that the dc voltage between main circuit terminals P and N does not exceed a safe voltage 25 V An electric shock may result if this warning is not heeded as there can be residual electric charge in the intermediate dc circuit capacitor
12. Possible Causes What to Check and Suggested Measures The coast to stop com mand was enabled CHECK Check the data of function codes E01 E02 E03 E98 and E99 using Menu 2 Data checking and the input signal status with Menu 4 I O checking SUGGESTED ACTIONS Disable the coast to stop command setting Broken wire incorrect connection or poor contact with the motor CHECK Check if the output current and connection are correct SUGGESTED ACTIONS Repair the wires to the motor or replace them Overload Torque generated by the motor was insufficient CHECK Check that the output current is not too large SUGGESTED ACTIONS Reduce the load e g operate the mechanical brake correctly CHECK Check that the motor starts running if the value of torque boost F09 is increased SUGGESTED ACTIONS Increase the value of torque boost F09 and try to run the motor CHECK Check the data of function codes F04 F05 H50 and H51 SUGGESTED ACTIONS Change the V f pattern to match the motor s characteristics 2 The motor rotates but the speed does not increase Possible Causes What to Check and Suggested Measures The maximum frequency was set to too low a value CHECK Check the data of function code F03 SUGGESTED ACTIONS Reset the maximum frequency F03 to a correct value The peak frequency of the frequency limiter was set to too low a value The set f
13. With the menu displayed use the and keys to select I O check 4 _0 2 Press the key to display the codes for the I O check item list e g 4_00 3 Use the and keys to select the desired I O check item then press the key The corresponding I O check data will appear For control I O signal terminal and control circuit terminal input under communication control use the 1 and keys to select one of the two different display methods 4 Press the key to return to the I O check item list Press the key again to return to the menu Table 3 10 I O Check Items LED monitor display Display contents Description I O signals on the control circuit Shows the ON OFF state of the digital I O terminals Refer to Displaying control terminals I O signal terminals below for details on the display contents I O signals on the control circuit Shows the ON OFF state for the digital input terminals that received a command terminals when communications via RS485 communications Refer to Displaying control I O signal terminals control LE is active below for details on the display contents Input voltage on terminal 12 Shows the input voltage on terminal 12 in volts V Input current on terminal C1 Shows the input current on terminal C1 in milliamperes mA Output voltage to analog meters FMA Shows the output voltage on terminal FMA in volts V Displaying control I O s
14. code F14 the drive automatically restarts running the motor when the power is recovered Design the machine so that human safety is ensured after restarting Otherwise an accident could occur F15 F16 Frequency limiter F15 limits the peak or maximum output frequency Frequency limiter F16 maintains the output frequency at a minimum level even if the set frequency is lower than that Refer to the figure below Frequency Limiter Peak and Minimum NOTE Set the peak and minimum frequencies correctly otherwise the drive may not operate Maintain the following relationship between the limiters Peak frequency gt Minimum frequency Starting frequency Stop frequency Minimum frequency lt Maximum frequency F18 Bias for Frequency Command 1 C50 _ Bias Bias reference point for frequency C32 command 1 C34 Analog Input Adjustment Gain and gain C37 reference point for terminal input 12 C39 Analog Input Adjustment Gain and gain reference point for terminal input C1 If you select any analog input for frequency command 1 it is possible to define the relationship between the analog input and the set frequency arbitrarily by combin ing the settings for bias F18 bias reference point C50 gains C32 and C37 and gain reference points C34 and C39 As illustrated in the graph on the next page the rela tionship between the set frequency and analog input for fre
15. of 10 V then the bias reference point should be 10 C50 10 Point B If the analog input is at 5 V the set frequency comes to be the maximum value Therefore the gain is 100 C32 100 Since 5 V is the gain reference point and it is equal to 50 of 10 V then the gain reference point should be 50 C34 50 NOTE When using the function codes for setting a standalone gain or bias without changing any reference points the setting procedure for the function codes is the same as that of GE Fuji s conventional drive models ae ring ied Pes DC Brake Starting frequency Braking level and Braking time F20 to F22 These function codes enable a dc brake to prevent the motor from coasting by its inertia while it is decelerat ing to a stop Set function codes F20 for the starting frequency F21 for the braking level and F22 for the braking time as follows CAUTION The brake function of the drive does not provide me chanical holding means Otherwise injuries could occur F43 F44 Current Limiter Operation condition and Limiting level F43 enables or disables the current limiter If it is enabled the drive controls the output frequency while keeping the current set to the value in F44 in order to prevent the motor from stalling With F43 you may select whether the current limiter works during constant speed operation only F43 1 or during both acceleration and constant
16. 0 Allocated bit data is displayed on the LED monitor in 4 digit hexadecimals 0 to F each In the AF 300 Mini digital input terminals FWD and REV are assigned to bit 0 and bit 1 respectively Terminals X1 through X3 are assigned to bits 2 through 4 The value 1 is set for each bit when the assigned input terminal is short circuited with terminal CM ON The value 0 when it opens OFF For example when FWD and X1 are ON and all others are OFF the display on LED4 to LED1 would be 0005 The value 1 is set when bit 0 is assigned to digital output terminal Y1 and the terminal is short circuited with Y1E and the value 0 is set when it opens The status of the mechanical relay contact output terminal 30A 30B and 30C are assigned to bit 8 The value 1 is set when the circuit between output terminals 30A and 30C is closed and the value 0 when the circuit between 30B and 30C is closed For example if Y1 is ON and the cir cuit between 30A and 30C are short circuited with each other then the display for LED4 to LED1 would be 0101 How the hexadecimal display is configured for the terminals to which bits 15 to 0 are assigned and the 7 segment LED is shown below LED No Bit Input terminal Output terminal E g of input binary LED monitor display hexadecimal no correlating contr
17. 2 Estimation of service life using maintenance information Menu 5 Maintenance Information in Program mode can be used to display the recommended time for replace ment of the intermediate dc circuit capacitor electrolytic capacitors on the printed circuit board and cooling fan When operating time exceeds the early warning level an early warning signal is output to any external device through terminal Y1 function code E20 When any replacement exceeds the recommended time terminal Y1 also outputs an ON signal Table 7 2 Parts Replacement Time Estimation with Menu 5 Maintenance Information Parts to be replaced Judgement level Intermediate dc circuit capacitor 85 or lower of the capacitance than that of the factory setting Electrolytic capacitor on the printed circuit board 61 000 hours or longer as accumulated run time Cooling fan 61 000 hours or longer as accumulated run time Applicable motor rating 2 to 5 hp Assumed life of cooling fan at ambient drive temperature of 40 C 1 Intermediate dc circuit capacitor Determine the capacitance of the intermediate dc circuit capacitor as follows Capacitance is displayed as a reduction ratio of the initial value written to the drive memory before shipment Capacitance measurement procedure 1 Remove the RS485 communications card option from the drive if it is mounted Disconnect the dc bus link circuit to other drives from terminals P and N
18. 4 digit display ROM version of keypad panel Shows the ROM version of the keypad panel as a 4 digit display For remote keypad only 3 17 3 9 Reading Alarm Information Alarm information Menu 6 Alarm information in Program mode shows the cause of the past 4 alarms as alarm codes Further it is also possible to display alarm information that indicates the status of the drive when the alarm occurred Table 3 13 shows the contents of the alarm information and Figure 3 10 shows the status transition of the alarm information kii La kn hiri Rune samia onio bi Poe biri iS diid wm ia eije erm Dama beers A A a U Dinin aiae et si Bama m owe Tama M oa Figure 3 10 Status Transition of Alarm Information Basic key operations 1 With the menu displayed use the and keys to select Alarm information 6 AL 2 Press the key to display the alarm list code e g 1 0L1 In the list of alarm codes the alarm information for last 4 alarms will be saved as an alarm history 3 Each time the and keys are pressed the last four alarms are displayed in order from the most recent one as 1 2 3 and 4 4 Press the key while the alarm code is displayed and the corresponding alarm item number e g 6_00 and data e g Output frequency are displayed continuously in turn for 1 second each It is possible to display the item number e g 6_01 and data e g Outp
19. Hz1 Function code data 11 Turning the digital input signal Hz2 Hz1 ON OFF may switch the frequency setting method between frequency command 1 defined by function code F01 and fre quency command 2 defined by function code C30 Turning the Hz2 Hz1 command ON allows the fre quency command 2 to be selected Enable editing of function code data from the keypad WE KP Function code data 19 Turning OFF the WE KP command prohibits changing of function code data from the keypad Only when the WE KP command is turned ON you may access function code data from the keypad accord ing to the setting of function code F00 as listed below If WE KP is F00 Function set to 0 Permit editing of function code data ON 1 Inhibit editing of function code data except F00 OFF Disabled Inhibit editing of function code data If the WE KP command is not assigned to any terminal the drive will interpret WE KP as being always ON Disable PID control Hz PID Function code data 20 Turning the Hz PID command ON OFF enables or disables the PID control If the PID control is disabled with the Hz PID being OFF the drive runs the motor with the frequency manu ally set by any of multi step keypad or analog input REFERENCE Refer to the AF 300 Mini User s Manual Chapter 4 Section 4 8 PID Frequency Command Generator for details Switch Normal Inverse operation IVS Function c
20. Link functions To be used for communications Link functions REFERENCE Refer to Chapter 5 FUNCTION CODES for details on the function codes Function codes that require simultaneous keying To change data for function codes F00 Protect data and HO3 Initialize data simultaneous keying operation is necessary keys or keys This prevents data from being lost by mistake 3 9 Changing reflecting and saving of function code data during running Some function code data can be changed while the motor is running and some can not Further amongst the function codes whose data can be changed while the motor is running there are some for which the changes can be reflected immediately and others for which that is not possible Refer to the Changes during running column in Chapter 5 Section 5 1 Function Code Tables Figure 3 4 shows the status transition for Menu 1 Data settings and Figure 3 5 shows an example of the function code data changing procedure Prey dieti bibi Bikra List of techn oes Funnies daia Mipu Ft Tui es Press the key when the y99 data is displayed to return to FOO Figure 3 4 Status Transition Diagram for Data Setting Basic key operation This section will give a description of the basic key operation following the example of the function code data changing procedure shown in Figure 3 5 This example shows you how to change function code F01 data from t
21. Possible Causes What to Check and Suggested Measures An instantaneous power SUGGESTED ACTIONS failure occurred Reset the alarm To restart running the motor without an alarm set F14 to a value of 4 or 5 depending on load The power to the drive CHECK was switched back on Only switch the drive on after the power for the control circuit has reached an appropriate level This can too soon with F14 1 be checked using the display on the LED monitor SUGGESTED ACTIONS Wait longer before switching the drive on The power supply voltage CHECK did not reach the range of Measure the input voltage the drive s specifications SUGGESTED ACTIONS Increase the voltage to specification Peripheral equipment CHECK for the power circuit Measure the input voltage to find where the peripheral equipment malfunctioned or which connection is malfunctioned or the incorrect connection was wrong SUGGESTED ACTIONS Replace any faulty peripheral equipment or correct any wrong connections High inrush current of CHECK other loads connected to Measure the input voltage and check the voltage variation the same power system SUGGESTED ACTIONS as the drive caused a Reconsider the power system configuration temporary voltage drop Inrush current caused the CHECK power voltage drop be Check if the alarm occurs when you switch on a molded case circuit breaker a ground fault circuit cause power transformer interrupte
22. Rectifier or moving iron Type of meter Symbol of meter NOTE When output voltage is measured by a rectifier type voltmeter errors may be occur or the voltmeter may burn out To measure with higher accuracy use a digital ac power meter Figure 7 1 Connection of Meters 7 4 7 4 Insulation Test Because an insulation test is performed in the factory before shipment avoid a Megger test If a Megger test is unavoidable follow the procedure below Caution an incorrect test procedure will damage the drive A dielectric strength test will also damage the drive if the wrong test procedure is used If a dielectric strength test is necessary contact the shop where you bought the product or GE Fuji 1 Megger test of main circuit Use a 500 Vdc Megger and be sure to shut off the main power supply during measurement If the test voltage leaks to the control circuit due to the wiring disconnect all the control wiring 3 Connect the main circuit terminals using a common cable as shown in Figure 7 2 The Megger test must be limited to across the common line of the main circuit and the ground terminal G 5 MQ ora larger value displayed at the Megger indicates a correct state The value is for a discrete drive Drive LIR LoS LT OB P1 P NE U Megger Figure 7 2 Megger Test 2 Dielectric strength test of control circuit Do not perform a Megger test or dielectric strength test for the control circu
23. a o Main oltage Terminal 1 Denotes the relay contact terminals for 30A 30B and 30C 2 Denotes control terminals except for 30A 30B and 30C 3 Use 75 Cu wire 4 See page 2 15 table 2 6 for details viii Precautions for Use Driving a 460V standard motor When operating a 460 V standard motor on a drive with extremely long cables damage to the insulation of the motor may occur Use an output circuit filter OFL if necessary after checking with the motor manufacturer GE motors do not require the use of output circuit filters because of their superior insulation Application with standard motors Torque characteristics and temperature rise Vibration Noise A standard motor will run hotter when operated with a drive than if connected to standard ac power Furthermore the effectiveness of the motor s cooling fan is reduced in the low speed range which in turn reduces the allowable output torque If constant torque is required in the low speed range either use a GE drive motor or a motor equipped with a separate cooling fan Use of a drive does not increase vibration of a standard motor but when the motor is mounted to a driven load mechanical resonances may be caused by the combined natural frequencies of the total machine system The use of a rubber coupling or vibration dampening rubber is recommended It is also recommended to use the drive Jump Frequency control function to avoid operati
24. by the 2 p early electronic thermal function for the purpose of protecting the motor warning Q Stall prevention Operates when the current limit is active Current limit Operates if the current limit set in the hardware is exceeded by the drive s output current avoiding tripping of the drive during constant speed operation or during acceleration External alarm input Stops the motor with an alarm through the digital input signal THR OH2 Yes Alarm relay output The drive outputs a relay contact signal when the drive issues an alarm and Yes for any fault stops the motor f Alarm Reset the alarm stop state is reset by pressing the key or by the digital input signal RST Saving the alarm history and detailed data information for the previous 4 alarms can be saved and displayed Memory error The drive checks memory data after power on and when the data is written If a Er1 Yes memory error is detected the drive stops Remote keypad The drive stops on detecting any communication error between the drive and the Er2 Yes communications error remote keypad option during operation from the remote keypad If the drive detects a communication error when the remote keypad is connected with the power on or when the power is turned on with the remote keypad con nected it displays Er2 without alarm relay output CPU error If the drive detects a CPU error caused by noise or some other factor the drive stops Er3 Yes Op
25. curve 0 to 240V 0 to 400Hz can be set Output voltage between 160 and 500V at base frequency and at maximum output frequency 400V common spec class AVR control can be turned ON or OFF Desired 1 point on non linear V f curve 0 to 500V 0 to 400 Hz can be set Torque boost Auto torque boost constant torque load Manual torque boost Constant torque load or variable torque load can be selected Starting Starting torque 150 or over Auto torque boost in 5 Hz operation Start Stop Keypad operation Start and stop with RUN STOP keys External signal FWD stop REV stop 3 wire operation possible Digital input coast to stop command external alarm alarm reset etc Timer operation Stop after elapse of the time set with the keypad Link operation Communication via RS485 option i range Output frequency Frequency setting Can be set with UP or DOWN key Can be set with built in potentiometer Can be set with variable resistor External potentiometer 1 to 5kQ1 2W Analog input 0 to 10 Vdc 5 Vdc 5V by changing the setting of analog input gain 200 1 to 5 Vdc adjustable by bias or analog input gain 4 to 20mA de Multistep freq setting Multistep speed operation Link operation Selectable from 8 steps by 3 bit external signal Can be set with communication via RS485 option Freq setting change Two types of freq settings can be switched with an external signal digital input Freq aux
26. even after the power has been turned off To switch the sink source of the input signal change the positioning of the jumper bar using a pair of long nose pliers as shown in Figure 2 16 At the factory setting the jumper bar is positioned at SINK a i Ae S Stea y i g zi EE s a k 7 ra a a a Le irm t his a AAE i dumper Bex Figure 2 16 Switching of SINK SOURCE Jumper Bar 2 3 8 Installing an RS485 Communications Card Option When an optional RS485 communications card is to be used install it before replacing the main circuit TB cover Align the card with the latch on the drive and attach the card to the connector that is located above terminals 30A 30B and 300 Liit Pel ASME Communications tog re Cond ein fl b _aiet yas few ie bor paisa ARAN i T A Tine Figure 2 17 Installing an RS485 Communications Card Option 2 3 9 Replacing the Control Circuit Terminal Block TB Cover Upon completion of the wiring of the control circuits fit the latches provided on the upper end of the control circuit TB cover into the openings in the front face of the drive and then close the TB cover NOTE Take care not to pinch the signal lines between the TB cover and drive body Barras Boe Pa HLS Como Citai Terria Tr ePi aai Prat i Huri acer f C ae eae ins ge yey e d a mi f 1 4 When connecting the RS485 communications cable remove the control circuit TB c
27. even if the braking resistor does not appear to be hot If the resistor is used to the limit of its capacity the data values for function codes F50 and F51 must be changed and the surface temperature of the resistor checked 10 OL1 Electronic thermal overload relay Problem Electronic thermal function for motor overload detection activated Possible Causes What to Check and Suggested Measures 1 Excessive load CHECK Measure the output current SUGGESTED ACTIONS Reduce the load e g lighten the load before overload occurs using the overload early warning E34 2 The acceleration CHECK deceleration time was Check that the motor generates enough torque for acceleration deceleration This torque is calculated too short using the moment of inertia for the load and the acceleration deceleration time SUGGESTED ACTIONS Lengthen the acceleration deceleration time F07 F08 E10 E11 and H54 6 12 Possible Causes What to Check and Suggested Measures 3 The characteristics of electronic thermal did not match those of the motor overload CHECK Check the motor characteristics SUGGESTED ACTIONS Reconsider the data of function codes P99 F10 and F12 Use an external thermal relay 4 Activation level for the electronic thermal relay was inadequate CHECK Check the continuous allowable current of the motor SUGGESTED ACTIONS Reconsider and change the data for function code F11
28. fi Cip beqemrcy li tel ec Pere Figure 3 7 Drive Monitoring Status Transition 1 With the menu displayed use the and keys to select drive monitoring 3 0PE 2 Press the key to display the desired code in the monitoring items list e g 3_00 3 Use the and keys to select the desired monitoring item then press the key The running status information for the selected item will appear 4 Press the key to return to the monitoring items list Press the key again to return to the menu LED monitor display 3_00 Contents Output frequency Output frequency Table 3 6 Drive Monitoring Display Items Description Output frequency before slip compensation Output frequency after slip compensation Output current Current output current Output voltage Current output voltage Set frequency Current set frequency Running direction Displays the running direction currently being outputted F forward R reverse stop Running status Displays the running status in hex format Refer to Displaying running status on the next page Load shaft speed line speed The unit for load shaft speed is rom and that for line speed is m min Display value Output frequency Hz before slip compensation x Function code E50 is displayed for 10000 rpm or m min or more When is displayed the data is overflowing which means that the function code should b
29. if it detects an output phase loss while it is running If a magnetic contactor that has been inserted in the drive output circuits switches off when the drive is run ning however this protection will not be activated 6 Troubleshooting 6 1 Before Proceeding with Troubleshooting WARNING If any of the protective functions have been activated first eliminate the cause Then after checking that the all run commands are set to OFF reset the alarm Note that if the alarm is reset while any run commands are set to ON the drive may supply power to the motor and cause it to start Injury may occur Even though the drive has interrupted power to the motor if voltage is applied to the main circuit power input terminals L1 R L2 S and L3 T L1 L and L2 N for 1 phase voltage input then voltage may also be present at the drive output terminals U V and W Some residual electric charge may remain in the intermediate dc circuit capacitor even after the power is turned off It may take some time until the intermediate dc circuit voltage reaches a safe level Before touching any part of the circuit wait for at least five minutes after the power has been turned off and verify that the dc voltage between main circuit terminals P and N is less than 25 V using a multimeter Electric shock may occur Follow the procedure below to resolve any problems 1 Ifa connection has been performed incorrectly refer to Chapter 2 Subse
30. in the primary circuit more than once an hour as a drive fault may result If frequent starts or stops are required during motor operation use FWD REV signals or the RUN STOP key When using a motor with a drive the motor can be protected using the electronic thermal control ability of the drive In addition to the operation level set the motor type standard motor Environmental or drive motor For high speed motors or water cooled motors set a small value for the thermal conditions time constant and protect the motor in combination with the cooling system OFF signal When ore Protecting the a s l a in combination with driving several motors with a drive connect a thermal relay to each motor and turn on the drive s motor peripheral devices electronic thermal relay function If you connect the motor thermal relay to the motor through continued a long cable a high frequency current may flow in the wiring due to its increased capacitance This could cause the relay to trip at a current lower than the set value for the thermal relay In this case lower the carrier frequency or use an output circuit filter OFL Power factor Do not install power factor correcting capacitors in the drive primary circuit Use a dc reactor correcting to improve the drive power factor Do not use power factor correcting capacitors in the drive capacitor output circuit An over current trip will occur disabling motor operation Combin
31. input signal with Menu 4 I O checking SUGGESTED ACTIONS Verify the power recovery sequence with an external circuit If necessary consider the use of a relay that can keep the run command on 6 2 2 Problems with drive settings 1 If the data of function codes cannot be changed Possible Causes What to Check and Suggested Measures An attempt was made to change function code data that cannot be changed when the drive is running CHECK Check if the drive is running using Menu 3 drive monitoring and whether the data of the function codes can be changed when the motor is running refer to the function code tables SUGGESTED ACTIONS Stop the motor then change the data of the function codes The data of the function codes is protected CHECK Check the data of function code F00 SUGGESTED ACTIONS Disable data protection of function codes The Edit enable for keypad WE KP com mand was not set ON after being assigned to a digital input terminal CHECK Check the data for function codes E01 E02 E03 E98 and E99 and the input signals using Menu 4 I O checking SUGGESTED ACTIONS Cancel data protection of the function codes or set the Edit enable for keypad command ON Intermediate dc circuit voltage was below the undervoltage detection level CHECK Check the DC voltage at the intermediate circuit with Menu 5 Maintenance information and mea
32. maintenance item codes e g 5_00 3 Use the and keys to select the desired maintenance item then press the key The data of the corresponding maintenance item will appear 4 Press the key to return to the list of maintenance items Press the key again to return to the menu LED Monitor Display Display contents Accumulated running time Table 3 12 Maintenance Display Items Description Shows the accumulated power on time of the drive Unit thousands of hours When the total ontime is less than 10 000 hours display 0 001 to 9 999 it is possible to check data in hourly units When the total time is 10 000 hours or more display 10 00 to 65 53 the display will change to units of 10 hours When the total time exceeds 65 535 hours the display will be reset to 0 and the count will start again DC voltage at intermediate circuit Shows the dc voltage at main intermediate circuit of the drive Unit V volts Max temperature of heat sink Shows the maximum temperature of the heat sink for every hour Unit C Max effective current Shows the maximum effective current for every hour Unit A amperes Capacity of the intermediate dc circuit capacitor Accumulated running time of electrolytic capacitor on the printed circuit board s Shows the factory default for capacity of the intermediate dc circuit capacitor as 100 Refer to Chapter 7 MAINTENANCE AND INSPECTION for details U
33. motor specifications CHECK Measure the temperature around the motor SUGGESTED ACTIONS Decrease the temperature Reduce the load Cooling system for the motor malfunctioned CHECK Check if the cooling system is operating normally SUGGESTED ACTIONS Repair or replace the cooling system Load was too heavy The set activation level H27 of the PTC thermistor for motor overheat protection was inadequate A PTC thermistor and pull up resistor were connected incorrectly or their resistance was inadequate CHECK Measure the output current SUGGESTED ACTIONS Reduce the load e g lighten the load before overload occurs using the overload early warning E34 function Lower the temperature around the motor Raise the carrier frequency F26 CHECK Check the thermistor specifications and recalculate the detection voltage SUGGESTED ACTIONS Reconsider the data of function code H27 CHECK Check the connections and resistance SUGGESTED ACTIONS Correct the connections and resistance 6 11 Possible Causes What to Check and Suggested Measures 6 The value set for the CHECK torque boost F09 was Check the data of function code F09 and readjust the data so that the motor does not stall even if you set too high a lower value SUGGESTED ACTIONS Change the data for this function code 7 The V f pattern did not CHECK match the motor Check if the base freq
34. number in indicates logical inverse OFF when short circuited _POT External singal input can be changed over by Hz2 Hz1 Acceleration time 2 Deceleration time 2 6o Y1 terminal function Select Selects from the followingitemsbycode N o 5 3 30A B C Ry output 1000 drive running Speed exists RUN_ _ 1001 Frequency equivalence signal _FAR_ _ 1002 Frequency level detection _FDT_ 1003 Undervoltage detection signal_LU_ 1005 Torque limiting Current limiting_TL_ 1006 Auto restarting_IPF_ 1007 Motor overload early warning_OL_ 0 1 2 3 5 6 T 26_ 1026 Retry in operation_TRY_ 30_ 1030 Lifetime alarm_LIFE_ 35_ 1035 drive outputting _RUN2_ 36_ 1036 Active drive in operation_ACT_ 37_ 1037 Current detection _ID_ 41_ 1041 Low level current detection _IDL_ 99_ 1099 Alarm fault for any fault ALM_ E31 _ Freq detection 1 FDT1 Level 0 0 to 400 0 Hz ot Hz y 600 E34 OL early warnging Current 0 00 Inactive 1 to 200 of drive rated current Level 1 rated E35 detection Low level current 0 01 to 600 005 0 01 10 00 E39 Coefficient of constant rate of 001 Y 0 000 cote sone Sic E40 _ PID display coefficient A 999 to 0 00 to 999 al 1 y I 10 E41 PID display coefficient B 999 to 0 00 to 999 oi y o Y E43 oO oO barg oO oO a oO oO LED monitor Select O_Speed monitor select by E48 3_Output current 4 Output voltage 9_Input power 10_PID final c
35. of either software F43 Function select F44 Operation level or hardware H12 1 Current limit The minimum ON duration is 100 ms e Auto restart after recovery of power IPF Function code data 6 This signal is turned ON during the period from when the drive detects the undervoltage of the intermediate dc circuit and shuts down the output if auto restart after recovery of power is selected F14 4 or 5 until auto restarting the output frequency has recovered up to the set frequency At the moment of auto restarting this signal is turned OFF e Motor overload early warning OL Function code data 7 This signal is used to issue a motor overload early warning in order to enable corrective action to be taken before the drive detects a motor overload 0L1 alarm and shuts down its output The motor properties are specified by function codes F10 electronic thermal selection and F12 thermal time constant If a value calculated from the settings of F10 and F12 exceeds the detection level of the early warn ing set by function code E34 this signal is turned ON Normally the recommended set current level for E34 is 80 to 90 of the allowable continuous load current set by function code F11 NOTE Function code E34 is effective not only for the motor overload early warning OL but also the current detection ID and low level current detection IDL e Retry in operation TRY Function code data 26 Th
36. of the drive with each other TIP It is recommended that a manual on off magnetic contactor be connected This is to enable you to discon nect the drive from the power supply in an emergency e g when the protective function is activated so as to prevent accidents or damage Figure 2 10 Main Circuit Power Input Terminal Connection 2 3 5 Replacing the Main Circuit Terminal Block TB Cover 1 As shown in Figure 2 11 pull out the wires from the main circuit terminals in parallel 2 Hold both sides of the main circuit TB cover between thumb and forefinger and slide it back into place Pull the wires out through the grooves of the main circuit TB cover NOTE When replacin the main circuit TB cover take care not to apply any stress to the wires Stress on the wires imposes a mechanical force on the main circuit terminal screws loosening them Man Croa Terraa Ja 1 i Ea or Bie Gover Sem a ey fe i a pi Le j j i raf y F e H wrt Sa T r E si lana TET P J fF dem La ie i N Fri ye oa r b rE te ten ea Wig Pan Figure 2 11 Replacing the Main Circuit Terminal Block TB Cover 2 3 6 Wiring for Control Circuit Terminals Warning The outer jacket of control circuit cable is generally not insulated for high voltage levels Therefore if the control circuit cabling comes into direct contact with the live main circuit terminal the insulation may be insufficient Accordingly there is a possibility that D
37. output current A output voltage V input power kW PID reference PID feedback value Select the speed monitor to be displayed from the following Output frequency before slip compensation Hz output frequency after slip compensation Hz set frequency Hz motor speed r min load shaft speed r min line speed m min constant rate of feeding Displays the cause of trip by codes as follows Trip mode Overcurrent during acceleration Overcurrent during deceleration Overcurrent during running at constant speed j Input phase loss Undervoltage Output phase loss Overvoltage during acceleration Overvoltage during deceleration Overvoltage during running at constant speed Overheating at heat sink External thermal relay tripped Motor protection PTC thermistor Overheating at DB circuit Motor overload Drive unit overload Memory error Remote keypad communication error CPU error Operation procedure error RS485 error Data save error due to undervoltage Trip history Saves and displays the last 4 trip cause codes and their detailed description trip mode 8 7 litem Explanation Stops the drive by detecting overcurrent caused by overload in the output circuit Short circuit Stops the drive by detecting overcurrent caused by short circuit in the output circuit Ground fault Stops the drive by detecting overcurrent caused by ground fault in the output circuit Detected when the drive is started
38. reactor input or output filter in an enclosure with minimum degree of protection of IP2X Top panel of enclosure shall be minimum IP4X when it can be easily accessed to prevent anyone from touching live parts of this equipment To make a drive with no integrated EMC filter conform to the EMC directive it is necessary to connect an exter nal EMC filter to the drive and install them properly so that the entire equipment including the drive conforms to the EMC directive Do not connect any copper wire directly to grounding terminals Use clamp terminals with tin or equivalent plating to connect it When you use a drive at an altitude of more than 2000 m you should apply basic insulation for the control circuits of the drive The drive cannot be used at altitudes of more than 3000 m When used in the drive a molded case circuit breaker MCCB residual current operated protective device RCD earth leakage circuit breaker ELCB or magnetic contactor MC should conform to the EN or IEC standards Supplemantary insulation is required for the control interface when the drive is installed in Overvoltage Category Ill in 230V class models and Overvoltage Category Il or Ill in 460V class models 10 The supply mains neutral has to be grounded for 3 phase 460V class drives Conformity to the Low Voltage Directive in the EU continued CAUTION 9 Use wires listed in EN60204 Appendix C Main power circuit input L1 R L2 S amp L3 T L1 L DC
39. shock or injuries could occur Ground the drive according to the requirements of national and local industrial safety regulations Otherwise electric shock could occur Check that the number of phases and the rated volt age of the product agree with the number of phases and the voltage of the ac power supply Otherwise fire or an accident could occur Do not connect the ac power source cables to the drive output terminals U V and W Do not connect a braking resistor to the dc link circuit terminals P and N Doing so could cause fire or an accident Wire the 3 phase motor to the drive s output terminals U V and W aligning phases each other Otherwise injuries could occur The drive motor and wiring generate electric noise which could interfere with nearby sensors or other devices To prevent the motor from malfunctioning take appropriate noise control measures Otherwise an accident could occur Operation WARNING Be sure to install the terminal cover before turning the power on Do not remove the cover while power is applied Otherwise electric shock could occur Do not operate switches with wet hands Doing so could cause electric shock If the Retry function has been enabled the drive may automatically restart after tripping Make sure that any automatic restart can not result in material damage or personal injury If the Stall Prevention function has been selected the drive may operate
40. speed operation F43 2 Set F43 to 1 for example to drive the motor at maximum performance in the acceleration zone and to limit the drive current in the constant speed zone WARNING If the current limiter function has been selected the drive may operate with an acceleration deceleration time or frequency different from those set Design the machine so that safety is ensured even if this happens Otherwise an accident could occur Electronic Thermal Discharging capability and Allowable loss F50 F51 These function codes configure the electronic thermal feature to protect the braking resistor from overheating For built in braking resistors set function codes F50 and F51 to 0 and 0 00 respectively NOTE Depending on the energy dissipation margin of the braking resistor the electronic thermal protection may operate and issue the overheat alarm dbH even though the actual temperature of the resistor is within limits Check braking resistor performance again and review the data setting of function codes F50 and F51 E01 oe Command Assignment for Terminals X1 to X3 FWD and REV E98 E99 E01 to E03 E98 and E99 may assign commands listed below to terminals X1 to X3 FWD and REV which are general purpose programmable input terminals These function codes may also switch the logic system between normal and negative to define the property of those input terminals so
41. that the drive logic may interpret either the ON or OFF status of each terminal as active The default setting is normal logic that is Active ON 5 13 To assign negative logic input to any input terminal set the function code to the value of 1000s shown in in Section 5 1 Function Code Tables To keep explana tions as simple as possible the examples shown below are all written for the normal logic system e Select multi step frequency 1 to 7 steps SS1 SS2 and SS4 Function code data 0 1 and 2 Switching digital input signals SS1 SS2 and SS4 ON OFF may switch the current set frequency to that defined by function codes C05 through C11 multi step frequencies With this the drive may drive the motor at amaximum of 8 different speeds The table below lists the frequencies that can be obtained by the combination of switching SS1 SS2 and SS4 In the column Selected frequency Other than multi step frequency represents the set frequen cies defined by frequency command 1 F01 frequency command 2 C30 and others SS4 SS2 SS1 Selected frequency OFF OFF OFF Other than multi step frequency OFF OFF ON C05 multi step frequency 1 OFF ON OFF C06 multi step frequency 2 OFF ON ON C07 multi step frequency 3 ON OFF OFF C08 multi step frequency 4 ON OFF ON C09 multi step frequency 5 ON ON OFF C10 multi step frequency 6 ON ON ON C
42. the acceleration deceleration time F07 F08 E10 E11 and H54 The wires to the motor are too long resulting in excessive leakage current CHECK Measure leakage current SUGGESTED ACTIONS Connect an output circuit filter OFL 6 13 12 Eri Memory error Problem Error occurred in writing the data to the memory in the drive Possible Causes What to Check and Suggested Measures 1 Power supply turned off CHECK i while drive was writing Check whether pressing the key resets the alarm after the function code data are initialized by setting data especially initial the data for function code H03 to 1 izing data and residual SUGGESTED ACTIONS control circuit voltage Return the initialized function code data to their previous settings then restart the operation was not high enough to enable writing of data High intensity noise was CHECK applied to the drive while Check if appropriate noise control measures have been implemented e g correct grounding and routing data especially initial of control and main circuit wires Alternatively perform the same check as described in 1 above izing data was being SUGGESTED ACTIONS written Improve noise control Alternatively return the initialized function code data to their previous settings then restart the operation The CPU did not operate CHECK normally Initialize the function code data by setting H03 to 1 then reset the alarm by pressing
43. time is short the Deceleration time drive may not start running the motor 6 00 sec gt Acceleration time 4 1 4 Test run WARNING If the user set the function codes wrongly or without completely understanding this Instruction Manual and the AF 300 Mini User s Manual the motor may rotate with torque or speed not permitted for the machine Accident or injury may result First follow the instructionsof the subsections 4 1 1 Inspection and Preparation Prior to Operation and 4 1 3 Preparation Prior to Running the Motor for a Test then begin test running the motor CAUTION If any abnormality is found to the drive or motor immediately stop operation and determine the cause referring to Chapter 6 TROUBLESHOOTING Procedure for Test Run 1 Turn the power on and check that the LED monitor flashes while indicating the 0 00 Hz frequency 2 Rotate the built in potentiometer clockwise set the frequency to a low frequency such as 5 Hz Check that set frequency flashes on the LED monitor 3 Press the key to start running the motor in the forward direction Check that the set frequency is displayed on the LED monitor correctly 4 To stop the motor press the key Check the following points e Check if the direction of rotation is correct e Check for smooth rotation without motor humming or excessive vibration e Check for smooth acceleration and deceleration If n
44. to within specification The acceleration time CHECK was too short Check if the overvoltage alarm occurs after sudden acceleration SUGGESTED ACTIONS Increase the acceleration time F07 E10 and H54 Select the S curve pattern H07 May need a braking resistor The deceleration time CHECK was too short for the mo Recalculate the deceleration torque from the moment of inertia for load and the deceleration time ment of inertia of load SUGGESTED ACTIONS Increase the deceleration time F08 E11 and H54 Enable automatic deceleration H69 1 so that when the intermediate dc circuit voltage exceeds the overvoltage suppression level the drive changes deceleration time to three times longer than the set value Set the rated voltage at base frequency F05 to 0 to improve braking ability May need a braking resistor Loads were suddenly CHECK removed Check if the alarm occurs when loads are suddenly removed Check if the drive operation suddenly changes from driving operation to braking operation SUGGESTED ACTIONS May need a braking resistor Loads were suddenly CHECK removed Check if the alarm occurs when loads are suddenly removed Check if the drive operation suddenly changes from driving operation to braking operation SUGGESTED ACTIONS May need a braking resistor 6 8 3 LU Undervoltage protection Problem Intermediate dc circuit voltage was below the undervolatge detection level
45. w xwnn x w x w GE Product Code AF 300 Drive Family Imput Voltage 1 115V 2 230V 4 460V Input Phase 1 1 Phase 3 3 Phase Horsepower F50 1 2 hp 001 1hp Factory Installed Options X Keypad E CE Filter R DB Resistor Enclosure Type 9 IP20 Product Revision A 1st Revision B 2nd Revision Minor Product Revision 1 1st Minor Revision 2 2nd Minor Revision xii AF 300 Mini Weights and Dimensions IP 20 Protected Enclosure Rated Output ree Model Number ahaa Current A 115 Vac 1 Phase 50 60Hz Input 230 Vac 1 Phase 50 60Hz Input mw ro os 12 acire oro araxaisxats 13 1 ro zs acre pr amxsisxssi 18 Ce fee e e T oocemeer ow aeaeo or e ro n ws ecis pro 7 00x551 547 230 Vac 3 Phase 50 60Hz Input mw ro os 12 acson orn amxsisxsis 13 2 ro amp 12 cise oris st2xassxsar 37 460 Vac 3 Phase 50 60Hz Input pos ro o s ecis orez roaxsstxsar s1 Indicates product revision xiii AF 300 Mini Weights and Dimensions continued IP 20 Protected Enclosure with Internal CE Filter Rated Hp Overload Catalog Output Model Number aby ommes Current ay 50 st pels mamom a 230 Vac 1 Phase 50 60Hz Input poo os 12 acms oro 472x315x394 P20 axxcratrasco gt 07302 472x315x394 P20 axxctairsoc 07300 472x315x453 P20 axxcrziooiea D7304 5
46. 0 00 to 65 53 is displayed the display increases by 0 01 every 10 startups Intermediate dc circuit voltage Shows the voltage of the intermediate dc circuit of the drive s main circuit Unit V volts Max temperature of heat sink Shows the maximum temperature of the heat sink Unit C Terminal I O signal status displayed with the ON OFF of LED segments Signal input terminal status in hexadecimal format Terminal output signal status in hexadecimal display Shows the ON OFF status of the digital I O terminals Refer to Displaying control I O signal terminals in Section 3 7 Checking I O Signal Status for details Number of consecutive occurrences Overlapping alarm 1 This is the number of times the same alarm occurs consecutively Simultaneously occurring alarm codes 1 is displayed if no alarms have occurred Overlapping alarm 2 Simultaneously occurring alarm codes 2 is displayed if no alarms have occurred NOTE When the same alarm occurs a number of times in succession the alarm information from the first time is retained and the information for the following alarms is not updated 3 19 Notes 3 20 4 Running the Motor 4 1 Running the motor for a test 4 1 1 Inspection and Preparation Prior to Operation Check the following prior to starting operation 1 Verify correct connection Carefully verify that the motor power ca
47. 1 when the drive output is shut down NVlolR ala l rnlalolsS 1 during dc braking 1 during running in the reverse direction LED No 1 during running in the forward direction Table 3 8 Running Status Display Bit Notation Display Input example binary On the LED monitor 3 13 Hexadecimal expression A 16 bit binary number is expressed in hexadecimal format 4 digits Table 3 8 shows the expression The hexadeci mals are shown as they appear on the LED monitor Table 3 9 Binary and Hexadecimal conversion Binary Hexadecimal Binary Hexadecimal 0 0 0 0 0 1 0 0j 0 8 0 1 1 3 7 Checking 1 0 Signal Status I O checking With Menu 4 I O checking you may display the I O status of external signals without using a measuring instru ment External signals that can be displayed include digital I O signals and analog I O signals Table 3 9 lists check items available The status transition for I O checking is shown in Figure 3 8 biers Lie af aD chaa Ber VO dais F T ay m fi 4 By LED ikg COMP Lace i ie pan temaj rat intan kpmg foi ak i Oy LED greri ORGE F Orgi e i r Pane borraa igal R 4 E i pul eee i herrea V2 ie JTI kat purai at baruna G mA Chuipui roiya fi be Arakg iar Figure 3 8 Status Transition of I O Check Basic key operation 1
48. 11 multi step frequency 7 e Select acceleration deceleration 2 steps RT1 Function code data 4 Digital input signal RT1 assigned to the specified terminal ON OFF may switch combinations between acceleration deceleration time 1 defined by function codes F07 and F08 and acceleration deceleration time 2 defined by E10 and E11 Turning RT1 ON for example enables the drive to drive the motor using acceleration deceleration time 2 e Select 3 wire operation command HLD Function code data 6 Digital input signal HLD may self hold the forward FWD reverse REV run commands given at the external signal input terminals to enable 3 wire drive operation Shorting the circuit between the HLD assigned terminal and terminal CM will self hold the FWD or REV com mand Opening the circuit will release the hold e Coast to stop command BX Function code data 7 Shorting the circuit between the BX assigned terminal and terminal CM will immediately shut down the drive output allowing the motor to coast to a stop without issuing any alarm e Reset alarm RST Function code data 8 When the protection facility has been activated the drive is in Alarm mode shorting the circuit between the RST assigned terminal and terminal CM will reset the alarm output on terminals Y1 and 30A B C Opening the circuit will release all the alarm indications to restart operation Allow 10 ms or more for th
49. 12x433x547 Pao e 12 akoro praos 709x551x709 P20 axxcrzio0sa Drao 709x551x717 230 Vac 3 Phase 50 60Hz Input ro oe RALES TAE AE Cu m 1s 28 oca on aasa 15 Ca m e 45 ooa o aas 15 P e fs s oomoo oroo araxarexsst Ga a a ee a pH _ eo E rere E ps mo w ekers orais zoaxsstxzt7 64 460 Vac 3 Phase 50 60Hz Input ps mo o 1s ekcmsose ovat roxssixrir s1 Indicates product revision xiv 1 Before Using the Drive 1 1 Acceptance Inspection Unpack and check the following items 1 A drive and instruction manual this manual is contained in the package 2 The drive is not damaged during transportation no dents 3 The drive is the model you ordered You may check the model name printed on the nameplate see Figure 1 1 OPH bos aoe 1 ace IB teen Figure 1 1 Nameplate INPUT Number of input phases 3 phase 3 ph 1 phase 1 ph input voltage input frequency input current OUTPUT Number of output phases rated output capacity rated output voltage output frequency range rated output current overload capacity SER NO Product number 390112R0001 Serial number of production lot Production month 1 to 9 January to September X Y or Z October November or December Production year Last digit of year If you suspect the product is not working properly or if you have any questions about it contact your de
50. 50 m In this situation add an output circuit filter option or lower the carrier frequency Function Code F26 Motor sound sound tune If the motor is driven by a PWM type drive surge volt age that is generated by switching the drive component may be superimposed on the output voltage and thus applied to the motor terminals Particularly if the wiring length is long this surge voltage may deteriorate the insulation resistance of the motor Consider any of the following measures 1 Use a motor with 1300V insulation 2 Connect an output circuit filter option to the output terminals of the drive 3 Take steps to minimize the wiring length between the drive and motor 3 DC reactor terminals P1 and P 1 Remove the jumper bar from terminals P1 and P 2 Connect a dc reactor option to terminals P1 and P NOTE If a dc reactor is to be connected to a braking resistor attach both wires of the dc reactor and braking resistor together to terminal P See next page Do not remove the jumper bar if a dc reactor is not used k aaa T oe f ha eT Pee ae i 5 Fh 1 a snr a a fw ram va LLENG ame LETS oe Se fart UE ey Figure 2 6 DC Reactor Connection 4 Braking resistor terminals P and DB NOTE Do not connect a braking resistor to any drive with a rated capacity of 1 8 or 1 4 hp If connected the braking resistor will not work 1 Connect terminals P and DB of the built in brakin
51. 6 Displays external interface information Section 3 7 Menu 6 Displays the latest four alarm codes You may refer to the running information at the Alarm information time when the alarm occurred Section 3 9 Menu 7 Allows you to read or write function code data as well as verifying it Data copying NOTE To use this function a remote keypad option is necessary 3 3 3 2 3 Alarm Mode When the protection facility is activated to trigger an alarm the drive automatically enters Alarm mode and the cor responding alarm code will appear in the LED display Figure 3 2 shows the status transition of Alarm mode Releasing the Alarm and Transferring the Drive to Run Mode Remove the cause of the alarm and press the key to release the alarm and return to running status The alarm can only be released using the key once the alarm code is displayed Displaying the Alarm History It is possible to display the most recent 3 alarm codes in addition to the one currently displayed Previous alarm codes can be displayed by pressing the key or the key while the current alarm code is displayed Displaying the Running Information when an Alarm Occurs If an alarm occurs you may check various running status parameters output frequency and output current etc by pressing the key when the alarm code is displayed The item number and data for each running information is displayed alternately In additio
52. 97 Directive EN61800 3 1996 A11 2000 EN5501 1 1998 A 1999 EMC Directives Second environment EN61800 3 A11 Indus trial Class 1A EN55011 A1 Applicable only to the EMC filter built in type of drives Immunity CAUTION The AF 300 Mini series of drives are categorized as a restricted sales distribution class of the EN61800 3 Therefore when you use these products with any home appliances or office equipment you may need to take appropriate countermeasures to reduce or eliminate any noise emitted from these products 10 3 Compliance with EMC Standards 10 3 1 Scope The CE marking on the EMC filter built in type of drives does not ensure that the entire equipment including our CE marked products is compliant with the EMC Direc tive Therefore CE marking for the equipment shall be the responsibility of the manufacturer For this reason GE Fuji s CE mark is indicated under the condition that the product shall be used within equipment meeting all requirements for the relevant Directives Implementation of such equipment shall be the responsibility of the manufacturer Generally machinery or equipment may include not only our products but other devices as well Manufacturers therefore shall design the whole system to be compliant with the relevant Directives In addition to satisfy the requirements noted above use the EMC filter built in type of drives according to the descriptions contained in t
53. ANGEROUSLY high voltage from the main power circuit could be applied to the control circuit wires Be sure to keep the control wires away from the live main circuit terminals An accident or electric shock could occur Caution Noise may be emitted from the drive motor and wires Implement appropriate measures to prevent malfunc tioning due to noise An accident could occur Table 2 4 lists the symbols names and functions of the control circuit terminals The wiring to the control circuit terminals may differ depending upon drive set up using function codes MEY Tam be a pari K n gia Figure 2 12 Example of Control Circuit Wiring Replace the main circuit TB cover and then connect wires to the control circuit terminals As shown in Figure 2 12 pull the wires out through the guides on the main circuit TB cover Route these wires correctly to reduce the influence of noise referring to the notes on the following pages 2 9 Table 2 4 Symbols Names and Functions of the Control Circuit Terminals Classifi cation Functions Potentiometer Power supply 10 Vdc for frequency command potentiometer Potentiometer 1 to power supply 5 kQ Allowable output current 10 mA Voltage input 1 The frequency is set according to the external analog input voltage 0 to 10 Vdc 0 to 100 Normal mode operation 10 to 0 Vdc 0 to 100 Inverse mode operation Used for reference signal PID process comman
54. D process command or PID feedback amount x factor A B B PID factors A and B Refer to function codes E40 and E41 PID feedback amount Note Timer sec Note Remaining effective timer count NOTE The PID process command and PID feedback amount are displayed only under the PID control using a process command J01 1 or 2 The timer for timer operation is only displayed when timer is enabled C21 1 Figure 3 3 shows the procedure for selecting the desired monitor item 3 7 Posar O Running Aipda imici of raring iaun Lip Comang on Wiii Du eee V j riri A Eg 7 i Ca oF Berin a Eg a 7 Fl pe cea Eg Fao eeban raia Eg Taran j Eg Figure 3 3 Monitor Item Selection Example 1 The speed monitor can display the output frequency Hz set frequency Hz load shaft speed rpm line speed m min and constant feeding rate time min which can be selected by with function code E48 2 This PlD related information will appear only when the drive is under the PID control Refer to Section 3 3 3 This will appear only when timer operation is enabled by setting up function code C21 Refer to Chapter 5 Table 3 2 lists the display items for the speed monitor that can be chosen with function code E48 Table 3 2 Display Items on the Speed Monitor Speed monitor items Output frequency before slip compensation Hz Factory default Function code E48 d
55. External soft start stop oo E 0 0 to 20 0 percentage against F05 Rated voltage 0 Setting becomes valid when F37 is set at 0 or 1 3 4 Electronic thermal Select 1_Active motor with self cooled fan standard motor overload relay 2_Active motor with forced cooled fan for motor protection 0 00 Inactive Approx 1 to 135 of drive rated current Level Boe Oo f a 0 5 to 75 0min 3 5 hermal time constant Restart mode after Select 0_Inactive Trip and alarm when power failure occurs momentary power 1_Inactive Trip and alarm when power recovers failure 4 Active Restarts at output frequency on power failure occurrence for general load gt oe Restarts at starting frequency for low inertia TI mim N oO D lo Gma oO oO uu Q 4 9 Jo Ju ua T N F15 Frequency limiter veoh se ut fp 0 0 F16 Hz a F18 0 00 _ F20_ DC brake Starting val oowoo To o0 Braking level a Braking time 0 00 _ Stop frequenc Motor sound Carrier freq i 2 T Sound tone 0 Level 0 jj L F30 FMATerminal Output gain Oto200 100 5 2 FMA Terminal Function Selects from the following items by code 0_Output frequency Before slip compensation 1_Output frequency After slip compensation 2_Output current 3_Output voltage 6_Input power 7_PID feedback value 9_DC link circuit voltage 14_Analog output test 0_Variable torque load Load s
56. GEH 6647 AF 300 Mint Startup Guide 2003 GE Fuji Drives USA All rights reserved These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met during installation operation and maintenance The information is supplied for informational purposes only and GE Fuji makes no warranty as to the accuracy of the information included herein Changes modifications and or improvements to equipment and specifications are made periodically and these changes may or may not be reflected herein It is understood that GE Fuji may make changes modifications or improvements to the equioment referenced herein or to the document itself at any time This document is intended for trained personnel familiar with the GE Fuji products referenced herein GE Fuji may have patents or pending patent applications covering subject matter in this document The furnishing of this document does not provide any license whatsoever to any of these patents All license inquiries should be directed to the address below If further information is desired or if particular problems arise that are not covered sufficiently for the purchaser s purpose the matter should be referred to GE Fuji Drives USA Post Sales Service 1501 Roanoke Blvd Salem VA 24153 6492 USA Phone 1 888 GE4 SERV 888 434 7378 United States 1 540 378 3280 International Fax 1 540 387 8606 All indicates
57. K broken Measure the output current SUGGESTED ACTIONS Replace the output wires 2 Open circuit in motor CHECK windings Measure the output current SUGGESTED ACTIONS Replace the motor The terminal screws for CHECK drive output were not Check if any terminal screws have become loose tight enough SUGGESTED ACTIONS Tighten the terminal screws to the recommended torque A 1 phase motor has SUGGESTED ACTIONS been connected 1 phase motors cannot be used Note that the AF 300 Mini only drives 3 phase induction motors 6 OH1 Overheat protection for heat sink Problem Temperature around heat sink rose Possible Causes What to Check and Suggested Measures 1 Temperature around the CHECK drive exceeded that of Measure the temperature around the drive drive specifications SUGGESTED ACTIONS Lower the temperature around the drive e g improve control board ventilation Reduce the load 2 Accumulated running CHECK time of the cooling fan Check the accumulated running time E52 2 Refer to Chapter 3 Section 3 8 Reading Maintenance exceeded the standard Information period for replacement SUGGESTED ACTIONS or the cooling fan Replace the cooling fan malfunctioned CHECK Visually check that the cooling fan rotates normally SUGGESTED ACTIONS Replace the cooling fan 3 Air vent is blocked CHECK Check if there is sufficient clearance around the drive SUGGESTED ACTIONS I
58. List of Periodical Replacement Parts css0 7 6 Inquiries about Product and Warranty 8 Specifications 8 1 Standard Models cccceceeeseecesseeseseeeseeeeesestenseaeeeees 8 2 Common Specifications 8 3 Terminal Specifications ccesececseseseseeseseeeseeeeeeeeeees 8 3 1 Terminal Functions ccccceeeeseeeseeteeeeeseeteeeeeeeees 8 9 8 3 2 Connection Diagram for Operation by External Signal INDuts cceeseeseseesseeseeeeeeees 8 9 8 4 External DiIMensiOns cceccsseeseeseeeteeeeeseseeeeeeeeeeeees 8 10 8 5 Protective FUNCTIONS ccceccseesesseeetseetesesieeseeteeeeees 8 14 9 Options 9 1 List Of Peripheral Equipment and Options e 9 1 10 Compliance with Standards 10 1 Compliance with UL Standard and Canadian Standards cUL Certification c8 10 1 10 2 Compliance with European Standard n s 10 1 10 3 Compliance with EMC Standards ccessceeiee 10 1 10 4 Harmonics Component Regulation in the EU 10 2 10 5 Compliance with the Low Voltage Directive tha EU ssania nann ena 10 3 Preface Thank you for purchasing an AF 300 Mini series drive This product is designed to control a 3 phase induction motor only Read through this instruction manual and make yourself familiar with proper use of the drive Improper use could prevent normal operation and result in failure or reduced life of the drive Deliver this manual to the end user of the product Keep thi
59. ON J codes Application Functions PID control Select 0_Inactive 1_Process control use Normal action Remote process command 0_Keypad panel 1_PID process command 1 4 Communication P gain I Integration time 0 0to36000s Cts y oo D Differentiation time 0 0 to 600 008 CC s y oo i 5 7 y codes LINK Functions 2_Operation for y03 timer and retry to communicate If retry fails the drive trips Er8 3_Continuous operation Parity check 0_No checking 1_Even parity 2_Odd parity Stop bits 0_2 bits 1_1 bits No response error 0_No detection detection time _1 to 60s Response interval Protocol select 0_Modbus RTU protocol 1_SX protocol Loader protocol 2_Fuji general purpose drive protocol Link function for Select Freq setting OPR command supporting data input 0_by H30 by H30 1_RS485 by H30 2_by H30 RS485 3_RS485 RS485 1 Change during operation N Disable Y Settled by FUNC DATA key Y Changed by UP DOWN key and settled by FUNC DATA key Note1 The above Setting ranges may be limited by the singns or the number of digits Note2 Do not change the settings in E45 to E47 H71 and H95 as Driive does not use them although they are displayed 5 8 5 2 Overview of Function Codes When F02 0 to specify the motor rotational direc This section provides an overview of the function codes tion by control signal input assign the comman
60. R P1 and L2 N Grounding G 2 Drive and P Recommended wire size output U Braking Control mm2 resistor P circuit 2 and DB 2 w DCR w o DCR 3 w DCR w o DCR 3 oe 25 25 Sa P 4 a shes 25 25 os ES gea 25 T of E eo Be Le a MCCB Molded case circuit breaker RDC Residual current operated protective device ELCB Earth leakage circuit breaker 1 The frame size and model of the MCCB or RCD ELCB with the exception of those exclusively designed for protection from ground faults will vary depending on the power transformer capacity Refer to the related technical documentation for details Rated current A of MCCB Applicable or RCD ELCB 1 motor rating Hp Power supply voltage st s s s 8 m aa m posts m m m ai e ai Ca ol a ie ae i 1 phase 230 V 3 phase 460 V 3 phase 230 V 2 The above wire size for main circuits is recommended for the 70 C 600V PVC wires used at an ambient temperature of 40 C 3 Wire sizes are calculated on the basis of the input current under the condition that the power supply capacity and impedance are 500 kVA and 5 respectively vi Conformity to UL standards and Canadian standards cUL certification continued If installed according to the guidelines given below Drives marked with UL cUL are considered as compliant with the UL and CSA cUL certified standards CAUTION 1 Solid state m
61. Special software suitable for this motor type must be used Contact GE Fuji for details special motor types 1 phase motors 1 phase motors are not suitable for drive driven variable speed operation Use 3 phase motors Even if a 1 phase power supply is available use a 3 phase motor as the drive only provides 3 phase output Use the drive in a location with an ambient temperature range of 10 to 50 C The drive and braking resistor surfaces become hot under certain operating conditions Install Installation location the drive on a nonflammable surface such as metal Ensure that the installation location meets the environmental conditions specified in Chapter 2 Section 2 1 Operating Environment Installing a GE Install a recommended molded case circuit breaker or a ground fault circuit interrupter GFCI Environmental Circuit Breaker in the primary circuit of the drive to protect the wiring Ensure that the circuit breaker rating is conditions MCCB equivalent to or lower than the recommended rating in combination with Magnetic peripheral devices contactor in the secondary circuit If a magnetic contactor is mounted in the drive s secondary circuit for switching the motor to commercial power or for any other purpose ensure that both the drive and the motor are fully stopped before operating this contactor Magnetic contactor in the primary circuit Do not switch on off the magnetic contactor
62. TIONS Change the current limiting level F44 to a correct value Increase the acceleration and deceleration time F07 F08 E10 and E11 Automatic deceleration was active CHECK Check the data for function code H69 SUGGESTED ACTIONS Consider the use of a braking resistor Increase the deceleration time F08 and E11 Overload CHECK Measure the output current SUGGESTED ACTIONS Reduce the load Torque generated by the motor was insufficient CHECK Check that the motor starts running if the value of the torque boost F09 is increased SUGGESTED ACTIONS Increase the value of the torque boost F09 An external frequency command device is being used CHECK Check that there is no noise in the external signal wires SUGGESTED ACTIONS Isolate the control signal wires from the main circuit wires as far as possible Use shielded wire or twisted wire for the control signal wires 6 5 7 Power is restored after an instantaneous power failure but the motor does not restart Possible Causes What to Check and Suggested Measures 1 The setting of function code F14 did not make the motor restart even if the power recovered after an instantaneous power failure CHECK Check if an undervoltage trip occurs SUGGESTED ACTIONS Change the data for function code F14 to 4 or 3 The run command stayed OFF even after the power recovered CHECK Check if the
63. ability When the input voltage is 165V or more the drive continues operation If it drops below 165V the drive operates for 15 ms Rated current 17 5 8 A Required power supply Capacity 5 kVA 150 Torque 7 ee Starting frequency 0 0 to 60 0 Hz braking time 0 0 to 30 0 s ae current 0 to 100 of rated current Conformity to safety standards UL508C C22 2No 14 EN50178 1997 Enclosure IEC60529 IP20 Cooling method Weight FE SC RE OS TH Output ratings Input 0 3 0 5 Braking DC injection braking GE 4 pole standard motor Drive output capacity kVA at 230V Output voltage cannot exceed the power supply voltage 4 Tested under standard conditions with 85 nominal motor load Obtained with a dc reactor Average braking torque with AVR control OFF varies with motor efficiency Average braking torque using external braking resistor optional No braking resistor is available for 1 8 hp 1 4 hp 8 Calculated under GE Fuji specified conditions 9 Indicates product revision 8 2 3 IP20 type 1 phase 115V series item SC Specifications S 1 phase 115V class Type ees 6KXC111__X9 Nominal applied motor 1 Rated capacity 2 kVA 3 phase 200V 50 Hz 200 220 230V 60 Hz 150 of rated current for 1 min 200 of rated current for 0 5 s 50 60 Hz 1 phase 100 to 120V 50 60 Hz Voltage 10 to 10 Frequency 5 to 5 Momentary voltage dip capability As long as input voltag
64. al board and connect the whole board to ground Connect a noise filter to the drive power wires 3 When implementing measures against noise gener ated from peripheral equipment For the control circuit wires use twisted or shielded twisted wires If using shielded twisted wires connect the shield of the shielded wires to the common terminals of the control circuit Connect a surge absorber in parallel with the coil or solenoid of the magnetic contactor 3 Leakage current Harmonic component current generated by transistors IGBT in the drive switching ON OFF becomes leakage current through stray capacitance of the drive input and output wires or the motor If any of the problems listed below occur take appropriate measures against them Table 2 5 Leakage Current Countermeasures A ground fault circuit interrupter GFCI that is connected to the power supply has isolated the drive from the power supply Decrease the carrier frequency Make the wires between the drive and motor shorter Use a less sensitive ground fault circuit interrupter Use a ground fault circuit interrupter that includes protection against harmonic component An external thermal relay was activated Decrease the carrier frequency Increase thermal time constant Use the thermal relay built in the drive 2 14 2 3 11 Recommended Wire Sizes Table 2 5 lists the recommended wire sizes The wire size for the main circuit denotes the va
65. aler or GE Fuji 1 1 1 2 External View and Terminal Blocks 1 External views 2 View of terminals oo Cer aA HN ij iad j a a 230V 3 Pht hp b 230V 3 Ph 2 hp When connecting the RS485 option card communications cable remove the control circuit terminal block cover and cut off the barrier provided in it using nippers Figure 1 3 Bottom View of AF 300 Mini 1 3 Transportation e When carrying the drive always support its bottom at the front and rear sides with both hands Do not hold only by the cover or other parts since they may detach and allow the drive to drop and break e Avoid appling force to the terminal block covers which are made of plastic and may break easily 1 4 Storage Environment 1 4 1 Temporary storage Store the drive in an environment that satisfies the requirements listed in Table 1 1 Table 1 1 Environmental Requirements for Storage and Transportation Item Requirements Storage temperature 1 25 to 65 C 4 to 149F Places not subjected to abrupt temperature changes or Relative humidity 5 to 95 condensation or freezing Atmosphere The drive must not be exposed to dust direct sunlight corrosive or flammable gases oil mist vapor water drops or vibration The atmosphere must contain only a low level of salt Less than 0 01 mg cm2 per year Atmospheric pressure 86 to 106 kPa 12 5 to 15 4 psi in storage 70 to 106 kPa 10 2 to 15 4 psi durin
66. and that the motor does not stall if you set a lower value than the large F37 0 1 3 or 4 present one for F09 SUGGESTED ACTIONS Lower the value for torque boost F09 if the motor is not going to stall 6 7 Possible Causes What to Check and Suggested Measures 5 Acceleration decelera CHECK tion time was too short Check that the motor generates enough torque during acceleration deceleration The torque requirement is calculated from the moment of inertia of the load and the acceleration deceleration time SUGGESTED ACTIONS Increase the acceleration deceleration time F07 F08 E10 E11 and H54 Enable current limiting F43 Increase the drive capacity 6 Malfunction caused by CHECK noise Check if noise control measures are appropriate e g correct grounding and routing of control and main circuit wires SUGGESTED ACTIONS Implement noise control measures Enable the auto reset function H04 2 OU Overvoltage protection Problem The intermediate DC circuit voltage was over the detection level of overvoltage OU1 Overvoltage occurs during the acceleration OU2 Overvoltage occurs during the deceleration OU3 Overvoltage occurs during running at constant speed Possible Causes What to Check and Suggested Measures The power supply volt CHECK age was over the range Measure the input voltage of the drive s specifica SUGGESTED ACTIONS tions Decrease the voltage
67. at came with the replacement parts and ship failed parts to GE Fuji Drives 7 7 Notes 8 Specifications 8 1 Standard Models 1 IP20 type 3 phase 230V 460V series litem Ss Specifications Input power source 3 phase 230V class 3 phase 460V class Type 19 6KXC123__X9 230V class F12 F25 F50 001 002 003 005 6KXC143__X9 460V class ta hel eE 15 22 37 eee tata ett tata te Rated voltage 3 V 3 phase 200V 50 Hz 200 220 230V 60 Hz S phase 380 400 415V 50 Hz 380 400 440 460V 60 Hz Rated aot HE 15 25 3 7 55 current A Low carrier 15 30 5 0 11 0 17 0 3 kHz Overload capabilit 150 of rated current for 1 min 200 of rated current for 0 5 s Rated ee 50 60 Hz Phase voltage frequency voltage frequenc 3 phase 200 to 240V 50 60 Hz 3 phase 380 to 480V 50 60 Hz Voltage frequency variations Voltage 10 to 15 Voltage unbalance 8 2 or less Frequency 5 to 5 Momentary voltage dip As long as input voltage is 165V or above the drive As long as input voltage is 300V or more capability 4 continues operation If it drops below 165V the drive the drive continues operation If it drops operates for 15 ms below 300V the drive operates for 15 ms pi emera paha a tester ae 0 85 9 A nena 5 3 Required power supply Ces wal tS Torque 7 ie See i DC injection braking Starting frequency 0 0 to 60 0 Hz braking time 0 to 30 0 s braking level 5 to 100 of rated current C
68. ata Meaning of Displayed Value Before slip compensation frequency Output frequency after slip compensation Hz Frequency actually being output Set frequency Hz Final set frequency Load shaft speed rpm Display value Output frequency Hz x E50 Line speed m min Display value Output frequency Hz x E50 Constant feeding rate time min Display value E50 Output frequency x E39 Output frequencies contained in these formulas are output frequencies before slip compensation 3 8 4 Jog Inch the Motor In Run mode pressing the keys at the same time simultaneous keying can make the drive ready for jogging The JoG appears on the LED monitor To return the drive from the ready to jog state to the usual running state press the keys simultaneously Using the external input signal command JOG also allows the transition between the ready to jog state and usual running state REFERENCE Refer to function codes E01 to E03 in Chapter 5 for details During jogging the jogging frequency C20 and acceleration deceleration time for jogging H54 will apply They are exclusively prepared for jogging and required to be set up individually When jogging the motor from the keypad the drive will only run while the key is held down and contrarily the moment the key is released the drive will decelerate and stop the motor NOTE The transition keys betwe
69. ata E52 Menus selectable 0 Function code data setting mode Menu 1 Data setting factory default 1 Function code data check mode Menu 2 Data checking 2 Full menu mode Menu 1 through 6 7 Menu 7 appears only when the remote keypad option is set up for use If the full menu mode is selected pressing the or key will cycle through menus With the key you may select the desired menu Once all of the menus have been cycled through the display will return to the first menu Table 3 2 Menus Available in Program Mode LED monitor Main functions Refer to shows F codes Fundamental functions E codes Extension terminal functions C codes Control functions of frequency Selecting each of these function codes P codes Motor parameters enables its data to be displayed Section 3 4 changed Menu 1 Data setting H codes High performance functions J codes Application functions y codes Link functions Menu 2 Displays only function codes that have been changed from their factory defaults Section 3 5 Data checking You may refer to or change those function codes data Menu 3 Drive monitoring Menu 4 I O checking Menu 5 Maintenance Displays maintenance information including accumulated running time Section 3 9 information Displays the running information required for maintenance or test running Section 3
70. ation with peripheral device wiring Reducing noise Measures against surge currents Megger test Use of a filter and shielded wires are typical measures against noise to ensure that electro magnetic interference standards are met If an overvoltage trip occurs while the drive is stopped or operated under a light load it is assumed that the surge current is generated by the open close action of the phase advancing capacitor in the power system Connect a dc reactor to the drive When checking the insulation resistance of the drive use a 500V megger and follow the instructions contained in Chapter 7 Section 7 4 Insulation Test Control circuit When using remote control limit the wiring length between the drive and operator box to wiring length 20 m 65 ft or less and use twisted or shielded cable Wiring lenath If extended length wiring is used between the drive and the motor the drive will overheat or trip eee ane as a result of over current high frequency current flowing due to cable capacitance in the wires connected to the phases Ensure that the wiring is shorter than 50 m 162 ft If this distance must and motor Ravi be exceeded lower the carrier frequency or include an output circuit filter OFL Wiring size Select cables with an adequate capacity by referring to the current value or recommended wire size Grounding Securely ground the drive using the grounding terminal Selecting
71. bles are connected to drive output terminals U V and W and that the ground cable is connected to the ground electrode correctly WARNING e Do not connect power supply wires to the drive output terminals U V and W Otherwise the drive may be dam aged if you turn the power on e Be sure to connect the ground leads of the drive and the motor to the ground electrodes Otherwise electric shock may occur 2 Check for short circuits between terminals and exposed live G L R L2S L38T U Vv WwW G parts and ground faults ooo eh ee Sy 3 Check for loose terminals connectors and screws 4 Check if the motor is not connected to a driven load POWER SUPPLY 5 Turn all switches off so that the drive does not start or operate erroneously at power on 6 Check that safety measures have been taken against runaway of Figure 4 1 Drive connection diagram the system e g a defense to protect people from unexpectedly approaching your power system 4 1 2 Turning on Power and Checking WARNING e Be sure to install the terminal cover before turning the power on Do not remove the cover while power is turned on e Do not operate switches with wet hands Otherwise electric shock could occur Turn the power on and check the following points This example shows when no function code data is changed from the factory setting 1 Check that the LED monitor displays 0 00 meaning that the set frequency is 0 Hz and is flashing S
72. cannot interpret the stop command due to internal external circuit failures 3 Cut off the drive from the power source when the MCCB inserted in the power source side cannot disconnect it for maintenance or inspection purposes For this purpose only it is recommended that you use an MC capable of being turned on off manually Note When your system requires the motor s driven by the drive to be started stopped with the MC the frequency of the starting stopping operation should be no more than once per hour The more frequent the operation the shorter the life of the MC and capacitor s used in the intermediate DC circuit due to thermal fatigue caused by the frequent establishment of the current flow If this is not necessary start stop the motor with the terminal commands FWD REV and or HLD or with the keypad E At the output side Prevents externally back fed current from being applied to the drive power output terminals U V and W unexpectedly An MC should be used for example if a circuit that switches the motor driving source between the drive output and commercial factory power lines is connected to the drive Note As application of high voltage external current to the drive s secondary output circuits may damage the IGBTs MCs should be used in the power control system circuits to switch the motor drive power source to the commercial factory power lines after the motor has come to a complete stop Also ensure that volta
73. compensation Output frequency after slip compensation Output current Output voltage Power consumption PID feedback value Intermediate dc circuit voltage Analog output test Input impedance of external device Max 5 KQ Analog common Common terminal for analog input and output signals Transistor output Transistor output common Alarm relay output for any fault RS485 commmuni cations I O 1 Various signals such as drive run status speed freq arrival and overload early warning can be assigned to the terminal Y1 by setting function code E20 Refer to the Section 5 2 in Chapter 5 titled Overview of Function Codes for details Switches the logic value 1 0 for ON OFF of the terminals between Y1 and Y1E If the logic value for ON between Y1 and Y1E is 1 in the normal logic system for example OFF is 1 in the negative logic system and vice versa ON level 2 Digital input circuit specification Operation voltage OFF level Maximum load current at ON Leakage current at OFF Note Check the polarity of the external power inputs When connecting a control relay first connect a surge absorbing diode across the coil of the relay Common terminal for transistor output signal Isolated from terminals CM and 11 Outputs a contact signal 1C SPDT when a protective function has been activated to stop the motor Contact rating 250 Vac 0 3 A cos 0 3 48 Vdc 0 54
74. constant feeding rate time load shaft speed or line speed and for displaying its output status Comet cl Space raian Eo Contin Fesdeng fe Tine pini Aa _ _ Frege Coeff for Corsi Ferdina Rate Time 639 Lidd Shih Spad Line Soeed E Dosti tor Speed indication 2 Frequency Hz ES Goat for Speal indication 0 Frequency Hi Where Freq is the set frequency if each expression is for one of the set data for the constant feeding rate time load shaft speed or line speed it is the output frequen cy if each expression is for the output status monitor NOTE PID display coefficients A and B E40 and E41 are the exclusive conversion factors to equate an indi cated value with the process command and feedback values in PID control C21 Timer Operation Enables or disables timer operation If it is enabled entering a run command will make the drive run the motor for the period preset in the timer An example of timer operation Setting up the timer conditions beforehand Set C21 to 1 to enable timer operation To display the timer count on the LED monitor set function code E43 LED monitor to 13 Timer count Set up the frequency for the timer operation using the built in potentiometer or the keys If the LED displays the timer count press the key to switch it to the speed monitor and then set the frequency for the timer operation Timer
75. constants used inside the drive When using GE standard motors select the data listed below according to model Bias Typical motors oe ht Other Heat sink overheated 0H1 kW hp ated in hp Hz Hz motors Hz Motor overheated 0H4 0 06 0 1 2 50 1 77 1 77 Braking resistor dbH 0 1 0 12 2 50 1 77 177 See Motor overloaded OLt 0 2 0 25 2 50 2 33 2 33 eee dri loaded OL 0 4 0 5 2 50 2 40 2 40 ee 2 0 75 1 2 50 2 33 2 33 1 5 2 2 50 2 00 2 00 Retry times 1104 Set the number of retry times for automatic exit from 2 2 3 1 17 1 80 1 80 l Alarm mode If the drive has entered Alarm mode many 3 7 5 1 50 1 93 1 93 times in excess of the number of times specified by the function code it issues a block alarm and does not exit alarm mode for restarting WARNING If the retry function has been selected the drive may automatically restart according to some causes after tripping Design the machine so that human safety is ensured after restarting Otherwise an accident could occur e Retry latency time H05 Sets the latency time for automatic exit from Alarm mode Refer to the timing scheme diagram below Operation timing chart Alarm Alarm mode Reset command Drive output frequency Signal in the retry operation Time Gradual Acceleration Deceleration Specifies the acceleration and deceleration patterns output frequency patterns Linear acceleration deceleration The drive run
76. ct the any settings which do not match 7 The RS485 communica tions card malfunctioned SUGGESTED ACTIONS Replace the card 17 ErF Data save error during undervoltage Problem The drive was unable to save data such as the frequency commands timer and PID process commands set through the keypad when the power was switched off Control circuit voltage dropped suddenly when power was turned off while data was being saved because the intermediate dc circuit capacitor was rapidly discharged CHECK Check how long it takes for the intermediate dc circuit voltage to drop to the preset voltage when the power is turned off SUGGESTED ACTIONS i Remove whatever is causing the rapid discharge After pressing the key and releasing the alarm reset the data such as the frequency commands timer and PID process commands set with the keypad to the correct settings and then restart the motor High intensity noise was applied to the drive while data was being written when the power was turned off CHECK Check if appropriate noise control measures have been implemented e g correct grounding and routing of control and main circuit wires SUGGESTED ACTIONS 7 Improve noise control Press the key to release the alarm then reset the data e g frequency commands timer and PID process commands set through the keypad to the correct settings Restart the motor The CPU did not operate normall
77. ction 2 3 4 Wiring for Main Circuit Terminals and Ground Terminals 2 Is an alarm code displayed on the LED monitor Quick reference table of alarm codes Refer Alarm to code Name OH4 PTC thermistor for motor protection Overcurrent protection dbH Overheat protection for braking resistor Electronic thermal overload relay Overload protection Overvoltage protection 6 1 Memory error Remote keypad communications error Undervolatge protection 6 1 CPU error Input phase loss protection 6 1 Operation protection Output phase loss protection 6 1 RS485 communications error Overheat protection for heat sink Data save error during undervoltage External alarm input 6 1 6 2 If no alarm code appears on the LED monitor 6 2 1 Motor is running abnormally 1 The motor does not rotate Possible Causes 1 No power supplied to the drive What to Check and Suggested Measures CHECK Check nput voltage output voltage and interphase imbalance SUGGESTED ACTIONS Connect a molded case circuit breaker a ground fault circuit interruptor with the exception of those exclusively designed for protection from ground faults or a magnetic contactor Check for voltage drop phase loss poor connections or poor contacts and fix them if necessary No forward reverse operation command was input or both the commands were inputted simultaneously external sig
78. ction code F02 data makes it possible to run the motor in the reverse direction by pressing the key determine the motor rotation direction by entering input signals to the terminals and control the motor by pressing the keys 2 Set up the Set Frequency and Others By using the potentiometer and keys on the keypad you may set up the desired set frequency and PID process commands It is also possible to set up the set frequency as frequency load shaft speed line speed and constant feeding rate time by setting function code E48 Setting up the set frequency with the potentiometer on the keypad factory default If you set function code F01 data to 4 Potentiometer on the keypad factory default and select frequency com mand 1 with function codes E01 through E03 Hz2 Hz1 OFF the potentiometer is then enabled to choose the set frequency Setting function code C30 to 4 Potentiometer on the keypad and selecting frequency command 2 Hz2 Hz1 ON also produce the same effect Setting up the set frequency with the and keys If you set function code F01 data to 0 Keypad operation and select frequency command 1 then the keys are enabled to set up the set frequency in Run mode In any other operation modes those keys remain disabled Pressing the key calls up the set frequency with the lowest digit flashing Pressing the key again makes it possible to change the set frequency The new setting wil
79. d or PID feedback signal Used as additional auxiliary setting for various main frequency commands Input impedance 22 kQ Allowable maximum input voltage is 15 Vdc If the input voltage is 10 Vdc or over the drive assumes it to be 10 Vdc Current input The frequency is set according to the external analog input current command 4 to 20 mA dc 0 to 100 Normal mode operation 20 to 4 mA dc 0 to 100 Inverse mode operation Used for reference signal PID process command or PID feedback signal Connects PTC thermistor for motor protection Used as additional auxiliary setting to various main frequency commands Input impedance 250 Q Allowable input current is 30 mA dc If the input current exceeds 20 mA dc the drive will limit it at 20 mA dc z gt 2 D 2 S lt Analog common Common terminal for analog input and output signals NOTE The control signal lines handle weak analog signals that are susceptible to external noise and interference so use shielded wires and keep them as short as possible less than 66 ft 20 m It is recommended that the shield ing conductor of those wires be grounded If grounding causes control signals to be affected by external induction noise connect the shield to terminal 11 which may be effective for noise reduction As shown in Figure 2 13 ground the single end of the shield to enhance the shielding effect Use a twin contact relay for weak s
80. d automatically lower the output fre quency On synchronization of the output frequency and motor speed the drive accelerates up to the previous output frequency Refer to the figure F14 4 on the following page for details However to synchronize output frequency and motor speed the momentary overcurrent limiter H12 1 should be enabled This setting is optimal for cases in which due to the heavy moment of inertia of its load the motor would take along time to coast to a stop because of power failure Power failure Power recovery Set value 4 Intermediate DC Undervoltage i circuit voltage j i Time A Synchronization Output frequency motor speed Acceleration time Auto restarting 4 IPF ON z Restart at the starting frequency F14 5 If an instantaneous power failure occurs when the drive is in Run mode so that the drive detects undervoltage of the intermediate dc circuit then the drive immediately shuts down its outputs After power is recovered entry of any run command will restart the drive at the frequency specified by function code F23 Refer to the figure F14 5 on the following page for details This setting is optimal for cases where due to a high load with a very low moment of inertia the motor quickly comes to a stop when de energized WARNING If you select the auto restart function active in the restart mode after instantaneous power failure function
81. d ihe moiy arc conics eiiim dares kir WER Fii ieee S aie oh Deia be PO pra Thua Figure 10 3 Installing the drive into a Controlboard 10 4 Harmonic Component Regulation in the EU 10 4 1 General comments When you use general purpose industrial drives in the EU the harmonics emitted from the drive to power lines are strictly regulated as stated below If a drive whose rated input is 1 kW or less is connected to public low voltage power supply it is regulated by the regulation related to harmonics emission from drives to power lines with the exception of industrial low voltage power lines Refer to Figure 10 4 below for details The drive connected here is ep Ey ae Pale PC PT ree wane Home heroes a iong io Be paar eee eis bhe Pmp a pie emi e by ae bm prem uppis yri be reje Figure 10 4 Power Source and Regulation 10 4 2 Compliance with the harmonic component regulation Table 11 1 Compliance with Harmonic Component Regulation w o DC w DC reactor reactor Power supply voltage Drive types marked with v in the table above are compliant with the EN61000 3 2 A14 so they may be connected to commercial power lines unconditionally Conditions apply when connecting models marked with If you want to connect them to commer cial power lines you need to obtain permission from the local electric power supplier In general you will need to provide the supplier with the harmonics curr
82. d is modified it will be saved internally Even if the drive is switched to another PID process command entry and then returned to the keypad entry the setting will be retained Turning off the drive will automatically save the setting into the non volatile memory The next time the drive is turned on the setting will become the default PID process command Even if the PID process command is selected SS4 ON in the multistep frequency it is still possible to set the process command using the keypad When function code J02 data has been set to any value except 0 pressing the or key displays the PID process command currently selected setting is not possible When the PID process command is displayed the decimal point next to the lowest digit on the LED display flashes to discriminate it from the regular frequency command Hat fae Setting up the set frequency with the and keys under the PID control To set the set frequency with the and keys under the PID control you need to specify the following conditions Set function code F01 data to 0 Keypad operation Select frequency command 1 Frequency commands from communications link Disabled and Multistep frequency commands Disabled as manual speed command Set the LED monitor to the speed monitor in Run mode The above setting is impossible in any operation mode except Run mode The setting procedure is the same as that for the frequency command 3 6
83. drive capacity Driving standard motor Select a drive with a capacity range corresponding to the applicable motor rating as shown in the standard specifications table for the drive When high starting torque is required or quick acceleration or deceleration needed select a drive with a capacity one size greater than the standard Driving special motors Select a drive that that has a rated current exceeding that of the motor Transportation and storage For details about transportation and storage of the drives refer to Chapter 1 Section 1 3 Transportation and Section 1 4 Storage Environment Terms The following terms are used throughout this manual NOTE This term indicates information which must be taken into account for full efficiency operation of the drive and information concerning incorrect operation and settings which can result in accidents TIP This term indicates information that can prove handy when performing certain settings or operations REFERENCE This term indicates a reference to more detailed information How this manual is organized This manual consists of chapters 1 through 10 1 Before Using the Drive This chapter describes acceptance inspection and precautions for transportation and storage of the drive 2 Mounting and Wiring the Drive This chapter covers operating environment precautions for installing the drive and wiring instructions for the motor a
84. ds frequently used for the AF 300 Mini series of drives FWD and REV to terminals FWD and REV Refer to the AF 300 Mini User s Manual Chapter 9 respectively Turn on the FWD or REV for the FUNCTION CODES for details forward or reverse direction respectively then press the key to run the motor F00 Data Protection If F02 1 the drive can run the motor by control Specifies whether function code data is to be protected signal inputs To specify the motor rotational from being accidentally changed by keypad operation direction assign the commands FWD and REV If data protection is enabled F00 1 the or key to terminals FWD and REV respectively Turn on operation to change data is disabled In this case no FWD or REV for the forward or reverse direction function code data except F00 data can be changed respectively If both of FWD and REV are turned from the keypad on simultaneously the drive immediately deceler 7 i ae ates to stop the motor F02 Running Stopping and Rotational Direction The table below lists the operational relationship Selects the source issuing a run command keypad or between function code F02 Running Stopping and external control signal input Rotational Direction control signal inputs to terminals FWD and REV and the key operation which f F02 0 2 or 3 the drive can run the motor using l T ASI determines the rotational direction th
85. e and keys on the built in keypad The motor rotational direction can be specified in two ways either by control signal input F02 0 or by use of prefixed forward or reverse rotation F02 2 or 3 Running Control Signal Inputs to Stopping and Terminals FWD and REV Rotational key on the built in keypad Motor rotational direction otatona Function code F98 Function code F99 Direction REV command FWD command ee OEE ON OFF ON OFF ON Vv Vv Vv Vv Vv 5 7 Stop z Vv Vv 0 v e Stop Vv Forward Vv Y Vv Reverse Vv Vv Stop Vv Stop Vv Forward 1 Not required Y Vv Reverse Vv Vv Stop 5 9 F03 Maximum Frequency Sets the maximum frequency to drive the motor Setting the frequency out of the rated range for the equipment driven by the drive may damage the system or cause it to malfunction Set a maximum frequency appropriate for the equipment CAUTION As the drive can easily set high speed operation care fully verify the allowable specifications of the motor and its load before changing speed settings Otherwise injuries could occur F04 Base Frequency Set the rated frequency printed on the nameplate labeled on the motor FOS Rated Voltage at Base Frequency Set 0 or the rated voltage printed on the nameplate labeled on the motor If Ois set the driv
86. e could result in serious accident or material loss An accident could occur Installation WARNING e install the drive on a nonflammable material base such as metal Otherwise fire could occur Do not place flammable matter nearby Doing so could cause fire CAUTION e Do not support the drive by its cover during trans portation The cover could detach allowing the drive to drop with risk of injury e Prevent lint paper fibers sawdust dust metallic chips or other foreign materials from getting into the drive or from accumulating on the heat sink Doing so could cause fire or an accident Do not install or operate a drive that is damaged or missing any parts Doing so could cause fire accident or injuries e Do not stand or sit on a shipping box e Do not stack shipping boxes higher than indicated by the information printed on those boxes Doing so could cause injuries Wiring WARNING e The drive should be wired to its power source through a recommended molded case circuit breaker MCCB and a ground fault circuit interrupt er GFCI Apply protective devices of the correct current range e Use wiring of the specified size Otherwise fire could occur WARNING The drive must be securely grounded Otherwise electric shock or fire could occur Wiring must only be performed only by a qualified electrician Be sure to do all wiring after installing the drive unit Otherwise electric
87. e is 85V or more the drive continues operation If it drops below 85V the 4 drive operates for 15 ms with DOR without DCR 0 3 0 4 0 7 1 3 Capacity 5 kVA Torque Oo o y 150 i i ime i 9 DC injection braking Sth ie 0 0 to 60 0 Hz braking time 0 0 to 30 0 s braking current 5 to 100 of Conformity to safety standards UL508C C22 2 No 14 nclosure IEC60529 IP20 Cooling method Natural cooling Weight lbs 13 GE 4 pole standard motor Drive output capacity kVA at 230V Output voltage cannot exceed the power supply voltage Tested under standard conditions with 85 nominal motor load Output ratings n D T g 5 gt 2 Obtained with a dc reactor Average braking torque with AVR control OFF varies with motor efficiency Average braking torque using external braking resistor optional No braking resistor is available for 1 8 hp 1 4 hp 8 Calculated under GE Fuji specified conditions 9 Indicates product revision 8 3 4 IP20 with built in EMC filter 3 phase 230V 460V series litem Specifications 3 phase 230V class 3 phase 460V class Type 10 6KXC123___E9 230V class F12 F25 F50 001 002 008 005 F50 001 002 003 005 6KXC143___E9 460V class 2 3 5 5 5 5 seni Rated voltage 3 V 3 phase 200V 50 Hz 200 220 230V 60 Hz eon den i He Rated 4 15 kHz 15 25 37 55 current A Low carrier l l l enen oe 15
88. e normal logic system e Drive running Speed gt 0 RUN Function code data 0 This output signal is used to tell the external equipment that the drive is running at a speed faster than 0 It switches ON when the drive output frequency exceeds the start frequency of the motor and switches OFF when it does not or when the drive is dc braking the motor e Frequency equivalence FAR Function code data 1 This signal is turned ON when the difference between the output and set frequencies has come into the allow able error zone preset to 2 5 Hz e Frequency detection FDT Function code data 2 This signal is turned ON when the output frequency of drive has come to the frequency detection level speci fied by function code E31 It is turned OFF when the output frequency drops lower than the detection level for 1 Hz hysteresis band of the frequency comparator preset to 1 Hz e Undervoltage detection LU Function code data 3 This signal is turned ON when the voltage of the inter mediate dc circuit of the drive drops below the specified level or when the motor stops due to activation of the undervoltage protection feature undervoltage trip It is turned OFF if the intermediate dc voltage exceeds the specified voltage e Torque limiting Current limiting IOL Function code data 5 This signal is turned ON when the drive is limiting the motor supply current by activating the current limiter
89. e outputs the same voltage and frequency of the the source power In this case the output voltage will vary in line with any variance in input voltage Ifthe data is set to anything other than 0 the drive automatically keeps the output voltage constant in line with the setting When any of the automatic torque boost automatic energy saving or slip com pensation are active the voltage settings should be equal to the rated voltage of the motor NOTE If the rated voltage of the motor is set to F05 the motor efficiency will be increased more than when 0 is set Therefore when brakes are applied to the motor energy loss decreases and the motor regenerates higher braking energy than it would otherwise Note that the allowable power consumption capacity of the drive for braking energy is limited by the specifications so it may be necessary to increase deceleration time or to use an external braking resistor Fo9 Load Selection Auto Torque Boost Auto Energy Saving F37 Torque Boost There are two different properties of loads the torque load reversal proportional to the square of speed and the constant torque load You can select a V f pattern optimized to the load properties Manual torque boost This feature manually adjusts the starting output voltage by setting F09 to an optimal torque boost rate to match the motor and its load Select a V f pattern from two types of loads with F37 Setting an excessive torque b
90. e reviewed For example Load shaft speed Displayed data x 10 rpm PID process commands These commands are displayed through the use of function code E40 and E41 data PID factors A and B Display value PID process command x Factor A B B If PID control is disabled appears PID feedback amount This value is displayed through the use of function code E40 data and function code E41 data PID factors A and B Display value PID feedback amount x Factor A B B If PID control is disabled appears 3 12 Displaying running status To display the running status in hexadecimal format each state has been assigned to bit 0 to 15 as listed in Table 3 6 Table 3 7 shows the relationship between each of the status assignments and the LED monitor display Table 3 8 gives the conversion table from 4 bit binary to hexadecimal Notation Table 3 7 Running Status Bit Allocation Content 1 when function code data is being written Always 0 Always 0 1 when communications is effective when running commands and set frequency commands are issued via communications iy 1 when an alarm has occurred 1 during deceleration 1 during acceleration 1 during current limitation 1 under voltage control Always 0 1 when intermediate dc voltage has increased up to the specified level 0 when the voltage is too low Always 0
91. e short circuit time RST should be kept OFF for normal drive operation e Alarm from external equipment THR Function code data 9 When the motor is running opening the circuit between the THR assigned terminal and terminal CH will immediately shut down the drive output and issue the alarm OH2 The motor will coast to a stop e Ready for jogging JOG Function code data 10 Turning ON the JOG command makes the motor ready for jogging Use this command for fine adjustment of workpiece positioning for example When the motor is ready for jogging with JOG being ON pressing the key or turning the FWD or REV command ON will start the motor to jog If the key is released the motor will decelerate to a stop Jogging operation follows the settings of Jogging frequency set by function code C20 Acceleration or deceleration time set by function code H54 Simultaneous keying may also make the motor ready for jogging depending upon whether keypad operation or terminal command operation is selected and whether the JOG command is ON or OFF as listed below When operated from keypad F02 0 2 or 3 If The motor becomes sa ls ready for ON Disabled Jogging Toggles between normal and Normal running OFF jogging Jogging When terminal command operation is selected F02 1 simultaneous keying is disabled e Select frequency command 2 or 1 Hz2
92. ection to terminals FWD and REV SUGGESTED ACTIONS Correct the function code data and the connection The setting for the direction of rotation via keypad operation is incorrect CHECK Check the data for function code F02 SUGGESTED ACTIONS Change the data of function code F02 to 2 forward rotation or 3 reverse rotation 4 If speed variation such as hunting and current fluctuation occur at regular speed Possible Causes What to Check and Suggested Measures 1 The frequency command CHECK varied Check the signals for the frequency command using Menu 4 I O checking SUGGESTED ACTIONS Increase the filter constants C33 and C38 for the frequency command 2 An external frequency CHECK command device was Check that there is no noise in the control signal wires from external sources used SUGGESTED ACTIONS Isolate the control signal wires from the main circuit wires as far as possible Use shielded or twisted wires for the control signal 3 The slip compensation gain was too large CHECK Check that the motor vibration is absorbed if the slip compensation P09 is cancelled SUGGESTED ACTIONS Correct or cancel the slip compensation P09 data 6 4 Possible Causes What to Check and Suggested Measures 4 The system vibrates due to a too compliant mechanical coupling between the motor and load or the current fluctuates due to motor characteristic
93. ee Figure 4 2 If the LED monitor displays numbers other than 0 00 turn the potentiometer to set 0 00 as the set frequency 2 Check that any built in cooling fan is functioning normally for models with 2 hp and above Figure 4 2 Display of the LED Monitor after Power on 4 1 3 Preparation before Running the Motor for a Test Setting Function Code Data Before initial running of the motor set the function code data specified in Table 4 1 to the corresponding motor rating and for your system design values For motor information check the rated values printed on the nameplate of the motor For your system design values check with the system designers 4 1 REFERENCE For details about how to set function code data refer to Chapter 3 Section 3 4 Setting the Function Codes Table 4 1 Settings of Function Code Data before Driving the Motor for a Test Function Function code data Factory setting code Base frequency 60 0 Hz Rated Voltage at 230V 460V base frequency Output voltage interlocked with the source voltage Motor ratings printed on the nameplate of the Motor Parameter motor Rated capacity Applicable motor rating capacity Motor Parameter Rated current Rated current of applicable motor rating Maximum frequency System design values 60 0 Hz 7 To test drive of the motor increase values so that they are longer than your system 6 00 sec a dea fe design values If the set
94. elect Auto torque 1_Constant torque load boost Energy saving operation 2_Automatic torque boost 3_Energy saving operation Variable torque load during ACC DEC 4 Energy saving operation Constant torque load during ACC DEC 5_Energy saving operation Automatic torque boost ACC DEC Current limiting 1 Mode 0_Inactive 1_At constant speed 2_During acceleration and at constant speed Level 20 to 200 Electronic thermal overload 0 Internal braking resistor optional Discharge capability 1 to 900kWs 999 cancel lay for braking resist Islay Hor braking rESISton 0 000 Braking resitor built in type 0 001 to 50 000 E codes Extension Terminal X1 terminal function Select Selects from the following items by code X2 terminal function X3 terminal function 1000 Multistep freq selection 0 to 7 stage _SS1_ 1001 Multistep freq selection 0 to 7 stage _SS2_ 1002 Multistep freq selection 0 to 7 stage _SS4_ 1004 ACC DEC time selection 2 stages RT1_ 1006 3 wire operation stop command_HLD_ 1007 Coast to stop command_BX_ 1008 Alarm reset_RST_ 1009 Trip command External fault THR_ 1010 Jogging operation JOG_ 1011 Freq set 2 Freq set 1_Hz2 Hz1_ 1019 Write enable for Keypad Data changeable 1020 PID control cancel_Hz PID_ 1021 Normal Inverse mode changeover_IVS_ 1024 Link enable RS485 standard BUS option 1 033 PID integration differentiation reset_PID RST_ _ 1034 PID integration hold_PID HLD_ _The
95. en the ready to jog state and usual running state is enabled only when the drive is at a halt 3 4 Setting the Function Codes Data setting Menu 1 Data setting in Program mode allows you to set function codes for making the drive functions match your needs The table below lists the function codes available in the AF 300 Mini The function codes are displayed on the LED monitor on the keypad as shown below gE m f ed Function Code Group ID number in each function code group Table 3 5 List of AF 300 Mini Function Codes Function code group Function Function Description code F codes F00 to F51 Basic functions To be used for basic motor running Fundamental functions E codes E01 to E99 Terminal To be used to select the functions of the control circuit terminals Extension terminal functions functions To be used to set functions related to the LED monitor display C codes C01 to C52 Frequency To be used to set application functions related to frequency Control functions of frequency control commands functions P codes P02 to P99 Motor To be used to set special parameters for the motor capacity etc Motor parameters parameters H codes H03 to H98 High level To be used for high added value functions and complicated High performance functions functions control etc J codes J01 to J06 Application To be used for PID control Application functions functions y codes y01 to y99
96. ent data of the drive To obtain the data contact us Note 1 When supplying 3 phase 230 Vac power stepped down from a 3 phase 460 Vac power line using a transformer the level of harmonic flow from the 460 Vac line will be regulated 10 5 Compliance with the Low Voltage Directive in the EU 10 5 1 General comments General purpose drives are regulated by the Low Voltage Directive in the EU GE Fuji has obtained the proper certification for the Low Voltage Directive from the official inspection agency GE Fuji states that all our drives with CE and or TUV marking are compliant with the Low Voltage Directive 10 5 2 Points for Consideration when using the AF 300 Mini series in a system to be certified by the Low Voltage Directive in the EU If you want to use AF 300 Mini series of drives in systems equipment appliances in the EU refer to the cautionary notes on page v Notes 10 4 FUJI EUSCT REIG GE Fuji Drives USA GE Fuji Drives USA Inc 1501 Roanoke Bivd Suite 435 Salem VA 24153 GEH 6647 www GEindustrial com 030205 INR Si47 0817 E
97. entarily exceeded the overcurrent level OC1 Overcurrent occurred during acceleration OC2 Overcurrent occurred during deceleration OC3 Overcurrent occurred when running at a constant speed Possible Causes What to Check and Suggested Measures 1 The drive output termi CHECK nals were short circuited Remove the wires connected to the drive output terminals U V and W and measure the interphase resistance Check if the resistance is too low SUGGESTED ACTIONS Remove the short circuit including replacement of the wires relay terminals and motor 2 Ground faults occurred CHECK at the drive output Remove the wires connected to the drive output terminals U V and W and perform a Megger test terminals SUGGESTED ACTIONS Remove the short circuit including replacement of the wires relay terminals and motor 3 Loads were too heavy CHECK Measure the motor current with a meter and observe the current variations Use this information to decide if the current may exceed calculated design values for your system SUGGESTED ACTIONS Reduce excessive load or use a larger drive CHECK Observe the current variations and check if there are any sudden changes in the current SUGGESTED ACTIONS If there are any sudden changes make the load variation smaller or raise the drive capacity Enable current limiting H12 4 The value set for torque CHECK boost F09 was too Check that the output current decreases
98. eration Protection STOP key Pressing i key on the keypad forces the motor to decelerate and Er6 Yes priority stop even if the drive is running by any run commands given via the terminals or communications link operation After the motor stops the drive issues an alarm Er6 Start check Any run operations are prohibited and the drive displays Er6 on the Er6 Yes function LED display if any run command is given when Powering up Releasing an alarm key turned ON Link command LE has switched drive operations RS485 On detecting an RS485 communication error the drive displays the alarm code Er8 Yes communication error Data save error If the data could not be saved during activation of the undervoltage protection ErF Yes during undervoltage function the drive displays the alarm code This alarm may not be triggered depending upon the function code data Not applicable 8 15 Notes 8 16 9 List of Peripheral Equipment and Options The table below lists the main peripheral equipment and options that may be connected to the AF 300 Mini Use them in accordance with your system requirements REFERENCE For details refer to the AF 300 Mini User s Manual Chapter 6 Selecting Peripheral Equipment Main peripheral equipment Name of peripheral Function and application equipment Molded case Molded Case Circuit Breakers MCCBs are designed to protect the power circu
99. ess of whether the motor is running or not Pressing the key will make the change effective and save it into the drive s memory Function codes marked with Y The difference from function codes marked with Y and others is that if the data for these codes is changed the ef fect is immediate However the change is not saved into the drive s memory To save the change press the key If you press the key to exit the current state without pressing the key then the changed data will be discarded and the previous data will be restored for the current drive operation Using negative logic for programmable I O terminals The negative logic signaling system can be used for the digital input and output terminals by setting the func tion codes that specify properties for those terminals Negative logic refers to inverted ON OFF logical value 1 true 0 false state of input or output signal An ON ac tive signal the function takes effect for the ON signal in the normal logic system is functionally equivalent to OFF active signal the function takes effect for the OFF signal in the negative logic system To set the negative logic system for an I O signal terminal display data as 1000s by adding 1000 to the data for the normal logic in the corresponding function code and then press the key For example if a coast to stop command BX data 7 is assigned to any one of digital input terminals X1 to X3 by setting an
100. ettings e g cancel the higher priority run command 6 The set frequency was CHECK set to the same or Check that a frequency command has been input using Menu 4 I O checking lower than the value SUGGESTED ACTIONS of the starting or stop Set the value of the set frequency to the same or higher than that of the starting or stop frequency F23 frequency or F25 Reconsider the starting and stop frequencies F23 and F25 and if necessary change to lower values Inspect the frequency command devices signal converters switches or relay contacts Replace any that are faulty Connect the external circuit wires correctly to terminals 13 12 11 and C1 7 A run command with CHECK higher priority than Check the higher priority run command using Menu 2 Data checking and Menu 4 I O checking the one attempted while referring to the block diagram of the drive command generator was active and the set Refer to Chapter 4 in the AF 300 Mini User s Manual frequency was set to the SUGGESTED ACTIONS same or lower than the Correct any incorrect function code data settings e g cancel the higher priority run command value of the starting or stop frequency 8 The peak and minimum CHECK frequencies for the Check the data for function codes F15 and F16 frequency limiters were SUGGESTED ACTIONS set incorrectly Change the peak and minimum frequencies F15 and F16 to the correct ones 6 2
101. fer to Chapter 8 Section 8 6 Protective Functions Figure 3 1 shows the status transition of the drive between these three operation modes Figure 3 1 Status Transition between Operation Modes 3 2 1 Run Mode If the drive is turned on it automatically enters Run mode in which you may 1 Run stop the motor 2 Set up the set frequency and others 3 Monitor the running status e g output frequency output current 4 Jog inch the motor REFERENCE For details refer to Section 3 3 Operation in Run mode 3 2 3 2 2 Program Mode Program mode provides various functions such as setting and checking function code data monitoring mainte nance information and checking input output I O signal status These functions can be easily selected with the menu driven system Table 3 2 lists menus available in Program mode The leftmost digit numeral of each letter string indicates the corresponding menu number and the remaining three digits indicate the menu contents When the drive re enters Program mode the menu that was selected last in Program mode will be displayed Restricting menus to be displayed In order to simplify operation the menu driven system has a special function specified by function code E52 that restricts the menus to be displayed The factory default is to display Menu 1 Data setting only allowing no switching to any other menu Function Code E52 Keypad Mode Selection Function code d
102. g resistor available to order or external braking resis tor option to terminals P and DB on the main circuit terminal block 2 When using an external braking resistor arrange the drive and braking resistor to keep the wiring length to 5 m or less and twist the two wires or route them together in parallel When a dc reactor is not to be connected together with the braking resistor 1 Remove the screws from terminals P1 and P together with the jumper bar 2 First connect the wire from terminal P of the braking resistor to terminal P then the jumper bar and secure them with the screw removed in 1 above Tighten the screw on terminal P1 FL Connect the wire from terminal DB of the braking resistor to the DB of the drive Figure 2 7 Braking Resistor Connection without DC Resistor When connecting a dc reactor together with the braking resistor 1 Remove the screw from terminal P 2 Overlap the dc reactor wire and braking resistor wire P as shown at left and then secure them to terminal P of the drive with the screw D Connect the wire from terminal DB of the braking resistor to terminal DB of the drive 4 Do not use the jumper bar Figure 2 8 Braking Resistor Connection with DC Resistor 2 7 When using an optional internal braking resistor An optional internal braking resistor should be con nected to terminals P and DB Connect the wires from the braking resistor following t
103. g for Main Circuit Terminals and Ground Terminals Follow the procedure below Figure 2 3 illustrates the wiring for peripheral equipment Wiring Procedure 1 Ground terminals G Drive output terminals U V and W 3 DC reactor connection terminals P1 and P DS 4 Braking resistor connection terminals P and DB DC link circuit terminals P and N 6 Main circuit power input terminals L1 R L2 S and L3 T or L1 L and L2 N Wire these as necessary oa i aasa of 1 jp IW Shee E afi A E ai ee a O ia q Fa Fering baritor aa CALITIOM Da roi c rrer Fari Paii be wma P jej Misiied Come Ciri kear CT Lage Driu Dit Same fa fhe cepa of thom mendes Geared bor Prick fees geen fatal Figure 2 3 Wiring Procedure for Peripheral Equipment The wiring procedure for the 6KXC is 2 Drive output terminals U V and W shown below as an example For other drive types 1 Connect the three wires of the 3 phase motor to perform wiring in accordance with their individual terminals U V and W aligning phases each other terminal arrangement Refer to page 2 3 2 The wiring length between the drive and motor should not exceed 50 m 165 ft If the wiring length 1 Ground terminals mG exceeds that length it is recommended that an For safety and noise reduction be sure to connect either output circuit filter option be inserted
104. g transportation 1 The storage temperature applies only to short periods of time such as during transportation Precautions for temporary storage 1 Do not place the drive directly on the floor 2 If the storage environment does not meet the specified requirements wrap the drive in an airtight vinyl sheet or similar for storage 3 If there is a possibility that the drive will be exposed to high humidity add a drying agent such as silica gel in the airtight package described in item 2 1 4 2 Long term storage The long term storage method for the drive varies according to the environment of the storage site General storage methods are described below 1 The storage site must satisfy the requirements specified for temporary storage However for storage exceeding three months the ambient temperature should be within the range of 10 to 30 C 14 to 86 F This is to prevent electrolytic capacitors in the drive from deterioration 2 The package must be airtight to protect the drive from moisture Add a drying agent inside the package to maintain the relative humidity inside the package at less than 70 3 If the drive has been installed to the equipment or control board at construction sites where it may be subjected to humidity dust or dirt then remove the drive and store it in a suitable environment Precautions for storage over 1 year If the drive has not been powered on for a long time its electr
105. ge is never mistakenly applied to the drive output terminals due to unexpected timer operation or similar E Driving the motor using commercial power lines MCs can also be used to switch the power source of the motor driven by the drive to a commercial power source 9 2 Name of option Function and application Main option Braking resistors Standard model DBRs A braking resistor converts regenerative energy derived from deceleration of the motor and converts it to heat for dissipation Use of a braking resistor results in improved deceleration performance of the drive DC reactors DCRs Output circuit filters OFLs A DCR is mainly used for power supply normalization and for supplied power factor correction for reducing harmonic components 1 For power supply normalization 2 For supplied power factor correction harmonic component reduction Note As shipped the drive has a jumper bar connected across the terminals P1 and P on the terminal block Remove the jumper bar when connecting a DCR Include an OFL in the drive power output circuit to Note Use an ACR within the allowable carrier frequency range specified by function code F26 The filter will overheat is any other ACR is used Use a DCR when the capacity of a power supply transformer exceeds 500 kVA and is 10 times or more the rated drive capacity In this case the percentage reactance of the power source decreases and
106. ground terminals provided indicated by the symbol in Figures A to D may be used inter changeably for either the power supply side primary circuit or the motor side secondary circuit 1 Arrangement of the main circuit terminals Applicable motor f Figure B i 7 7 FOB K Er K Piei Nii amp D D e E Os Figure B akai ERTA E EE ou fv i l Goni size M d Taghbearenig borgu 15 9 i i Figure O 1 phase 1 4 hp Figure C Moy 1 2 hp i TG alsials Be Pisy i mia j J alale leef Le Lean Lv WwW Serew size Ma Tightening torge 15 9 fis inch 2 3 2 Arrangement of the control circuit terminals common to all AF 300 Mini models Pe Poe Pel os Pe Screw size M 2 Tightening Torque 1 8 Ib inch Screw size M 2 5 Tightening Torque 3 5 Ib inch Strip length of Dimension of openings in the control Terminal rewdriver t d Allowable wire siz x i See S x e a Serewd o be use able wire siz wire covering circuit terminals for stick terminals 30A 30B 30C Phillips screwdriver 18 to 22 AWG 0 24 to 0 31 0 11 W x 0 07 H equivalent to 1 size 0 34 to 0 75 mm 6 to 8 mm 2 7 mm x 1 8 mm Phillips screwdriver for Others precision machinery equivalent to 0 size 18 to 22 AWG 0 2 to 0 28 0 07 W x 0 06 H 0 25 to 0 75 mm 5 to 7 mm 1 7 mm x 1 6 mm 2 3 3 Wiring Precautions Follow the rules be
107. harmonic components and their peak levels increase These factors may damage rectifiers or capacitors in the converter section of drive or degrade the capacitor which can shorten the drive s service life Also use a DCR when there are thyristor driven loads or when power factor correction capacitors are being turned on off Use a DCR when the interphase unbalance ratio of the drive power source exceeds 2 ae F l gt War VS M n vitja V se ee LW ae te ee ke z Generally a capacitor is used to correct the power factor of the load However it cannot be used in a system that includes a drive Using a DCR increases the reactance of the drive s power source so as to decrease harmonic components on the power source lines and correct the drive s power factor Using a DCR corrects the input power factor to approximately 95 Suppress voltage fluctuation at the motor input terminals This protects the motor from insulation damage caused by the application of high voltage surge currents in 460 V drives Suppress leakage current from the power output lines due to harmonic components This reduces the leakage current when the motor is connected by long power feed lines It is recommended that the length of the power feed line be kept to less than 1200 feet 400 m Minimize emission and or induction noise in the power feed lines OFLs are effective in reducing noise from long power feed lines such as those used in plants etc 9 3 Name
108. he factory default of Potentiometer operation on the keypad F01 4 to key operation F01 0 1 With the menu displayed use the and keys to select the desired function code group In this example select 1 F__ 2 Press the key to display the function codes in the function code group selected in 1 In this example func tion code F00 will appear Even if the function code list for a particular function code group is displayed it is possible to transfer the display to a different function code group using the keys 3 Select the desired function code using the and keys and press the key In this example select function code F01 The data for this function code will appear In this example data 4 of F01 will appear 4 Change the function code data using the and keys In this example press the key four times to change data 4 to 0 5 Press the key to establish the function code data SAUE will appear on the display and the data will be saved into non volatile memory The display will return to the function code list then move to the next function code In this example F02 Pressing the key before the key cancels the change made to the data The data reverts to the previous value the display returns to the function code list and the original function code reappears 6 Press the key to return to the menu from the function code list TIP Cursor movement Yo
109. he procedure described in When a dc reactor is not to be connected together with the braking resistor or When using a dc reactor together on the previous page as applicable pose f i SoBe ia bas Te 4 A oe p pa ee j J a im ea tea aN in LELEL amen i Mae ter he he he go ee a s f CAC there _ th Fer it Figure 2 9 Braking Resistor Connection TIP The option internal braking resistor type is available only in 3 phase 230V and 460V models of 2 hp and above 5 DC link circuit terminals P and N These are provided for the dc bus link circuit system Connect these terminals with terminals P and N of other drives NOTE Consult GE Fuji if these terminals are to be used 6 Main circuit power input terminals L1 R L2 S and L3 T for 3 phase voltage input or L1 L and L2 N for 1 phase voltage input 1 For safety make sure that the Molded Case Circuit Breaker MCCB or Magnetic Contactor MC is disconnected before wiring the main circuit power input terminals 2 Connect the ground wire of the main circuit power input terminals L1 R L2 S and L3 T or L1 L and L2 N to the ground terminal G 3 Connect the main circuit power supply wires L1 R L2 S and L3 T or L1 L and L2 N to the input terminals of the drive via an MCCB or Ground Fault Circuit Interrupter GFCI and MC if necessary It is not necessary to align phases of the power supply wires and the input terminals
110. heck item Abnormal noise and excessive vibration Loose bolts Deformation and breakage Discoloration and deformation caused by overheat Check for dirt and dust How to inspect 1 Visual and audible inspec tion 2 Retighten 3 4 5 Visual inspection Evaluation criteria 1 2 3 4 5 No abnormalities Common Check if bolts and screws are tight and not missing Check the devices and insulators for defor mation cracks breakage and discoloration caused by overheat and deterioration Check for dirt and dust Retighten Visual inspection 1 2 3 No abnormalities Conductor and wire Check the conductor for discoloration and distortion caused by overheat Check the sheath of the cable for cracks and discoloration 1 2 Visual inspection 1 2 No abnormalities Terminal block Filtering capacitor Note 1 Main circuit Resistor Magnetic contactor and relay Printed circuit board Note 1 Control circuit Cooling fan Note 1 Ventilation path Cooling system Check that the terminals are not damaged Check for electrolyte leakage discoloration cracks and swelling of the case Check if the safety valve does not protrude remarkably Measure the capacitance if necessary Check for odor caused by overheating and cracked insulator Check for broken wire Check for chattering during operation Check for rough contacts Check for
111. his instruction manual Install ing the drive s in a metal shielded control board may be necessary depending upon the operating environment of the equipment that the drive is to be used with 10 3 2 Recommended installation To make the machinery or equipment be fully compli ant with the EMC Directive have certified technicians wire the motor and drive in strict accordance with the procedure described below Use EMC filter built in type of drives 1 Mount the EMC grounding flange that comes with the drive to the drive with screws in order to ground the wire shield s See Figure 10 1 2 Use shielded wires for the motor power cable and route it as short as possible Firmly clamp the wire shield to the flange to ground it Further connect the wire shield electrically to the grounding terminal of motor See Figure 10 2 Use shielded wires for the control signals of the drive to input to output from the control terminals Firmly clamp the control wire shields to the EMC grounding flange in the same way as the power wires Ciar Srey oe of Erte Cae ki ERUS Farge EAC Flag Shasta Maker Cates Maer Canal Pier iy Lati EPak Garii Canin Figure 10 2 Connecting Shielded Cables If noise from the drive exceeds the permissible level enclose the drive and its peripherals within a metal control board as shown in Figure 10 3 Bide Connect than stein leper of hobkied Ghie ip Pe Pade Ped a ae ke eT an wel gecun
112. ified by these function codes are also used for the overload early warning Therefore even if you need only the overload early warning set these property data to function codes F10 and F12 F10 selects the motor s cooling method built in cooling fan or external forced ventilation Set F10 to If the cooling property of the motor is 1 Built in cooling fan of general purpose motor self cooled The cooling performance will decrease in low frequency operation 2 Drive driven or high speed motor force ventilated Cooling performance remains constant with speed F11 sets the operation level of the electronic thermal detection to the current value Set approximately 1 0 to 1 1 multiples of the allowable continuous current rated current of the motor at the rated drive frequency of the motor under normal running conditions To disable the electronic thermal detection set F11 to 0 00 F12 sets the thermal time constant of the motor The drive interprets the time constant as an operation period of the electronic thermal detection During the speci fied operation period the drive will activate electronic thermal deection if 150 of the operating current speci fied by F11 flows continuously The time constant of GE instantaneous power failure occurs If the drive detects that the voltage of the intermediate dc circuit drops to below the specified undervoltage limit it interprets the state as a momentary p
113. ignal terminals The status of control I O signal terminal status may be displayed with ON OFF of the LED segment or in hexadeci mal display E Display I O signal status with ON OFF of the LED Segment As shown in Table 3 10 and the figure below segments a to e on LED1 light when the digital input terminals FWD REV X1 X2 and X3 are short circuited with the terminal CM ON and do not light when they are opened OFF Segment a on LED3 lights when the circuit between output terminal Y1 and terminal Y1E is closed ON and does not light when the circuit is open OFF LED4 is for terminals 30A 30B 30C Segment a on LED4 lights when the circuit between terminals 30C and 30A are short circuited ON and dos not light when they are opened NOTE This LED monitor displays hardware terminal information which means that it may not light when it is in negative logic refer to Chapter 5 FUNCTION CODES for details even when it is active Table 3 10 Segment Display for External Signal Information Segment No correlating control circuit terminals XF and XR are assigned for communication Refer to Displaying control I O signal terminal block under com munication control Displaying I O signal status in hexadecimal format Each I O terminal is assigned to bit 15 through bit 0 as listed in Table 3 11 An unassigned bit is interpreted as
114. ignals if a relay is used in the circuit Do not connect the relay s contact to terminal 11 When the drive is connected to an external device putting out an analog signal malfunctions may be caused by electric noise generated by the drive If this happens depending on the circumstances connect a ferrite core a ring core or its equivalent to the device outputting the analog signal and or connect a capacitor with good cut off characteristics for high frequency between the control signal cables as shown in Figure 2 14 F Enia ra Cais Soho iu gt ipa ares eS b Pon Pan peepee eo bF aF Figure 2 13 Connection of Shielded Wire Figure 2 14 Example of Electric Noise Prevention 2 10 Table 2 4 Continued Classifi cation Functions Digital input 1 1 The various signals such as coast to stop alarm from external equipment and mul tistep frequency selection can be assigned to terminals X1 to X3 FWD and REV by setting function codes E01 to E03 E98 and E99 For details refer to Chapter 5 E Section 5 2 Overview of Function Codes Digital input 2 Input mode i e Sink Source is changeable by using the built in jumper switch Switches the logic value 1 0 for ON OFF of the terminals between X1 to X3 FWD or REV and CM If the logic value for ON between X1 and CM is 1 in the normal logic system for example OFF is 1 in the negative logic system and vice versa Digital input 3 Digital input circuit s
115. in the EU If installed according to the guidelines given below drives marked with CE or TUV are considered as compliant with the Low Voltage Directive 73 23 EEC CAUTION 1 The ground terminal amp G should always be connected to the ground Do not use only a residual current oper ated protective device RCD earth leakage circuit breaker ELCB as the sole method of electric shock protec tion Be sure to use ground wires whose size is greater than power supply lines With the exception of those exclusively designed for protection from ground faults When you use a residual current operated protective device RCD earth leakage circuit breaker ELCB for protection from electric shock in direct or indirect contact power lines or nodes be sure to use type B of RCD ELCB at the power supply side of the electric equipment for three phase 230 460 V power supplies For single phase 230 V power supplies use type A When you use no RCD ELCB take any other protective measure that isolates the electric equipment from other equipment on the same power supply line using double layered or reinforced insulation or that isolates the power supply lines connected to the electric equipment using an isolated transformer The drive should be used in an environment that does not exceed pollution degree 2 requirements If the environment conforms to pollution degree 3 or 4 install the drive in a enclosure of IP54 or higher Install the drive ac or dc
116. is signal is turned ON when the retry facility specified by function codes H04 number of retries and H05 retry interval is activated Refer to function codes H04 and H05 for details of the output timing and number of retries e Service life alarm LIFE Function code data 30 This signal is turned ON when it is judged that the service life of capacitors in the intermediate dc circuit and electrolytic capacitors on the printed circuit boards or the cooling fan has expired This facility provides tentative information for parts service life If this signal is issued check the service life of these parts in your system according to the mainte nance procedure to determine whether they should be replaced or not To maintain stable and reliable opera tion and avoid unexpected failures daily and periodic maintenance must be performed REFERENCE For details refer to Chapter 7 Section 7 2 Table 7 2 Replacement Parts Judgement with Menu 5 Maintenance Information as a Guide e Drive running RUN2 Function code data 35 This signal is turned ON when the main switching circuit Insulated Gate Bipolar Transistor IGBT gates is activated it is OFF when it is not activated Related item Refer to drive running Speed gt 0 RUN e Overload prevention control OLP Function code data 36 This signal is turned ON when the overload prevention facility is activated if the frequency d
117. it Prepare a high resistance range tester for the control circuit 1 Disconnect all the external wiring from the control circuit terminals 2 Perform a continuity test to the ground 1 MQ or a larger measurement indicates a correct state 3 Dielectric strength test of main circuit and sequence control circuit Disconnect all the drive terminals so that the test voltage is not applied 7 5 List of Periodical Replacement Parts Each part of the product has its own service life that will vary according to the environmental and operating condi tions It is recommended that the following parts be replaced as specified below When the replacement is necessary contact your dealer where you purchased the product or GE Fuji Table 7 4 Replacement Parts Standard replacement intervals Cooling fan Intermediate dc circuit capacitor Electrolytic capacitor on the printed circuit board 7 years 7 5 7 6 Inquiries about Product and Warranty The purpose of this section is to provide specific instructions to the user of the standard drive referenced in this book regarding warranty administration and how to obtain assistance on both in warranty and out of warranty equipment If assistance is required to determine warranty status identify defective parts or obtain the name of your local distributor call 1501 Roanoke Blvd Salem VA 24153 6492 USA Phone 1 888 GE4 SERV 888 434 7378 United States 1 540 378 3280 Internationa
118. its between the power circuit breaker distribution panel and the drive s main terminals L1 R L2 S and L3 T for 3 phase or L1 L and L2 N for MCCB 1 phase power source from overload or short circuit This in turn prevents secondary damage caused by the drive malfunctioning Use the MCCBs with recommended rated currents listed in the table below Recommended rated current A Applicable Motor of MCCB Rating hp w o DC w DC Reactor Reactor 3 phase 230 V 1 8 9 1 Name of peripheral equipment Function and application juawdinbe jeseydiued uren WARNING When connecting the drive to the power supply add a recommended molded case circuit breaker in the power supply circuit Do not use the devices with the rated current out of the recommenced range Fire could occur Magnetic contactor MC An MC can be used on both the power input and output sides of the drive On each side the MC works as described below When inserted in the output circuit of the drive an MC can also switch the motor drive power source between the drive output and commercial power lines E At the power source side Insert an MC in the power source side of the drive in order to 1 Forcibly disconnect the drive from its power source generally commercial factory power lines with the protection facility built into the drive or with the terminal signal line 2 Stop drive operation in an emergency when the drive
119. kPa 12 5 to 15 4 psi enclosure daisies Note 2 If the drive is to be used at an altitude of more Vibration 3 mm max amplitude 2 to less than 9 Hz than 3 300 ft 1 000 m derate the output current by the 9 8 m s 9 to less than 20 Hz factor listed in Table 2 2 above 2 m s 20 to less than 55 Hz 1 m s 5 to less than 200 Hz 2 2 Installing the drive 1 Mounting base The temperature of the heat sink may rise up to about 90 C during operation of the drive so it should be mounted on a base made of material that can withstand temperatures at this level WARNING Install the drive on a base constructed from metal or other non flam mable material A fire may result with other material 2 Clearances Ensure that the minimum clearances indicated in Figure 2 1 are maintained at all times When installing the drive in a power control board take extra care with ventilation inside the control board as the temperature around the drive will tend to increase Bottom 4 in Figure 2 1 Mounting Direction and Required Clearances 2 1 When mounting two or more drives Horizontal layout is recommended when two or more drives are to be installed in the same enclosure or power control board As long as the ambient temperature is 40 C 104 F or lower drives may be mounted side by side without any clearance between them If it is necessary to mount the drives vertically install a partition plate or similar divider bet
120. ke correctly 6 3 Possible Causes 7 The current limiting op eration did not increase the output frequency 8 Bias and grain set incor rectly What to Check and Suggested Measures CHECK Check whether the current limiting is active or not using Menu 3 drive monitoring and the data for the current limiting level F44 SUGGESTED ACTIONS Change the level of the current limiting F44 to an appropriate value CHECK Decrease the value of torque boost F09 then turn the power off and back on again and check if the speed increases SUGGESTED ACTIONS Adjust the value of the torque boost F09 CHECK Check the data for function codes F04 F05 H50 and H51 to ensure that the V f pattern is right SUGGESTED ACTIONS Match the V f pattern values with the motor ratings CHECK Check the data of function codes F18 C50 C32 C34 C37 and C39 SUGGESTED ACTIONS Set correct data values if necessary 3 The motor runs in the opposite direction to the command Possible Causes What to Check and Suggested Measures Wiring has been connected to the motor incorrectly CHECK Check the wiring to the motor SUGGESTED ACTIONS Connect terminals U V and W of the drive to the respective U V and W terminals of the motor Incorrect connection and settings for run commands and rotation direction command FWD and REV CHECK Check the data entered for function codes E98 and E99 and the conn
121. l Fax 1 540 387 8606 All indicates the international access code required when calling from outside of the USA Warranty Coverage The warranty covers all major parts of the drive such as the main printed circuit boards transistor modules etc Warranty period is 12 months after installation or 18 months after shipment from the Company whichever occurs first However the guarantee will not apply in the following cases even if the guarantee term has not expired 1 Damage was caused by incorrect use or inappropriate repair or modification 2 The product was used in an environment outside the standard specified range 3 Damage was caused by dropping the product after purchase or occurred during transportation 4 Damage was caused by an earthquake fire flooding lightning abnormal voltage or other natural calamities and secondary disasters Before calling the number at left to determine warranty status the drive serial number will be required This is located on the drive nameplate If the drive is still under warranty further information will be required per the In Warranty Failure Checklist shown on page 7 7of this Start up Guide Out of Warranty Procedures When the defective part has been identified contact your local authorized GE standard drives distributor to order replacement parts Motors Motor repairs on General Electric motors are generally handled by GE Authorized Electric Motor Service
122. l be saved internally Even if the drive is switched to some other frequency entry and then returned to the keypad entry the setting will be retained Even turning off the drive will automatically save the setting into the non volatile memory The next time the drive is turned on the setting will become the default frequency If you set function code F01 data to 0 Keypad operation but do not select frequency command 1 then the keys cannot be used for setting up the set frequency Pressing those keys will just display the currently selected set frequency Setting up the frequency from any other displayed item depends on function code E48 data 4 5 or 6 LED moni tor details Select speed monitor as listed in the following table E48 data LED monitor details Select speed monitor Set frequency display Conversion of displayed value 0 Output frequency before slip compensation Frequency command 1 Output frequency after slip compensation Frequency command 2 Set frequency Frequency command 4 Load shaft speed Load shaft speed setting Frequency command x E50 5 Line speed Line speed setting Frequency command x E50 6 Constant feeding rate time Constant feed rate time setting E50 frequency setting x E39 If you set function code C30 data to 0 Keypad operation and select frequency command 2 then the keys are enabled to select the set frequency 3 5 Make setting u
123. loose screws and connectors Check for odor and discoloration Check for cracks breakage deformation and corrosion Check the capacitors for electrolyte leaks and deformation Check for abnormal noise and excessive vibration Check for loose bolts Check for discoloration caused by overheat Check the heat sink intake and exhaust ports for clogging and foreign matter Visual inspection Visual inspection Measure discharge time with capacitance probe Smelling and visual inspec tion Visual inspection or mea surement with multimeter under disconnection of one lead Hearing inspection Visual inspection Retighten Smelling and visual inspec tion Visual inspection Hearing and visual inspec tion or turn manually be sure to turn the power off Retighten Visual inspection Visual inspection No abnormalities No abnormalities The discharge time is shorter than time speci fied by the replacement manual No abnormalities Within 10 of displayed resistance ane abnormalities 1 2 3 4 No abnormalities Smooth rotation No abnormalities No abnormalities Note 1 The judgement level of part replacement interval with Menu 5 Maintenance information is used as a guide Determine the replacement interval on the basis of the standard replacement years See page 7 8 If the drive is stained wipe it off with a chemically neutral cloth to remove dust use a vacuum cleaner 7
124. low when wiring the drive 1 Make sure that the supply voltage is within the range specified on the nameplate 2 Be sure to connect the power wires to the main circuit power input terminals L1 R L2 S and L3 T for 3 phase voltage input or L1 L and L2 N for 1 phase voltage input of the drive If the power wires are connected to other terminals the drive will be damaged when the power is turned on 3 Always connect the ground terminal to prevent electric shock fire or other disasters and to reduce electric noise s Use solderless terminals for the main circuit terminal wiring to ensure a reliable connection 5 Keep the power supply wiring primary circuit and motor wiring secondary circuit of the main circuit and control circuit wiring as far away from each other as possible WARNING e Always connect ground wires Failure to do so may result in electric shock or fire e Qualified electricians should always perform the wiring e Check that the power is turned off before proceeding with any wiring Failure to do so may result in electric shock CAUTION e Check that the number of phases and the rated voltage of the drive match those of the ac power Failure to do so may result in a fire e Do not connect the ac power line to the drive output terminals U V and W Doing so may result in injury e Do not connect a braking resistor to the dc link circuit terminals P and N Doing so may result in a fire 2 3 4 Wirin
125. lues for 75 C Cu wires at an ambient temperature of 50 C Table 2 6 Recommended Wire Size Recommended wire size AWG 1 Main circuit Main power circuit input Applicable L1 R L2 S and L3 T motor rating Drive hp L1 L and L2 N DC reactor hp Grounding G Drive output P1 and P U Vand W Braking resistor P and DB Control circuit Power supply voltage w o dc w dc reactor reactor 2 1 8 to 3 hp 1 8 to 3 hp 5 hp 5 hp 1 2 to 5 hp 1 2 to 5 hp gt Q ise N Q na a o gt Q r on o 1 8 to 1 hp 1 8 to 1 hp 2hp 2 hp 1 phase 230 V 1 8 to 1 2 hp 1 8 to 1 2 hp 1 phase 115 V 1 hp 1 hp 1 Use solderless terminals covered with an insulated jacket or insulating sleeve 2 Wire sizes are calculated on the basis of input RMS current under the condition that power supply capacity and impedance are 500 kVA and 5 respectively 2 15 Notes 2 16 3 Operation Using the Keypad 3 1 Keys Potentiometer and LED on the Keypad As shown in the figure at below the keypad consists of an LED monitor a potentiometer POT and six keys The keypad allows you to run and stop the motor monitor running status and switch to the menu mode In the menu mode you may set the function code data to match your operating requirements and monitor I O signal states maintenance information and alarm information Program Reset Key LED Monitor Pote
126. lure Slip compensation Compensates for decrease in speed according to the load during constant speed operation Current limit By hardware Limits the current to prevent overcurrent trip caused by rapid load change or instantaneous power failure when current limitation by the software is impossible This function can be canceled By software Automatically reduces the frequency to make output current under the preset value Current limit condition can be selected from between constant speed operation only and acceleration and constant speed operation Process PID control can be made PID control Process command Keypad built in potentiometer analog input 12 C1 RS485 communication Feedback signal Analog input 12 C1 Automatic Makes the deceleration time 3 times longer to avoid OV trip when dc link circuit voltage exceeds the deceleration overvoltage limit Aino eneravisaiih Controls output voltage to minimize motor loss during constant speed operation ope aoa g Torque boost during acceleration can be selected from manual variable torque manual constant torque and auto torque Overload A Decreases the output frequency automatically to prevent tripping before the inverter s overload preventive A function is activated by ambient temperature rise frequent use or large motor load a fan stop Detects drive inside temperature and stops cooling fan when the temperature is low a Running stopping Speed monitor
127. ment even if the drive reduces the output frequency enable this control NOTE Do not use this function with equipment whose load does not diminish with reduced drive output frequency as it will have no effect H98 Protection Maintenance Selection Specify a combination between the output phase loss protection input phase loss protection and automatic carrier frequency lowering Automatic lowering of carrier frequency When using a drive in a critical system or any other system where drive operation should not be interrupted select this feature to protect the system from any failure resulting from the drive tripping due to the heat sink overheating 0H1 or overload OLU abnormally high ambient temperature or a cooling mechanism failure This feature lowers the drive frequency before the drive enters the alarm mode However the level of motor noise may increase Input phase loss protection L The drive will enter the alarm mode and issue an alarm Len if a phase loss is detected in the three phase input power source Do not enable this protection with drives with single phase input as it is not applicable When operating a drive with three phase input with a single phase for testing purposes this protection may be disabled but only if the load can be reduced Output phase loss protection OPL The drive will enter the alarm mode activated by the output phase loss protection and issue the alarm OPL
128. n you can switch between the various running parameters using the key or key Detailed running information is the same as for Menu 6 Alarm information in Program mode Refer to Table 3 13 in Section 3 9 Reading Alarm Information Pressing the key while the running information is displayed returns the display to the alarm codes NOTE When the running information is displayed after removal of the alarm cause pressing the key a number of times in succession will cause the drive to shift the alarm code display and then release the alarm status Be careful with a run command If a run command has been entered at this stage the motor will start running Switching to Program Mode It is also possible to switch the drive to Program mode by pressing the key key simultaneously while the alarm is displayed and then to check and adjust the function code data Fae Prayag ae Be Co TETE M ia Eg 20 aiea germ code a Ta Eg Iwej Lujan aaa ech 5 in Si a ot Ea Lt T Fusing ANLA i al a re oR A aa Let ot eh ook Figure 3 2 Alarm Mode Status Transition 3 4 3 3 Operation in Run Mode If the drive is turned on it automatically enters Run mode in which you may operate the following 1 Run Stop the Motor By factory default pressing the key starts running the motor in the forward direction and pressing the key decelerates the motor to stop The key is enabled only in Run mode Changing fun
129. nal operation CHECK Check input status of the forward reverse command using Menu 4 I O checking SUGGESTED ACTIONS Input a run command Set either the forward or reverse operation command to OFF if both commands are being inputted Correct the assignment of commands FWD and REV to function codes E98 and E99 Connect the external circuit wires to control circuit terminals FWD and REV correctly If the printed circuit board is malfunctioning replace it No indication of rotation direction keypad opera tion CHECK Check input status of the forward reverse rotation direction command using Menu 4 I O checking SUGGESTED ACTIONS Input the rotation direction FO2 0 or select the keypad operation with which the rotation direction is fixed FO2 2 or 3 The drive could not ac cept any run commands from the keypad because it was not in Run mode CHECK Check which operation mode the drive is in SUGGESTED ACTIONS Make a transition from existing mode to Run mode 5 A run command with CHECK higher priority than the Check the higher priority run command with using Menu 2 Data checking and Menu 4 I O checking one attempted was while referring to the block diagram of the drive command generator active and the run Refer to Chapter 4 in the AF 300 Mini User s Manual command was stopped SUGGESTED ACTIONS Change any incorrect function code data s
130. ncrease the clearance CHECK Check if the heat sink is clogged SUGGESTED ACTIONS Clean the heat sink 6 10 Possible Causes What to Check and Suggested Measures 4 Excessive load CHECK Measure the output current SUGGESTED ACTIONS Reduce the load e g lighten the load before the overload protection occurs using the overload early warning E34 Lower the carrier frequency F26 Enable the overload protection control H70 7 OH2 External alarm input Problem External alarm was signalled THR What to Check and Suggested Measures Possible Causes An alarm function of the external equipment was activated CHECK Inspect external equipment operation SUGGESTED ACTIONS Remove the cause of the alarm Connection has been performed incorrectly CHECK Check if the wire for the external alarm signal is correctly connected to the terminal to which the Alarm from external equipment has been assigned SUGGESTED ACTIONS Connect the wire for the alarm signal correctly Incorrect settings CHECK Check if the Alarm from external equipment has been assigned to an unassigned terminal SUGGESTED ACTIONS Correct the assignment 8 OH4 PTC thermistor for motor protection Problem Possible Causes Temperature of the motor rose abnormally What to Check and Suggested Measures Temperature around the motor exceeded that of
131. nd drive 3 Operation Using the Keypad This chapter describes drive operation using the keypad The drive features three operation modes Run Program and Alarm modes which enable you to run and stop the motor monitor run status set function code data display run information required for maintenance and display alarm data 4 Operation This chapter describes preparations to be made before testing the motor and practical operation 5 Function Codes This chapter provides a list of the function codes Both common and special function codes are described individually 6 Troubleshooting This chapter describes troubleshooting procedures to be followed when the drive malfunctions or detects an alarm condition First check whether or not an alarm code is displayed and then proceed to the trouble shooting items 7 Maintenance and Inspection This chapter describes inspection measurement and insulation tests which are required for safe drive operation It also provides information about periodical replacement parts and guarantee of the product 8 Specifications This chapter lists specifications including output ratings control system external dimensions and protective functions 9 List of Peripheral Equipment and Options This chapter describes main peripheral equipment and options which can be connected to the AF 300 Mini series of drives xi AF 300 Mini Model Numbering System Diagram Description ox xer w
132. nder PID control To enable PID control you need to set function control code J01 data to 1 or 2 Under the PID control the items that can be set or checked with the keys are different from those under regular frequency control depending upon the current LED monitor setting If the LED monitor is set to the speed monitor E43 0 you may access manual feed commands Set frequency with the keys if it is set to any other you may access PID process commands with those keys REFERENCE Refer to User s Manual Chapter 4 Section 4 8 PID Frequency Command Generator for details on the PID control Setting the PID process command with the built in potentiometer Set function code E60 data to 3 PID process command and J02 to 1 PID process command After that selecting PID control remote process command enables you to set the PID process command using the built in potentiometer Setting the PID process command with the and keys Set function code J02 data to 0 Keypad operation and set the LED monitor to the setting other than the speed monitor E43 0 in Run mode This makes it possible to set the PID process command using the and keys This setting is possible only in Run mode Pressing the or key displays the PID process command with the lowest digit flashing on the LED monitor Pressing the or key again makes it possible to change the PID process command Once the PID process com man
133. ng TEE E GE 4 pole standard motor Drive output capacity kVA at 230V Output voltage cannot exceed the power supply voltage Tested under standard conditions with 85 nominal motor load Obtained with a dc reactor z Average braking torque with AVR control OFF varies with motor efficiency Average braking torque using external braking resistor optional No braking resistor is available for 1 8 hp 1 4 hp 8 Calculated under GE Fuji specified conditions 9 Indicates product revision 8 5 8 2 Common Specifications 25 to 400 Hz 25 to 400 Hz Starting Starting frequency 0 1 to 60 0 Hz Carrier frequency 0 75 to 15k Hz Frequency may drop automatically to protect the drive running at 7kHz or over Accuracy Stability Analog setting 2 of max freq at 25 C temperature drift 0 2 of max freq at 25 10 C ing 0 01 of max freq at 25 C temperature drift 0 01 of max freq at 10 to 50 C Setting resolution Analog setting 1 1000 of max freq Keypad setting 0 01 Hz 99 99 Hz or less 0 1 Hz 100 0 to 400 0Hz Link setting Selectable from 2 types 1 20000 of max freq ex 0 003 Hz at 60 Hz 0 006 Hz at 120 Hz 0 02 Hz at 400 Hz Control method V f control Simplified torque vector control Voltage freq Output voltage between 80 and 240V can be set at base frequency and at maximum characteristic 100V AVR control can be turned ON or OFF class Desired 1 point on non linear V f
134. ng at resonance points Note that operation of a 2 pole motor at 60 Hz or above may cause abnormal vibration When a drive is used with a standard motor the motor noise level will be higher than that with a commercial power supply To reduce noise raise carrier frequency of the drive High speed operation at 60 Hz or higher frequencies can also result in increased noise Explosion proof motors When using an explosion proof motor with a drive use a only an approved drive motor combination This type of motor has a higher current rating than standard motors Select a drive capacity that Submersible will ensure that these motors run within the rated current capacity of the drive These motors Application with special motors and also differ from standard motors in their thermal characteristics Bir P pumps Set a low value in the thermal time constant of the motor when setting the electronic thermal protection Do not use motors with parallel connected brakes that obtain their braking power from the Motors fitted primary circuit commercial power supply If the brake power is connected to the drive power with brakes output circuit by mistake problems may occur Do not use drives on motors equipped with series connected brakes When the power transmission mechanism uses an oil lubricated gearbox or speed changer Gearmotors CR reducer continuous motor operation at low speed may cause poor lubrication Using a drive with OS
135. nit Shows the total use time for the capacitor mounted on the printed circuit board s The display method is the same as for accumulated run time However when the total time exceeds 65 535 hours the count stops and the display remains at 65 53 Accumulated run time of the cooling fan Shows the accumulated operating time of the cooling fan The cooling fan ON OFF control function code H06 is effective so the time when the fan is stopped is not counted The display method is the same as for accumulated run time However when the total time exceeds 65 535 hours the count stops and the display remains at 65 53 Number of startups The motor run times the number of times the drive running command is set to ON are calculated and displayed 1 000 indicates 1 000 times When any number ranging from 0 001 to 9 999 is displayed the display increases by 0 001 per startup and when any number from 10 00 to 65 53 is displayed the display increases by 0 01 every 10 startups Number of RS485 errors Shows the total number of times and RS485 communications error has occurred after the power is turned on Once the number of errors exceeds 9 999 the display count returns to 0 RS485 error contents Shows the latest error that has occurred with RS485 communications in hexadecimal format Refer to the user s manual of RS485 communication ROM version of drive Shows the ROM version of the drive as a
136. nters or GE Apparatus Service Shops For specific instructions on your motor call the distributor from which it was purchased and be prepared to furnish complete nameplate data In Warranty Failure Checklist To assist with warranty troubleshooting the following information is required This data is needed to evaluate the cause in an effort to eliminate any further failures Model No Serial No Start Up Date Failure Date Status When Failure Occurred check one Power Up Running Accel Decel Explanation of Failure Application Information check Yes or No Input Transformer Yes No If Yes KVA L1 Volts L2 Volts L3 Volts Power Factor Correction Capacitors Yes No If Yes Microfarrad Other Equipment on Same Power Yes No If Yes what Line Reactor on Input Yes No Input Starter Yes No Output Starter Yes No Motor Overloads Yes No Control Terminals Used circle if used Y a vie mal C1 PLC X1 X2 X3 11 12 13 11 CM FWD REV CM 30A 30B 30C Function Codes Different From Factory Settings Function Code Setting Function Code Setting Failure Message see Section 4 Latest Fault Previous Faults No Message Hz 1 A 2 V 3 After all of the Checklist information is acquired contact the following number for assistance 540 387 5739 or 800 533 5885 When returning failed parts reference on the shipping documents th
137. ntiometer RUN Key Function Data Key Down Key UpKey STOP Key Table 3 1 Overview of Keypad Functions Monitor Potentiometer Functions and Keys Four digit 7 segment LED monitor which displays the running status data settings and alarm status of the drive nAn depending on the operation modes b IERTE in Run mode the monitor displays running status information e g output frequency current and voltage In Program mode it displays menus function codes and their data In Alarm mode it displays an alarm code which identifies the error factor if the protection facility is activated oO Potentiometer POT which is used to manually set frequency auxiliary frequencies 1 and 2 or PID process command T RUN key Press this key to run the motor p STOP key Press this key to stop the motor e ile UP DOWN keys Press these keys to select the setting items and change the function data displayed on the LED monitor Program Reset key Press this key to switch the operation modes of the drive Pressing this key in Run mode switches the drive to Program mode and vice versa In Alarm mode pressing this key after removing the error factor will switch the drive to Run mode Function Data key Pressing this key in Run mode switches the information displayed output frequency Hz current Amps or voltage Pressing this key in Program mode displays the function code and sets the data entered using the mS se key
138. o abnormality is found turn the potentiometer clockwise to raise the set frequency Check the above points for the test driving of the motor 4 2 Operation After checking that the operations finished correctly through the above test driving start normal operation 5 Function Codes 5 1 Function Code Tables Function codes enable the AF 300 Mini series of drives to be set up to match your system requirements Each function code consists of a 3 character string The first is a letter identifying the group and the following two are numerals that defining each individual code in the group Function codes are classified into seven groups Fundamental Functions F codes Extension Terminal Functions E codes Control Functions of Frequency C codes Motor Parameters P codes High Performance Functions H codes Application Functions J codes and Link Function y codes To determine the property of each function code set data to the function code Changing reflecting and saving function code data when the motor is running Function codes are indicated by the following based on whether they can be changed or not while the motor is running Function codes marked with N in the Change when running column of the function code tables given below The data of these codes cannot be changed when the motor is running Function codes marked with Y The data for these codes can be changed with the and keys regardl
139. ode data 21 Turning the IVS command ON OFF switches the output frequency control between normal proportional to the set frequency components and inverse operation for the PID process or manually set frequencies To select the inverse operation switch the IVS command to ON When the PID control is enabled turning the IVS command ON inverts the PID process control selected by function code J01 For example if the PID process control is normal turning it ON switches it to inverse or vice versa ba ra a A al i i P Po ee Select link operation LE Function code data 24 Turning ON the LE command selects link operation The drive will run the motor with the frequency com mand or drive command given via the RS485 communi cations facility defined by function code H30 If the LE command is not assigned to any terminal the drive will interpret LE as being always ON e Reset PID integral and differential components PID RST Function code data 33 Turning ON the PID RST command resets the PID integral and differential components Hold PID integral component PID HLD Function code data 34 Turning ON the PID HLD command holds the cur rent drive output voltage constant by suppressing an increase of PID integral component Run forward FWD Function code E98 E99 data 98 If the FWD command is turned ON the drive runs the motor forward if OFF it decelerates the motor to a st
140. of option Function and application Main option Ferrite ring reactors for reducing radio frequency noise ACL An ACL is used to reduce radio frequency noise emitted by the drive An ACL suppresses the outflow of high frequency harmonics caused by the switching operation in the drive s internal power supply lines Pass the power supply lines together through the ACL If wiring length between the drive and motor is less than 66 ft 20 m place an ACL around the power supply lines if it is more than 66 ft 20 m put it in the power output lines of the drive Options for 100 V single phase power supply An optional 100 V single phase power supply may be used to operate a drive designed for a 230 V 3 phase power supply Options for Operation and Communications External potentiometer for frequency command An external potentiometer may be used to set the drive frequency Connect the potentiometer to control signal terminals 11 to 13 of the drive Remote keypad Used when performing drive remote operations with the remote keypad Extension cable for remote operation RS485 communications card Drive support loader software The extension cable connects the drive with the remote keypad to enable remote operation of the drive For communicating with a PLC or personal computer system The Windows based drive support loader software makes setting function codes easy Requires use of the RS485 communication
141. of the main circuit if any A dc reactor option or braking resistor option need not be disconnected Keep the ambient temperature at 25 10 C 2 Turn off the digital inputs FWD REV and X1 to X3 at the control terminals f an external potentiometer is connected to terminal 13 remove it Set the data of function codes E20 and E27 so that the transistor output Y1 or relay output 30A B C do not come ON while the drive power is turned off The recommended settings are to assign normal logic signal RUN and ALM to terminals Y1 and 30A B C respectively 3 Turn the drive power on 4 Check that the cooling fan rotates and the drive is at a stop 5 Turn the main power supply off Start measuring the capacitance of intermediate dc circuit capacitor 6 After the LED monitor goes completely dark turn the main power supply on again 7 Select Menu 5 Maintenance information in Program mode and check the reduction ratio of the capaci tance of the intermediate dc circuit capacitor 2 Electrolytic capacitors on the printed circuit boards The drive counts hours for which the power has been applied to the control circuit The accumulated time will be multiplied by the life constant depending on the temperature inside the drive and displayed on the LED monitor According to the displayed hours determine when capacitors should be replaced The display unit is 1000 hours 3 Cooling fan The drive accumulates hou
142. ol connector RST XF and XR are assigned for communication Refer to Displaying control I O signal terminal block under communication control Figure 3 9 Segment Display for I O Signal Status in Hexadecimal Format Displaying control I O signal terminal block under communication control There are two control circuit input displays under communications link control display with ON OFF of the LED segment and in hexadecimal format for input commanded from RS485 communications link The content is simi lar to that of the control I O signal terminal status display however XF and XR are added as inputs and nothing is assigned as output terminals REFERENCE Refer to the user s manual of RS485 communication for details on input by commands sent through RS485 communications 3 8 Reading Maintenance Information Maintenance information Menu 5 Maintenance information in Program mode contains information necessary for performing maintenance on the drive Table 3 12 lists the maintenance information display items and Figure 3 9 shows the status transition for maintenance information Aiga La H ardi Lares arc aoa E Carel 7 a m me DO ae el Ae m 6 Ll I hegad PS eee Figure 3 9 Status Transition of Maintenance Information Monitoring Basic key operations 1 With the menu displayed use the and keys to select Maintenance information 6 CHE 2 Press the key to display the list of
143. olytic capacitors may deteriorate Power the drives on once a year and keep the drives powered on for 30 to 60 minutes Do not connect the drives to motors or run the motor 1 3 Notes 2 Mounting and Wiring the Drive 2 1 Operating Environment Install the drive in an environment that meets the requirements listed in Table 2 1 Table 2 1 Environmental Requirements Table 2 2 Output Attenuation Ratio with Altitude Item Specifications Site location Indoors Ambient 10 to 50 C 14 to 122 F temperature Output current Altitude derate factor 3300 ft 1000m or lower 3300 4950 ft 1000 to 1500 m 4950 6600 ft 1500 to 2000 m Relative humidity 5 to 95 non condensing 6600 8250 ft 2000 to 2500 m 8250 9900 ft 2500 to 3000 m Atmosphere The drive must not be exposed to dust direct sunlight corrosive gases flammable gas oil mist vapor or water drops Note 1 The atmosphere must contain only a low level of salt 0 01 mg cm or less per year Note 1 Do not install the drive in an environment where The drive must not be subjected to sudden it may be exposed to cotton waste or moist dust or dirt ee cause which may clog the heat sink in the drive If the drive condensation to form y 29 da aes is to be used in such an environment install it in the Altitude 1 000 m 3 300 ft max Note 2 control board of your system or in another dust proof Atmospheric 86 to 106
144. ommand value 12_PID feedback value 13_Timer value timer operation E45 _ See Note2 E46 I o N LED monitor detail Speed monitor select 0_Output frequency before slip compensation 1_Output frequency after slip compensation 2_Setting frequency 4_Load shaft speed 5_Line speed 6_Constant rate of feeding time E50 Speed display coefficient 0 01 to 200 00 0 01 K E52 EYPAD Mode 0_Function code data setting menu only 1_Data verification menu only 2_All menu E60 Potentiometer on the keypad 0_No function selection Function 1_Aux freq setting 1 2_Aux freq setting 2 3_PID process command 1 Terminal 12 Function E62 Terminal C1 Selects from the following by code 0_No function selection 1_Aux freq setting 1 2_Aux freq setting 2 3_PID process command 1 5_PID feedback value 5 4 FWD terminal function Select Select from the following items by code REV terminal function 0_ 1000 Multistep freq selection 0 to 7 stage 1_ 1001 Multistep freq selection 0 to 7 stage 2_ 1002 Multistep freq selection 0 to 7 stage 4 1004 ACC DEC time selection 2 stages 6_ 1006 3 wire operation stop command 7_ 1007 Coast to stop command 8_ 1008 Alarm reset 9_ 1009 Trip command External fault 10 1010 Jogging operation 11_ 1011 Freq set 2 Freq set 1 Hz2 Hz1 19_ 1019 Write enable for Keypad Data changeable WE KP 20_ 1020 PID control cancel Hz PID 21 1021 Normal Inverse mode change
145. onformity to safety standards UL508C C22 2No 14 EN50178 1997 Enclosure IEC60529 Cooling method Natural cooling Natural cooling GE 4 pole standard motor Drive output capacity kVA at 230V 460V Output voltage cannot exceed the power supply voltage Tested under standard conditions with 85 nominal motor load Obtained with a dc reactor Average braking torque with AVR control OFF varies with motor efficiency Average braking torque using external braking resistor optional Output ratings Input ratings Braking Re N N YS reo re DOSY LE a NO OO A No braking resistor is available for 1 8 hp 1 4 hp 8 Voltage unbalance Max voltage V Min voltage V 3 phase average voltage V x 67 IEC61800 3 5 2 3 If this value is 2 to 3 use ac reactor option 9 Calculated under GE Fuji specified conditions 10 Indicates product revision 8 1 2 IP20 type 1 phase 230V series Input power source 1 mare 230V class Type 9 _ X9 k es E Rated capacity 2 kVA T Rated voltage 3 V 3 phase 200V 50 Hz 200 220 a Hz High carrier 4 Rated 4 15 kHz current A Low carrier EA a AJN w P a E Overload capabilit 150 of rated current for 1 min 200 of rated current for 0 5 s 50 60 Hz Phase voltage oe ee 1 phase 200 to 240V 50 60 Hz Voltage frequency variations variations Voltage 10 to 10 Frequency 5 to 5 oe voltage dip cap
146. oost rate may result in over excitation and overheating of the motor during no load operation Manual torque boost keeps the output voltage constant even if the load varies assuring stable motor operation Automatic torque boost This feature automatically optimizes the output voltage to match the motor and its load Under a light load it decreases the output voltage to prevent the motor from over excitation under heavy load it raises the output voltage to increase torque Since this feature is related to the motor characteristics it is necessary to set the rated voltage at base frequency F05 and motor parameters P codes properly Auto energy saving This feature controls the terminal voltage of the motor automatically to minimize motor power loss Note that this feature may not be effective depending on the properties of the motor Check the properties before using this feature The drive enables this feature only for constant speed operation During acceleration and deceleration the drive will run with manual or automatic torque boost depending on the data setting of function code F37 If auto energy saving operation is enabled switching the motor from constant speed will become less responsive Do not use this feature for a system that requires quick acceleration and deceleration Given below are proper setting examples with the combination of F09 and F37 If auto energy saving operation is not selected
147. op Run reverse REV Function code E98 E99 data 99 If the REV is turned ON the drive runs the motor in reverse if OFF it decelerates the motor to a stop E20 E27 Terminal Function for Y1 30A 30B and 30C E20 to E27 may assign output signals to terminals Y1 transistor switch and 30A 30B and 80C mechani cal relay contacts which are general purpose program mable output terminals These function codes may also switch the logic system between normal and negative to define the property of those output terminals so that the drive logic may interpret either the ON or OFF status of each terminal as active Terminals 30A 30B and 30C are mechanical relay contacts In normal logic if an alarm occurs the relay will be excited so that 30A and 30C will be short circuited signaling an occurrence of the error to external equipment On the other hand in negative logic the relay will cut off the excitation current to open 30A and 30C This may be useful for the implementation of failsafe power systems NOTE When negative logic is utilized the drive switches all output signals to the active side for example the alarm side Therefore if it is desirable to avoid system malfunctions caused by this interlock the signals to keep them ON using an external power source or similar To keep explanations as simple as possible the ex amples shown below are all written assuming th
148. operation by giving a run command with the key 1 Use the or key to set the timer count in sec onds while monitoring the current count displayed on the LED monitor Note that the timer count is expressed as integers 2 Press the key to run the motor and the timer will start to count down The moment the timer finishes the countdown the drive stops running the motor even if the key is not pressed Timer operation is possible even when the timer count is not displayed on the LED monitor 3 After the drive decelerates the motor to a stop the timer count on the LED monitor will flash NOTE If timer operation started by the terminal com mand FWD is finished and the drive decelerates the motor to a stop then the LED monitor displays End a and the monitor indication 0 if the timer count is selected alternately Turning FWD OFF will switch the LED back to the monitor indication Refer to the AF 300 Mini User s Manual Chapter 4 BLOCK DIAGRAMS FOR CONTROL LOGIC for details Motor Parameter Rated capacity and rated current P02 P03 Set the nominal rated capacity denoted on the rating nameplate of the motor P09 Motor Parameter Slip compensation gain Set the gain to compensate the motor slip frequency as a reference at 100 based on the typical slip of any drive model Set the compensation gain with respect to motor speed Typical rated slip frequencies for 100
149. otor load Average braking torque with AVR control OFF varies with motor efficiency Average braking torque using external braking resistor optional No braking resistor is available for 1 8 hp 1 4 hp Voltage unbalance Max voltage V Min voltage V 3 phase average voltage V x 67 IEC61800 3 5 2 3 If this value is 2 to 3 use ac reactor option Obtained with a dc reactor 9 Calculated under GE Fuji specified conditions 10 Indicates product revision 8 4 5 IP20 with EMC filter built in type 1 phase 230V series item Specifications Input power source 1 phase 230V class Type rtg 6KXC12__E9 Nominal applied motor 1 Rated capacity 2 ea Rated voltage 3 S phase 200V 50 Hz 200 220 230V 60 Hz High carrier Low carrier Overload capabilit 150 of rated current for 1 min 200 of rated current for 0 5 s 50 60 Hz Phase voltage eee cae eam 1 phase 200 to 240V 50 60 Hz Voltage frequency variations variations Voltage aoe 10 Frequency 5 to 5 Output ratings If it drops below 165V the drive operates for 15 ms Rated current 8 A Required power supply Capacity 5 T Torque 6 Input Torque 7 x DC injection braking ai eee 0 0 to 60 0 Hz braking time 0 0 to 30 0 s braking current 5 to 100 of Conformity to safety standards UL508C C22 2No 14 EN50178 1997 Conformity to EMC standard Enclosure IEC60529 Cooling method Natural cooli
150. otor overload protection motor protection by electronic thermal overload relay is provided in each model Adjust function F10 to F12 decide the protection Level 2 Connect the power supply satisfying the characteristics shown in the table below as an input power supply of the drive Short circuit rating Use 75 C Cu wire only Use Class 1 wire only for control circuits Field wiring connection must be made by a UL Listed and CSA Certified closed loop terminal connector sized for the wire gauge involved Connector must be fixed using the crimp tool specified by the connector manufac turer Short circuit rating Suitable for use on a circuit capable of delivering not more than B rms symmetrical amperes A Volts maximum Power supply max voltage A Power supply current B 240 Vac 100 000 A or less 480 Vac 100 000 A or less 240 Vac 100 000 A or less 120 Vac 65 000 A or less vii Power supply voltage lalo r Z falon Siini x k oO N gt Q ise N o n 2 o S vT o n 2 Lop gt Q v N o n 2 _ gt wo tam e N Q i Conformity to UL standards and Canadian standards cUL certification continued CAUTION 6 Install a UL certified fuse or curciut breaker between the power supply and the drive referring to the table below Class J Fuse Circuit Breaker Required torque Ib in N m Wire size AWG or kcmil mm Current A Current A Power
151. over IVS 24 1024 Link enable RS485 standard BUS option LE 33_ 1033 PID integration differentiation reset PID RST _ 1034 PID integration hold PID HLD 98_Forward Stop command FWD 99_Reverse Stop command REV _The number in indicates logical inverse OFF when short circuited _POT External signal input can be changed over by Hz2 Hz1 C codes Control Functions of Frequency Jump frequency 0 0 to 400 0Hz Hysteresis 0 0 to 30 0Hz Multistep frequency setting 1 0 00 to 400 00Hz ae y oa Timer operation Mode select bee O O Ol inactive we a O _Active z y 1_Voltage input Terminal 12 0 to 10v DC 2_Current Input Terminal C1 4 to 20mA DC 3_Voltage Input Terminal 12 and current Input Terminal C1 4 Potentiometer on the keypad terminal 12 i C AA i i Analog input adj Gain terminal C1 Filter Gain reference point 5 5 C50 Bias Freq command 1 aoao 0 01 Bias reference point 2 C51_ Bias PID Bias value 100 00 to 100 00 C52 command1 Bias pen 0 00 to 100 00 P codes Motor Parameters Capacity 0 01 to 10 00kW when P99 0 3 4 0 01 to 10 00 HP when P99 1 Rated current 0 00 to 99 99A N al Slip compensation gain 0 0 to 200 0 1 o1 vy 00 Motor select 0_Motor Specification FUJI 8 Series N 1 1_Motor Specificationt HP Motor 3_Motor Specification3 FUJI 6 Series 4 Others H03 Data initializing 0_Manual set value 04
152. over and snip off the barrier of the RS485 communications cable port using nippers Figure 2 18 Replacing the Control Circuit Terminal Block TB Cover 2 3 10 Cautions Relating to Harmonic Component Noise and Leakage Current 1 Harmonic component Input current to a drive includes a harmonic component which may affect other loads and power factor improve ment capacitors that are connected to the same power supply If the harmonic component causes any prob lems connect a dc reactor option to the drive It may also be necessary to connect an ac reactor to the power factor improvement capacitors 2 Noise If noise generated from the drive affects other devices or that generated from peripheral equipment causes the drive to malfunction follow the basic measures outlined below 1 If noise generated from the drive affects the other devices through power wires or grounding wires Isolate the grounded metal frame of the drive from other devices Connect a noise filter to the drive power wires Isolate the power system of the other devices from that of the drive with an isolating transformer If induction or radio noise generated from the drive affects other devices through power wires or grounding wires Isolate the main circuit wires from the control circuit wires and other device wires Put the main circuit wires through a metal conduit and connect the pipe to the ground near the drive Mount the drive onto the met
153. ower failure However if the drive runs with a light load and the period of the power failure is short then it does not detect the power failure and continues to run Trip immediately F14 0 If an instantaneous power failure occurs when the drive is in Run mode such that the drive detects undervoltage of the intermediate dc circuit then the drive immediately shuts down its outputs and displays the undervoltage alarm LU on the LED monitor The motor will coast to a stop The drive will not restart automatically Trip after recovery of power F14 1 If an instantaneous power failure occurs when the drive is in Run mode so that the drive detects undervoltage of the intermediate dc circuit then the drive immediately shuts down its outputs without transferring to Alarm mode or displaying the undervoltage alarm LU The motor will coast to a stop When the power is recovered the drive will enter Alarm mode for undervoltage Restart at the frequency at which the power failure occurred F14 4 If an instantaneous power failure occurs when the drive is in Run mode so that the drive detects undervoltage of the intermediate dc circuit then the drive saves the current output frequency When the power is recovered with any run command being ON the drive will restart at the saved frequency During the instantaneous power failure if the motor speed drops the current limiter facility of the drive will be activated an
154. pecifications Forward operation command Operation voltage SINK Reverse operation command Operation voltage SOURCE pe gt 2 D 2 c lt Operation current at ON Input Voltage at OV Allowable leakage current at OFF PLC signal power Connects to PLC output signal power supply Rated voltage 24 Vdc Maximum output current 50 mA Digital input Common terminal for digital input signals common TIP As shown in Figure 2 15 the digital input terminals cast oe or X1 to X3 FWD and REV can be switched on or off ji yt with the open collector transistor outputs by connecting the power input of the external device such as a PLC to terminal PLC that supplies power to the device E xi To do so switch the jumper to SINK NOTE Do not connect terminal CM of the drive to the common terminal of a programmable controller Figure 2 15 External Power Supply Connection NOTE To switch terminals X1 through X3 FWD and Table 2 4 Continued REV on or off with contact input use reliable contacts 2 11 Classifi cation Analog output gt Q E ej fo pe io Kz N c g 30A 30B 30C Relay output RS485 port Analog monitor Functions The monitor signal for analog dc voltage 0 to 10 Vdc is output The signal functions can be selected from the following with function code F31 Output frequency before slip
155. quency command 1 is shown by a straight line passing through points A and B A is determined by the bias F18 and its reference point C50 B is determined by the gain C32 or C37 and its reference point C34 or C39 The combination of C32 and C34 will apply for terminal 12 and that of C37 and C39 for terminal C1 The bias F18 and gain C32 or C37 should be set supposing the maximum frequency as 100 The bias reference point C50 and gain frequency point C34 or C39 should be set supposing the full scale 10 Vdc or 20 mAdc as 100 NOTE Analog input under the bias reference point is limited by the bias data The relations stated above are indicated in the following expressions 1 If analog input lt bias reference point Frequency Setting 1 Bias F18 2 If analog input gt bias reference point Piguet tse 1 fk ors al rm Flake ere pid ae eros Poe Bae ree ice ee etre Bay eer peer Geen ierat poe Bl pelea pent GF mjas Analog ingad Gi a Fife CH Cit aimee Di CH CS0 Ce ao In the above expressions it is assumed that each func tion code expresses its data Example Setting the bias gain and its reference point when analog input range from 1 to 5 Vdc is selected for the frequency command 1 Point A If the analog input is at 1 V the set frequency is 0 Hz Therefore the bias is 0 F18 0 Since 1 V is the bias reference point and it is equal to 10
156. r GFCI or a magnetic contactor capacity was insufficient SUGGESTED ACTIONS Reconsider the power transformer rating 4 L a Input phase loss protection Problem Input phase loss occurred or rate of unbalance of interphase power voltage was large Possible Causes What to Check and Suggested Measures Main circuit power input CHECK wires broken Measure the input voltage SUGGESTED ACTIONS Repair or replace the wires The terminal screws for CHECK the main circuit power Check if the terminal screws have become loose input were not tight SUGGESTED ACTIONS enough Tighten the terminal screws to the recommended torque Interphase unbalance CHECK rate of 3 phase voltage Measure the input voltage was too large SUGGESTED ACTIONS Connect an ac reactor ACR or a dc reactor DCR to lower the rate Raise the drive capacity 6 9 Possible Causes What to Check and Suggested Measures 4 Cyclic overload occurred CHECK Measure ripple wave of intermediate dc circuit voltage SUGGESTED ACTIONS If the ripple is large raise the drive capacity 5 1 phase voltage was CHECK supplied to the drive Check the drive type instead of 3 phase SUGGESTED ACTIONS voltage Change the drive to one for 1 phase voltage input 5 OPL Output phase loss protection Problem Output phase loss occurred Possible Causes What to Check and Suggested Measures 1 Drive output wires are CHEC
157. requency was set to too low a value CHECK Check the data of function code F15 SUGGESTED ACTIONS Reset the peak frequency of the frequency limiter F15 to a correct value CHECK Check the signals for the set frequency from the control circuit terminals using Menu 4 I O checking SUGGESTED ACTIONS Increase the set frequency If external potentiometers for frequency command signal converter switches or relay contacts are malfunctioning replace them Connect the external circuit wires to terminals 13 12 11 and C1 correctly Arun command with higher priority than the one attempted e g multi step frequency communications or jogging operation etc was active and the set frequency was set to too low a value CHECK Check the higher priority run command using Menu 2 Data checking and Menu 4 I O checking while referring to the block diagram of the drive command generator Refer to Chapter 4 in the AF 300Mini User s Manual SUGGESTED ACTIONS Correct any incorrect function code data settings e g cancel the higher priority run command etc The acceleration deceleration time was too long Overload CHECK Check the data of function codes F07 F08 E10 E11 and H54 SUGGESTED ACTIONS Change the acceleration deceleration time to match the load CHECK Measure the output current SUGGESTED ACTIONS Reduce the load e g operate the mechanical bra
158. rop rate comes to be the setting specified by function code H70 The minimum ON duration is 100 ms REFERENCE For details of the overload prevention control refer to the descriptions of function code H70 e Current detection ID Function code data 37 This signal is turned ON when the output current exceeds the operation level specified by function code E34 and stays in this status for the duration specified by function code E35 on delay timer The minimum ON duration is 100 ms NOTE Function codes E34 and E35 are effective not only for current detection ID but often also for overload early warning OL and low level current detection IDL e Low level current detection IDL Function code data 41 This signal is turned ON when the output current drops below the operation level specified by function code E34 and stays in this status for the duration specified by function code E35 on delay timer The minimum turning ON time is 100 ms NOTE Function codes E34 and E35 are effective not only for the low level current detection IDL but often also for the overload early warning OL and current detection ID e Alarm relay contact output for any fault ALM Function code data 99 This signal is turned ON if the protection facility is activated so that the drive enters Alarm mode E50 Coefficient for Speed Indication This function code sets a coefficient to be used for setting the
159. rrent exceeds the limit value during acceleration deceleration or constant speed operation Retry function When the motor is tripped and stopped this function automatically reset the tripping state and restarts operation Waiting time before resetting and the number of retry times can be set Installation location Shall be free from corrosive gases flammable gases oil mist dust and direct sunlight Pollution degree 2 Indoor use onl Open air 10 to 50 C IP20 10 to 40 C NEMA1 Ambient humidity 5 to 95 RH no condensation Vibration 3mm 2 to less than 9 Hz 9 8m s2 9 to less than 20 Hz 2m s2 20 to less than 55 Hz 1m s2 55 to less than 200 Hz Storage ambient 25 to 65 C temp Storage ambient 5 to 95 RH no condensation humidit 8 8 8 3 Terminal Specifications 8 3 1 Terminal Functions For details about the main and control circuit terminals refer to Chapter 2 Subsection 2 3 4 and Subsection 2 3 6 Table 2 4 respectively 8 3 2 Connection Diagram for Operation by External Signal Inputs MOCHE or ELCH Moi MG Mody 2 GOR Piati 3 DBR a Ponar aS i i L 1 ye ae es F ed riots 4 S00 io A ai T Cie THR Stu ts SS amp MOCE o i ELGE Mote 17 MC ede 2 Power dune repast e Od te AH Parrett a eh a ee thnah th ie Be bo 4 E Cirmi terrina Garpyndirgy permira fe Poe pyr ii eg 5 Emr pro l pretio rs f 7 Alar ceil E Wiege input 5 A E i i ier bety fe
160. rs for which the cooling fan has run The display unit is 1000 hours The accumulated time should be used just a guide since the actual service life will be significantly affected by temperature and operating environment 7 3 7 3 Measurement of Electrical Values in Main Circuit Because the voltage and current of the power supply input of the main circuit of the drive and the output motor include harmonic components the indicated values vary according to the type of meter used to measure them Use meters indicated in Table 7 3 when measuring for commercial frequencies The power factor cannot be measured by a commercially available power factor meter that measures the phase difference between the voltage and current To obtain the power factor measure the power voltage and current on each of the input and output sides and calculate using the following formula e 3 phase input e 1 phase input lite coe fii Dieiis peer PA T fsg NP uni A tH frem ia Ms I age fT Corre pA Paved Sacha Table 7 3 Meters for Measurement of Main Circuit Intermediate dc Input power supply side Output motor side circuit voltage P N waveform j Ammeter Voltmeter Wattmeter Ammeter Voltmeter Wattmeter DC voltmeter AR AS AT VR VS VT WR WT AU AV AW VU VV VW WU WW V Name of meter Digital Digital Digital iine fine power power Digital power meter power Moving coil type yp yP meter meter meter Moving iron
161. s CHECK Cancel the automatic control system automatic torque boost slip compensation energy saving operation overload prevention control current limiting and check that the motor vibration is suppressed F37 P09 H70 and F43 SUGGESTED ACTIONS Cancel the functions causing the vibration Adjust the data of the current oscillation suppression gain H80 CHECK That the motor vibration is suppressed if you decrease the carrier frequency F26 or set the sound tuning F27 to 0 level 0 SUGGESTED ACTIONS Decrease the carrier frequency F26 or cancel the sound tune F27 5 If grating sound can be heard Possible Causes What to Check and Suggested Measures 1 The carrier frequency was set to too low a value CHECK Check the data for function codes F26 and F27 SUGGESTED ACTIONS Increase the carrier frequency F26 Make tone selection function F27 effective and select the correct value 6 The motor does not accelerate and decelerate at the set time Possible Causes What to Check and Suggested Measures The drive ran the motor by S curve or curvilinear pattern CHECK Check the data for function code H07 SUGGESTED ACTIONS Select the linear pattern Current limiting prevented the output frequency from increas ing CHECK That current limiting is enabled using Menu 3 drive monitoring and the data for the current limiting level F44 SUGGESTED AC
162. s card Other peripheral equipment Surge absorbers A surge absorber suppresses surge currents and noise from the power lines to ensure effective protection of your power system from the malfunctioning of the magnetic contactors mini relays and timers Surge suppressor A surge suppressor absorbs high surge currents induced by lightning and noise from the power supply lines Use of a surge suppressor is effective in preventing electronic equipment including drives from damage or malfunction from these causes Arresters An arrester suppresses surge currents and noise from the power supply lines Use of an arrester is effective in preventing electronic equipment including drives from damage or malfunctioning caused by such surges and or noise Frequency meter Displays the frequency in accordance with signal output from the drive Other options Mounting adapters The AF 300 Mini series of drives can be installed in the control board of your system using mounting adapters which use the mounting holes intended for conventional drives E11 series of 1 hp or below or 5 hp The E11S 2 hp 3 hp and E11 1 hp 2 hp series may be replaced with any of the AF 300 Mini series drives without the use of adapters Rail mounting bases A rail mounting base allows any of the AF 300 Mini series of drive to be mounted on a 35 mm standard DIN rail 9 4 10 Compliance with Standards 10 1 Compliance wi
163. s manual in a safe place until the drive is no longer in service Safety precautions Read this manual thoroughly before proceeding with installation connecting or wiring operation or maintenance and inspection Ensure you have sound knowledge of the device and familiarize yourself with all safety information and precautions before proceeding to operate the drive Safety precautions are classified into the following two categories in this manual WARNING Failure to heed the information indicated by this symbol may lead to dangerous operation and could result in risk of death or serious bodily injury CAUTION Failure to heed the information indicated by this symbol may lead to dangerous operation and could result in mi nor bodily injuries and or substantial property damage Failure to heed the information contained under the CAUTION title can also result in serious consequences These safety precautions are of utmost importance and must be observed at all times Purposes WARNING e The AF 300 Mini is designed to drive a 3 phase induction motor only Never use it for 1 phase mo tors or for any other purpose Fire or an accident could occur e The AF 300 Mini must not be used for any life sup port system or other purpose directly related to human safety e Although the AF 300 Mini is manufactured under strict quality control be sure to install appropriate safety devices for applications where drive failur
164. s or the POT Pressing this key in Alarm mode displays information concerning the alarm code currently displayed on the LED monitor The AF 300 Mini features three operation modes Running Programming and Alarm modes Refer to Section 3 2 Overview of Operation Modes 3 1 Simultaneous keying Simultaneous keying means depressing two keys at the same time expressed by The AF 300 Mini supports simultaneous keying as listed below For example the expression keys stands for pressing the key while holding the key down Operation modes Simultaneous keying Usedto S Control entry to exit from jogging operation Program mode keys Change special function code data Refer to codes F00 and H03 in Chapter 5 FUNCTION CODES Switch to Program mode 3 2 Overview of Operation Modes The AF 300 Mini features the following three operation modes E Run mode This mode allows entering run stop commands in regular operation Running status may also be monitored in real time E Program mode This mode allows checking function code data as well as a variety of other information relating to drive status and maintenance E Alarm mode If an alarm occurs the drive automatically enters Alarm mode The corresponding alarm code and its related information are displayed on the LED display Alarm code Shows the error factor that has activated the protection facility For details re
165. s the motor with the constant acceleration and deceleration S curved acceleration deceleration To reduce the impact that the drive motor gives its load during acceleration deceleration the drive gradually accelerates decelerates the motor at the both ends of the acceleration deceleration zones Curvilinear acceleration deceleration The drive controls the motor for maximum performance with the following acceleration deceleration pattern Linear acceleration deceleration of constant torque output for the motor in the zone under the base frequency Two times speed and a half acceleration deceleration at the base frequency in the zone over the base frequency H12 Instantaneous Overcurrent Limiting Selects whether the drive will perform current limiting processing or cause an overcurrent trip if the output cur rent exceeds the instantaneous overcurrent limit level If instantaneous overcurrent limiting is enabled the drive will immediately turn off its output gates to suppress the increase of current and control the output frequency If current limiting processing makes the motor decrease its torque temporarily and causes a problem then dis able the overcurrent limiting to cause an overcurrent trip and apply brake to the motor NOTE The same functions to limit the output current are implemented by software as the function codes F43 and F44 Generally software features have an operation delay Even if
166. setting Built in potentiometer terminal 12 input or terminal C1 input can be selected to add the frequency Inverse operation Possible to switch 0 to 10 Vdc 0 to 100 to 10 to 0 Vdc 0 to 100 with an external signal Possible to switch 4 to 20mA dc 0 to 100 to 20 to 4mA dc 0 to 100 with an external signal Acceleration Changeable with the range from 0 00 to 3600s Two times each for acceleration and deceleration can deceleration time be set internally Acceleration and deceleration pattern can be selected from 4 kinds Linear S curve weak S curve strong Non linear Max constant output DC injection braking Starting frequency 0 0 to 60 0 Hz Braking time 0 0 to 30 0s Braking level 5 to 100 of rated current 8 6 aun limiter High and low limiters Hz can be set Setting range 0 to 400 Hz Biases of set freg and PID command can be set between 0 and 100 Gain for frequency Analog input gain can be set within the range from 0 to 200 setting At voltage input proportional frequency can be set to 10 5V and 21mA by adjusting gain Jump frequency Three operation points and their jump hysteresis width 0 to 30Hz can be set control Jogging operation Operation by the RUN key or digital input signal FWDoOREV Frequency setting and ACC DEC time common setting exclusive for jogging Auto restart after Restarts the drive without stopping the motor after instantaneous power failure momentary power fai
167. sure the input voltage SUGGESTED ACTIONS Supply power to match the drive input rating and change the data of the function codes 2 The desired menu is not displayed Possible Causes Check and Measures 1 The limiting menus func tion was not selected appropriately CHECK Check the data for function code E52 SUGGESTED ACTIONS Change the data for function code E52 to display the desired menu 6 6 3 Nothing appears on the LED monitor Possible Causes What to Check and Suggested Measures No power supplied to the CHECK drive Check input voltage output voltage and interphase unbalance SUGGESTED ACTIONS Connect a molded case circuit breaker an ground fault circuit interruptor with the exception of those designed for protection from ground faults only or a magnetic contactor Check for voltage drop phase loss poor connections or poor contacts and fix them if necessary The power for the control CHECK circuit did not reach a Check if the jumper bar has been removed between terminals P1 and P or if there is poor contact high enough level between the jumper bar and the terminals SUGGESTED ACTIONS Connect the jumper bar to terminals P1 and P or tighten the screws Or connect a DC reactor Replace the drive if it is malfunctioning 6 3 If an alarm code appears on the LED monitor 1 OC Overcurrent protection Problem The drive output current mom
168. t in Type is supplied the total height is 9 65 which includes the EMC flange for shielded cable connection i i 8 13 8 5 Protective Functions LED Alarm Name Description monitor output displays 30A B C Overcurrent Stops the motor to protect the drive from an overcurrent During acceleration 0C1 Yes protection resulting from overload i Stops the motor to protect drive from an overcurrent due to During deceleration 0C2 a short circuit in the output circuit During running at 0C3 Stops the motor to protect drive from an overcurrent due to constant speed a ground fault in the output circuit Overvoltage The drive stops the motor by detecting an overvoltage 400 Vdc During acceleration 0U1 Yes protection for 230 V series 800 Vdc for 460 V series in the intermediate dc i 5 circuit During deceleration 0U2 This protection is not assured if excess ac line voltage is During running at 0U3 accidentally applied constant speed Stopped Undervoltage Stops the motor when the intermediate dc circuit voltage drops below the undervoltage LU Yes protection level 200 Vdc for 230 V series 400 Vdc for 460 V series However if data 4 or 5 are selected for F14 there is no alarm output even if the intermediate dc circuit voltage drops Input phase loss Detects input phase loss stopping the motor Len Yes protection Output phase Detects outp
169. t wet e n 1 3 1 4 1 Temporary Storage cecceceseseseeesesesteeeeeeeees 1 3 1 4 2 Long term Storage ceeeecseeseeeseseeeeteeeeeeeees 1 3 2 Mounting and Wiring the Drive 2 1 Operating EnvironmMent cccccscseseseseseeseseseseeteeeeeeens 2 1 2 2 Installing the Drive cceccceseesessseeeteeseeceeeesereesaeeeees 2 1 223 WADING ga sesicuvia EE A ATAT 2 2 2 3 1 Removing the Terminal Block TB Covers 2 2 2 3 2 Terminal Arrangement and Screw Specifications 2 3 2 3 3 Wiring Precautions cceeeseteeseeesseeteeeseeeeaees 2 4 2 3 4 Wiring for Main Circuit Terminals and Ground Terminals ccecececseeeseseeeeeeeeeeeeeeeees 2 5 2 3 5 Replacing the Main Circuit Terminal Block TB COVER As aaa aa a a AMAIA 2 8 2 3 6 Wiring for Control Circuit Terminals 2 9 2 3 7 Switching of SINK SOURCE Jumper Batr 2 13 2 3 8 Installing an RS485 Communications Card Option ceseeesesseeseseseeeeteesteeeeeeeaeees 2 13 2 3 9 Replacing the Control Circuit Terminal Block TB GoVetiaii estes dedicate ven 2 13 2 3 10 Cautions Relating to Harmonic Component Noise and Leakage Current 2 13 2 3 11 Recommended Wire Sizes s s 2 15 3 Operation Using the Keypad 3 1 Keys Potentiometer and LED on the Keypad 3 2 Overview of Operation Modes 3 2 1 Run Mode ceceeeeeeeeeee 3 2 2 Program Mode 3 2 3 Alarm Mode 3 3 Operation in Run Mode eke 3 4 Setting the Function Codes Data Set
170. th UL Standards and Canadian Standards cUL certification 10 1 1 Originally the UL standards were established by Underwriters Laboratories Inc as private criteria for inspections investigations pertaining to fire accident insurance in the USA Later these standards were authorized as the official standards to protect operators service personnel and the general populace from fires and other accidents in the USA cUL certification means that UL has given certification for products to clear CSA Standards cUL certified products are equivalent to those compliant with CSA Standards 10 1 2 Considerations when using AF 300 Mini in systems to be certified by UL and cUL General descriptions If you want to use the AF 300 Mini series of drives as a part of a UL Standards or CSA Standards cUL certified certified product refer to the related notes described on page vii 10 2 Compliance with European Standards The CE marking on GE Fuji products indicates that they comply with the essential requirements of the Electro magnetic Compatibility EMC Directive 89 336 EEC issued by the Council of the European Communities and Low Voltage Directive 73 23 EEC Only the EMC filter built in type of drives that bear a CE marking is compliant with these EMC Directives Drives that bear a CE marking or TUV mark are compli ant with the Low Voltage Directive The products comply with the following standards Low Voltage EN50178 19
171. the key and check that the alarm is triggered SUGGESTED ACTIONS Replace malfunctioning printed circuit board PCB 13 Er2 Remote keypad communications error Problem A communications error occurred between the remote keypad and the drive Possible Causes What to Check and Suggested Measures Break in the communica CHECK tions cable or poor Check continuity of the cable contacts and connections contact SUGGESTED ACTIONS Replace the cable High intensity noise was CHECK applied to the drive Check if appropriate noise control measures have been implemented e g correct grounding and routing of control and main circuit wires SUGGESTED ACTIONS Improve noise control The remote keypad CHECK malfunctioned Check that alarm Er2 does not occur if you connect another remote keypad to the drive SUGGESTED ACTIONS Replace the remote keypad The RS485 communica CHECK tions card malfunctioned Check that alarm Er2 does not occur even if you connect another remote keypad to the drive SUGGESTED ACTIONS Replace the card 6 14 14 Er3 CPU error Problem A CPU error e g erratic CPU operation occurred Possible Causes What to Check and Suggested Measures 1 High intensity noise was CHECK applied to the drive Check if appropriate noise control measures have been implemented e g correct grounding and routing of control and main circuit wires SUGGESTED ACTIONS Impro
172. the heat sink or braking resistor both of which can become very hot in operation Doing so could cause burns It is possible to set the drive to operate at speeds higher than allowed by the driven load Check the performance of the motor and connected load before changing the setting The brake function of the drive does not provide mechanical holding means Injuries could occur Maintenance and inspection and parts replacement WARNING e Turn the power off and wait for at least five minutes before starting inspection Also check that the LED monitor is unlit and verify that the dc voltage across the P and N terminals is lower than 25 Vdc Otherwise electric shock could occur e Maintenance inspection and parts replacement should be made only by qualified persons e Remove watches rings and other metallic objects before starting work e Use insulated tools Otherwise electric shock or injuries could occur Disposal e Treat the drive as industrial waste for disposal purposes Otherwise injuries could occur Others e Never attempt to modify the drive Doing so could cause electric shock or injuries GENERAL PRECAUTIONS For explanatory purposes drawings in this manual may show the drive without required covers or safety shields Be sure to replace such covers and shields and follow all safety instructions in the manual before operation Conformity to the Low Voltage Directive
173. the international access code required when calling from outside the USA This document contains proprietary information of GE Fuji Drives USA and is furnished to its customer solely to assist that customer in the installation testing operation and or maintenance of the equipment described This document shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Fuji Drives GE FUJI PROVIDES THE FOLLOWING DOCUMENT AND THE INFORMATION INCLUDED THEREIN AS IS AND WITHOUT WARRANTY OF ANY KIND EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED STATUTORY WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE AF 300Mini is a trademark of GE Fuji Drives USA Inc Contents Preface Safety Precautions cccccccseseeeseeeseseeeeeseeeeseeeteeeeeteeeeeteees ji Conformity to UL standards and Canadian standards CUL certification 0 eects ceeeteseeeeeeeeteteeeteteteneens Conformity to the Low Voltage Directive in the EU Precautions for USC cceccsecsesesesestesteesseseeeetseeteeeees How this Manual is Organized Model Numbering System rn sis Weights and Dimensions cececceseeseseeeetseeeeeeseeeeeeees jii 1 Before Using the Drive 1 1 Acceptance Inspection ssssssssssssisrssrerssiersrsrenisrsnrnrenns 1 1 1 2 External View and Terminal BIOCKS ccsssseeeeeeeeees 1 2 1 3 Transportation 2 1 4 Storage Environmen
174. them in the same wire duct When control circuit wiring must cross the main power circuit wiring position the cables at right angles 8 4 External Dimensions See dimensions table on next page Dimensions inches mm 3 phase 230V BKXC123F12x9 3 15 60 2 64 67 0 26 6 5 4 72 120 433 010 0 20 6 3 15 60 276_7o foso 10 6KXC123F25X9 3 15 _ 80 2 64 67 o 26 6 5 472 020 4 33 110 0 20 315 60 276 go 0 39 1 0 06 1 5 6KXC123F50X9 3 15_ 80 2 64 67 0 26 6 5 472 020 4 33 110 0 20 374 085 2 76_ 70 0 98 26 0 06 1 5 4 0 2x0 24 4 56 6KXC123001X9 3 15 80 2 64 67 0 26 6 5 472 120 4 33 110 0 20 6 472 120 2 76 go 1 97 60 0 06 1 5 0 06 1 5 1 phase 230V 39 1 39 10 0 06 1 5 4 02 x0 24 4 5x6 2 76_ 70 10 98 25 0 06 1 5 97 60 0 06 1 5 i phase 115V 0 39 10 0 06 1 5 0 39 10 0 06 1 5 4 0 2 x 0 24 4 5x6 0 98 25 0 06 1 5 EMC Filters Built in Type 3 phase 230V 3 15 3 15 3 15 ofo w Joo jo k gt o ofo tw Joo two jo x 2 e 2 o oo Er o x 2e o 39 10 0 06 1 5 4 0 2 x 0 24 4 5x6 39 10 0 06 4 0 2 x 0 24 4 5x6 4 5x6 98 26 0 06 80 3 54 00 80 54 00 80 90 6KXC123001E9 3 15 80 54 90 1 97 60 0 06 1 5 4 0 2x0 24 4 5x6 1 phase 230V 6KXC121F12E9 3 15 60 2 64 67 0 26 65 6 67 070 438 110 0 20 6 3 24 100
175. ting 3 5 Checking Changed Function Codes Data Checking 3 11 3 6 Monitoring the Run Status Drive Monitoring 3 12 3 7 Checking I O Signal Status I O Checking 3 14 3 8 Reading Maintenance Information Maintenance Information ccseeseseeeeseeeeeeeeeees 3 16 3 9 Reading Alarm Information Alarm Information 3 18 4 Running the Motor 41 Motor Testing iinn dees aaitianunniees 4 1 4 1 1 Inspection and Preparation prior to Operation sien weenie 4 1 2 Turning on Power and Checking 4 1 3 Preparation Before Running the Motor for a Test Setting Function Code Data 4 1 4 Test run iets 42 Operation vce scan wea hunter delle ctens 5 Function Codes 5 1 Function Code Tables ccccssscssscsesessessseseeasasecees 5 1 5 2 Overview of Function Codes ccsscscssseseesseseesseeeees 5 9 6 Troubleshooting 6 1 Before Proceeding with Troubleshooting 6 1 6 2 If No Alarm Code Appears on the LED Monitor 6 2 6 2 1 Motor is Running Abnormally 6 2 2 Problems with Drive Settings 6 3 If an Alarm Code Appears on the LED Monitor 6 7 7 Maintenance and Inspection TAL Daily INSpection 4 23 ciccactndit casi neiaddve dens 7 1 7 2 Periodic Inspection ccseeesseteeseeeeeeeeteeeteeeeeeetataeees 7 1 7 3 Measurement of Electrical Values in Main Circuit 7 4 CA NSulation TeSt isse inaia 7 5
176. u F uiii aga TORBA DER Dynamic Braking Resistor BCR DC Reactor Analog mater ELCE Earth Leakage Circuit Breakes RC Magnetic Contactor MECE Mokied Case Circul Breaker F F q Tamale ABU Note 1 Install a recommended molded case circuit breaker or a ground fault circuit interrupter GFCI in the primary circuit of the drive to protect wiring At this time ensure that the circuit breaker rating is equivalent to or lower than the recommended rating Note 2 If magnetic contactors or solenoids are near the drive connect a surge suppressor across their coils Note 3 When connecting a dc reactor option remove the jumper bar from across terminals P1 and P Note 4 The THR function can be used by assigning code 9 Alarm from external equipment to any of terminals X1 to X3 FWD or REV function code E01 to E03 E98 or E99 For details refer to Chapter 9 Note 5 Frequency can be set by connecting a frequency command device external potentiometer between the terminals 11 and 13 instead of inputting voltage signal 0 to 10 Vdc or 0 to 5 Vdc between the terminals 12 and 11 Note 6 Use shielded or twisted wires for control circuit wiring When using shielded wires connect the shields to amp G To prevent malfunction due to noise keep the control circuit wiring as far away from the main circuit wiring as possible 10 cm or farther recommended and never install
177. u may move the cursor when changing function code data in the same way as with the frequency commands Refer to Subsection 3 3 2 Setting the Set Frequency and Others Mie Let of function occa Puncpon pode dais Saran date ed oo io be reed function coma Figure 3 5 Example of Function Code Data Changing Procedure 3 5 Checking Changed Function Codes Data checking Menu 2 Data checking in Program mode allows you to check function codes that have been changed Only data that has been changed from the factory defaults are displayed on the LED monitor You may refer to the function code data and change again if necessary Figure 3 6 shows the status transition diagram for Data checking Miers Lind of function codes Finain ocak Aa Press the key when the E01 data is displayed to return to F01 Figure 3 6 Data Checking Status Transition Diagram Changes made only to F01 F05 E01 Basic key operation The basic key operation is the same as for Menu 2 Data setting 3 6 Monitoring the Running Status Drive monitoring Menu 3 drive monitoring is used to check the running status during maintenance and test running The display items for drive monitoring are listed in Table 3 5 Using keys you may check those items in succession Figure 3 7 shows the status transition diagram for drive monitoring Basic key operation Mera Lt ri ae ihai iri meg Mae iz amp m
178. uency F04 and rated voltage at base frequency F05 match the values on the motor nameplate SUGGESTED ACTIONS Match the function code data to the motor nameplate values 9 dbH Overheat protection for braking resistor Problem Thermal protection for braking resistor activated Possible Causes What to Check and Suggested Measures 1 Braking load was too CHECK heavy Recalculate the relation between the braking load and braking capacity SUGGESTED ACTIONS Reduce the braking load Revise the braking resistor in order to improve braking ability Resetting the data of function codes F50 and F51 is also required 2 The deceleration time CHECK was too short Recalculate the required deceleration torque and time from the moment of inertia for the load and the deceleration time SUGGESTED ACTIONS Increase the deceleration time F08 E11 and H54 Use a bigger braking resistor in order to improve braking ability Resetting the data for function codes F50 and F51 is also required Incorrect data values set CHECK for function codes F50 Check the braking resistor specifications and F51 SUGGESTED ACTIONS Change the data for function codes F50 and F51 as necessary NOTE The drive estimates braking resistor overheating by monitoring load not by measuring actual temperature If the resistor is used more frequently than the data values for function codes F50 and F51 indicate the alarm may be triggered
179. ut current for each desired alarm using the and keys 5 Press the key to return to the alarm list Press the key again to return to the menu Table 3 13 Alarm Information Contents LED monitor display item No Display contents Output frequency Description Output frequency before slip compensation Output current Current output current Output voltage Current output voltage Set frequency Current set frequencies Run direction This shows the running direction being output F normal R reverse stop Running status This shows the running status as a hexadecimal display Refer to Displaying running status in Section 3 6 Monitoring the Running Status Accumulated running time Shows the accumulated power on time of the drive Unit thousands of hours When the total ontime is less than 10 000 hours display 0 001 to 9 999 it is possible to check data in hourly units When the total time is 10 000 hours or more display 10 00 to 65 53 the display will change to units of 10 hours When the total time exceeds 65 535 hours the display returns to 0 and the count is started again Number of startups The motor run times the number of times the drive running command is set to ON are calculated and displayed 1 000 indicates 1 000 times When any number from 0 001 to 9 999 is displayed the display increases by 0 001 per startup and when any number from 1
180. ut phase loss during starting and running stopping the drive OPL Yes loss protection Overheat Stops the motor by detecting excess heat sink temperature in case of cooling fan 0H1 Yes protection failure or overload When the built in or external braking resistor overheats the drive stops running dbH Yes It is necessary to set the function code corresponding to the resistor used built in or external Overload Stops the motor if the IGBT internal temperature calculated from the output current and OLU Yes protection cooling fan temperature detection is over the preset value Electronic In the following cases the drive stops running the motor to protect the motor in accordance OL1 Yes thermal with the electronic thermal function setting 2 overload 3 relay Protects general purpose motors over the entire frequency range Protects drive motors over the entire frequency range The operation level and thermal time constant can be set g PTC A PTC thermistor input stops the motor for motor protection 0H4 Yes thermistor A PTC thermistor is connected between terminals C1 and 11 and a 1 kQ external resistor is connected between terminals 13 and C1 This alarm may not be triggered depending on the function code data 8 14 LED Alarm Name Description monitor output displays 30A B C L5 Overload Outputs a preliminary alarm at a preset level before the motor is stopped
181. ve noise control Possible Causes What to Check and Suggested Measures 2 The printed control SUGGESTED ACTIONS circuit board in the drive Replace the board malfunctioned 15 Er6 Operation protection Problem An error occurred due to incorrect operation of the motor Possible Causes What to Check and Suggested Measures The key was pressed CHECK when H96 1 or 3 Change the setting for H96 so that the STOP key priority function is invalid to ensure that the drive does not operate unexpectedly The start check function CHECK was activated when Check that Er6 occurs when H96 2 or 3 The power is switched ON An alarm is released the key is pressed The link command LE has switched the drive operations SUGGESTED ACTIONS Reconsider the running sequence to avoid input of the run command when Er6 has occurred Change the setting for H96 so that the STOP key priority function is invalid to ensure the drive does not operate unexpectedly To reset the alarm turn the run command off 16 Er8 RS485 communications error Problem A communications error occurred during RS485 communications Possible Causes What to Check and Suggested Measures 1 High level controllers CHECK e g PLCs and per Check the controllers sonal computers did not SUGGESTED ACTIONS operate due to incorrect Remove the cause of the controller error settings and or defective software hard
182. ware 2 Relay converters e g CHECK RS232C RS485 con Check the converter e g check for poor contact verter did not operate SUGGESTED ACTIONS due to incorrect connec Change the various converter settings reconnect the wires or replace hardware as appropriate tions and settings and defective hardware 3 Broken communications CHECK cable or poor contact Check continuity of the cable contacts and connections SUGGESTED ACTIONS Replace the cable 6 15 Possible Causes What to Check and Suggested Measures 4 Even though a response error detection time y08 has not been set communications did not occur cyclically CHECK Check the high level controllers SUGGESTED ACTIONS Change the settings of high level controller software or make the no response error detection time invalid y08 0 5 High intensity noise was applied to the drive CHECK Check if appropriate noise control measures have been implemented e g correct grounding and routing of control and main circuit wires SUGGESTED ACTIONS Improve noise control Improve measures against noise from high level controllers Replace the relay converter with a recommended insulated converter 6 Incompatible com munications protocols between the drive and high level controllers CHECK Compare the settings of the y codes y01 to y10 with those of the high level controllers SUGGESTED ACTIONS Corre
183. ween the drives so that any heat radiating from one drive will not affect the those above 3 Mounting direction Secure the drive to the mounting base with four screws or bolts M4 so that the AF 300 Mini logo faces outwards Tighten those screws or bolts perpendicular to the mounting base Do not mount the drive upside down or horizontally CAUTION Prevent lint paper fibers sawdust dust metallic chips or other foreign materials from getting into the drive or from accumulating on the heatsink This may result in a fire or accident 2 3 Wiring Follow the procedure below In the following description the drive has already been installed 2 3 1 Removing the Terminal Block TB Covers 1 Removing the control circuit terminal block TB cover Insert your finger in the cutout near PULL in the bottom of the control circuit TB cover then pull the cover towards you 2 Removing the main circuit terminal block TB cover Hold both sides of the main circuit TB cover between thumb and forefinger and slide it towards you Cumi Crrouet Terminal Block Coser Mimin Choui Tenm nal Bleck Cove tos a efase E i k n RE lt to Se oo Bhd l z aor jt i r p ie eee fig Esi i P i Figure 2 2 Removing the Terminal Block TB Covers 2 3 2 Terminal Arrangement and Screw Specifications The figures below show various arrangements of the main and control circuit terminals This differs according to drive type The two
184. with acceleration deceleration times or frequencies different from those selected The drive installation must be such that safety is ensured if this occurs Otherwise an accident could occur WARNING The STOP key is only effective when enabled by the correspnding function setting function code F02 For safety a separate emergency stop switch should always be installed If you disable the STOP key priority function and activate the FWD or REV commands it will no longer be possible to stop the motor using the STOP key on the built in keypad If an alarm reset happens with the operation signal turned on a sudden start will occur Check that the operation signal is turned off in advance Otherwise an accident could occur If you enable the Auto Restart function in the restart mode after an instantaneous power failure function code F14 the drive will automatically restart the motor when power is restored If you set the function codes wrongly or without completely understanding the instruction manual and the AF 300 Mini User s Manual the motor may operate at a torque or speed not authorized for the driven load An accident or injuries could occur Do not touch the drive terminals while power is applied to the drive even if the drive stops Doing so could cause electric shock Do not turn the main circuit power on or off in order to start or stop the drive Doing so could result in drive failure Do not touch
185. y CHECK Check if ErF occurs each time the power is switched off SUGGESTED ACTIONS Replace the malfunctioning printed circuit board PCB 6 16 7 Maintenance and Inspection To avoid failures and assure reliable long term operation make daily and periodic inspections Take the following precautions while performing any maintenance work WARNING The intermediate dc circuit capacitor may retain its charge for some time after power is turned off Therefore it may take some time until the intermediate dc circuit voltage falls to a safe level Do not open the control circuit terminal block cover for at least 5 minutes after the power has been turned off Then remove the control circuit and main circuit terminal block covers and before starting any maintenance and inspection use a multimeter verify that the dc voltage between main circuit terminals P and N does not exceed a safe level lt 25 V Electric shock may occur e Maintenance inspection and parts replacement should be carried out only by authorized persons e Remove watches rings and other metallic materials before starting work e Use insulated tools e Never attempt to modify the drive Electric shock or injuries could occur 7 1 Daily Inspection Without removing the covers while the drive operates or while it is turned on perform an external visual inspection for operating abnormalities e Check that the drive is performaing to specification as expected
186. y of function codes E01 through E03 then turning BX ON will make the motor coast to a stop Similarly if the coast to stop command BX data 1007 is assigned turning BX OFF will make the motor coast to a stop Restriction of data displayed on the LED monitor Only four digits can be displayed on the 4 digit LED monitor If you enter more than 4 digits of data valid for a function code any digits after the 4th digit of the set data will not be displayed however they will be pro cessed correctly 5 1 The following tables list the function codes available for the AF 300 Mini series of drives F codes Fundamental Functions code 1 setting F codes Fundamental Functions pF codes Fundamental Functions eea ee Data protection 0_Data change enable eet eee ee ee 1_Data protection 0_Keypad operation or key N 4 Frequency command 1_Voitage Input Terminal 12 0 to 10 Vdc 2_Current Input Terminal C1 4 to 20mA dc 3_Voltage Input Terminal 12 and current Input Terminal C1 4 Potentiometer on the keypad Operation method ia operation FWD REV change by external 1_External signal Digital input alee see maa 750 t0 4000 25 0 to 400 0 Hz Hz Rated voltage OV_ Voltage in proportion to power supply voltage V at Base frequency 80 to 240V_ AVR active 115V 230V class 160 to 500V_ AVR active 460V class 0 00 means acceleration time ignored External soft start stop 0 00 means acceleration time ignored
187. you have enabled the function codes F43 and F44 enable the function code H12 H69 Regenerative Energy Suppressing The moment that regenerative energy exceeding the absorbtive capacity of drive occurs during motor braking the drive will trip and enter into Alarm mode due to overvoltage If regenerative energy suppressing is enabled the drive lengthens the deceleration time for 3 times the set time as long as the intermediate dc voltage exceeds the preset voltage suppressing level and de creases the deceleration torque for 1 3 In this way the drive decreases the regenerative energy progressively This control is to suppress the torque generated by the motor in deceleration However when a load brakes the motor the control has no effect and should not be used When the drive features a braking resistor disable this control Otherwise the braking resistor and the control may conflict with each other and may adversely affect the deceleration time H70 Overload Prevention Control Enables overload suppressing control If enabled this function code is used to set the deceleration Hz s Before the drive enters alarm mode due to the heat sink overheating or an overload alarm code 0H1 or OLU this control decreases the drive s output frequency to suppress the trip Apply this control to equipment such as pumps whose drive frequency drops in line with any decrease in load If you want to drive this kind of equip

AF-300 Mini - Dealers Electric Motor

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