GE Power Supply AF 300 User Manual

AF-300

1/4 - 5 Horsepower

MICRO-$AVER II

Instructions

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TABLE OF CONTENTS

Section

Title

Page

1 .

SAFETY PRECAUTIONS ..........................................................................1 -1

DESCRIPTION, COMPONENT IDENTIFICATION,

AND SPECIFICATIONS ............................................................................2-1

General Description .................................................................................. 2-1

Delivery Inspection Procedures ............................................................... 2-1

Nameplate Data......................................................................................... 2-1

Dri v e K e y p ad Functions and La y o ut ........................................................ 2 -2

Drive Components .................................................................................... 2-3

Table 1: Standard Specifications .............................................................. 2-4

Table 2: Drive Dimensions ....................................................................... 2-7

Table 3: Drive Ratings, Efficiencies and Watts Loss................................ 2-7

INSTALLATION GUIDELINES ..................................................................3-1

Installation Environment.......................................................................... 3-1

In s tallation Mounting Clearance ............................................................. 3 -1

Dimension Drawings ................................................................................. 3-2

Dimensions of Keypad Mounting Holes.................................................. 3-4

WIRING PROCEDURES ...........................................................................4-1

Remove Terminal Top Cover ................................................................... 4-1

Control Circuit Wiring.............................................................................. 4-2

Main Circuit Wiring .................................................................................. 4-3

Table 4: Drive Wire Size Recommendations ........................................... 4-4

and Circuit Protection Rating

Control/ Circuit Terminal Block .............................................................. 4-5

Drive Wiring Diagram ............................................................................... 4-6

Table 5: Terminal Identification/ Function ............................................ 4-7

Drive Interface Details .............................................................................. 4-9

DRIVE OPERATION ..................................................................................5-1

Keypad Panel Identification/ Operation ................................................. 5-1

Function Code and Data Code Description/ Selection .......................... 5-1

Keypad and Display Operation Programming ........................................ 5-2

Stop Mode ................................................................................................. 5-3

Run Mode .................................................................................................. 5 -4

Program Mode while stopped .................................................................. 5-5

Program Mode while running .................................................................. 5-6

Trip Mode .................................................................................................. 5-7

Summary of Operating Modes ................................................................. 5-8

Pre-Operation Inspection ......................................................................... 5-9

Table 6: Function Code List ..................................................................... 5-10

FUNCTION CODE DESCRIPTIONS (01 thru 79) .....................................6 -1

(Settings and Diagrams)

MAINTENANCE AND INSPECTION .........................................................7-1

Megger Test ............................................................................................... 7-1

Periodic Parts Replacement ..................................................................... 7 -1

Inspection Items........................................................................................ 7-2

Measurement Points and Meters ............................................................. 7-3

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TABLE OF CONTENTS (continued)

Section

Title

Page

TROUBLESHOOTING............................................................................. 8-1

Table 8: Fault Condition Description and Operation ............................... 8-1

(1) Overcurrent ............................................................................................ 8-2

(2) Overvoltage ............................................................................................. 8-3

(3) Undervoltage .......................................................................................... 8-4

(4) Drive Overheat ........................................................................................ 8-5

(5) External Alarm Input ............................................................................. 8-5

(6) Dri v e O v e rload ........................................................................................ 8 -6

(7) Memory Error, Keypad Communication, CPU Error .......................... 8-7

(8) Drive Output Circuit Error .................................................................... 8-8

(9) Motor will not run .................................................................................. 8-9

(10) Motor will run but speed will not change ........................................... 8-10

(11) Motor will stall during acceleration .................................................... 8-11

(12) Motor Heating Abnormal .................................................................... 8-12

WARRANTY PARTS AND SERVICE ..................................................... 9-1

Warranty Coverage .......................................................................................... 9-1

Out-of-Warranty Procedure ............................................................................ 9-1

Motors.............................................................................................................. 9 -1

In-Warranty Failure Check List ................................................................. 9-2

(Data necessary for Warranty Administration)

AF-300M$II Spare Parts List ........................................................................... 9-3

10.

CE MARK .............................................................................................. 10 -1

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Section 1

SAFETY PRECAUTIONS

DANGER, WARNING, CAUTION AND NOTES

The following format is used on the equipment or found

in this manual. Read all labels and follow the directions

whenever working on the equipment.

WARNS ABOUT HAZARDS THAT

WILL RESULT IN IMMEDIATE SERIOUS PERSONAL

INJURY OR DEATH IF IGNORED.

Denotes operating procedures and

practices that may result in personal injury or loss of

life if not correctly followed.

Denotes operating procedures and

practices that, if not strictly observed, may result in

damage to, or destruction of the equipment.

NOTE: Notes call attention to information that is

especially significant in understanding and operating

the equipment.

DANGER,WARNING,CAUTION

AND NOTE PARAGRAPHS WITHIN

THIS INSTRUCTION MANUAL

The above paragraphs list some general safety

reminders and safety recommendations to be followed

when operating or installing this equipment. These

safety precautions will be repeated throughout this

instruction book where applicable.

Due to CSA requirements, pertinent warnings are also provided in French and set off by ( )

1-1

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WARNINGS

The Drive leakage current to

MECHANICAL MOTION

HAZARD: Drive systems cause mechanical

motion. It is the responsibility of the user to

insure that any such motion does not result in

an unsafe condition. Customer provided

interlocks, and operating limits should not be

bypassed or modified.

ground is higher than 3mA. Use grounding

conductor as specified in Table 250-95 of

National Electric Code, ANSI/NFPA 70-1993 or

Table 31 CSA22.2, No. 14-M91.

HAZARD OF MOTOR

OVERSPEED:

ELECTRICAL SHOCK

AND BURN HAZARD: When using

ANY APPLICATIONS REQUIRING OPERATION

ABOVE 120 HZ MUST BE APPROVED BY THE

MOTOR MANUFACTURER.

instruments such as oscilloscopes to work on

live equipment, the oscilloscope’s chassis

should be grounded and a differential amplifier

input should be used. Care should be used in

the selection of probes and leads and in the

adjustment of the oscilloscope so that accurate

readings may be made. See instrument

Bias frequency setting is available when analog

frequency setting method (i.e. the Function

code "01" data is set at 1) is selected. At the

stop condition, the reference frequency will be

blinking on the LED display. If the Bias

frequency is set at a certain level and the

reference frequency is Zero, during the stop

condition, the display will be blinking Zero.

Thus, when a RUN command is given to the

Drive, the motor will run at the Bias frequency

setting (up to 400 Hz) even if the reference

frequency is Zero.

With 400 Hz Drive output possible, the Drive will

allow the motor to run up to 6 - 7 times its base

speed. Never operate the motor above its top

mechanical speed or a catastrophic failure may

occur.

manufacturer’s instruction book for proper

operation and adjustments to the instrument.

FIRE AND EXPLOSION

HAZARD: Fires or explosions might result

from mounting Drives in hazardous areas such

as locations where flammable or combustible

vapors or dusts are present. Drives should be

installed away from hazardous areas, even if

used with motors suitable for use in these

locations.

STRAIN HAZARD:

Improper lifting practices can cause serious or

fatal injury. Lift only with adequate equipment

and trained personnel.

Before disassembling,

disconnect and lock out power from the Drive.

Failure to disconnect power may result in death

or serious injury. A bus charge Light "CRG"

provides visual indication that bus voltage is

present; verify the bus voltage level by

measuring the voltage between power terminals

P(+) and N(-) using an analog meter. Do not

attempt to service the Drive until the charge

indicator ("CRG" lamp) has extinguished and

the bus voltage has discharged to zero volts.

ELECTRICAL SHOCK

HAZARD: All motor bases and equipment

enclosure housings should be grounded in

accordance with the National Electric Code or

equivalent.

(AVERTISSEMENT)

HAZARD OF ELECTRICAL SHOCK

(RIS QUE DE CHOC ELECTRIQUE)

- Separate motor overcurrent, overload, and

overheating protection is required to be

provided in accordance with the Canadian

Electrical Code, Part 1.

Replace all covers before

applying power to the Drive. Failure to do so

may result in death or serious injury.

- (Le moteur dolt etre muni d'une protection

distincte contre les surintensites, la

surcharge et la surchauffe confrmement au

Code Canadian de L'electricite, premierb

partie.)

1-2

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CAUTIONS

This product is suitable for use

with the NEC or Canadian Electrical Code. The

connection shall be made by a UL listed or CSA

certified closed-loop terminal connector sized for

the wire gauge involved. The connector is to be

fixed using the crimp tool specified by the

connector manufacturer.

on a circuit capable of delivering not more than

1,000 (1HP or less) or 5,000 (2 HP or more) rms

symmetrical amperes.

AC input fuses to be customer supplied and may

be branch circuit protection fused. The maximum

allowance fuse ratings per TABLE 4.

Do not perform a megger test

between the Drive terminals or on the control

circuit terminals.

Do not connect power supply

voltage that exceeds the standard specified

voltage permissible. If excessive voltage is

applied to the Drive, damage to the internal

components will result.

The Drives are an IGBT drive

which develops an adjustable frequency via pulse

width modulation. While this does not present a

problem on 200-240 VAC applications, it may on

380-480 VAC applications. When using the

Drives on 380-480 VAC, get the motor

Do not connect power supply to

the output terminals (U, V, W). Connect power

supply only to the power terminals (L1, L2, L3).

manufacturer's approval that his insulation system

can withstand the voltage spikes (up to twice the

dc bus voltage 2 x 621 VDC for a 480 VAC power

source of the Drive, in conjunction with the long

motor cable lengths). If the insulation system

does not meet this limit, utilize a RLC filter.

Do not connect power supply to

the breaking resistor connection terminals (P (+),

DB). Never short-circuit between P (+) – DB

terminals, and do not connect any resistance with

an ohm and/or wattage value less than standard

application breaking resistor.

Because the ambient

temperature greatly affects Drive life and

reliability, do not install the Drive in any location

that exceeds the allowable temperature. Leave

the ventilation covers attached for temperatures

of 40 degrees C or below, and remove the

ventilation port side and top covers for

temperatures of between 40 (104° F) and 50

(122° F) degrees C. If the covers need to be

removed, another type of enclosure may be

required for safety purposes.

Do not connect a power supply

to the control circuit terminals (except 30A, B, C,

maximum rating 250 volts, 0.3A ac/dc).

For RUN and STOP, use the

FWD-CM (forward) and REV-CM (reverse)

terminals. Do not use a contactor (ON/OFF)

installed on the line side of the Drive for RUN and

STOP.

If the Drive’s Fault Alarm is

activated, consult the TROUBLESHOOTING

section of this instruction book, and after

correcting the problem, resume operation. Do

not reset the alarm automatically by external

sequence, etc.

Do not use a switch on the

output side of the Drive for ON/OFF operation.

Do not connect power factor

correcting capacitors on the output side of the

Drive.

Be sure to remove the desic-

cant packet(s) when unpacking the Drive. (If not

removed these packets may become lodged in

the fan or air passages and cause the Drive to

overheat.)

Do not operate the Drive

without the ground wire connected. The motor

chassis should be grounded to earth through a

ground lead separate from all other equipment

ground leads to prevent noise coupling. The

grounding connector shall be sized in accordance

1-3

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CAUTIONS (continued)

AC induction motors require

The Drive must be mounted on

a building or enclosure wall that is constructed of

heat resistant material. While the Drive is operat-

ing, the temperature of the Drive's cooling fins can

rise to a temperature of 90°C (194°F.)

that they be sized based on the applications speed

range and associated torque requirements for the

motor-Drive system; this is to avoid excessive

motor heating. Observe motor manufacturer's

recommendations when operating any ac induction

motor with the Drive. Also observe motor

manufacturer's recommended voltage/torque boost

at lower operating frequencies.

If the Drive protective function

is activated, consult Section 8 "Troubleshooting",

and after correcting the problem, resume opera-

tion. Do not reset the alarm automatically by

external sequence, etc.

The available power source con-

nected to the Drive is not to exceed 500KVA. If the

ac power source is greater than 500KVA and the

Drive's rated (HP) is less than 10% of the power

source'sKVA;aclinereactorswillhavetobeinstalled

in L1, L2 & L3 power leads of the Drive.

Be sure to provide fuses, as

specified on "Application of Wiring And Equipment"

in Section 4, on line terminals of Drive. Provide

power line disconnect or contactor as needed.

NOTES

NOTE:

➂ Total wiring between the Drive and the motor must

① When terminal operation mode (Function code

F_02 setting is 1) - RUN and STOP are being

controlled by a maintained contact (e.g., selector

switch, toggle switch, etc.) which is connected

between the terminal CM and FWD or REV:

• Closing/opening the maintained contact starts/

stops the Drive.

not exceed the length shown below.

Function

F_12 data

200V Series

1/4 1/2 1 2 3 5

400V Series

1/2

F_12 = 0, 1, 2 or 3

538 ft. 754 ft.

1076 ft.

F_12 = 4 – 15

213 ft.

➃ Error in current detection may increase when;

a) A specially designed motor is used.

b) A Drive's capacity is 2 Hp ratings or greater than

the motor capacity.

➁ Function code F_02 setting can be changed only

when connection between the terminals CM and

FWD or REV is open. (i.e. STOP MODE).

Drive ships with shorting bar between

terminals FWD-CM.

UL/CSA Drive Caution Label

Use 60/70°C copper wire only. Use Class 1 wire only.

Suitable for use on a circuit capable of delivering not more than 1,000

(1HP or less) or 5,000 (2 HP or more) rms symmetrical amperes.

WARNING: HAZARD OF ELECTRICAL SHOCK. DISCONNECT INCOMING

POWER BEFORE WORKING ON THIS CONTROL.

ADVERTISSEMENT: RISQUE DE CHOC ELECTRIQUE COUPER

L'ALIMENTATION AVANT LE DEPANNAGE DE CETTE COMMANDE.

CAUTION: DANGEROUS VOLTAGE EXIST UNTIL CHARGE "CRG" LIGHT IS OFF.

ATTENTION: PRESENCE DE TENSIONS DANGEREUSES TANT QUE LE

VOYANT N'EST PAS ETEINT.

WARNING: MORE THAN ONE LIVE CIRCUIT. SEE DIAGRAM.*

AVERTISSEMENT: CET EQUIPEMENT RENFERME PLUSIEURS CIRCUITS

SOUS TENSION. VOIR LE SCHEMA.

SA523154-01

*See diagram on page 4-6.

1-4

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Section 2

DESCRIPTION, COMPONENT

IDENTIFICATION, and SPECIFICATION

The Drive is available in ratings of 1/4 to 3 HP 200-240 VAC single phase input, 1/4 to 5 HP 200-230 VAC three phase,

and 1/2 to 5 HP 380-480 VAC three phase. The Drive incorporates advanced Pulse Width Modulated (PWM)

"TORQUE VECTOR" control for high starting torque. The Drives are housed in either a NEMA 1 or NEMA 4 type

enclosure and all Drives are furnished with a detachable cover to allow ease of accessing control and power wiring.

Drive operation and Function Code setting is performed from the “Keypad Panel” that features a Digital Display and

6 dual function keys. The 6 function keys are used for Drive programming and operation.

General data and specifications for each Drive are listed on the nameplate attached to the Drive.

Refer to TABLE 1, for complete Drive specification listing.

INSPECTION PROCEDURES UPON DELIVERY

Upon receipt of your Drive, inspect the equipment for the following items:

1. Check the nameplate to insure that the specifications correspond to those

ordered, and to application requirements.

2. Inspect the unit for any damage that may have occurred during shipment.

– If shipping damage is found or the wrong Drive is received, contact the

Distributor from which the equipment was purchased.

™

AF-300M$ II

MODEL NO.

69489

7898

IND. CONT. EQ.

SERIAL NO.

INPUT:

OUTPUT:

VOLTS

*IN CASE OF "L.V. DIRECTIVE 73/23/EEC"

FREQ RANGE (HZ)

AMPS

FREQ (HZ)

PHASE (S)

AMPS CONT.

PHASE

ROTATION

MAX 60 SEC. AMPS

INSTRUCTION BOOK GEI-100272

MADE IN JAPAN

All models are UL Listed and CSA Approved. CE MARK applies to the 240 VAC single-phase and 480 VAC 3-phase

Figure 2-1. NAMEPLATE DATA IDENTIFICATION

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(1) Keypad Part Names and Functions

Digital Display

Operation Mode Indicator

Program Mode

Unit Display

Drive RUN Indicator

RUN Key

UP Key

Program/Reset Key

STOP Key

Function Key (Data Key)

DOWN Key

Digital Display (4 digits) -

RUN Key - Key used for starting

operation. The LED (green) lights up

during operation.

drive you must remove the RUN

command and press RESET.

When function 2 is set to 2:

Displays the various Function

Codes and data values during

setting of the program. During

operation, it displays the output

frequency, current, voltage, etc.

If a fault occurs the cause of the

problem will be displayed as a

code.

This key does not function when

terminaloperationcontrol isselected.

operation command input is

accepted by means of the

external signal terminal (FWD,

REV). STOP key on the keypad

is inactive.

STOP Key - This key is used for

stopping drive operation. When set

as follows:

PROGRAM Key (Reset Key) -

Normal mode or program setting

mode select key. When any of

the protection functions are

activated; this key is used to reset

the fault.

UP / DOWN Keys - These keys

increase or decrease the

frequencyreference. Whenunitis

in program setting mode, they

changetheFunctionCodeordata

values.

operation command input is

accepted from the Keypad (RUN

and STOP keys).

FUNCTION Key (Data Key) -

When function 2 is set to 1:

Unit Display - Unit information is

displayed by the LED (red). All

three LEDs flash to indicate that

the unit is in the program mode.

During the normal mode, this key

canbeusedtochangethedisplay

unit while operation is either

stopped or running.

Operation command input by

means of the external signal

terminal (FWD, REV). STOP key

on the keypad is active. If

selection "1" is chosen, and the

stop button is depressed while the

drive is running, the drive will

perform the normal stop

Operation Mode Indicator -

During the program mode, this

key can be used to read and write

the Function Codes and the data.

The LED (green) lights up when

keypad panel operation is

selected.

Drive RUN Indicator -

The LED (green) lights up in the

RUN mode.

sequence until the output

frequency reaches zero at which

point an "Er6" fault shall be

indicated on the LED. To reset the

2-2

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(2) Controlling Method for Keypad Panel

When the power supply is activated, the keypad panel display will be as shown

in the figure on the right (60.00 FLASHING).

RUN

If the

key is pressed, the Drive will start and accelerate up to 60 Hz

according to the factory setting. Use the STOP key to stop operation.

WARNING-RUNandSTOPkeysfunctiononlyinKeypadoperationmode.(FunctionCodeF_02settingis0)

DriveComponents

1. Unit Cover (Middle)

2. Unit Cover (Top)

3. Keypad Panel (Optional)

4. Heat Sink and Mounting Tabs

5. Mounting Screw Holes

6. Top Cover Screw

Figure 2-3. TYPICAL DRIVE COMPONENTS

NOTE: NEMA 1 unit does not include keypad. Keypad is sold separately.

Keypad type is 6KM$2KP1 for NEMA 1 unit.

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TABLE 1: Standard Specifications

ITEM

SPECIFICATION

Environmental Conditions

Enclosure

InstallationLocation:NEMA1

NEMA 1or NEMA 4

Suitable for indoor mounting only, less than 1000 meters (3281 feet) elevation,

not in contact with corrosive gas, oil mist, or dust.

Suitable for use indoors or outdoors to protect the enclosed equipment against

splashing water, seepage of water, falling or hose directed water and severe

external condensation. Installation should be less than 1000 meters (3281 feet)

elevation, not in contact with corrosive gas, or oil mist.

NEMA4

StoredTemperature

AmbientTemperature

-20° to +65°C (-4° to +149°F)

-10° to +50°C (+14° to +122°F) (remove ventilation covers if temperature is

over (+40°C +104° F)

Humidity

20% to 95% relative humidity (non-condensing)

0.6G or less

Vibration

CoolingMethod

1/4 to 1 HP – Convection

2 HP and greater – Forced air (Integral fan)

Output

RatedOutputVoltage

FrequencyRange

3-Phase, 3-Wire, 80-240 VAC or 160-480 VAC

(Can not exceed power supply voltage)

0 - 400 Hertz (0.2 to 15 Hz Start Frequency; 15 to 400 Hz Base Frequency)

Above 120 Hz, contact the motor manufacturer for approval of application

OverloadCurrentRating

150% for 1 minute duration (inverse time characteristic)

200% for 0.5 seconds

Power Supply

RatedInputACVoltage

ControlSystem

– 200 to 240 VAC 50/60 Hz, 1 phase (1/4 to 3 HP)

– 200 to 230 VAC 50/60 Hz, 3 phase (1/4 to 5 HP)

– 380 to 480 VAC 50/60 Hz, 3 phase (1/2 to 5 HP)

Voltage: +10% to -15%; Voltage Unbalance: Within 3%; Frequency ±5%

Sinusoidal PWM "TORQUE VECTOR" Control

Control

FrequencySetting

Resolution

– Analog: 0.02 Hz step at Maximum frequency of 60 Hz

– Digital Keypad: 0.01 Hz Maximum frequency up to 99.99 Hz; 0.1 Hz (100

Hz or more)

Accuracy(Stability)

Analog setting: ± 0.2% of Maximum frequency (59° to 95° F)

Digital Keypad setting: ± 0.01% of Maximum frequency (14° to 122° F)

2-4

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SPECIFICATION

ITEM

Control (continued)

Voltage/Frequency

Characteristics(V/F)

Voltage - 80-240 VAC or 160-480 VAC

Frequency - 0.2 to 400 Hz

TorqueBoost

0: Automatic torque boost or 1 to 31.0 code settings (includes selection for

variable torque load)

Acceleration/Deceleration

Characteristics

0.01 to 3600 seconds (independent acceleration/deceleration)

Alternative accel/decel time available as well as linear or 2 S-curves (selectable)

MotorSound

The pitch of the motor sound can be changed by selecting Carrier frequency

(F_12: 0 to 15)

FrequencyMeterAdjustment

Scale calibration of externally connected analog meter or pulse

frequency

DataProtection

Data lock is possible to ensure that the function codes are not changed

Output frequency upper and lower range limit 0 to 400 Hz; 1 Hz step settings

High/LowFrequencyLimiter

Bias

Magnitude of the zero offset can be set from 0 to ±100% of maximum

frequency (1Hz steps)

Gain

Output frequency gain corresponding to the reference signal can be

set from 0 to 250%

15StepPresetSpeed

15 programmable preset speeds selectable by 4 contact closures

MaintainedContactOperation

TerminalFunctionChange

Maintained contact operation/stop command (2-wire operation)

Multi-Use terminal changed via Function Code settings (X4 input; Y1 output)

Operation

FrequencyReferenceSignal

InputSignal(contacttype)

Speed potentiometer: 0 to +10 VDC 4 to 20 mA [(0 to +5VDC) gain adjust 0-250%]

Forward, reverse, multistep speed setting, alternate accel/decel time settings,

coast-to-stop, external alarm, 3-wire control and reset

ExternalOutputSignals

One Dry Form "C" alarm output contact rated 250 VAC, 0.3 amp

1 – Open collector output rated 27 VDC, 50mA from external power

– Drive Run – FDT – FAR – LV– TL – Auto restart mode after momentary

power loss (IP)

FrequencyMeterOutputSignal

Pulse frequency (adjustment to 6 kHz maximum)

Analog - 0 to +10 VDC (adjustment range of 6.5 to 10.3 VDC)

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ITEM

SPECIFICATION

Operation (continued)

ProtectiveFunctions:

– Stall prevention

– Surge input

– Undervoltage

– Overcurrent

– Drive overheating

– External faults

– CPU malfunction

– Motor overload

(electronic thermal)

– Memory error

– Overvoltage

– Short circuit for output terminals

– Communication error

– Ground fault (at start)

– Output wiring not connected

(during auto tuning only)

Keypad

Digital Display - 4 digit LED

DriveOperation

Output frequency, output current, output voltage, motor speed, line speed

(m/min), machine speed (r/min) can be displayed

DriveSetting

DataInitializing

DriveFault

Function Code and Setting Data can be displayed

Resets all Function Codes to initial factory settings

– OC1 - Acceleration overcurrent

– OC2 - Deceleration overcurrent

– OC3 - Constant speed overcurrent

– LU (LV) - Undervoltage

– OU1 - Overvoltage during acceleration

– OU2 - Overvoltage during deceleration

– OU3 - Overvoltage at constant speed

– OH1 - Drive overheat

– OH2 - External alarm input

– OLU - Electronic Overload - Semiconductor Overload Protection

– OL - Electronic Overload - 4 Pole Motor Overload Protection

– Er1 - Setting error

– Er2 - Communication error

– Er3 - CPU error

– Er4 - Optional circuit board communication error with Drive

– Er5 - Optional Problem - when a link error etc. is detected

– Er6 - Operating Proc. error

– Er7 - Output wiring error

Charge"CRG"Lamp(LED)

Illuminates when DC Link capacitor voltage is present

2-6

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Table 2:

Drive Dimensions

240 Volt – Single Phase

Weight

Height

Width

Depth

Dim. Figure

Pages

Model

Const LBS

TRQ

KGS Inches MM

Inches

NEMA 1

NEMA 4

3-2 to 3-5

1 and 4

2 and 6

3 and 8

6KM$221F25N1A1 6KM$221F25X4A1

6KM$221F50N1A1 6KM$221F50X4A1

6KM$221001N1A1 6KM$221001X4A1

6KM$221002N1A1 6KM$221002X4A1

6KM$221003N1A1 6KM$221003X4A1

1/4

1/2

2.7

3.8

4.0

6.2

6.4

1.2

1.7

1.8

2.8

2.9

6.22

158

4.29

5.67

8.03

109

144

204

3.15

4.29

5.28

109

134

230 Volt – Three Phase

6KM$223F25N1A1 6KM$223F25X4A1

6KM$223F50N1A1 6KM$223F50X4A1

6KM$223001N1A1 6KM$223001X4A1

6KM$223002N1A1 6KM$223002X4A1

36KM$223003N1A1 6KM$223003X4A1

36KM$223005N1A1 6KM$223005X4A1

1/4

1/2

2.4

2.9

3.3

4.6

6.2

7.0

1.1

1.3

1.5

2.1

2.8

3.3

6.22

158

4.29

5.67

8.03

109

144

204

3.15

3.54

4.69

5.28

5.87

119

134

149

1 and 4

1 and 5

1 and 7

2 and 7

3 and 8

3 and 9

480 Volt – Three Phase

6KM$243F50N1A1 6KM$243F50X4A1

6KM$243001N1A1 6KM$243001X4A1

6KM$243002N1A1 6KM$243002X4A1

6KM$243003N1A1 6KM$243003X4A1

6KM$243005N1A1 6KM$243005X4A1

1/2

4.2

6.2

1.9

2.8

3.3

6.22

158

5.67

8.03

144

204

4.29

5.28

5.87

109

134

149

2 and 6

3 and 8

3 and 9

Table 3:

Drive Rating Efficiency and Watts Loss Table

240 Volt – Single Phase

Output Current

Carrier Frequency

Output

Power

Efficiency

Percentage

Model

Watts Loss

NEMA 1

NEMA 4

Low

1.5

3.0

5.0

8.0

High

1.3

2.5

4.0

7.0

Low

High

80.9

83.2

88.8

91.5

92.4

Low

High

6KM$221F25N1A1 6KM$221F25X4A1

6KM$221F50N1A1 6KM$221F50X4A1

6KM$221001N1A1 6KM$221001X4A1

6KM$221002N1A1 6KM$221002X4A1

6KM$221003N1A1 6KM$221003X4A1

1/4

1/2

0.19

0.37

0.75

1.50

2.20

87.6

88.1

90.4

92.9

93.6

115

150

140

180

11.0

10.0

230 Volt – Three Phase

6KM$223F25N1A1 6KM$223F25X4A1

6KM$223F50N1A1 6KM$223F50X4A1

6KM$223001N1A1 6KM$223001X4A1

6KM$223002N1A1 6KM$223002X4A1

36KM$223003N1A1 6KM$223003X4A1

36KM$223005N1A1 6KM$223005X4A1

1/4

1/2

1.5

1.3

0.20

0.40

0.75

1.50

2.20

3.70

87.6

88.1

90.4

92.9

93.6

94.6

80.9

83.2

88.8

91.5

92.4

93.4

115

150

212

140

180

260

3.0

2.5

5.0

4.0

8.0

7.0

11.0

17.0

10.0

16.5

480 Volt – Three Phase

6KM$243F50N1A1 6KM$243F50X4A1

6KM$243001N1A1 6KM$243001X4A1

6KM$243002N1A1 6KM$243002X4A1

6KM$243003N1A1 6KM$243003X4A1

6KM$243005N1A1 6KM$243005X4A1

1/2

1.6

2.5

3.7

5.5

9.0

1.4

2.1

3.7

5.3

8.7

0.37

0.75

1.50

2.20

3.70

86.0

90.4

93.2

94.4

94.9

79.9

86.9

88.1

89.4

91.0

110

130

200

113

203

260

366

NOTE: Carrier Frequency: High setting F_12 = 15

Low setting F_12 = 0

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Section 3

INSTALLATION GUIDELINES

INSTALLATION ENVIRONMENT

Install the Drive in an indoor location that meets the

following requirements:

INSTALLATION MOUNTING

CLEARANCE

— Install at a sufficient distance from other equip-

ment, walls, or wiring ducts as shown in Figure

3-1 (these clearances are required to allow the

heat generated by the Drive to escape).

— The ambient temperature is between -10° C and

+50° C (+14° F to +122° F). Remove the ventila-

tion covers when the temperature exceeds +40° C

[+104° F].

— Install the Drive perpendicular to the ground and

with the lettering right side up. (If the Drive is

installed upside-down or horizontally, heat build-

up will occur.)

— The relative humidity is between 20% and 95%.

Avoidanylocationsubjecttocondensation, freezing,

or where the Drive would come in contact with water.

— Mountingscrewsorboltsshouldbeofappropriate

size for weight of Drive.

— Donotinstallinanylocationsubjecttodirectsunlight,

dust, corrosive gas, inflammable gas, or oil mist.

— See the appropriate figures on pages 3-2 and

3-3 for the location of mounting holes.

— Vibration should be less than 0.6G.

— The Drive should be installed at an elevation below

1000meters(3281feet). Forinstallationabove1000

meters (3300 feet) the Drive will need to be derated

1% per 333 feet.

— After removing the knockouts in the wiring lead-in

plate, install the rubber bushings supplied to pre-

vent cable damage and to minimize dust entry.

Example: 5 HP, 460 VAC, output current 9 amps.

Application altitude 3900 feet.

CAUTION: The mounting wall for the Drive must be

constructed of heat resistant material because during

operation, the temperature of the Drive's cooling fins

rises to approximately 90 degrees C (194° F).

3900 - 3300

% derate =(

) ^{x 1% = 1.8%}

333

100 - 1.8

100

(

)

(9 amps) x

= 8.84 amps

derated output current.

Motor derate may also be required,

contact motor manufacturer.

NOTE: When installing two or more Drives in close

proximity, allow sufficient space as shown in Figure 3-1

and install them in a horizontal row. If they must be

installedinaverticalcolumn,atleast19.7inches(50cm)

internal space must be provided between each one or a

ventilation baffle should be provided to prevent the

ambient temperature from rising.

CAUTION: Because the ambient temperature greatly

affects Drive life and reliability, do not install the Drive in

any location that exceeds the allowable temperatures.

➛

5" or more

or more

➛

5" or more

Figure 3-1. DRIVE MOUNTING CLEARANCE

3-1

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Dimensions

4.29 (109)

4.13 (105)

3.66 (93)

0.24 (6)

NOTE: NEMA 1 unit does not have Keypad.

Shown with optional Keypad

0.20 (5)

Figure 1

8.03 (204)

7.87 (200)

5.67 (144)

5.51 (140)

0.08 (2)

0.24 (6)

0.08 (2)

0.24 (6)

0.08 (2)

0.24 (6)

7.40 (188)

5.04 (128)

2-ø5 (0.20)

0.24 (6)

0.20 (2-ø5)

0.20 (5)

Figure 2

Figure 3

Note: Inches (MM)

3-2

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Dimensions

4.29 (109)

3.15 (80)

3.54 (90)

0.24 (6)

0.20 (5)

Figure 4

Figure 5

Figure 6

5.28 (134)

4.69 (119)

0.24 (6)

5.87 (149)

0.24 (6)

Figure 7

Figure 8

Figure 9

Note: Inches (MM)

3-3

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Dimensions of Keypad and Keypad Mounting Holes

Mounting Hole (panel cut-out)

Keypad Part #

6KM$2KP1 for NEMA 1 unit

6KM$2KP4 for NEMA 4 unit

Inches (MM)

3-4

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Section 4

WIRING PROCEDURES

Removing Top Cover

To access Main and Control Circuit Terminals remove the top

cover as follows (see Figure 4-1):

1. Loosen the screw located at the bottom of the top cover.

2. Press upward on the bottom of the top cover (see arrows

Figure 4-1 step 2) and lift off.

3. See Figure 4-1 for the location of the Main Circuit

Terminal Block and the Control Circuit Terminal Block.

WARNING: Some printed circuit boards and Drive com-

ponents may contain hazardous voltage levels. If LED

light "CRG" on the Base Driver Board is illuminated,

hazardousvoltagesarepresentintheDrivecircuitboards.

Remove and lock out power before you disconnect or

reconnect wires, and before you remove or replace fuses

and circuit boards. Do not attempt to service the Drive

until the "CRG" indicator has extinguished and the bus

voltage has discharged to zero volts.

Mounting Screw

Holes

Keypad Panel

Unit Cover (Middle)

Unit Cover (Top)

Top Cover Screw

Heat Sink

and Mounting Tabs

Control

Circuit

Terminal

Block

Main Circuit

Teminal Block

Step 2:

Step 1:

Drive

Charge "CRG" Lamp

Press Upward at the locations indi-

cated by the arrows to remove the top

cover.

Loosen Top Cover

screw. (1 to 2 turns)

Figure 4-1. REMOVING THE TOP COVER

4-1

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Control Circuit Wiring

Drive is wired at shipment for operation and frequency

setting through the keypad panel (frequency is set at 60

Hz.)

– See Figure 4-2, and 4-4 for wiring connections.

– See TABLE 5 for description of all terminals.

Make wire connections as shown in Figure 4-4 through 4-6

for desired mode of external operation through Control

Circuit Terminals.

CAUTION: The Control Circuit Terminal wiring should be

kept as far away as possible from the main power wiring to

prevent operational error due to noise interference. Never

install both types of wiring in the same duct or conduit. (A

separation distance of 4 inches [10 centimeters] or more is

recommended.) If the control circuit wiring must cross the

main power wiring, it should cross at a right angle.

CAUTION: Use shielded or twisted wire for the control

circuit wiring (wiring should be as short as possible, i.e. 65

feet or less [20 meters.]) Connect outer covering of the

shielded wires to the Drive ground terminal and leave the

other end open, but taped with electrical insulating tape.

DC RELAY

AC CONTACTOR

Figure 4-2. CONNECTION OF SURGE SUPPRESSION DEVICES

CAUTION: Install a suppressor in parallel with any relay or

solenoid type coil as shown above, that may be close to the

Drive to prevent noise from causing erratic Drive operation.

4-2

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Main Circuit Wiring

CAUTION: Be sure that the power supply is never

connected to the U, V, W terminals or the P (1), P (+),

DB terminals.

3. Connect the 3-phase motor wires to the U, V, and

1. Connect the ground terminal as shown in the appro-

priate view of Figure 4-3. (Do not operate without

the unit being grounded.)

W terminals of the Main Circuit Terminal Block as

shown in the appropriate view of Figure 4-3. (See

TABLE 5 for description of all terminals and TABLE

4 for recommended wire sizes.)

— The ground wire must be minimum 14 AWG

and short as possible

4. Suitableforuseonacircuitcapableofdeliveringnot

more than 1000A (1 HP or less) or 5000A (2 HP or

more) RMS symmetrical.

2. Connect the power supply wires to the L1, L2, and

L3 terminals of the Main Circuit Terminal Block as

shown in the appropriate view of Figure 4-3. (See

TABLE 5 for description of all terminals and TABLE

4forrecommendedwiresizes.) Notethat L1andL2

terminals only, are available on single phase input

models.

5. ACinputfusesaretobecustomersuppliedandmay

be branch circuit protection fuses. The maximum

allowance fuse rating per TABLE 4.

NOTE: Motor will rotate counterclockwise when viewed from

the shaft end when connected normally. If the motor rotates in

reversedirection, interchangeanytwooftheU, V, orWterminal

connections.

240V – Single Phase 1/4 to 3 HP

L1 L2 P1 P(+) DB*

✟

E (G)

230 & 480V – Three Phase 1/4 to 5 HP

L1 L2 L3 P1 P(+) DB U

E (G)

✟

Thermal Relay

Fuses: Rating per TABLE 4

Reference UL power circuit

protection requirements.

3–Phase Motor

50/60 Hz, 3–Phase AC

✟ Factory installed jumper (Remove when installing DC Reactor)

* The DB resistor connection is not available on models 6KM$221F25X1A1,

6KM$221F25A4A1, 6KM$223F25X1A1, 6KM$223F25A4A1.

# Optional

Figure 4-3. MAIN CIRCUIT TERMINAL LAYOUT

4-3

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Table 4:

Wire Size Recommendations

& Circuit Protection Ratings

240V – Single Phase and 230V Three Phase

Resistor**

Wire

Incoming Power

AC – Line Devices

Circuit

Model

Const

TRQ

Output Current

Carrier Frequency

Low

Power

Wire

AWG

NEMA 1

NEMA 4

Input

High

AWG

Fuses*

Breaker

6KM$221F25N1A1 6KM$221F25X4A1

6KM$221F50N1A1 6KM$221F50X4A1

6KM$221001N1A1 6KM$221001X4A1

6KM$221002N1A1 6KM$221002X4A1

6KM$221003N1A1 6KM$221003X4A1

6KM$223F25N1A1 6KM$223F25X4A1

6KM$223F50N1A1 6KM$223F50X4A1

6KM$223001N1A1 6KM$223001X4A1

6KM$223002N1A1 6KM$223002X4A1

6KM$223003N1A1 6KM$223003X4A1

6KM$223005N1A1 6KM$223005X4A1

1/4

1/2

1/4

1/2

1.5

1.3

2.5

1.5

1.3

2.5

16.5

480V – Three Phase

Resistor**

Incoming Power

AC – Line Devices

Circuit

Model

Const

TRQ

Output Current

Power

Wire

AWG

NEMA 1

NEMA 4

Carrier Frequency

Wire

AWG

Input

Low

High

Fuses*

Breaker

6KM$243F50N1A1 6KM$243F50X4A1

6KM$243001N1A1 6KM$243001X4A1

6KM$243002N1A1 6KM$243002X4A1

6KM$243003N1A1 6KM$243003X4A1

6KM$243005N1A1 6KM$243005X4A1

1/2

1.6

2.5

3.7

5.5

9.0

1.4

2.1

3.7

5.3

8.7

WARNING - Device ratings such as system coordination, short-circuit

rating and type must be carefully reviewed by the user.

NOTE: Wire size from NEC table 310-16. Copper wire rated 60° C for 100 amps or less,

75° C for over 100 amps in 30° C ambient and 1.25 times Drive rated amps. These

are minimum wire sizes; consult and conform to local and national codes.

*NOTE: AC input fuses are required to validate the drive's UL and CSA approvals.

The fuse should be Class J type such as Bussman, JKS or equivalent. Circuit breaker

ratings are shown for reference, but UL and CSA approval can only be validated by

the use of Class J fuses.

** Optional Item.

4-4

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30A 30B Y1 FMA PLC BX RST C1 13 12 11

30C FMP X1 X2 X3 X4 REV FWD THR CM

* Factory installed jumper

CONTROL CIRCUIT TERMINAL BLOCK LAYOUT

#1 CAUTION:

Remove jumper from between terminals THR and CM when

a motor overload or a motor temperature switch is used.

Wire the device thermal switch in series with the THR and

CM terminals.

#2 NOTE:

FWD to CM jumper required for operation using keypad

RUN-STOP.

Figure 4-4.

L1 L2 L3 P1 P(+) DB* U V W

RESISTOR

E(G)

* Not available on 6KM$221F25X1A1, 6KM$221F25A4A1, 6KM$223F25X1A1, 6KM$223F25A4A1.

^{Figure 4-5.}DYNAMIC BRAKING RESISTOR CONNECTIONS

4-5

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DISCONNECT/

CIRCUIT

BREAKER #

1 or 3PH

50/60 Hz

230/480 Vac

(Based on

Model selected)

✟

GROUND

FUSE

DC REACTOR #

BRAKING RESISTOR

1/2 TO 5HP #

DO NOT CONNECT

TO CM

BRAKING RESISTOR

THERMAL SWITCH

DIGITAL METER

ALARM RELAY OUTPUT

PROGRAMMABLE LOGIC

CONTROL POWER

PLC

RST

X4(HLD)

ANY ADDITIONAL NORMALLY

CLOSED PROTECTIVE

INTERLOCKS SHOULD BE

ADDED IN SERIES

* Terminal 11 should not be connected to CM.

✟ L3 not supplied on single phase units.

# Optional

Figure 4-6. WIRING DIAGRAM

CAUTION:

1. The Control Circuit Terminal wiring should be kept as far as possible from the main circuit wiring to prevent

operationerrorduetonoiseinterference. Neverinstalltheminthesameductorconduit. Aseparationdistance

of 4 inches or more is recommended. If the control circuit wiring must cross the main circuit wiring, make sure

it crosses at a right angle.

2. Use shielded wire for the control circuit wiring, which should be as short as possible (66 feet or less). Connect

shield to the Drive ground terminal and leave the other end open but taped.

3. Installasurgeprotectorinparallelwithanymagneticcontactors,solenoids,relaysortimercoilswhichareclose

to the Drive.

4-6

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TABLE 5: Terminal Identification/Function

Terminal

Label

Terminal

Name

Function

POWER TERMINAL BOARD

L1, L2,

AC Supply Line

Input Terminals

Connection for 200-230 VAC or 380-480 VAC, 3-phase, 50/60 Hz;

L1 & L2 for single phase input, 200-240 VAC 50/60 Hz

U, V, W

P+, DB

Drive Output

Terminals

Connection for 3-phase induction motor

External Braking

Resistor Terminals

Connection for external braking resistor option for single phase and

three phase drives (Only on 1⁄2 HP to 5 HP; not on 1/4 HP)

P1, P+

DC Reactor Terminals Connection for external DC reactor for power factor improvement

(Option). (Remove factory installed jumper)

CONTROL TERMINAL BOARD

Frequency Setting &

Analog Freq. Meter

Common Terminal

Common connector for terminals 12, 13, C1 and FMA (Do not

connect to CM terminal or electrical noise immunity may be lost).

Frequency Setting

Voltage Input

When 0 to +10 VDC (0 to 5V*) is applied, the maximum frequency is

reached at +10 VDC (5V*) and is proportional to output frequency

down to 0 VDC. Input impedance is 22K ohm ( *250% gain setting F_35)

Frequency Setting

Regulated +10 VDC power supply for frequency setting potentiometer,

Voltage Output Term. 10mA or less (13 to terminal 11)

Frequency Setting

Current Input (+)

When the input signal is +4 to +20mA dc, the maximum frequency is

reached at 20mA and is proportional down to a minimum frequency

setting at 4mA. Input impedance is 250 ohm, must be isolated source

Control Circuit

Common Terminal

Common terminal for control input commands, X1-X4, FWD, REV, BX,

RST, THR, Y1 and FMP pulse output signal

(Do not connect to terminal 11)

FWD

Forward Command

Input Terminal

Forward command via FWD-CM (closed). Reverse command via

REV-CM (closed). When FWD-CM and REV-CM are closed

at the same time, the Drive will decelerate to stop

Reverse Command

Input Terminal

REV

Motor Coast-To-Stop Motor will coast-to-stop with BX-CM (closed). (For use when

Command Input

Terminal

applying mechanical brake with Drive in operation.) Note: If BX-CM is

opened with FWD or REV closed, the Drive will start the motor

RST

Fault Reset Input

Terminal

After removal of fault condition, Faults are reset when a momentary

contact closure is made between the RST-CM terminals for more

than 0.1 seconds

If there is an input to the FWD or REV terminals with F_02 = 1 OR

2 and F_14 = 4 or 5 the Drive will suddenly restart.

4-7

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TABLE 5: Terminal Identification/Function (continued)

Terminal

Label

Terminal

Name

Function

CONTROL TERMINAL BOARD (Continued)

THR

External thermal trip

command

With THR-CM (open), OH trip will occur and the motor will

coast-to-stop.

NOTE: With no external thermal relay or external braking resistor

thermostat, the THR-CM terminals must be closed or the Drive

will not operate. THR-CM is factory pre-jumpered, remove prior to

connecting an external NC contacts.

FMA*

FMP*

Analog Frequency

Meter Connection

F_40=0

Provides an output of 0 to +10 VDC (+10VDC at max frequency),

available for connection of a voltmeter with internal resistance of

10K ohms. See Function Code 41 for monitoring selection. Meter

connects between terminal FMA & 11. Note: FMP cannot be used

Digital Frequency

Meter Connection

F_40=1

Pulse frequency output equal to Drive output frequency.

Pulse voltage: Peak 5 VDC, 50% duty, Adjustable range = 600 to

6000 Hz (Max) See Function Code 42 Pulse Rate Multiplier.

Meter connects between FMP and CM. Note: FMA cannot be used

30A

30B

30C

Fault Relay Output

Terminals

During normal operation, the relay is not energized and contact is made

between 30B and 30C. When a fault is detected, the relay is energized

and contact is made between 30A and 30C. (Contact rating resistive

load: 250 VAC, 0.3 Amps)

X1-X3

Multistep Frequency

Input Function

Selection

Seven individual preset frequency selections via binary combination

(closure) between X1, X2, X3, and CM.

Frequency selections determined using functions F_21 thru F_27.

Function Extension

(Input)

F_43=0 acceleration/deceleration time #2 is selected when X4-CM is

closed. When not closed #1 setting is activated.

(F_43=1) 8 additional frequencies can be selected by X1, X2, X3 and X4.

(F_43=2) 2nd Motor selection when X4 - CM is closed.

(F_43=3) Functions as hold signal if 3-wire operation is desired.

Output Function

(Programmable)

Outputs one of the following signals depending on setting of F_54;

0: Drive running (RUN)

3: Undervoltage stop mode (LV)

4: Torque limiting mode (TL)

5: Auto restart mode after

1: Frequency level detection (FDT)

2: Frequency equivalence (FAR)

momentary power loss (IP)

Allowable load: Maximum 27VDC, 50mA or less

PLC

Prevents PLC fault caused by leakage current from the drive. (See Drive

interface details, Figure 4-7)

* Either an analog (FMA) or digital (FMP) frequency meter, not both.

4-8

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Drive Interface Details

27 Vdc MAX Load

50 mA MAX

Output Terminal Y1

Input Terminal FWD, REV, X1-X4, BX, RST, THR

DC24 - 27V

6 mA MAX

Input Terminal

Reference Input

22K Ohms

1 - 5K Ohms

2 WATT

+4 to +20 mA dc

250 Ohms

With PLC Terminal Connection Between PLC and Drive

PLC

Drive

Note: Do Not

Connect

Figure 4-7. DRIVE INTERFACE DETAILS

4-9

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Section 5

DRIVE OPERATION

PRE-OPERATION INSPECTION

After mounting and wiring has been completed, check the Drive for the following items before applying AC power:

— Check for wiring errors.

— Verify that there are no wiring chips, screws, etc. remaining in the Drive.

— Check that all screw and terminal connections are tight.

— Verify that no exposed wire ends are touching other terminals.

KEYPAD PANEL IDENTIFICATION / OPERATION

See the following diagrams for Display and Keypad Operation description when in the Operation Mode, Program

Mode or Trip Mode.

FUNCTION CODE AND DATA CODE DESCRIPTION / SELECTION

When AC power is applied to the Drive, the keypad panel display will be as shown in Figure 5-1 and will be

flashing on and off. If the RUN key is pressed at this point, operation will be at 60 Hertz according to the

Function Code set at the factory. (Use the STOP key to halt operation.)

-- A Flashing display indicates when a run command is not present.

-- A Solid display indicates the actual output when the Drive is running.

If a test run is desired, press the

key to change the flashing display of 60.00 Hz frequency setting to

5.00 Hz. Press RUN to conduct the test run and check for smooth motor operation and direction of rotation.

Removal of AC power will store a frequency reference in memory.

Figure 5-1. KEYPAD PANEL DISPLAY WHEN AC POWER IS APPLIED

5-1

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Keypad and Display Operation Programming

Mode Selection

The Drive has five (5) modes as shown below. The mode can be changed with the keys on the keypad panel.

(1) Stop Mode:

(2) Run Mode:

Drive stopped

Drive operational

(4) Program Mode: Motor Running

(5) Trip Mode:

Drive system faults

(3) Program Mode: Motor Stopped

Run Mode

Stop Mode

PRG

RESET

PRG

RESET

All Function Codes

Can Be Changed

Restricted Function

Code Access

Trip Mode

PRG

RESET

Data Setting

Changing Function Codes in the STOP Mode

➀

RUN

This is the state in which all operation signals (

signal)

Stop mode

[Keypad operation], FWD and REV signals (Terminal operation)

are OFF.

The last keypad display (frequency, amps, volts etc.) flashes

repeatedly.

PRG

RESET

The mode is switched to Function Code setting mode (All

Function Code settings can be changed).

FUNC

DATA

Each time the key is pressed, the display changes between

indication of a Function Code and its data.

When these keys are pressed while the Function Code is dis-

played, the Function Code number will change. By pressing

them while data is displayed, the data can be changed.

FUNC

DATA

The data is stored and the Function Code advances to the next

Function Code number.

Are

there any

more functions

to change?

To change other data, repeat the above procedure.

PRG

RESET

The program mode is ended and the Drive returns to STOP

mode.

Changing Function Codes in the RUN Mode (See TABLE 6)

➁

5-2

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Display and Key Operation

1. Operations and displays in each mode

The keypad panel modes can generally be classified into five types. The operation method and the display

contents of each mode are shown below.

NOTE: Following examples are with maximum frequency, F_03 set higher than 60 Hz

STOP Mode (Display continually flashes)

➀

A display

Hz display

r/min display

m/min display

V display

FUNC

DATA

FUNC

DATA

FUNC

DATA

FUNC

DATA

➛

PRG

Reset

PRG

Reset

PRG

Reset

PRG

Reset

PRG

Reset

To PROGRAM

mode while stopped

To PROGRAM

mode while stopped

To PROGRAM

mode while stopped

To PROGRAM

mode while stopped

To PROGRAM

mode while stopped

➛

RUN

Keypad panel

operation:

Drive will run

Keypad panel

operation:

Drive will run

Keypad panel

operation:

Drive will run

Keypad panel

operation:

Drive will run

Keypad panel

operation:

Drive will run

➛

Display = V

Terminal operation:

Not operational.

Display = r/min

Terminal operation:

Not operational.

Display = Hz

Terminal operation:

Not operational.

Display = A

Terminal operation:

Not operational.

Display = m/min

Terminal operation:

Not operational.

STOP

Not effective

➛

5-3

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RUN Mode

➁

r/min display

V display

m/min display

Hz display

A display

FUNC

DATA

FUNC

DATA

FUNC

DATA

FUNC

DATA

➛

PRG

Reset

PRG

Reset

PRG

Reset

PRG

Reset

PRG

Reset

PROGRAM Mode

while running

PROGRAM Mode

while running

PROGRAM Mode

while running

PROGRAM Mode

while running

PROGRAM Mode

while running

➛

RUN

Not effective

➛

Keypad panel

operation:

Keypad panel

operation:

Keypad panel

operation:

Keypad panel

operation:

Keypad panel

operation:

Drive will stop

Display = Hz

Drive will stop

Display = A

Drive will stop

Display = V

Drive will stop

Display = r/min

Terminal operation:

F_02=1 Drive will stop

LED will show Er6

F_02=2 Stop key not

operational

Drive will stop

➛

Display = m/min

Terminal operation:

F_02=1 Drive will stop

LED will show Er6

F_02=2 Stop key not

operational

STOP

Terminal operation:

F_02=1 Drive will stop

LED will show Er6

F_02=2 Stop key not

operational

Terminal operation:

F_02=1 Drive will stop

LED will show Er6

F_02=2 Stop key not

operational

Terminal operation:

F_02=1 Drive will stop

LED will show Er6

F_02=2 Stop key not

operational

* NOTE: See TABLE 6 (page 5-12) for Functions that can be changed while in RUN Mode.

5-4

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PROGRAM mode while stopped (example: changing the Torque Boost 1data)

➂

FUNC

DATA

Data is Stored*

➛

FUNC

DATA

FUNC

DATA

Data is Stored*

➛

FUNC

DATA

Data is Stored*

➛

PRG

Reset

PRG

Reset

Exit PROGRAM mode

to keypad display**

Exit PROGRAM mode

to keypad display**

➛

RUN

Not effective

➛

STOP

Not operational

➛

Not operational

➛

FUNC

DATA

*NOTE: After changing function data with

keys, the

key must be pressed. If this is not

FUNC

PRG

Reset

done, the data will not be stored. If the

key is pressed before

key is pressed, the

DATA

changed data will be canceled and operation will continue with the previous data.

* * NOTE: Keypad displays Frequency, Amps, Voltage, etc. based on selection.

5-5

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PROGRAM mode while running (example: changing the Torque Boost 1data)

➃

FUNC

*NOTE: After changing function data with

the data will not be stored. If the

keys, the

key is pressed before

key must be pressed. If this is not done,

FUNC

DATA

PRG

Reset

key is pressed, the changed data

DATA

will be canceled and operation will continue with the previous data.

* * NOTE: Keypad displays Frequency, Amps, Voltage, etc. based on selection.

See Table 6 for Functions that can be changed while in RUN mode.

5-6

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TRIP mode

➄

NOTE: Past fault records also can be displayed with Function Code 29.

Display of

present fault

status

Display of

previous fault

status

Display of

third-to-last

fault status

Display of

second- to-last

fault status

END

PRG

Reset

PRG

Reset

PRG

Reset

PRG

Reset

PRG

Reset

Resets Fault

➛

MECHANICAL MOTION

HAZARD: If there is an input to the FWD-CM or REV-CM

with F_02 = 1 or 2 and F_14 + 4 or 5 (Terminal

Mode) the Drive will suddenly restart.

Not effective

➛

Not effective

➛

FUNC

DATA

FUNC

DATA

FUNC

DATA

FUNC

DATA

FUNC

DATA

Not effective

➛

RUN

Not effective

➛

STOP

Not effective

➛

5-7

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Summary of each operation mode : The following table shows a summary of the various modes.

5-8

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Operation

Pre-Operation Inspection

After completion of installation and wiring work, inspect the following items before the power supply to the Drive is

switched on.

CAUTION:

1. Check for wiring errors. (Especially the main circuit wiring: connection of the three

(single) phase AC power supply to the terminals L1, L2, L3 (L1, L2)).

2. Check that all loose wire strands, metal chips and unnecessary screws, etc. have been removed.

3. Check that all screws, terminals, and components are tight.

4. Check that the wire ends of crimp terminals are not in contact with other terminals.

CAUTION: Megger Test:

Do not conduct megger tests between the Drive main circuit terminals, or control circuit terminals.

Refer to Section 7 "Maintenance and Inspection."

Test Run Check Points

Use a low frequency reference setting of about 5 Hz to test Drive operation.

The following operating conditions must be confirmed:

1. Smooth motor rotation.

2. Correct direction of equipment rotation.

3. No abnormal vibrations and noise from the motor over full speed range.

4. Smooth acceleration and deceleration over full speed range.

Selecting Operation Method

The following methods can be selected to input the RUN/STOP signals and for frequency setting.

Keys

Analog signal (4 to 20 mA dc)

or (0 to 10Vdc)

STOP Keys

RUN

Keys

Analog signal (4 to 20 mA dc)

or (0 to 10Vdc)

NOTES:

*1: F_02 cannot be changed when there is a short circuit (jumper)between either FWD-CM or REV-CM.

*2: Multistep speed operation (up to 8 steps are possible)

The frequencies of step 1 to step 7 are set with the Function Codes F_21 to F_27 and selected

with the terminals X1, X2 and X3 (Additional 8 steps available with F_43 = 1 and F_44 to F_51

using X4).

If input signals are provided to terminals X1, X2 and X3, then data setting of F_01 (settings made by

keypad panel or analog signal are ignored) and multistep speed operation is controlled by these

terminal signals.

*3: F_02 =1 Stop key on the keypad active

F_02 = 2 Stop key on the keypad inactive

5-9

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TABLE 6: Function Codes

Function Code Numbers Followed by Function Descriptions

* Function can be changed while the Drive is operating.

BasicFunctions(cont'd)

BasicFunctions

Page 6–

–

22 *Multistep Frequency

43 X4 Terminal Function

00 Data Protection

Setting 2

44 *Multistep Frequency Setting 8 17

45 *Multistep Frequency Setting 9 17

01 Frequency Command

02 Operation Command

03 Maximum Frequency

04 Base Frequency 1

23 *Multistep Frequency

Setting 3

24 *Multistep Frequency

46 *Multistep Frequency Setting 10 17

47 *Multistep Frequency Setting 11 17

48 *Multistep Frequency Setting 12 17

49 *Multistep Frequency Setting 13 17

50 *Multistep Frequency Setting 14 17

51 *Multistep Frequency Setting 15 17

Setting 4

25 *Multistep Frequency

Setting 5

05 Maximum Output Voltage

06 *Acceleration Time 1

07 *Deceleration Time 1

08 *Torque Boost 1

26 *Multistep Frequency

Setting 6

27 *Multistep Frequency

Setting 7

52 *Signal Filter

Frequency Setting

28 S-curve Acceleration/

Deceleration

09 *FMA Terminal Voltage

Adjustment

53 Timer

(Operation Selection)

10 *Number of Motor Poles

54 Y1 Terminal (Function)

29 * Fault Memory/History

30 Starting Frequency

11 *Line Speed Display

Coefficient

55 *Frequency Level Detection

(FDT Operation Level)

31 * (During Accel/Decel)

Torque Limit

32 * (At Constant Speed)

12 *Motor Sound (Carrier Freq.)

13 Number of Restart Attempts

56 *Hysteresis Width

57 THR Terminal (Function)

33 Braking Torque

Selection

14 Restart After Momentary

Power Failure

58 *Jump Frequency Hysteresis

34 * Bias Frequency

15 Electronic Overload 1

35 * Gain for Frequency Setting

Selection

59 *Jump Frequency 1

60 *Jump Frequency 2

61 *Jump Frequency 3

62 Base Frequency 2

63 *Acceleration Time 2

64 *Deceleration Time 2

65 *Torque Boost 2

Signal

16 Electronic Overload

36 * High Frequency Limiter

37 * Low Frequency Limiter

38 * Motor Characteristics

Setting 1

17 DC Brake Operation

18 *DC Brake Starting Frequency 9

39 Data Initialization (Default

19 *DC Braking Level

20 *DC Braking Time

Settings)

40 FMA, FMP terminals

(Operation Selection)

21 *Multistep Frequency

Setting 1

cont'd on next page

41 FMA Terminal (Function)

42 * FMP Pulse Rate Multiplier

5-10

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TABLE 6: Function Codes (Cont'd)

Function Code Numbers Followed by Function Descriptions

* Function can be changed while the Drive is operating.

BasicFunctions(cont'd)

BasicFunctions

Page 6–

–

66 Electronic Overload 2

Selection

67 Electronic Overload

Setting 2

68 *Slip Compensation

69 Torque Vector Control

70 Motor HP Capacity 1

71 Rated Current 1

72 No-load Current 1

73 Rated Current 2

74 Automatic Tuning

75 Motor 1 (%R1 Setting)

76 Motor 1 (%X Setting)

77 *Torque Limiting Response

at Constant Speed

78 *Torque Limiting Response

During Acceleration/

Deceleration

79 Option Card Selection

5-11

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LED

Data

Factory

Setting

Customer

Setting

Display

Description

Section 6^Setting

FUNCTION CODE DESCRIPTIONS

Basic Functions

NOTE: * = Function can be changed while Drive is operating.

LED

Data

Display

Factory

Setting

Customer

Setting

Description

F_00

DATA PROTECTION

This Function protects the data setting from

accidental changes.

Data Changeable

Data Protected

To change the Data Protection Setting,

simultaneously press the

STOP

key and either the

key.

F_01

FREQUENCY COMMAND

0/1*

The frequency reference setting method can be selected.

Using the Keypad Panel

Using analog signal input

and

keys

Note: The frequency setting will be the sum of the

values at terminal 12 (0 to 10 VDC) and terminal C1

(4 to 20mA dc).

UP/DOWN Control

Output frequency can be increased or decreased by signal

input to the terminals X1 and X2.

The adjustable range is from minimum frequency to max

frequency. If the terminals X1-CM is held closed, output

frequency increases by F63 (2nd acceleration time). When

the terminals X2-CM is held closed, output frequency

decreases by F64 (2nd deceleration time). The rotation

direction can not be changed. The rotation direction

depends on input to the terminal FWD or REV.

*Default value = 0

Factory setting for NEMA1 = 1. Will reset to 0 when default is selected

6-1

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

The initial value for frequency setting is always zero after

the drive is stopped by operation command or after power

shut off.

Same as data setting 2 except the initial value for frequency

setting is the previous value before the drive is stopped by

operation command or power shut off.

Example of UP/DOWN control operation

*1) Initial value = 0

*2) Initial value = prevous value

*3) 1st Acc. time by F06

*4) 1st Dec. time by F07

*5) 2nd Acc. time by F63

*6) 2nd Dec. time by F64

Max. frequency

Data 2

Output

freq.

FWD-CM

X1-CM

X2-CM

Max. frequency

Data 3

Output

freq.

FWD-CM

X1-CM

X2-CM

*Default value = 0

Factory setting for NEMA1 = 1. Will reset to 0 when default is selected

6-2

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

F_02

OPERATION COMMAND

0/1*

Selection of the input method for operation commands

Operation command input using the keypad

(RUN and STOP keys)

Operation command input by means of the

external signal terminal (FWD, REV). STOP key on

the keypad is active.

Operation command input by means of the

external signal terminal (FWD, REV). STOP key on

the keypad is inactive.

If selection "1" is chosen, and the stop button is depressed

while the drive is running, the drive will perform the

normal stop sequence until when the output frequency

reaches zero at which point an "Er6" fault shall be

indicated on the LED.

NOTE: To change the Operation Command Setting

the following three conditions must be met:

1. Remove jumper between CM to FWD

2. Open between CM to FWD and CM to REV

3. F_43 = 3 for Three Wire Control cannot be selected.

F_03

MAXIMUM FREQUENCY

Maximum operating frequency can be set within

the range of 50 to 400 Hz in steps of 1 Hz.

400

WARNING: Prior to operating a motor above its base

frequency, you must review the operational capabilities

of the motor. Failure to do so could result in severe

damage to the motor and could result in injury to

personnel.

F_04

BASE FREQUENCY 1

400

The range is 15 to 400 Hz in steps of 1 Hz.

Normally set to the rated nameplate frequency

of the motor.

NOTE: If the Base Frequency is greater than the

Maximum Frequency, the output voltage will not

rise to the rated voltage. Set so that the ratio

between the Base Frequency and the Maximum

Frequency is less than 1:8.

*Default Value = 0

Factory Setting for NEMA 1 = 1

Setting will reset to 0 when default is

selected

6-3

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LED

Data

Factory

Setting

Customer

Setting

Display

Setting

Description

F_05

MAXIMUM OUTPUT VOLTAGE

230

This sets the maximum output voltage for the

Drive in steps of 1V (230V/240V▲) and 2V (480V).

230/240 ▲

160

480

460

NOTE: The output voltage cannot be higher than the

voltage input from the power supply.

*F_06

*F_07

ACCELERATION TIME 1

DECELERATION TIME 1

6.0

0.01

3600

The time from start to maximum frequency

(acceleration) and from maximum frequency to stop

(deceleration) can be set within the range of 0.01

to 3600 seconds. Set values according to the load

characteristics for Wk².

Setting Range

0.00* to 9.99s

10.0 to 99.9s

100 to 999s

Setting Step

0.01s

0.1s

* When set to 0.00

the time becomes

0.01 seconds.

1,000 to 3,600s

10s

*F_08

TORQUE BOOST 1

Torque boost can be set to optimize the V/Hz

characteristics of the Drive according to the type of

load the motor will see. Set only high enough to

develop sufficient low frequency torque; too high of a

value will cause diminished performance and

excessive motor heating.

Torque boost is automatically controlled.

Squared torque characteristics

(for fans and pumps)

Proportional torque characteristics

(Weak)

(Strong)

▲ 240V is for single phase input only.

6-4

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

*F_09

FMA (Analog Meter) VOLTAGE ADJUSTMENT

This function adjusts the full scale voltage level of

the analog voltage signal from the FMA terminal.

0: Approx. 6.5V

The value can be adjusted to one

of 100 settings within this range.

99: Approx.10.5V

NOTE: This function is only active if F_40 = 0 (FMA

terminal output).

Select the type of signal output from the FMA

terminal by means of F_41 (FMA terminal function

selection).

*F_10

MOTOR POLES

This sets the number of poles of the motor being used

for synchronous speed display.

2 : 2 poles

4 : 4 poles

6: 6 poles

8: 8 poles

10 : 10 poles

12 : 12 poles

Example: If running a 4-pole motor at 60 Hz, the

display will be 120 x 60 ÷ 4 = 1800.

If running a 4-pole motor at 50 Hz, the display will

be 120 x 50 ÷ 4 = 1500.

*F_11

0.01

200.0

LINE SPEED DISPLAY COEFFICIENT

This sets the display coefficient for displaying the

line speed [m/min.]

0.01

Display value [m/min.]= Output frequency [Hz] x

display coefficient

Display Coefficient

Setting Range

Setting Step

0.01 to 9.99

0.01

0.1

10.0 to 200.0

*F_12

MOTOR SOUND ADJUSTMENT

(Carrier Frequency)

This adjusts the carrier frequency of the Drive

within the range of 0.75 to 15 kHz. The acoustic

and electromagnetic noise generated by the motor

increases as the carrier frequency is decreased.

If set to 0, the carrier frequency will be set to 0.75

kHz (maximum noise). The adjustment from 1 to

15 kHz can be carried out in 1 kHz steps.

NOTE: The higher the carrier frequency, the

greater the adverse affects on the motor

insulation.

6-5

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

F_13

NUMBER OF RESTART ATTEMPTS

This sets the number of times the Drive automatically

tries to restart after a trip caused by overcurrent or

overvoltage within the range of 0 to 10 times

with F_14 = 4 or 5.

Iftheretryfunctionhasbeenactivatedandatripoccurs,

theDrivewillrestartautomaticallydependingonthe

causeofthetrip.

Makesurethatthesystemissetupproperlysothat

therewillbenodangertopersonnelwhenthe

Drivestarts,otherwiseaccidentsmayoccur.

F_14

RESTART AFTER MOMENTARY POWER FAILURE

(Operation Selection)

This sets the operation mode when a momentary power

failure occurs and when power is restored.

Alarm LU activates, drive output immediately ceases.

If power outage is lengthy and AC power is reapplied

with a run command present, error "Er6" will occur.

Also, resetting of faults while a run command is

present shall not be allowed.

Drive output immediately ceases, alarm LU activates

upon power recovery. If power outage is lengthy and

AC power is reapplied with run command present,

error "Er6" will occur. Also resetting of faults while a

run command is present will not be allowed.

Alarm LU does not activate, drive output creases

(i.e. motor coasts) awaiting reapplication of power. If

power outage is momentary, drive output resumes at

frequency at the time of power failure. If, however,

output is lengthy and AC power is reapplied with a

run command present, error "Er6" will occur. Also

resetting of faults while a run command is present

shall not be allowed.

Alarm LU does not activate, drive output caeses

(i.e. motor coasts) awaiting reapplication of power.

If power outage is momentary drive output resumes

at frequency = 0. If, however, output is lengthy and

AC power is reapplied with a run command present,

error "Er6" will occur. Also resetting of faults while

a run command is present shall not be allowed.

Alarm LU does not activate, drive output ceases

(i.e. motor coasts) awaiting reapplication of power.

If power outage is momentary the same behavior as

setting of "2" occurs. If power outage is lengthy and

AC power is reapplied with a run command present,

the drive will start up normally. Resetting of faults is

allowed even if a run command is present.

Alarm LU does not activate, drive output ceases

(i.e. motor coasts) awaiting reapplication of power.

If power outage is momentary the same behavior as

setting of "3" occurs. If power outage is lengthy and

AC power is reapplied with a run command present,

the drive will start up normally. Resetting of faults is

allowed even if a run command is present.

If restarting (data 4 or 5) is

selected for the restart after

momentary power failure

function, the drive will restart

after power is restored

6-6

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

F_15

ELECTRONIC OVERLOAD 1

The Drive's Electronic Overload can be selected to

help protect the motor from thermal overload due to

various operating conditions. Selection should be

based on operating conditions, type of load, motor

thermal characteristics, applicable NEC and

local electrical code requirements.

The motor thermal characteristics and the diagram

shown in Function Code 16 should be reviewed.

Their characteristics should be coordinated to determine

what is the protection level available with the Drive/motor

combination, and what additional protection will be

required (Refer to Function Code 16).

Inactive (External motor thermal overload device)

Active (Review motor thermal characteristics)

Special factory setting for forced air cooled motor.

(Consult Motor Manufacturer)

1) For a standard 4-pole motor

Drive frequency (Hz)

2) For a special design motor

Drive frequency (Hz)

6-7

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

F_15

(cont'd)

Electronic Overload operation

characteristics

1) For a standard 4-pole motor

2) For a special design motor

F_16

0.01

ELECTRONIC OVERLOAD LEVEL

Rated

99.9

The level for the electronic overload protection

algorithm (see Function Code 15) can be adjusted

from the factory default setting of rated Drive nameplate

amps. The setting range is approximately 20 to 105%

of rated Drive current.

Current (A)

(Std. 4-Pole Motor)

or more

6-8

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

F_17

DC BRAKE (Operation Selection)

This selects the DC brake operation to active or inactive

Inactive - (Regenerative braking only)

Active - (DC braking after regenerative braking)

*F_18

*F_19

0to60

DC BRAKE (Starting Frequency)

Sets the frequency to start DC injection brake

operation during deceleration.

0 Hz

50%

0to100

DC BRAKE (Brake Level)

Sets the output braking level (brake output) for the DC

injection brake. The braking strength will

vary depending on the characteristics of the motor.

*F_20

0.00to30

DC BRAKE (Braking Time)

Sets the operation time for the DC injection brake.

0.5s

Starting Range

Unit Setting Step

1 Hz

Starting Frequency

Braking Level

0¹to 60

0 to 100

0.01

0.1

0.00 to 9.99

10.0 to 30.0

Braking Time

¹If the data is set to "0", the frequency will be 0.2 Hz.

Operating

Speed

Operating

Speed

Time

→

TheDrivebrakingfunctioncannotbesubstituted

formechanicalmeans.Attemptingtodosomay

resultininjury.

6-9

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

*F_21

*F_22

*F_23

*F_24

*F_25

*F_26

*F_27

MULTISTEP FREQUENCY #1

5.00Hz

10.00Hz

20.00Hz

30.00Hz

40.00Hz

50.00Hz

60.00Hz

MULTISTEP FREQUENCY #2

MULTISTEP FREQUENCY #3

MULTISTEP FREQUENCY #4

MULTISTEP FREQUENCY #5

MULTISTEP FREQUENCY #6

MULTISTEP FREQUENCY #7

These Functions set the frequency for multistep

frequency operation. The frequencies are selected as

shown in the table below by setting control terminals

X1-CM, X2-CM and X3-CM to ON/CLOSED.

[Relationship between terminals and multistep

frequencies1-7]•=ON/CLOSED

Function

Multistep Speed Speed Speed Speed Speed Speed Speed Speed

Frequency

X1 – CM

X2 – CM

X3 – CM

•

(1) Speed 0 (when X1-CM, X2-CM and X3-CM are all

OFF/OPEN) depends on the frequency setting method

selected by means of function F_01. In other words, the

setting becomes digital (using the

and

keys) or

analog ([0 to 10VDC] or [4 to 20mA VDC]).

(2) The actual operation frequency is limited by the maximum

frequency F_03 and the frequency limiters F_36 and F_37.

6-10

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

F_28

S-CURVE ACCELERATION/DECELERATION

(Operation Selection)

Selects whether S-curve acceleration/deceleration

is active or inactive and which of the two S-curve

patterns is used.

Inactive - linear acceleration and deceleration (Fig. 1)

S-curve acceleration/deceleration (weak) Fig.2

S-curve acceleration/deceleration (strong) Fig. 3

NOTE:

➀ Shocks at the start and end of acceleration and

deceleration can be softened by selecting a S-curve

pattern.

➁ The maximum gradient in the output frequency

when a S-curve pattern is selected is the same as

for linear acceleration and deceleration time.

➂ The actual acceleration and deceleration times when

a S-curve pattern is selected is extended by 10%

(when 1 is set) or 20% (when 2 is set) from the times

set by F_06 and F_07 or by F_63* and F_64*.

* Alternate acceleration (F_63) and deceleration (F_64)

times are selected when the terminal X4 function is set so

that F_43 = 0 and X4-CM is ON/CLOSED.

6-11

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

*F_29

PROTECTION HISTORY/FAULT MEMORY

The Last 4 drive faults are displayed in order

– –

–

when the

key is pressed.

Operation Procedure

Contents of the

last trip are

displayed.

Contents of the

second-last trip

are displayed.

Contents of the

third-last trip

are displayed.

Contents of the

fourth-last trip

are displayed.

This example

shows there is no

trip history for this.

F_30

0to15

STARTING FREQUENCY

1 Hz

This sets the starting frequency within the range of 0 to

15Hz in 1Hz steps.

If the data is set to 0, the frequency will be 0.2Hz.

*F_31

TORQUE LIMIT

(During Acceleration/Deceleration)

Sets the Torque Limit level during acceleration/

deceleration in steps of 1%.

No limit

20%

Limit

180

180%

*F_32

TORQUE LIMIT

(At Constant Speed)

This sets the torque limit level during constant speed

operation in steps of 1%.

No limit

20%

Limit

180

180%

Ifthetorquelimitfunctionhasbeenselected,theDrivemay

startrunningwithdifferencesintheacceleration/deceleration

timeandspeedsettings.Makesurethatthesystemissetup

properlysothattherewillbenodangertopersonnelwhenthe

Drivestarts,otherwiseaccidentsmayoccur.

6-12

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

F_33

BRAKING TORQUE SELECTION

This sets the limit level for braking torque in accordance

with the brake being used.

Low (no Dynamic Braking option)

High (with Dynamic Braking option)

NOTE: Always connect an extra braking resistor. Contact

GE Fuji Technical Services for proper brake

resistor option selection.

*F_34

-400

BIAS FREQUENCY

+400

This function adds the bias frequency offset to the analog

reference frequency to produce the output frequency.

The setting range is between -400 to +400Hz in

steps of 1Hz.

*The bias frequency is only active when the frequency

setting function F_01 = 1

Ifthebiasfrequencyhasbeenset,theDrivewilloperate

whenanoperationcommandisgiven,eveniftheanalog

frequencyiszero.

6-13

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

*F_35

0.00

250

GAIN FOR FREQUENCY SETTING SIGNAL

This sets the size (gradient) of the output frequency

corresponding to the analog frequency setting as a

percentage of the maximum frequency.

100.0%

[Example:for70%gain]

[Examplefor200%gain]

*ThegainsettingisonlyactivewhenF_01=1

Example:

If the bias frequency function (F_34) and the gain for

frequency setting signal function (F_35) are used together,

the gain for frequency setting signal has priority, and the

bias is applied to the frequency with gain already applied.

The bias frequency f^biasand setting frequency gain at

this time can be calculated by the following formulas.

f¹– f2

fbias = f1 –

x V1

V1 – V2

1000 x (f1 – f2)

100 x (V1 – V2) + f1 x V2 – f2 x V1

Gain =

Example:

If the analog frequency setting voltage is 1 to 5Vdc

and the output frequency is weighted to 0 to 100% then:

(V¹, f1) = ( 1, 0) , (V2, f2) = ( 5,100), so that

[V] [%]

fbias = –25% and gain = 200%

6-14

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LED

Data

Factory

Setting

Customer

Setting

Display

Setting

0to400

Description

*F_36

*F_37

HIGH FREQUENCY LIMITER

70 Hz

0 Hz

LOW FREQUENCY LIMITER

The high and low limits for the output frequency can be

set within a range of 0 to 400Hz in stages of 1Hz.

NOTE:

If the high and low limit settings are reversed, the high

limit has priority and the low limit is ignored.

*F_38

0to10

MOTOR CHARACTERISTICS

This adjusts the output current in cases where there is

an irregularity such as current fluctuation. If a current

fluctuation occurs, adjust the setting value while

referring to the tables below.

Number of Higher

Motor Poles

Lower

Load High

Setting

Low

Setting

F_39

DATA INITIALIZATION

This resets all Function Codes to factory settings.

Inactive (manual setting)

Initial values (Initialization with factory defaults)

[Operation Procedure]

➀ When 0 is being displayed, press the STOP +

keys simultaneously to change the display to 1.

FUNC

DATA

➁ In this condition, press the

key to reset

all data to the factory default settings. The display

will then automatically switch to show the frequency

setting for STOP mode.

6-15

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

F_40

FMA, FMP TERMINALS

(Operation Selection)

This switches the output destination for the external

monitoring signal.

Analog signals are output from the FMA terminal.

(TheFMPterminalcannotbeused.)

The type of analog signal output to the FMA terminal is

selected by function F_41.

Pulse signals are output from the FMP terminal.

(TheFMAterminalcannotbeused.)

Frequency of pulse signal output to the FMP terminal is

adjusted by function F_42.

F_41

FMA TERMINAL

(Function selection)

This sets the type of analog signal which is output

to the FMA terminal.

Output frequency: 0 to 100% full scale

Output current: 0 to 200% full scale

Output torque: 0 to 200% full scale

Output power: 0 to 200% full scale

*F_42

1to100

FMP TERMINAL

(Pulse Rate Multiplier)

This sets the pulse rate multiplier for the pulse signal

frequency output to the FMP terminal with respect to

the Drive output frequency. The setting range is

1 to 100.

FMP terminal pulse frequency = Drive output frequency X [Pulse rate multiplier]

6-16

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

F_43

X4 TERMINAL FUNCTION

The function for the X4 input terminal can be selected from

the following four options.

Functions as a command input terminal X4 for

switching to acceleration/deceleration time 2.

The acceleration time 2 and deceleration time 2 are set

by F_63 and F_64.

Enables the use of multistep frequency settings 8 to 15.

Frequencies 8 to 15 are set by means of F_44 to F_51.

Functions as a command terminal X4 for switching

to base frequency 2 when using a second motor, etc.

When base frequency 2 is selected, acceleration/

deceleration time 2, torque boost 2 and electronic

overload 2 are selected simultaneously.

Base frequency 2 is set using function F_62, acceleration/

deceleration time 2 are set by function F_63 and F_64,

torque boost 2 is set by function F_65, and electronic

overload 2 is set by F_66 and F_67.

Functions as a hold signal (HLD) for operation commands

during 3-wire control operation.

*F_44

*F_45

*F_46

*F_47

*F_48

*F_49

*F_50

*F_51

MULTISTEP FREQUENCY SETTING 8

MULTISTEP FREQUENCY SETTING 9

MULTISTEP FREQUENCY SETTING 10

MULTISTEP FREQUENCY SETTING 11

MULTISTEP FREQUENCY SETTING 12

MULTISTEP FREQUENCY SETTING 13

MULTISTEP FREQUENCY SETTING 14

MULTISTEP FREQUENCY SETTING 15

0.00

0to400

These set the 8 multistep frequencies from frequency 8 to

frequency 15 within the range of 0 to 400Hz.

The setting step is the same as for functions F_21 through

F_27.

(Relationship between terminals and multistep frequencies

8 through15)•=ON/CLOSED.

Function

Multistep Speed Speed Speed Speed Speed Speed Speed Speed

Frequency

X1 – CM

X2 – CM

X3 – CM

X4 – CM

•

NOTE: These functions are only active when F_43 = 1 (X4).

6-17

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LED

Data

Factory

Setting

Customer

Setting

Display

Setting

0.02to5.0

Description

*F_52

FREQUENCY SETTING SIGNAL FILTER

This Function Code is used to set the time constant

for the input filter in order to eliminate the effects of

noise present in the analog signals (voltage and current

references). If the time constant set point is too long,

the response to changes in analog commands

will become inadequate for the required performance

level. Adjustable from 0.02 to 5.00 seconds in 0.02

increments.

.06s

F_53

TIMER (AUTOMATIC RUN/STOP CYCLE)

This sets the timer to active or inactive, and also sets

the time from the start of operation until operation

automatically stops (when the timer is active).

Inactive (Normal Operation)

0.00s

001to

3600

Active (0.01 second)

Active (3,600 seconds)

Setting Range

0.00 to 9.99

10.0 to 99.9

100 to 999

Setting Step

Unit

0.01

0.1

second

(s)

1000 to 3600

RUN LED

Lit

To restart the cycle, the closed FWD(REV)-CM has to

be opened and then re-closed. F_02 = 1.

When FWD (REV)-CM is opened during timer operation,

the timer is cleared.

When power failure occurs during timer operation, the

timer is cleared.

6-18

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

F_54

Y1 TERMINAL FUNCTION

(Function Selection)

This selects the output signal for the Y1 terminal from

the following 6 types:

Drive running state (RUN)

Frequency level detection (FDT)

Y1-CM is ON when the frequency detected is

identical to the frequency set by function F_55.

The hysteresis is set by function F_56.

Frequency equivalence signal (FAR)

Y1-CM is ON when the frequency reaches the frequency

set by the keypad panel, analog input, multistep

frequency setting etc.

The hysteresis is set by function F_56.

Under-voltage stop mode (LV)

Torque limiting mode (TL)

Auto-restart mode after momentary input power failure (IP)

*F_55

0.00to400.0

FREQUENCY LEVEL DETECTION

0.00 Hz

(FDT Operation Level)

This sets the operation level for frequency detection signal

(FDT) output within the range of 0.00 through

400.0 Hz (depends on F_03 setting). F_54 = 1

Setting resolution:

Setting step

0.01

Unit

Setting range

0.00 to 99.99

100.0 to 400.0

0.1

6-19

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LED

Data

Factory

Setting

Customer

Setting

Display

Setting

0to30

Description

HYSTERESIS WIDTH

*F_56

0 Hz

This sets the hysteresis for the frequency detection signal

(FDT) and frequency equivalence signal (FAR) within the

range of 0-30 Hz.

The FAR is in the middle of the hysteresis width. F_54 = 2

FDT

HYSTERESIS

FAR

→

FDT

HYSTERESIS

FAR

SIGNAL

OFF

(Y1-CM)

F_57

THR TERMINAL

(Function Selection)

This sets the function for the THR input terminal.

Used for THR functions (Trip Command Functions)

Used for Edit Permit Commands

THR-CM off: Function data change not possible.

THR-CM on: Function data change possible.

The relationship between this function and function F_00

(Data protection) is shown in the table below:

F_57

F_00

Data changing

possible

Edit permit command Data protection

0 (OFF)

1 (ON)

Yes

6-20

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

*F_58

*F_59

*F_60

*F_61

0to30

JUMP FREQUENCY (Hysteresis)

JUMP FREQUENCY 1

JUMP FREQUENCY 2

JUMP FREQUENCY 3

3 Hz

0 Hz

0to400

This sets the three midpoints and the hysteresis for the

jump frequencies which are used to prevent vibration

from occurring at certain frequencies due to mechanical

resonance between the load and the motor.

[Jump frequency 1] The midpoints for the frequencies

[Jump frequency 2] to be jumped can be set in steps

[Jump frequency 3] of 1 Hz.

NOTE:

- If jump frequencies have been set, they will be

ignored during acceleration and deceleration.

- If a jump frequency is set to zero, the jump function

becomes inactive.

F_62

15to400

BASE FREQUENCY 2

60 Hz

This sets Base Frequency 2 to within a range of 15 to

400 Hz in steps of 1 Hz. It is used when the terminal

X4 has been set to function as a command terminal

for switching to Base Frequency 2 (F_43 = 2 ).

NOTE: If the Base Frequency is greater than the

Maximum Frequency, the output voltage will not rise to

the rated voltage. Set the ratio between the Base

Frequency and the Maximum Frequency to less than 1:8.

*F_63

*F_64

0.00to3600

ACCELERATION TIME 2

DECELERATION TIME 2

10.0 s

This sets the acceleration time 2 and deceleration time 2

when terminal X4 has been set to function as a command

input terminal for switching to:

acceleration/deceleration time 2 (X4: F_43 = 0) or to

base frequency 2 (F_43 = 2).

Setting details are the same as for function F_06 and

F_07.

6-21

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LED

Data

Factory

Setting

Customer

Setting

Display

Setting

Description

TORQUE BOOST 2

This sets the torque boost 2 to one of 31 patterns when

terminal X4 has been set to function as a command input

terminal for switching to base frequency 2 (F_43 = 2).

Setting details are the same as for function F_08.

*F_65

NOTE: For manual torque boost only; no pattern can be

selected for automatic torque boost.

F_66

F_67

SeeF_15

SeeF_16

ELECTRONIC OVERLOAD 2

(Operation Selection)

ELECTRONIC OVERLOAD 2

Rated motor

Current

(Std. 4

(Operation Level)

When terminal X4 has been set to function as a

command input terminal for switching to base frequency 2

(F_43 = 2), this sets the electronic overload

to 2 (motor overload detection) for the second motor

to active or inactive, and also sets the operation pattern

and the operation level.

Pole

Motor)

Setting details are the same as for function F_15 and F_16.

NOTE: Base frequency 2, torque boost 2 and electronic

overload 2 are only active when the X4

terminal function has been set to F_43 = 2 and

X4-CM is ON/CLOSED.

*F_68

0.0to5.0

SLIP COMPENSATION

0.0 Hz

Functions to suppress fluctuations in the motor speed

which result from variations in the load torque.

The slip frequency with respect to the base frequency

during rated load output (100%) can be set within the

range of 0.0 to 5.0 Hz in steps of 0.1 Hz.

If the slip compensation value is set to 0.0 Hz, then the

slip compensation function will be inactive.

6-22

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

F_69

TORQUE VECTOR CONTROL

This selects whether Torque Vector Control is active

or not.

Torque Vector Control inactive

Torque Vector Control active

NOTE: Torque Vector Control does not function if

is selected when the X4 terminal function has been set

to (F_43 = 2) and X4-CM is ON/CLOSED. The manual

torque boost selected by F_65 will apply.

NOTE:ForbestresultsperformAutoTuningFunction

(F_74)priortoactivationofTorqueVectorControl.

F_70

MOTOR HP CAPACITY

This sets the HP capacity of the motor which is connected

in relation to the Drive capacity.

1-frame up capacity for standard applied motor

Standard capacity for standard applied motor

1-frame down capacity for standard applied motor

2-frame down capacity for standard applied motor

F_71

F_72

0.00

99.9

MOTOR 1 RATED CURRENT

MOTOR 1 NO-LOAD CURRENT

These set the rated current (A) and no-load current (A)

for the motor which is connected to the Drive.

4-pole

(Std.

Design B)

EXPLANATION: Theprimaryresistance(R₁)and

leakage reactance (X₁) are automatically rewritten

with the rated value of the motor capacity (F_70),

motor 1rated current F_71 and motor 1no-load

current (F_72) are set.

F_73

0.00

99.9

MOTOR 2 RATED CURRENT

This sets the rated current (A) for the second motor which

is selected when base frequency 2 (F_62) is active.

Rated

Current

(Std. 4-Pole

Motor)

6-23

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

F_74

AUTOMATIC TUNING

This function is used to automatically tune the primary

resistance (R1) and leakage reactance (X1) of the motor

in order to achieve optimum performance of F_69

(Torque Vector Control).

Inactive

Automatic tuning

[Operation procedure]

➀ Connect the motor and the Inverter correctly.

➁ Set the data for this function to "1" while the Inverter is

stopped.

➂ Press the

FUNC

DATA

key.

➯➯ Tuning operation (approx. 10 seconds) ➯➯ F_75

→The display changes when tuning is completed.

➃ The results of tuning can be confirmed using F_75 (R1)

and F_76 (X1).

F_75

0.00to50

MOTOR 1 (%R1 Setting)

Std. 4-Pole

motor

▲

This function displays the primary resistance R1 of the

motor in terms of percentage, and is set manually.

The data can be overwritten and changed automatically by

automatic tuning using function F_74, or by setting the

motor capacity, rated current and no-load current using

functions F_70 to F_72.

Calculation Formula for %R1

R1 + cable R

%R1

x 100 [%]

▲

V / ( 3 • I)

R1: Motor resistance

Cable R: Resistance of cable between Drive and motor

V: Rated voltage of motor

I: Rated current of motor

▲ : Value calculated for Y connection

6-24

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LED

Data

Display

Factory

Setting

Customer

Setting

Description

F_76

0.00to50

MOTOR 1 (%X Setting)

This function displays the leakage reactance X1 of the

motor in terms of percentage, and is set manually

Std. 4-pole

motor

▲

The data can be overwritten and changed automatically

by automatic tuning using function F_74, or by setting

the motor capacity, rated current and no-load current

using functions F_70 to F_72.

Calculation Formula for %X1

X1 + X2 = Xm/ (X2 + Xm) + cable X

%X1 =

▲

x 100 [%]

V / ( 3 • I)

X1: Primary inductance of motor 1[Ohm]

X2: Secondary inductance of motor 1 [Ohm]

Xm ▲ : Mutual inductance of motor 1 [Ohm]

Cable X: [Ohm]

V: Rated voltage of motor

I: Rated current of motor

: Value calculated for Y connection

▲

%R1and%X1shouldbesettovalueswhichareappropriate

forthemotorbeingused.Themotormaynotoperate

correctlyifthesevaluesarenotsetcorrectly,whichcould

resultinaccidents.

*F_77

*F_78

000to999

TORQUE LIMITING RESPONSE

(At Constant Speed)

TORQUE LIMITING RESPONSE

(During Acceleration/Deceleration

369

394

(Quick)

0 0

(Slow)

9 9

000

999

0 (Low)

9 (High)

P – Represented by the Hundreds Digit (Gain Value)

I – Represented by the Tens and Units Digit (Time Constant)

F_79

OPTION SELECTION

This function sets whether an option is being used or

not, and also what type of option is being used if any.

No Options

DI option card used

DI/O option card used

RS option card used

NOTE: For details on setting specifications when

using an option card, refer to the instruction

manual which is supplied with the option card.

6-25

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Section 7

MAINTENANCE and INSPECTION

To prevent potential problems and provide long periods of trouble-free operation, the following checks should be

periodically conducted.

CAUTION: Do not conduct any inspections until after disconnecting

the power supply and after the “CRG” light on the Drive has gone out.

MEGGER TEST

1. Disconnect all Drive terminals and never apply test voltage to the Drive when conducting an external circuit

megger test. Use a 250 VDC megger for 230/240V input Drives and a 500VDC Megger for 480V input Drives.

2. Perform the test only on the main circuit as shown in Figure 7-1 when conducting a megger test on the Drive itself.

— Do not conduct a megger test on the control circuits.

— Short L1, L2, L3, U, V, W, P1, P(+), and DB, then megger to the Drive ground terminal E(G).

3. Use a high resistance range type tester to conduct a continuity test on the control circuits and not a megger or

a buzzer.

PERIODIC PARTS REPLACEMENT

The life of the Drive will vary according to the installation environment and the amount of running time. However, if

continuous operation is within the allowable limits, the life of the DC Link capacitor is approximately five years and

the life of the cooling fan is approximately three years. It is recommended that these parts be replaced before failure

occurs.

MEGGER TEST OUTLINE

•

AC Induction

Motor

P1 P(+) DB

•

IF SINGLE PHASE

}

POWER

–

MEGGER

–

•

E (G)

GROUND

Figure 7-1. MAIN CIRCUIT MEGGER TEST CONNECTIONS

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INSPECTION ITEMS

Refer to the Inspection Items Chart in this section for inspection points and corrective action.

INSPECTION ITEMS CHART

Item

Inspection Criteria

Corrective Action

Power Supply Within permissible limits (170-264 Vac)

Adjust the power supply voltage.

Voltage

for 1 Phase 240 VAC Drives; (170-253)

for 3 Phase 230 VAC Drives; and

(323-528) for 3 Phase 480 Vac Drives.

Ambient

Temperature

Within permissible limits (-10° to +50° C)

(+14° to +122°F.)

Investigate cause and make corrections

until environment is within permissible limits.

Ambient

Humidity

Within permissible limits (20 - 95% RH)

No dew condensation or freezing.

Investigate cause and make corrections

until environment is within permissible limits.

Vibration

Noise

Odor

Within permissible limit (0.6G or less)

until within permissible limits.

Investigate cause and make adjustments.

Abnormal audio noise from cooling

fan, etc.

Contact the supplier where the Drive

was purchased.

Smell or burning.

Contact the supplier where the Drive

was purchased.

Dust

Dust accumulation on cooling fins,

cooling fan, or on the control board.

Clean and blow out with dry and filtered

compressed air.

Screws/

Check for any loosening.

Re-tighten as needed.

Connectors

7-2

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MEASUREMENT POINTS AND METERS

Since the Drive's input/output voltage and current contain high frequencies, selection of the wrong measuring device

canleadtogrossmiscalculations. WhenusingaCT(current-detectiontransformer)tomeasurethecurrent,theamount

of error will be large if the frequency is low. Because of this, always use a CT with as large a capacity as possible. See

the following chart and Figure 7-2 for recommended measurement devices.

RECOMMENDED MEASUREMENT DEVICE CHART

Item

Simple Measurement Precision Measurement

Input Voltage

Input Current

Input Power

Tester - (Voltmeter)

Clamp Meter

—

Moving-Iron type voltmeter

Moving-Iron type ammeter

Electrodynamometer type wattmeter

Rectifier type voltmeter

Output Voltage

Output Current

Output Power

Tester - (Voltmeter)

Clamp Meter

—

Moving-Iron type ammeter

Electrodynamometer type wattmeter

Figure 7-2. MEASUREMENT LOCATIONS AND DEVICES EXAMPLE

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Section 8

TROUBLESHOOTING

TABLE 8: Fault Condition Description and Operation

The following Drive protection functions have been incorporated in the basic Drive software and will be indicated in the

LED display. Use F_29 to check fault history.

Protective

Function

LED

Display

Function Explanation

Protective Operation

Protects the Drive if

• Drive output frequency drops to 0.0 Hz

• Motor coasts to a stop

OC1,

OC2,

OC3

Overcurrent

protection

During

Acceleration

During

Deceleration

OC1

OC2

OC3

the Drive output

current momentarily

exceeds the

overcurrent detection

level. Protects the

Drive from

overcurrent resulting

from an output phase-

to-phase or phase-to-

ground short circuit.

• Alarm terminals 30A, 30B, and 30C

are activated

• Alarm signal is maintained internally

Short circuit,

Ground fault

During

constant

speed

until alarm reset command is given¹⁾

operation

Momentary

power failure

• Drive output frequency drops to 0.0 Hz

If the "restart after momentary power

failure" mode is selected, operation

will restart automatically when power

is restored.

Avoids loss of control of the Drive

caused by drops in the power supply.

NOTE: Operation will continue if the

momentary power failure or under-

voltage period is less than 15 msec.

Undervoltage

protection

Protects the Drive if

During

• Drive output frequency drops to 0.0 Hz

• Motor coasts to a stop

OU1,

OU2,

OU3

Overvoltage

protection

OU1

OU2

OU3

momentary

Acceleration

overvoltage

• Alarm terminals 30A, 30B, and 30C

are activated

During

Deceleration

(regenerative

overvoltage) exceeds

the overvoltage

detection level.

• Alarm signal is maintained internally

until alarm reset command is given¹⁾

During

constant speed

operation

Detects overheating of the Drive

caused by an overload, cooling

fan problem or abnormal ambient

temperature.

• Drive output frequency drops to 0.0 Hz.

• Motor coasts to a stop

OH1,

OH2,

Drive

overheating

OH1

OH2

• Alarm terminals 30A, 30B, and 30C

are activated

• Alarm signal is maintained internally

Acts as an external alarm to stop

output. If protective device such

as the overload relay is connected

between THR and CM terminals

switches from ON to OFF.

External alarm

input

until alarm reset command is given¹⁾

• Drive output frequency drops to 0.0 Hz.

• Motor coasts to a stop

OL,

OLU

Protects semiconductor devices

such as the IGBT from overloads.

Electronic

overload

OLU

• Alarm terminals 30A, 30B, and 30C

are activated

Protects a standard 4-pole motor

or a forced air cooled motor from

overloads even if an overload

relay is not connected.

• Alarm signal is maintained internally

until alarm reset command is given¹⁾

Er1,

Er2,

Er3,

Er4,

Er5,

Er6,

Er7

• Drive output frequency drops to 0.0 Hz.

• Motor coasts to a stop

Operates when a memory error

occurs due to a data writing error,

Memory Error

Er1

Er2

• Alarm terminals 30A, 30B, and 30C

are activated

Displayed when a communication

error occurs between the Drive

and the keypad panel.

Communication

Error ²⁾

• Alarm signal is maintained internally

until alarm reset command is given¹⁾

Stops the Drive when an error is

detected in the CPU.

CPU error

Er3

Er4

Displayed when there is a

communication "checksum error"

or interruption of communication

between the Drive and the option

circuit board.

Optional

circuit board

communication

error

Displayed when a link error etc. is

detected.

Option

problem

Er5

Er6

Operating

Proc. error

Detects Drive operating procedure error

during Drive startup. FWD or REV

connected to terminal CM at time of main

power being applied to Drive.

Stop keypad in remote operation

Output wiring

error

Stops the Drive when it is

detected that the output wiring is

not connected during automatic

tuning.

Er7

NOTE 1

NOTE 2

Alarm signal hold

When a protection function has been activated and the alarm signal is output; if an AC contactor provided on the

power supply side is switched off, and the Drive's control power is not supplied, the alarm signal will not be

retained.

During external terminal operation (F02=1), the Drive will continue running without an alarm being tripped even if

error Er2 is displayed. If communication is restored, the Er2 display will disappear, and normal operation will

resume.

8-1

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TROUBLESHOOTING

If the function of the Drive is lost by a failure or if an abnormal condition has occurred, refer to the following diagnosis

for its probable cause.

If the cause does not fall under the following explanation, or if the Drive is damaged, please contact GE Fuji Technical

Services for assistance.

( 1 ) Overcurrent

Overcurrent

during

Overcurrent

during

Overcurrent at

constant speed

acceleration

deceleration

O C 2

O C 3

O C 1

Repair

short-circuit

and/or

Yes

Is motor circuit (U,V, W) of motor shorted or grounded?

grounding.

Reduce the

torque boost

setting

Is the load too large?

Reduce the

load fluctua-

tion or use a

Drive with

higher

Yes

There is the

possibility of

failure in the

Drive or a

noise problem.

Contact GE

Fuji Electric

Is the

deceleration

Does the load

change

suddenly?

Is the torque

boost setting

correct?

Can the torque

boost setting

be reduced?

capacity.

time setting

too short for

the load?

Yes

There is a

Reduce the

load

fluctuation

or use a Drive

with higher

capacity.

Is the

possibility of

Drive failure

or a motor

noise problem.

Contact GE Fuji

Electric.

acceleration

time setting too

short for the

load?

Can the

Yes

deceleration

time be

increased?

Yes

Increase the

setting time.

Can the

acceleration

time be

Yes

Increase the

setting time.

increased?

Review the system

application.

Reduce the

load fluctua-

tion or use a

Drive with

higher

Contact GE Fuji

Electric.

capacity.

8-2

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( 2 ) Overvoltage

O U

The power

supply

voltage

should be

corrected.

Is the power supply voltage within the specified limits?

Yes

Will fault take place when the load is removed suddenly?

Yes

Was DC bus voltage above alarm level when alarm occurred?

Possible Drive

failure or

Yes

malfunction due

to electrical

noise. Contact

GE Fuji Electric.

Yes

Increase

Can the deceleration time be

increased?

Does action take place after

rapid acceleration is completed?

the timed

setting

Yes

Can the acceleration time be

increased?

Yes

Decrease until the

failure does not

occur.

Can the load inertia be decreased?

Is a braking resistor installed and activated?

Investigate braking

resistor for correct

connection rating and

control settings.

Yes

Review the control and system application again. Contact GE Fuji

Electric.

8-3

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( 3 ) Undervoltage

L U

Has power failure

(including

momentary power

failure) taken place?

Reset and

continue

operation.

Yes

Has the power

circuit been

subjected to

component failure

or poor power

connection?

Replace the

Yes

defective compo-

nent or repair the

poor connection.

Is the power supply

voltage within the

range of the

specified value?

Yes

Does another load

exist which

requires a large

starting current

within the same

power system?

Investigate the

power system and

correct to satisfy

the system

Yes

specification.

Does the condition

occur when the

circuit breaker

and/or electro-

magnetic

Is the power

transformer rated

at the correct KVA?

Yes

contactor are

turned "ON"?

Yes

Possible Drive

control circuit or

noise related

malfunction.

Contact GE Fuji

Electric.

NOTE 1 – When the DC bus capacitor is discharged by a system power failure and the control

power of the Drive is reduced, automatic restart after momentary power outage may take

place. (Refer to Funtion Code 14 setting.)

8-4

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( 4 ) Drive overheated

– Drive Overheating

– Drive Overload

O H 1

Reduce the load or

use a Drive with

higher capacity.

Yes

Is the Drive load

too large?

Is the cooling fan

in the Drive operat-

ing? (Above 2 HP)

Replace the cooling

fan.

Yes

Is the movement of

the Drive cooling

air obstructed?

Yes

Remove

obstructions.

Possible Drive

Is the ambient

temperature within

the specified limit?

failure or malfunc-

tion due to electrical

noise. Contact GE

Fuji Electric

Bring the ambient

condition to within

the specified limit.

Terminal C1–CM or

12-11 connected in

reverse.

Yes

Connect

correctly.

( 5 ) External alarm input

O H 2

Is the connection

between THR and

CM correct?

Repair the wiring

and/or connections.

Yes

Possible Drive

failure or malfunc-

tion to electrical

noise. Contact GE

Fuji Electric

Is the alarm function

of externally

connected equip-

ment activating?

Yes

Eliminate the cause of

the alarm.

8-5

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( 6 ) Overload

Overload Protection Overload Protection

of Drive Unit

of Motor

O L

O L U

Is the electronic

overload character-

istic correct for the

motor's thermal

overload

Install an external

overload relay in the

motor power circuit.

characteristics?

Yes

Is the electronic

overload set

correctly?

Set to the correct

level.

Yes

Is the load too

large?

Possible Drive

failure or malfunc-

tion due to

Yes

electrical noise.

Contact GE Fuji

Electric.

Reduce the load or

use a Motor and

Drive with higher

capacity.

8-6

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( 7 ) Memory error, keypad communications error, CPU error

Keypad Communications

Memory Error

Er1

CPU Error

Er3

Error

Display abnormal

Er2

Replace the

defective parts.

Er4

Er5

Option Communications

Error

Option Link Error

Turn the power supply

off. Wait until the

Yes

CHARGE “CRG” lamp

goes OFF. Then turn

ON Power Supply.

Are the connectors for

the printed circuit card

and the socket

mounted ICs inserted

properly? Is there any

source of noise close

to the Drive’s control

printed circuit card?

Check for contamina-

tion due to the environ-

ment.

Does data appear on

digital display?

Yes

The Drive is operational.

The Drive failure

should be referred to

Product Service.

Contact GE Fuji

Electric.

8-7

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( 8 ) Drive output circuit error

Er7

Yes

Are terminals U, V and W

not yet connected or open?

Connect or replace the wiring.

Turn BX-CM signal OFF/OPEN.

Is BX-CM signal ON/CLOSED?

Yes

Was an operation com-

mand input or was the

STOP key pressed during

tuning?

Do not operate any key and

control circuit terminal during

tuning.

Is data F_70 and F_71

correct?

Set the correct data.

Yes

Contact GE Fuji Electric.

8-8

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( 9 ) Motor will not run.

The motor

will not run

Has the power

supply circuit

breaker or contactor

been turned on?

Yes

Turn the power

supply circuit

breaker or

Is the CHARGE

"CRG" Lamp on?

Yes

contactor to on.

Check for the

Check the display

Is the digital

display indicating

a protection

Yes

presence of low

voltage, missing

phase, improper

connection, failure

input line circuit

breaker or AC line

contactors.

contents and press

the reset switch

after the failure is

corrected.

Is the voltage of the

power terminal

L1,L2, L3* correct?

function operation?

Yes

When there is no

abnormal condition

continue operation.

Local or remote

operation?

L3* Not supplied on 1 phase drives.

Yes

Remote

Local

Will the motor run if

Keypad RUN key is

pressed?

Is the wiring

No Has FWD or

Yes

Poor contact in

switch or relay.

between FWD, or

REV-CM terminals

connected

REV

command signal

been applied?

correctly?

Yes

Set the frequency

Has the frequency

set signal (0 to

10V or 4 to 20mA)

been input?

by pressing

or key.

key

Is the wiring

between Terminals

13, 12, 11 and C1

connected

Yes

Will the motor run if

Yes

Keypad

correctly?

pressed?

Is high limiter or

frequency set

Yes

signal below the

starting frequency?

Yes

Replace the fre-

quency reference

voltage or current

source and check

for ground in

Set the correct

frequency.

Do the output

terminals (U, V, W)

have applied

voltage?

Possible Drive

failure. Contact GE

Fuji Electric.

reference circuit.

Yes

Correct wiring.

Is the wiring to the

motor connected

properly?

Yes

Release the

lock.

Has the motor

been locked?

Yes

Is the load too

large?

Has the torque

boost value been

correctly set?

Failure in

electric motor.

Decrease the load

or increase the

Drive capacity.

Increase or de-

crease the torque

boost value.

Motor will not run under these conditions:

① BX coast to stop command ON/CLOSED.

➁ Wrong setting at one of F_71, 72, 73, 75, or 76. When F_08 torque boost setting is 00 or F_69 torque vector control is active

while using the wrong capacity motor (F_70, 75, 76.)

8-9

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( 10 ) Motor will run but speed will not change.

The electric

motor will

run but the

speed will

not change.

Is max frequency (F_03)

set too low?

Yes

Are the high limiter (F_36),

and low frequency limiter

(F_37) operating?

Yes

Change or check the setting.

Yes

Keypad

Determine which

frequency method is

active:

Will speed change by

pressing key?

• Keypad (F_ 01) = 0

• Analog (F_ 01) = 1

• Multistep (F_21~F_27)

Analog

Yes

Will frequency setting signal

change (0-10V or 4-20mA)

Multistep

Is the wiring of

multistep frequency

selection terminals

X1, X2, X3 and X4

correct?

Is the wiring between

Terminals 13, 12, 11,

and C1 correct?

Correct wiring.

Yes

Do the set

Replace the frequency

setter, process signal,

or check for ground &

reference circuit.

frequencies of

each selection

step change?

Change the set

frequency.

Yes

Is the setting of the

acceleration and

deceleration time

excessively long?

Possible Drive failure or

malfunction due to

electrical noise. Contact

GE Fuji Electric.

Yes

Change the setting

to the time suitable

for the load.

Motor speed change is very small under these conditions:

① Wrong setting of F_34 bias frequency, F_35 gain for frequency setting.

➁ If using terminal 12, and C1 check polarity inputs to insure they are correct and do not offset.

③ During torque limiting or current limiting with excessive load.

8-10

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( 11 ) Motor will stall during acceleration.

The motor will stall

during acceleration

Yes

Increase the set

time.

Is the acceleration

time setting short?

Yes

Contact GE Fuji Electric.

Is Wk²of the motor

and/or load

excessive?

Yes

Is a special

motor in use?

Reduce the load Wk²or use a

Drive with higher capacity.

Correct the wire size

between the Drive

and the motor or

shorten the wiring

distance.

Is the motor terminal

voltage lower than

output terminal

voltage?

Yes

Increase or de-

crease the torque

boost setting.

Is the torque boost

set correctly?

Is the load torque

high?

Yes

Reduce the load

torque or use a

Drive with a higher

capacity.

Possible Drive failure or

malfunction due to

electrical noise. Contact

GE Fuji Electric.

8-11

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( 12 ) Motor heating abnormal.

Abnormal motor

heating.

Is the V/Hz

characteristics

suitable for the

motor? (F_03, 04, 05)

Change the setting.

Use a motor designed

exclusively for Drive

use and low speed

operation or consider

increasing speed ratio

by mechanical method

(i.e. gearing.)

Yes

Is the motor contin-

uously operated at

very low speed

(frequency)?

Yes

Reduce the load or use

a Motor and Drive with

higher capacity.

Is the load too large?

Is the output voltage

(Terminals U, V, and

W) of the Drive well

balanced?

Failure in motor

possible.

Possible Drive failure.

Contact GE Fuji Electric.

8-12

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Section

WARRANTY PARTS AND SERVICE

The purpose of the following section is to provide

specific instructions to the user of the AF-300 Micro-

$aver II Drive regarding warranty administration and

how to obtain assistance on both in-warranty and out-

of-warranty equipment.

"Warranty period is 12 months after installation or 18

months after shipment from the Company, whichever

occurs first."

Beforecallingthenumberatlefttodeterminewarranty

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 9-2 of this Instruction Book.

For all troubleshooting procedures, refer to Section 8

of this Instruction Book. To identify the part or assem-

bly use the noted troubleshooting procedures in Sec-

tion 8 and the information on page 9-2.

If assistance is required to either determine warranty

status or identify defective parts call:

OUT-OF-WARRANTY PROCEDURES

When the defective part has been identified, contact

your local Authorized AF-300 Micro-$aver II Distribu-

tor to order replacement parts.

GE Fuji Drives USA, Inc.

1501 Roanoke Blvd. Suite 435

Salem, VA 24153

1-540-387-5739

MOTORS

Repairs on motors are generally handled by the motor

manufacturer. Forspecificinstructionsonyourmotor,

callthedistributorfromwhichitwaspurchasedandbe

prepared to furnish complete nameplate data.

WARRANTY COVERAGE

The Warranty set forth in Section 1 of FN-1090 (1/91)

of GE's Condition of Sale covers all major parts of the

Drive such as the main printed circuit boards, transis-

tor modules, etc. The warranty covers replacement of

the entire Drive.

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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

If Yes: KVA

L1 Volts

L2 Volts

L3 Volts

Yes

Power Factor Correction Capacitors:

If Yes: Microfarad

Other Equipment on Same Power

If Yes, what?

Line Reactor on Input

Input Starter

Yes

Output Starter

Motor Overloads

Control Terminals Used (circle if used)

THR

30A

30B

30C

RST/BX

RUN

FWD

RT1

REV

Function Codes Different From Factory Settings

Function Code

Setting

Function Code

Setting

Failure Message (see Section 5)

Latest Fault

Previous Faults:

No Message

After all of the Checklist information is acquired, contact the following Service Center number for assistance:

540-387-5739 (8am - 5pm Central Standard time Monday thru Friday).

540-387-8292 (24-hour emergency)

When you return the unit or parts for warranty you need to get a RMA number from your Service Center.

9-2

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AF-300 Micro-$aver II Spare Parts List

Description Part No.

6KM$223***N1A1(X4A1)

6KM$221***N1A1(X4A1)

6KM$243***N1A1(X4A1)

F25 F50 001 002 003 005 F25 F50 001 002 003 F50 001 002 003 005

Control PCB E9-CPCBF25-M$2

E9-CPCBF50-M$2

E9-CPCB001-M$2

E9-CPCB002-M$2

E9-CPCB003-M$2

E9-CPCB005-M$2

E9-CPCBF25-M$7

E9-CPCBF50-M$7

E9-CPCB001-M$7

E9-CPCB002-M$7

E9-CPCB003-M$7

E9-CPCBF50-M$4

E9-CPCB001-M$4

E9-CPCB002-M$4

E9-CPCB003-M$4

E9-CPCB005-M$4

Terminal PCB E9-TPCB-SW

Capacitor

Unit

E9-CU2-0.2

E9-CU2-0.4

E9-CU2-0.8

E9-CU2-1.5

E9-CU2-2.2

E9-CU2-3.7

E9-CU7-0.4

E9-CU7-1.5

E9-CU7-2.2

E9-CU4-0.4

E9-CU4-0.8

E9-CU4-1.5

E9-CU4-2.2

E9-CU4-3.7

E9-FAN1.5

E9-FAN3.7

4613-02-2

4624-04-2

4634-08-2

4704-15-2

4714-22-2

4724-37-2

4655-02-7

4665-04-7

4675-08-7

4735-15-7

4745-22-7

8406-04-4

8416-08-4

8426-15-4

8436-22-4

8446-37-4

Fan

Power

Module

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Section 10

CE MARK

Electromagnetic Compatibility (EMC)

General

In accordance with the provisions described in the

European Commission Guidelines Document on

Council Directive 89/336/EEC, GE Fuji Electric Co.,

Ltd. has chosen to classify the 1 phase, 240 VAC,

3 phase 415 VAC range of Drives as “Complex

Components”. Classification as “Complex

Components” allows a product to be treated as an

“apparatus”, and thus permits compliance with the

essential requirements of the EMC Directive to be

demonstrated to both an integrator of Micro-$aver II

Drive and to his consumer or the installer and user.

Emissions will be predominantly conducted through

the motor and the main supply cables, although

some radiated emissions will be detected in close

proximity to the drive system. It is essential that

precautions are taken at the design stage, and at

the time of installation, to prevent radio frequency

interference. (RFI) from the drive system affecting

sensitive equipment in close proximity.

The RFI filters range are designed especially for the

Micro-$aver II Drive and help to ensure EMC

compliance of machinery as installations using

Inverters. The Drives may be mounted on top of the

filter using integral fixing positions, the intention

being that valuable space inside wiring cabinets

may be saved. (Refer to Fig. 10 - 1 and Table 10- 1)

Micro-$aver II Drives up to 5 Hp are supplied ‘EC -

marked’, signifying compliance with EC Directive 89/

336/EEC when fitted with specified filter units

installed and earthed in accordance with this sheet..

This specification requires the following

performance criteria to be met.

Immunity : EN50082 - 2

Emissions : EN50081 - 1

RFI Filters

Drive

It is strongly recommended that the appropriate

Micro-$aver II Drive input filter be used to limit RF

current flowing into the main supply circuit. (Refer to

Table 10-1.) Without an input filter a Micro-$aver II

Drive installation may not meet statutory

requirement. Micro-$aver II Drive contain high -

power semi - conductor devices which are switched

at high speeds to synthesize a near - sinusoidal

current waveform across the frequency range of

output. Rapidly changing voltages and currents will

generate some degree of electromagnetic emission.

Fig. 10-1 RFI Filters

Filter

Part No.

AFL-0.2 E9-7 6KM$221F25N1A1

6KM$221F25X4A1

EFL-0.75 E9-7 6KM$221F50N1A1

6KM$221F50X4A1

Applied

Drive

Rated

Current

Max Rated Dimensions

Mount

Dim. X, Y

84x186

Inverter

Fixings

M4x12(4)

Required

Sub FIlter

Ferrite Ring

OC1x1pcs

Ferrite Ring

OC1x1pcs

Voltage

L,W,D mm

200x110x34

1 Phase

240 VAC

10A

200x145x40

200x205x40

118x186

M4x12(4)

6KM$221001N1A1

6KM$221001X4A1

EFL-2.2 E9-7 6KM$221002N1A1

6KM$221002X4A1

23A

178x186

Ferrite Ring

OC1x1pcs

6KM$221003N1A1

6KM$221003X4A1

EFL-0.75 E9-4 6KM$243F50N1A1

6KM$243F50X4A1

3 phase

415 VAC

200x145x45

200x205x45

118x186

178x186

M4x12(4)

Ferrite Ring

OC1x1pcs

6KM$243001N1A1

6KM$243001X4A1

EFL-4.0 E9-4 6KM$243002N1A1

6KM$243002X4A1

12A

Ferrite Ring

OC1x1pcs

6KM$243003N1A1

6KM$243003X4A1

6KM$243005N1A1

6KM$243005X4A1

Table 10-1 RFI Filters Dimensions - Conforms to EN55011 Class B

10-1

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Recommended Installation Instructions

These instructions must be followed in order to

conform to the EMC Directive. Follow the usual

safety procedures when working with electrical

equipment. All electrical connections to the filter,

Inverter, and motor must be made by a qualified

electrical technician. (Refer to Fig.2, Fig. 3, and

Fig.4)

(if two ferrite rings are required, refer to table 1),

and connect the filter terminals marked “LOAD” to

the main input of the of the Drive using a short

length of appropriate gauge wire.

5. Fit the output Ferrite Ring as close to the Inverter

as possible and connect the motor. Armored or

screened cable should be used with the 3 phase

conductors passing twice through the center of

the Output Ferrite Ring. The earth conductor

should be securely earthed at both the ground

terminal in the cabinet and at the motor ends. The

screen should be connected to the enclosure.

6. It is important that all lead lengths are kept as

short as possible and that incoming mains and

outgoing motor cables are kept well separated.

7. Segregate power cables from control wiring, as

thoroughly as possible, and avoid parallel cable

run to minimize ‘noise coupling’. When ever runs

of power and control cable must cross, try to

achieve this at right angles.

1. Check the filter rating label to ensure that the

current, voltage rating, and part number are

correct.

2. The back panel of the wiring cabinet board should

be prepared for the mounting dimensions of the

filter. Care should be taken to remove any paint

etc. from the mounting holes and face area

around the hole of the panel. This will ensure the

best possible earthing of the filter.

3. The filter should be securely mounted in position,

and the Inverter mounted to the front of the filter

with the screws provided.

4. Connect the incoming main supply to the filter

terminals marked “LINE” and any earth cables to

the earth stud provided. Fit the Input Ferrite Ring

8. Micro-$aver II Drive should be installed, and are

designed to operate, with an electrically -

shielded metal enclosure.

Drive

Fig. 10-2 Recommended installation

10-2

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P (+)

Fig. 10-3 Recommended installation detail inside the enclosure (1)

10-3

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P(+)

Fig. 10-4 Recommended installation detail inside the enclosure (2)

10-4

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EC Declaration of Conformity

Product identification

Product:

Inverter

Brand:

GE Fuji Electric

Model/type:

6KM$221F25N1A1 to 6KM$221003N1A1

6KM$221F25X4A1 to 6KM$221003X4A1

6KM$243F50N1A1 to 6KM$243005N1A1

6KM$243F50X4A1 to 6KM$243005X4A1

to which this Declaration relates is in conformity with the EMC requirements of the following standards.

Immunity:

Emission:

EN50082-2 “Generic immunity standard Part 2 (industrial environment)”

EN50081-1 “Generic emission standard Part 1 (Residential, commercial and light industrial)”

and conforms to the protection requirements of Council Directive:

relating to Electromagnetic Compatibility

89/336/EEC

When: Wired and earthed in accordance with the installation instructions.

Installed in a steel enclosure.

Used in conjunction with power input filter and ferrite rings which are recommended by

GE Fuji Electric.

Product identification

Product::

Brand:

Inverter

GE Fuji Electric

Model/Type:

6KM$221F25N1A1 to 6KM$221003N1A1

6KM$221F25X4A1 to 6KM$221003X4A1

6KM$243F50N1A1 to 6KM$243005N1A1

6KM$243F50X4A1 to 6KM$243005X4A1

to which this Declaration relates is in conformity with the Low Voltage requirements of the following

standard(s):

DIN VDEO160/1988

Category : Overvoltage category II/Pollution degree 2

and conforms to the protection requirements of Council Directive:

73/23/EEC

relating to low voltage

When: Wired and earthed in accordance with the installation instructions.

Installed in a steel enclosure satisfied ‘Pollution degree 2’.

Used in conjunction with 3AC power supply (Line) which has an earthed neutral-point for 3 phase

Input Drive and used in conjunction with 1AC power supply (Line) whose one line is earthed for

1-phase Input Drive.

10-5

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GE Fuji Drives USA, Inc.

1501 Roanoke Blvd. Suite 435

Salem, VA 24153

1-800-543-6196

Internet Address: http://www.ge.com

GEI-100272B (3/98)

Printed in Japan

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