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GE AF-300 Power Supply User Manual

1. 7 1 Inspection Item utente d det ro a trcs 7 2 Measurement Points and Meters sse 7 3 ii Section 8 10 TABLE OF CONTENTS continued Title Page TROUBLESHOOTING 8 1 Table 8 Fault Condition Description peration 8 1 CL O Ver Dd satis 8 2 2 Overvoltage i rarus nere e n c ER EE a 83 3 etta mcer Cond ci ento ek ER E d e RR 84 4 Drive Overligab edi etn eee n aranea P n ad te n an 8 5 5 External Alarm 8 5 6 Drive Overload sont utet t 8 6 7 Memory Error Keypad Communication CPU 8 7 8 Drive Output Circuit ETFOE rc ee t eor cords 8 8 9 Motor Will MOETU dice m c Pa ore rn dr D PED Dc RR 8 9 10 Motor will run but speed will not change eeenne 8 10 11 Motor will stall during acceleration eene 8 11 12 Motor eating Abnormal 8 12 WARRANTY PARTS AND SERVICE eere nnns 9 1 Warranty CoVerage tos taie n deese Duties dbi beer era 9 1 Qut of Warranty Procedure
2. S c Exit PROGRAM mode to keypad display RUN I 5 Not effective STOP Not operational NOTE After changing function data with done the data will not be stored If the PRG Reset keys the FUNC DATA FUNC Data is Stored E DATA ais JJ Exit PROGRAM mode gt to keypad display RUN STOP Not effective Not operational key must be pressed If this is not key is pressed before FUNC 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 key is pressed the 4 PROGRAM mode while running example changing the Torque Boost 1data If the Function Data can be changed while running data is temporarily stored If the Function Data cannot be changed OR i
3. 4 1 Remove Terminal Top Cover 4 1 Control Circuit G 4 2 Main Circuit WIRING aie e t n er eon ne aes 4 3 Table 4 Drive Wire Size Recommendations sse 4 4 and Circuit Protection Rating Control Circuit Terminal Block sse 4 5 Drive Wiring Diagram iai iret trece i e dd 4 6 Table 5 Terminal Identification Function 4 7 Drive Interface Details 4 9 DRIVE OPERATION no cau ee Gee nc n reni 5 1 Keypad Panel Identification Operation 5 1 Function Code and Data Code Description Selection 5 1 Keypad and Display Operation Programming 52 Stop mpi ba betta b rd nene 5 3 Run MOdQ usn tte pe cid 5 4 Program Mode while stopped sssseee 5 5 Program Mode while running sese 5 6 OCs AT ET 5 7 Summary of Operating Modes ssssssssseeeeeeennnnns 5 8 Pre O peration Inspection oo 5 9 Table Function Code List sirs erre merce 5 10 FUNCTION CODE DESCRIPTIONS 01 thru 79 6 1 Settings and Diagrams MAINTENANCE AND INSPECTION 7 1 ESSE 7 1 Periodic Parts Replacement
4. STOP 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 stog 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 STOP 5 4 NOTE See TABLE 6 page 5 12 for Functions that can be changed while in RUN Mode RUN RUN RUN gt Not effective gt Not effective gt Not effective Keypad panel Keypad panel Keypad panel operation operation operation Drive will stop Drive will stop Ley Drive will stop Display V Display r min Display m min Terminal operation F_02 1 Drive will stop LED will show Er6 F_02 2 Stop key not operational 3 PROGRAM mode while stopped example FUNC DATA changing the Torque Boost 1data g en CIO a FUNC DATA Data is Stored M TOP Data is Stored gt
5. 2 66 67 55 34 872 Ale 47 5 2 079 02 12 5 0 5 2 95 0752 3937 402 SS O4 49 167 42 5 89 22 5 69 02 17 54 0 5 2 5 217 55 Mounting Hole panel cut out Keypad Part 6KM 2KP1 for NEMA 1 unit Inches MM 6KM 2KP4 for NEMA 4 unit Section 4 WIRING PROCEDURES A FUJI Step 1 Loosen Top Cover screw 1 to 2 turns 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 hazardous voltages are present in the Drive circuit boards 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 ei B ___ Keypad Panel Unit Cove
6. J L ee Loe PRG PRG PRG Reset Reset 4 Rese 2 3 Reset To PROGRAM To PROGRAM To PROGRAM To PROGRAM To PROGRAM mode while stopped gt mode while stopped I mode while stopped gt mode while stopped gt mode while stopped ro We 180 1 ens A di ru p A gt M v BHR gmn g RUN RUN Keypad pane RUN Keypad panel RUN Keypad panel Keypad panel RUN Keypad panel operation m operation Lt operation operation gt operation Drive will run Drive will run Drive will run Drive will run Drive will run Display Hz Display A Display V Display r min Display m min Terminal operation Terminal operation Terminal operation Terminal operation Terminal operation Not operational Not operational Not operational Not operational Not operational STOP STOP STOP STOP STOP L Not effective L gt Not effective L gt Not effective __ Not effective Not effective 5 3 2 RUN Mode Hz display A display V display r min display
7. Jr uu 4 r Jr 4 V ZH ZH JON 9 gt gt JON 11 JON 52 4 pejeedeu 17 Duiuse peeds eui peeds eDeyoA Seieoipu uano 1ndino Jo ejdsip 1n Buiyse 4 Buys yne pue peeds peeds sojow snjejs Kejdsiq ejep pue sepoo uonounj ejdsiq ueuno Aouenbejj 1ndino ejdsiq PON diH L Buluuny eiu peddois spol NNY 3015 9epoiN INVHOOHd spol INVHOOHd uonounJj uonound uonounJ uonounJj uonound uonounJj uoneoipul uonound uoneoipu uoneoipul uonounJ 9poIN OHLINOO TANVd r ulul ul 4 V JON ZH 0101010 pue 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
8. NOTE After changing function data with the data will not be stored If the NOTE Exit PROGRAM mode to keypad display Not effective STOP 2 0 Drive Stops 2 1 Drive Stops 2 2 Not operational PRG Reset key is pressed before v If the Function Data cannot be changed L gt Not effective data display Data is stored Not effective Data can be temporarily stored 21 If the Function changed while running data is gt Data is Stored Exit PROGRAM mode to keypad display RUN Not effective F_02 0 Drive Stops F_02 1 Drive Stops F_02 2 Not operational keys the Key must FUNC DATA be pressed If this is not done key is pressed the changed data will be canceled and operation will continue with the previous data Keypad displays Frequency Amps Voltage etc based on selection See Table 6 for Functions that can be changed while in RUN mode 5 6 5 TRIP mode NOTE Past fault records also can be displayed with Function
9. Not effective Not effective gt Not effective Not effective Not effective Not effective STOP STOP STOP Not effective L gt Not effective L gt Not effective L Not effective gt Not effective Summary of each operation mode The following table shows a summary of the various modes 1 20 4 10 0 20 4 40 po dois 07 20 4 9 12943 JON peddois epo 9Al2903 JON 9 199 3 ION BANDANA JON uny Ajurje10dui81 51015 eyeq pue pue peeds 10 ney sAeldsiq Sopoo uonounJj seseoJoop peeds Soseoloep pue seseeJou pue seseeJou pue seseeJou 4 pue ejep seiJoig 9 099 43 ION epo uogounj pue sejeoipul ejep pue uoloun4 ueewjeq Kejdsiq 5 031 8 seuoiMs jne4 seieoipu apoyy uny epo N dois epo N 11 40N 17 ION xI 11 10N jne4 sejeoipu peddojs sejeoipu Buluuny sejeoipu peddojs sejeoipu 11 uone1edo jeueg ped ey 17 pei ejes jeuiuue jaueq pedAsy sejeoipu r
10. The Drive that Powers AF 300 MICRO SAVER II 1 4 5 Horsepower Instructions General Information AF 300 Micro aver Il Drive Instructions These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met during installation operation and maintenance Should further information be desired or should particular problems arise that are not covered sufficiently for the purchaser s purpose the matter should be referred to GE Fuji Electric Customer Service This document contains proprietary information of GE Fuji Electric and is furnished to its customers solely to assist that customer in the installation testing and or maintenance of the equipment described This document shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Fuji Electric NOTE The terms inverter controller and drive are sometimes used interchangeably through out the industry We will use the term Drive in this document AF 300 Micro Saver II and X D are trademarks of General Electric Company Energy Saver amp is a registered trademark of General Electric Company The terms AF 300 Micro Saver and AF 300M ll will be used interchangeably throughout this document WARNING Always read the complete instructions priortoapplying power ortroubleshooting the equipment and follow all pr
11. Factory Setting 0 1 60 60 Customer Setting Data a Factory Display Setting Description Seiting F 05 80 MAXIMUM OUTPUT VOLTAGE 230 This sets the maximum output voltage for the 230 240 A Drive in steps of 1V 230V 240VA and 2V 480V 858 460 NOTE The output voltage cannot be higher than the voltage input from the power supply Maximum IF 5 Output output voltage voltage M i ee frequency 3 ONES E Base frequency Output frequency F 06 ACCELERATION TIME 1 6 0 F 07 DECELERATION TIME 1 6 0 001 The time from start to maximum frequency to acceleration and from maximum frequency to stop 3600 deceleration can be set within the range of 0 01 to 3600 seconds Set values according to the load characteristics for Wk Setting Range Setting Step 0 00 to 9 99s 0 01s 10 0 to 99 95 0 15 When set to 0 00 100 to 999s 15 the time becomes 1 000 to 3 600s 10s 0 01 seconds F 08 TORQUE BOOST 1 2 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 value will cause diminished performance and excessive motor heating 0 Torque boost is automatically controlled M 1 Squared torque characteristics for fans and pumps _ a Proportional torque characteristics 8 soU Wea
12. tte i i d a 9 1 9 1 In Warranty Failure Check 5 92 Data necessary for Warranty Administration AF 300M Spare Parts List i riso ore te nr eed ris 9 3 CE MERK 10 1 iii 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 AWARNING Denotes operating procedures and practices that may result in personal injury or loss of life if not correctly followed ACAUTION 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 WARNINGS PPE MECHANICAL
13. Ambient Within permissible limits 20 95 RH Investigate cause and make corrections Humidity No dew condensation or freezing until environment is within permissible limits Vibration Within permissible limit 0 6G or less Investigate cause and make adjustments until within permissible limits Abnormal audio noise from cooling Contact the supplier where the Drive fan etc was purchased Smell or burning Contact the supplier where the Drive was purchased Dust accumulation on cooling fins Clean and blow out with dry and filtered cooling fan or on the control board compressed air Screws Check for any loosening Re tighten as needed Connectors 7 2 MEASUREMENT POINTS AND METERS Since the Drive s input output voltage and current contain high frequencies selection of the wrong measuring device canleadto gross miscalculations When using a CT current detection transformer to measure the current the amount of error will be large if the frequency is low Because ofthis 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 te Simple Measurement Precision Measurement Input Voltage Tester Voltmeter Moving lron type voltmeter Input Current Clamp Meter Moving lron type ammeter Input Power Electrodynamometer type wattmeter Output Voltage Tester Voltmeter Rectifier type voltmeter Output Curren
14. Drive output frequency drops to 0 0 Hz power failure caused by drops in the power supply If the restart after momentary power NOTE Operation will continue if the failure mode is selected operation Undervoltage momentary power failure or under will restart automatically when power protection voltage period is less than 15 msec is restored OU1 Overvoltage Protects the Drive if During Drive output frequency drops to 0 0 Hz 002 momentary Motor coasts to a stop OU3 protection overvoltage Acceleration Alarm terminals 30A 30B and 30C regenerative During are activated overvoltage exceeds Deceleration Alarm signal is maintained internally the overvoltage Duri 1 detection level uring until alarm reset command is given constant speed operation OH1 Drive Detects overheating of the Drive Drive output frequency drops to 0 0 Hz OH2 overheating caused by an overload cooling Motor coasts to a stop fan problem or abnormal ambient Alarm terminals 30A 30B and 30C temperature are activated Alarm signal is maintained internally External alarm Acts as an external alarm to stop input output If protective device such until alarm reset command is given as the overload relay is connected between THR and CM terminals Switches from ON to OFF OL Electronic Protects semiconductor devices Drive output frequency drops to 0 0 Hz OLU overload such as the IGBT from overloads Motor coasts to a stop Alarm terminals
15. Function 1 21 22 23 24 25 26 27 Multistep Speed Speed Speed Speed Speed Speed Speed Speed Frequency 0 1 2 3 4 5 6 7 xi cM Jle oe Speed 4 Output frequency Keypad panel or Analog Speed 1 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 A 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 E 5 00Hz 10 00Hz 20 00Hz 30 00Hz 40 00Hz 50 00Hz 60 00Hz Setting F 28 Setting Description 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 Factory Setting S curve 1 S curve 2 gt 1 Fig 2 Shocks at the start and end of acceleration and deceleration can be softened by selecting a S curve pattern Q The maximum gradient in the output frequency when S curve pattern is selec
16. Operation Selection Multistep Frequency Setting 10 Multistep Frequency Setting 11 Multistep Frequency Setting 12 Multistep Frequency Setting 13 Multistep Frequency Setting 14 Multistep Frequency Setting 151 Signal Filter 18 Frequency Setting 18 8g 2 8 8 8 8 S 8 8 amp 8 Number of Motor Poles Fault Memory History 12 Y1 Terminal Function Line Speed Display Coefficient Starting Frequency 2 2 1 Frequency Level Detection Motor Sound Carrier Freq During Accel Decel 1 FDT Operation Level Torque Limit Number of Restart Attempts At Constant Speed 12 Braking Torque 13 THR Terminal Function Restart After Momentary 13 4 Hysteresis Width Power Failure Bias Frequency Jump Frequency Hysteresis Electronic Overload 1 Selection Gain for Frequency Setting 1 Signal Jump Frequency 1 Setting 1 High Frequency Limiter Jump Frequency 2 15 DC Brake Operation Low Frequency Limiter 15 Jump Frequency 3 15 DC Brake Starting Frequency Motor Characteristics Base Frequency 2 Electronic Overload DC Braking Level Data Initialization Default Acceleration Time 2 Settings DC Braking Time Deceleration Time 2 FMA FMP terminals Multistep Frequency Operation Selection Torque Boost 2 Setting 1 FMA Terminal Function 16 cont d on next page FMP Pulse Rate Multiplier 16 5 10 TABLE 6 Function Codes Cont d Function Code
17. RFI FILTER 50 60Hz RING F 012 OL3 o gt 30C Alarm signal 6 30B 0 304 13 D gt 12 Potentio meter Frequency setting Current 7 DC4 20mA i i O i Analogue pe uu 4 frequency meter Digital A n frequency meter TT Pulse counter 5 gt EFL 4 029 4 only DB resistor Y1E Output terminal CMC Common for YIE wy Control REV Ho Qe input T 08 THR 43 3 2x CM o ame e 13 ito o pio e 00 Ho o c m Fig 10 4 Recommended installation detail inside the enclosure 2 10 4 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 EN50082 2 Generic immunity standard Part 2 industrial environment Emission EN50081 1 Generic emission standard Part 1 Residential commercial and light industrial and conforms to the protection requirements of Council Directive 89 336 EEC relating to Electromagnetic Compatibility When Wired and earthed in accordance with the installation instructions Installed in a steel enclosure Used in conjun
18. 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 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 Active 0 01 second Active 3 600 seconds Setting Range Setting Step Unit 0 000 9 88 10 0 to 99 9 second 100 to 999 e 100010 3600 FWD REV CM 4 RUNLED Lit LED lt _ Timer 9 1 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 Factory Setting 06s 0 00s Customer Setting F54 F 55 Setting 0 00t0400 0 Description 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
19. 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 I AC Induction P1 P DB Motor L1 UR TTIE Was SINGLE PHASE vig __________ IM GROUND Figure 7 1 MAIN CIRCUIT MEGGER TEST CONNECTIONS 7 1 INSPECTION ITEMS Refer to the Inspection Items Chart in this section for inspection points and corrective action INSPECTION ITEMS CHART Des meno Power Supply Within permissible limits 170 264 Vac Adjust the power supply voltage Voltage for 1 Phase 240 VAC b 170 253 for 3 Phase 230 VAC Drives and 323 528 for 3 Phase 480 Vac Drives Ambient Within permissible limits 10 to 450 C Investigate cause and make corrections Temperature 414 to 122 F until environment is within permissible limits
20. 122 F 2 4 ITEM Voltage Frequency Characteristics V F TorqueBoost Acceleration Deceleration MotorSound FrequencyMeterAdjustment DataProtection High LowFrequencyLimiter 15StepPresetSpeed MaintainedContactOperation TerminalFunctionChange FrequencyReferenceSignal InputSignal contacttype ExternalOutputSignals FrequencyMeterOutputSignal SPECIFICATION Control continued Voltage 80 240 VAC or 160 480 VAC Frequency 0 2 to 400 Hz 0 Automatic torque boost or 1 to 31 0 code settings includes selection for variable torque load 0 01 to 3600 seconds independent acceleration deceleration Alternative accel decel time available as well as linear or 2 S curves selectable The pitch of the motor sound can be changed by selecting Carrier frequency F_12 0 to 15 Scale calibration of externally connected analog meter or pulse frequency 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 Magnitude of the zero offset can be set from 0 to 100 of maximum frequency 1Hz steps Output frequency gain corresponding to the reference signal can be set from 0 to 250 15 programmable preset speeds selectable by 4 contact closures Maintained contact operation stop command 2 wire operation Multi Use terminal changed via Function Code settings X4 input Y1 output Operation Speed poten
21. 37 F 38 F 39 Setting 0to400 0to400 01010 Description HIGH FREQUENCY LIMITER 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 poene ess eqbency High frequency FI ls Output frequency Mee Low frequency FL PIA Frequency setting 100 NOTE If the high and low limit settings are reversed the high limit has priority and the low limit is ignored 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 4 Lower High Low Motor Poles 10 DATA INITIALIZATION This resets all Function Codes to factory settings Inactive manual setting Initial values Initialization with factory defaults Operation Procedure When 0 is being displayed press the STOP A keys simultaneously to change the display to 1 G In this condition press the FYNG 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 Factory Setting 70 Hz 0 Hz Customer Setting F 40 F 41 F 42 Setting 110100 Description FMA FMP TERMINALS Operation Select
22. 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 Factory Customer Setting Setting 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 comm
23. Code 29 status Display of present fault Display of previous fault status Display of second to last fault status Display of third t last fault status END LU Jf manm 1 E Du CONTRO a qup ov D nalis RUN 229 5 7 Reset Reset gt Resets Fault Resets Fault X Resets Fault gt Resets Fault Fault MECHANICAL MOTION HAZARD If there is an input to the FWD CM or REV CM m gt Not effective with F_02 1 or 2 and F_14 4 or 5 Terminal Mode the Drive will suddenly restart Not effective gt Not effective Not effective gt Not effective Not effective
24. Customer Setting F 15 contd F 16 Setting 999 Description Electronic Overload operation characteristics 1 For a standard 4 pole motor Operation time min 20 a 120 vao red up Load factor 96 2 For a special design motor Operation time min 0 t e y i 0 20 40 60 80100 120140 160 180 200 Load factor 96 ELECTRONIC OVERLOAD LEVEL 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 10 Nes 1 DON d 5 e Heer BO 60Hz or more 3 tos 1 pees 20Hz Pissa MURS bee be 2 i 10Hz NE 20 40 60 80 100 120 140 160 180 200 6 8 Facton Setting Rated Current A Std 4 Pole Motor Customer Setting Data m Factory Customer Display Setting Description Setting Setting F 17 DC BRAKE Operation Selection This selects the DC brake operation to active or inactive 0 0 Inactive Regenerative braking only 1 Active DC braking after regenerative braking F 18 0to60 DC BRAKE Starting Frequency Sets the frequency to start DC injection brake 0 Hz operation during deceleration F 19 0to100 DC BRAKE Brake Level Sets the output braking level brake output for th
25. 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 2 3 4 Smooth motor rotation Correct direction of equipment rotation No abnormal vibrations and noise from the motor over full speed range 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 Run Stop Frequency setting Keypad panel FL Je E E 1o operation Analog signal 4 to 20 mA dc RUN STOP or 0 to 10Vdc Fy el 1111 281 00 Multistep speed selection by Either of the above terminals X1 X2 and 2 data is acceptable Terminal operation 3 operation by FWD REV or terminals 117 Multistep speed selection by terminals X1 X2 and X3 data is acceptable NOTES 1 F 02 cannot be changed when there is a short circuit juimper between either FWD CM or REV CM 2 Mult
26. LIMIT 0 During Acceleration Deceleration Sets the Torque Limit level during acceleration deceleration in steps of 196 0 No limit 20 20 34 to Limit 180 18096 TORQUE LIMIT 0 At Constant Speed This sets the torque limit level during constant speed operation in steps of 196 0 No limit 20 2096 34 Limit 180 18096 Ifthetorquelimitfunctionhasbeenselected theDrivemay AWARNING startrunningwithdifferencesintheacceleration deceleration timeandspeedsettings Makesurethatthesystemissetup properlysothattherewillbenodangertopersonnelwhenthe Drivestarts otherwiseaccidentsmayoccur 6 12 F 33 F 34 Setting 8 8 Description 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 BIAS FREQUENCY 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 Max output frequency output frequency oi 0 4 Frequency 10V 20mA setting The bias frequency is only active when the frequency setting function F 01 1 Factory Setting AWARNING Ifthebiasfrequencyhasbeenset theDrive
27. 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 AWARNING ELECTRICAL SHOCK AND BURN HAZARD When using 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 manufacturer s instruction book for proper operation and adjustments to the instrument AWARNING 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 AWARNING STRAIN HAZARD Improper lifting practices can cause serious or fatal injury Lift only with adequate equipment and trained personnel AWARNING ELECTRICAL SHOCK HAZARD All motor bases and equipment enclosure housings should be grounded in accordance with the National Electric Code or equivalent AWARNING AVERTISSEMENT HAZARD OF ELECTRICAL SHOCK RIS QUE DE CHOC ELECTRIQUE Separate motor overcurrent overload and
28. 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 Tochange 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 48 3 for Three Wire Control cannot be selected MAXIMUM FREQUENCY Maximum operating frequency can be set within the range of 50 to 400 Hz in steps of 1 Hz 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 BASE FREQUENCY 1 The range is 15 to 400 Hz in steps of 1 Hz Normally set to the rated nameplate frequency of the motor NOTE Ifthe 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
29. for external DC reactor for power factor improvement Option Remove factory installed jumper CONTROL TERMINAL BOARD Common connector for terminals 12 13 C1 and FMA Do not connect to CM terminal or electrical noise immunity may be lost 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 Regulated 10 VDC power supply for frequency setting potentiometer 10mA or less 13 to terminal 11 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 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 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 Motor will coast to stop with BX CM closed For use when applying mechanical brake with Drive in operation Note If BX CM is opened with FWD or REV closed the Drive will start the motor 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 2and F 14z
30. green lights up in the RUN mode 2 Controlling Method for Keypad Panel 5 PANEL CONTRI PRG MODE Ov When the power supply is activated the keypad panel display will be as shown AUN in the figure on the right 60 00 FLASHING If the RUN key is pressed the Drive will start and accelerate up to 60 Hz CI according to the factory setting Use the stop key to stop operation WARNING RUNandSTOPkeysfunctiononlyinKeypadoperationmode FunctionCodeF_02settingis0 DriveComponents PRG MODE O Creda Qv Q fria Tied 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 2 3 ITEM Enclosure InstallationLocation NEMA1 NEMA4 TABLE 1 Standard Specifications SPECIFICATION Environmental Conditions NEMA tor 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 condensati
31. 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 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 AWARNING Replace all covers before applying power to the Drive Failure to do so may result in death or serious injury CAUTIONS ACAUTION This product is 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 AC input fuses to be customer supplied and may be branch circuit protection fused The maximum allowance fuse ratings per TABLE 4 ACAUTION 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 ACAUTION not connect power supply to the output terminals U V W Connect power supply only to the power terminals L1 L2 L3 ACAUTION 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 o
32. may be mounted on top of the marked signifying compliance with EC Directive 89 filter using integral fixing positions the intention 336 EEC when fitted with specified filter units being that valuable space inside wiring cabinets installed and earthed in accordance with this sheet may be saved Refer to Fig 10 1 and Table 10 1 This specification requires the following performance criteria to be met Mains input Immunity EN50082 2 emais ln fope Emissions EN50081 1 Earth stud 11213 L RFI Filters It is strongly recommended that the appropriate Drive Micro aver II Drive input filter be used to limit RF fixing positions current flowing into the main supply circuit Refer to Table 10 1 Without an input filter a Micro aver Earth stud Drive installation may not meet statutory requirement Micro aver Il Drive contain high Load power semi conductor devices which are switched terminals W at high speeds to synthesize a near sinusoidal to Inverter current waveform across the frequency range of input output Rapidly changing voltages and currents will Fig 10 1 RFI Filters generate some degree of electromagnetic emission Filter Applied Rated Max Rated Dimensions Mount Inverter Required Part No Drive Current Voltage L W D mm Dim X Y Fixings Sub Filter AFL 0 2 E9 7 6KM 221F25N1A1 3A 200x110x34 84x186 4 12 4 F
33. motor in use N 9 Reduce the load Wk or use a Drive with higher capacity Correct the wire size between the Drive and the motor or shorten the wiring distance Is Wk of the motor and or load excessive Is the motor terminal voltage lower than output terminal voltage No Is the load torque Is the torque boost Increase or de high set correctly crease the torque Yes boost setting Reduce the load torque or usea Drive with a higher Possible Drive failure or malfunction due to electrical noise Contact capacity GE Fuji Electric 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 Is the motor contin use and low speed uously operated at operation or consider very low speed increasing speed ratio frequency by mechanical method i e gearing Reduce the load or use a Motor and Drive with higher capacity Is the output voltage Failure in motor Terminals U V and possible W of the Drive well balanced Possible Drive failure Contact GE Fuji Electric 8 12 Section 9 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 warrant
34. noise coupling When ever runs of power and control cable must cross try to achieve this at right angles Micro aver Drive should be installed and are designed to operate with an electrically shielded metal enclosure Enclosure 2 These connections to be as short as possible and earth conductor to be as thick as possible 3 in case of single phase power supply models L N L and are substituted for L1 L2 L3 L1 L2 and 3 Fig 10 2 Recommended installation Power factor correcting DC reactor Power supply S 16 200 240V P1 50 60Hz Q L1 2 oO E 306 Alarm signal O 30B Q 30A 3 Gee x Rn A 49 131 Potentio meter 49 12 1 E T 911 Frequency setting Current C1 DC4 20mA c Analogue 7 T frequency meter Digital frequency meter Pulse counter DB resistor ARMOURED or SCREENED CABLE Q3 S lt YIE gt O Output terminal CMC gt Common for FID 9 7 9 Control REV o o input DB THO pijoa dq x CM 9 35 o X2 9 7 0 o go eee BX 9 i 9 o RST Q 9 o aa ve d i 4 Fig 10 3 Recommended installation detail inside the enclosure 1 10 3 Power factor correcting DC reactor aoe 3
35. 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 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 1 Connectthe ground terminal as shown in the appro priate view of Figure 4 3 Do not operate without the unit being grounded 3 Connect the 3 phase motor wires to the U V and 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 The ground wire must be minimum 14 AWG Be 4 for recommended wire sizes and short as possible 4 Suitable for use on a circuit capable of delivering not more than 1000A 1 HP or less or 5000A 2 HP or more RMS symmetrical 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 4 for recommended wire sizes Note that L1 and L2 terminals only are available on single phase input models 5 AC
36. range of the specified value Yes Does another load exist which requires a large starting current within the same power system Does the condition occur when the circuit breaker and or electro magnetic contactor are turned ON Possible Drive control circuit or noise related malfunction Contact GE Fuji Electric place Refer to Funtion Code 14 setting Reset and continue operation Replace the defective compo nent or repair the poor connection Investigate the power system and correct to satisfy the system specification Is the power transformer rated at the correct KVA Yes 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 4 Drive overheated 5 External alarm input Drive Overheating Drive Overload Reduce the load or use a Drive with higher capacity Is the cooling fan in the Drive operat Replace the cooling ing Above 2 HP fan Is the movement of the Drive cooling air obstructed Is the Drive load too large Remove obstructions Possible Drive Is the ambient failure or malfunc temperature within tion due to electrical the specified limit noise Contact GE Fuji Electric Bring the ambient condition to within the specified limit Terminal C1 CM or 12 11 connected in rever
37. than 0 6G The Drive should be installed at an elevation below 1000 meters 3281 feet For installation above 1000 meters 3300 feet the Drive will need to be derated 196 per 333 feet Example 5 HP 460 VAC output current 9 amps Application altitude 3900 feet derate 3900 3300 x 1 1 8 100 1 8 9 amps x 1095 8 derated output current 8 84 amps Motor derate may also be required contact motor manufacturer CAUTION Because the ambient temperature greatly affects Drive life and reliability do not install the Drive in any location that exceeds the allowable temperatures 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 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 Mounting screws or bolts should be of appropriate size for weight of Drive See the appropriate figures on pages 3 2 and 3 3 for the location of mounting holes 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 CAUTION The mounting wall for the Drive must be constructed of heat resistant material because during op
38. 2X4A1 6KM 223003X4A1 6KM 223005X4A1 WOWWWWWA HAHAHA Output Current Carrier Freq Wire AWG Resistor AC Line Devices X eeu AWG Fuses Breaker 6 5 16 DB Incoming Power Resistor AC Line Devices Model Output Current Power AWG AWG Fuses Breaker 6KM 243F50N1A1 6KM 243F50X4A1 16 1 6 6KM 243001N1A1 6KM 243001X4A1 16 14 6KM 243002N1A1 6KM 243002X4A1 16 14 6KM 243003N1A1 6KM 243003X4A1 16 14 6KM 243005N1A1 6KM 243005X4A1 14 14 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 2 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 t
39. 30A 30B and 30C are activated Protects a standard 4 pole motor Alarm signal is maintained internally or a forced air cooled motor from overloads even if an overload until alarm reset command is given relay is not connected Memory Error Operates when a memory error Drive output frequency drops to 0 0 Hz Er2 occurs due to a data writing error Motor coasts to a stop Er3 Alarm terminals 30A 30B and 30C 4 Communication ayed when a communication are activated Erb Error occurs between the Drive Alarm signal is maintained internally Er6 he keypad panel Er7 until alarm reset command is given CPU error Stops the Drive when an error is Er3 detected in the CPU Optional Displayed when there is a circuit board communication error icati or interruption of communication communication between the Drive and the option error circuit board Option Displayed when a link error etc is problem detected Operating Detects Drive operating procedure error Proc 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 Stops the Drive when it is error detected that the output wiring is not connected during automatic tuning NOTE 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 cont
40. 4or 5the Drive will suddenly restart 4 7 TABLE 5 Terminal Identification Function continued Terminal Label Terminal Name Function CONTROL TERMINAL BOARD Continued THR External thermal With THR CM open OH trip will occur and the motor will command 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 connecting an external NC contacts FMA Analog Frequency Provides an output of 0 to 10 VDC 10VDC at max frequency Meter Connection available for connection of a voltmeter with internal resistance of F_40 0 10K ohms See Function Code 41 for monitoring selection Meter connects between terminal FMA amp 11 Note FMP cannot be used FMP Digital Frequency Pulse frequency output equal to Drive output frequency Meter Connection Pulse voltage Peak 5 VDC 50 duty Adjustable range 600 to F_40 1 6000 Hz Max See Function Code 42 Pulse Rate Multiplier Meter connects between FMP and CM Note FMA cannot be used 30A Fault Relay Output During normal operation the relay is not energized and contact is made 30B Terminals between 30B and 30C When a fault is detected the relay is energized 30C and contact is made between 30A and 30C Contact rating resistive load 250 VAC 0 3 Amps X1 X3 Multistep Frequency Seven individual preset frequency se
41. 6 and low frequency limiter F 37 operating Change or check the setting Yes Determine which Will speed change by frequency method is pressing key active e Keypad F_ 01 0 e Analog F_ 01 1 Will fre quency setting signal Multistep F 21 F 27 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 Do the set Replace the frequency frequencies of Change the set setter process signal each selection frequency or check for ground amp step change reference circuit Is the setting of the acceleration and Possible Drive failure or deceleration time malfunction due to excessively long electrical noise Contact GE Fuji Electric Change the setting to the time suitable for the load Motor speed change is very small under these conditions Wrong setting of F 34 bias frequency F 35 gain for frequency setting Q If using terminal 12 and C1 check polarity inputs to insure they are correct and do not offset During torque limiting or current limiting with excessive load 8 10 11 Motor will stall during acceleration The motor will stall during acceleration Is the acceleration time setting short No Increase the set time Contact GE Fuji Electric Is a special
42. 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 FREQUENCY LEVEL DETECTION 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 542 1 Setting resolution 0 00 to 99 99 100 0 to 400 0 t Y1 signal output starting frequency Output d p 1 Hysteresis frequency eee Nope FDT or ON OFF Y1 CM gt t 6 19 Factory Setting 0 00 Hz Customer Setting F 56 F57 Setting 01030 Description HYSTERESIS WIDTH 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 22 FDT HYSTERESIS FDT HYSTERESIS FAR SIGNAL Y1 CM 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 relati
43. F 300 Micro aver Spare Parts List Description NM 5243 1 1 X4A 1 F25 005 Control PCB 9 25 2 E9 CPCBF50 M 2 E9 CPCB001 M 2 E9 CP CB002 M 2 E9 CP CB003 M 2 Capacitor Unit Fan Power Module 9 3 Section 10 CE MARK Electromagnetic Compatibility EMC General In accordance with the provisions described in the Emissions will be predominantly conducted through European Commission Guidelines Document on the motor and the main supply cables although Council Directive 89 336 EEC GE Fuji Electric Co some radiated emissions will be detected in close Ltd has chosen to classify the 1 phase 240 VAC proximity to the drive system It is essential that 3 phase 415 VAC range of Drives as Complex precautions are taken at the design stage and at Components Classification as Complex the time of installation to prevent radio frequency Components allows a product to be treated as an interference RFI from the drive system affecting apparatus and thus permits compliance with the sensitive equipment in close proximity essential requirements of the EMC Directive to be demonstrated to both an integrator of Micro aver The RFI filters range are designed especially for the Drive and to his consumer or the installer and user Micro aver Il Drive and help to ensure EMC compliance of machinery as installations using Micro aver II Drives up to 5 Hp are supplied EC Inverters The Drives
44. Frequency 2 F_43 2 2 NOTE Ifthe 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 ACCELERATION TIME 2 DECELERATION TIME 2 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 Factory Setting 3Hz 0 Hz 0 Hz 0 Hz 60 Hz 10 0s 10 0s Setting F 65 F 66 F 67 F 68 Setting 2S SeeF_15 SeeF_16 0 0105 0 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 NOTE For manual torque boost only no pattern can be selected for automatic torque boost ELECTRONIC OVERLOAD 2 Operation Selection ELECTRONIC OVERLOAD 2 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 operati
45. Numbers Followed by Function Descriptions Function can be changed while the Drive is operating BasicFunctions BasicFunctions cont d BasicFunctions cont d Page 6 6 Page 6 6 Electronic Overload 2 Selection 67 Electronic Overload Setting 2 meom n a T aj Te afroa fe 25 5 Torque Limiting Response at Constant Speed Torque Limiting Response 2 During Acceleration Deceleration Option Card Selection 25 5 11 Section 6 FUNCTION CODE DESCRIPTIONS Basic Functions NOTE Function can be changed while Drive is operating LED Data Factory Customer Display Setting Description Setting Setting F 00 DATA PROTECTION 0 This Function protects the data setting from accidental changes 0 Data Changeable 1 Data Protected To change the Data Protection Setting simultaneously press the STOP key and either the or Y key F 01 FREQUENCY COMMAND 0 1 The frequency reference setting method can be selected 0 Using the Keypad Panel A and V keys 1 Using analog signal input 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 2 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 frequen
46. PANEL DISPLAY WHEN AC POWER IS APPLIED 5 1 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 Drive stopped 4 Program Mode Motor Running 2 Run Mode Drive operational 5 Trip Mode Drive system faults 3 Program Mode Motor Stopped 1 All Function Codes Can Be Changed Restricted Function Code Access Data Setting D Changing Function Codes in the STOP Mode _ lt This is the state in which all operation signals RUN signal Keypad operation FWD and REV signals Terminal operation are OFF The last keypad display frequency amps volts etc flashes RESET repeatedly The mode is switched to Function Code setting mode All FUNC Function Code settings can be changed 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 ple CR The data is stored and the Function Code advances to the next Function Code number there any more functions To change other data repeat the above procedure to change The program mode is ended and the Drive returns to STOP
47. PS HP FREQ HZ AMPS CONT PHASE S 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 2 1 1 Keypad Part Names and Functions Operation Mode Indicator Program Mode 8688 PANEL CONTROL MODE m Hz A v Lr niaJ Loaiad Program Reset Key Function Key Data Key Digital Display 4 digits 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 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 FUNCTION Key Data Key During the normal mode this key can be used to change the display unit while operation is either stopped or running During the program mode this key can be used to read and write the Function Codes and the data Digital Display Unit Display Drive RUN Indicator RUN Key DOWN Key RUN Key Key used for starting operation The LED green lights up during operation This key does not function when terminal operation control is s
48. TION 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 ramen MODEL NO re SERIAL NO IND CONT EQ INPUT OUTPUT VOLTS VOLTS IN CASE OF L V DIRECTIVE 73 23 EEC FREQ RANGE HZ AM
49. VE INTERFACE DETAILS 4 9 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 L rPRG MODE4 mhz Lr nis 1 AE EJ E ME ae Figure 5 1 KEYPAD
50. X1 MOTOR 1 81 Setting 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 9oR1A x 100 Vi 3 1 R1 Motor resistance Cable R Resistance of cable between Drive and motor V Rated voltage of motor I Rated current of motor A Value calculated for Y connection 6 24 Factory Setting Std 4 Pole motor Customer Setting F 76 F 78 F 79 Factory Setting Description Setting 0 00t050 MOTOR 1 X Setting A Std 4 pole This function displays the leakage reactance X1 of the motor 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 X1 X1 X2 Xm X2 Xm cable X 1 x 100 96 A 48 1 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 A Value calculated for Y connection R1and X1shouldb
51. X4A1 6KM 223001X4A1 6KM 223002X4A1 6KM 223003X4A1 6KM 223005X4A1 6KM 243F50X4A1 6KM 243001 X4A1 6KM 243002X4A1 6KM 243003X4A1 6KM 243005X4A1 Table3 Drive Rating Efficiency and Watts Loss Table 240 Volt Single Phase 2 Output Current Output Efficiency 1 4 1 2 1 2 3 Carrier Frequency Power Percentage Watts Loss High Hon iw low Han Low 27 50 80 115 150 6KM 221F25X4A1 6KM 221F50X4A1 6KM 221001X4A1 6KM 221002X4A1 6KM 221003X4A1 230 Volt Three Phase 1 4 1 2 1 6KM 223F25X4A1 6KM 223F50X4A1 6KM 223001X4A1 6KM 223002X4A1 2 6KM 223003X4A1 3 6KM 223005X4A1 5 480 Volt Three Phase 6KM 243F50X4A1 6KM 243001 X4A1 6KM 243002X4A1 6KM 243003X4A1 6KM 243005X4A1 E N awn NOTE Carrier Frequency High setting F_12 15 Low setting F 12 0 2 7 Section 3 INSTALLATION GUIDELINES INSTALLATION ENVIRONMENT Install the Drive in an indoor location that meets the following requirements The ambient temperature is between 10 C and 50 C 414 F to 4122 F Remove the ventila tion covers when the temperature exceeds 40 104 The relative humidity is between 20 and 95 Avoid any location subjectto condensation freezing or where the Drive would come in contact with water Donotinstall in any location subject to direct sunlight dust corrosive gas inflammable gas or oil mist Vibration should be less
52. and present the drive will start up normally Resetting of faults is allowed even if a run command is present AWARNING 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 F 15 Setting Description 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 110096 Setting value 105 0 0 10 20 30 40 50 60 70 80 Drive frequency Hz 2 For a special design motor 100962 Setti Mb etting value 10596 100 90 80 70 60 50 40 3096 30 20 10 0 M E ns 10 20 30 40 50 60 70 80 Drive frequency Hz 6 7 Factory Setting
53. applications When using the Drives on 380 480 VAC get the motor 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 ACAUTION 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 ACAUTION 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 ACAUTION 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 CAUTIONS continued ACAUTION AC induction motors require that they be sized based on the applications speed range and associated torque requirements for the motor Driv
54. arthing of the filter The filter should be securely mounted in position and the Inverter mounted to the front of the filter with the screws provided 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 Basic Standard EN55011 Class 3 ph 3 50Hz Power Supply Input Contactor Noise Filter Footmounte HRC Fuses or Circuit Breaker Ferrite Ring Through Screening must be electrically continuous EFL 4 0E9 4 only and earthed at the Enclosure and the motor 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 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 Itis important that all lead lengths are kept as short as possible and that incoming mains and outgoing motor cables are kept well separated Segregate power cables from control wiring as thoroughly as possible and avoid parallel cable run to minimize
55. ction with power input filter and ferrite rings which are recommended by GE Fuji Electric 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 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 SAC 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 GEI 100272B 3 98 FuJT ELECTRIC The Drive that Powers GE Fuji Drives USA Inc 1501 Roanoke Blvd Suite 435 Salem VA 24153 1 800 543 6196 Internet Address http www ge com Printed in Japan
56. cy 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 Factory Customer Setting Description Setting Setting The initial value for frequency setting is always zero after the drive is stopped by operation command or after power shut off 3 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 2 3 Initial value 0 Initial value prevous value 1st Acc time by F06 5 6 2nd Acc time by F63 2nd Dec time by F64 4 1st Dec time by F07 Data 2 Output freq FWD CM X1 CM X2 CM Max frequency Default value 0 Factory setting for NEMA1 1 Will reset to 0 when default is selected 6 2 Data Display Setting F 02 0 1 2 F 03 5 400 04 15 400 Default Value 0 Factory Setting for NEMA 1 1 Setting will reset to 0 when default is selected Description OPERATION COMMAND Selection of the input method for operation
57. d fluctuation or use a Drive with higher capacity Can the deceleration Yes time be Increase the increased setting time Review the system application Can the setting time 9 increased Reduce the load fluctua Contact GE Fuji Electric tion or usea Drive with higher capacity 8 2 2 Overvoltage The power supply No Is the power supply voltage within the specified limits voltage should be Yes corrected Will fault take place when the load is removed suddenly Yes No Possible Drive Was DC bus voltage above alarm level when alarm occurred failure or Yes Yes malfunction due to electrical noise Contact GE Fuji Electric Does action take place after Can the deceleration time be Yes Increase rapid acceleration is completed increased the timed Yes setting Can the acceleration time be Yes increased Yes i Can the load inertia be decreased Decrease until the failure does not No occur Is a braking resistor installed and activated No Investigate braking Yes resistor for correct Review the control and system application again Contact GE Fuji Electric connection rating and control settings 3 Undervoltage Has power failure including momentary power failure taken place Has the power circuit been subjected to component failure or poor power connection Is the power supply voltage within the
58. dard capacity for standard applied motor 1 frame down capacity for standard applied motor 2 frame down capacity for standard applied motor 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 EXPLANATION Theprimary resistance R and leakage reactance X 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 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 6 23 Factory Setting 4 pole 4 pole Std Design B Rated Current Std 4 Pole Motor Customer Setting F 74 F 75 Setting 0 00t050 L The display changes when tuning is completed Description 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 Connect the motor and the Inverter correctly Set the data for this function to 1 while the Inverter is stopped Press the ENC key gt gt Tuning operation approx 10 seconds gt F 75 1 The results of tuning can be confirmed using F_75 R1 and F 76
59. dervoltage OU1 Overvoltage during acceleration OU2 Overvoltage during deceleration 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 5 Optional Problem when a link error etc is detected Er6 Operating Proc error Er7 Output wiring error when DC Link capacitor voltage is present 2 6 Model NEMA 1 6KM 221F25N1A1 6KM 221F50N1A1 6KM 221001N1A1 6KM 221002N1A1 6KM 221003N1A1 6KM 223F25N1A1 6KM 223F50N1A1 6KM 223001N1A1 6KM 223002N1A1 36KM 223003N1A1 36KM 223005N1A1 6KM 243F50N1A1 6KM 243001N1A1 6KM 243002N1A1 6KM 243003N1A1 6KM 243005N1A1 Model NEMA 1 6KM 221F25N1A1 6KM 221F50N1A1 6KM 221001N1A1 6KM 221002N1A1 6KM 221003N1A1 6KM 223F25N1A1 6KM 223F50N1A1 6KM 223001N1A1 6KM 223002N1A1 36KM 223003N14A1 36KM 223005N14A1 6KM 243F50N1A1 6KM 243001N1A1 6KM 243002N1A1 6KM 243003N1A1 6KM 243005N1A1 Table 2 Drive Dimensions 240 Volt Single Phase HP Weight Hem Width 3 2 to 3 5 Const TRQ 1 4 1 2 6KM 221F25X4A1 6KM 221F50X4A1 6KM 221001X4A1 6KM 221002X4A1 6 221003 4 1 6KM 223F25X4A1 6KM 223F50
60. e DC 5096 injection brake The braking strength will vary depending on the characteristics of the motor F 20 0 001030 DC BRAKE Braking Time Sets the operation time for the DC injection brake 0 5s Starting Range Setting Step Starting Frequenc Braking Level 0 to 100 0 00 to 9 99 0 01 If the data is set to 0 the frequency will be 0 2 Hz Operatin Output T 1 4 Coast to stop ency fi Yee 128 t Brake starting t t frequency Regenerative braking Operatin FI lag 5 i peed gt DC braking time N ILES current Poo DC braking A p 43 t 5 to stop Braking 1 t current Time gt Time TheDrivebrakingfunctioncannotbesubstituted formechanicalmeans Attemptingtodosomay resultininjury ACAUTION 6 9 F 21 F 22 F 28 F 24 F 25 F 26 F 27 Setting Description MULTISTEP FREQUENCY 1 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 1 X2 CM and X3 CM to ON CLOSED Relationship between terminals and multistep frequencies 1 7 ON CLOSED
61. e 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 ACAUTION 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 s KVA ac line reactors will have to be installed in L1 L2 amp L3 power leads of the Drive ACAUTION 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 ACAUTION 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 ACAUTION 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 amp 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 a
62. elected F 0 2 1 or F 0 2 2 STOP Key This key is used for stopping drive operation When set as follows F 1002 0 operation command input is accepted from the Keypad RUN and STOP keys When function 2 is set to 1 F 0 2 1 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 sequence until the output frequency reaches zero at which point an Er6 fault shall be indicated on the LED To reset the 2 2 UP Key STOP Key drive you must remove the RUN command and press RESET When function 2 is set to 2 F 0 2 2 operation command input is accepted by means of the external signal terminal FWD REV STOP key on the keypad is inactive UP DOWN Keys These keys increase or decrease the frequency reference When unitis in program setting mode they change the Function Code or data values Unit Display Unit information is displayed by the LED red All three LEDs flash to indicate that the unit is in the program mode Operation Mode Indicator The LED green lights up when keypad panel operation is selected Drive RUN Indicator The LED
63. enerated 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 Factory Setting 85 0 01 Setting F 13 F 14 Setting AWARNING Description 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 Makesurethatthesystemissetupproperly sothat therewillbenodangertopersonnelwhenthe Drivestarts otherwiseaccidentsmayoccur 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 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
64. eration the temperature of the Drive s cooling fins rises to approximately 90 degrees C 194 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 installed in a vertical column atleast 19 7 inches 50cm internal space must be provided between each one or a ventilation baffle should be provided to prevent the ambient temperature from rising 5 or more cus SUERTIE 5 or more Figure 3 1 DRIVE MOUNTING CLEARANCE 3 1 4 29 109 Dimensions e aid we 060 RO o BT NOTE NEMA 1 unit does not have Keypad Shown with optional Keypad Figure 1 u S5 a uo 5 67 144 0 08 2 0 24 6 0 20 5 9 0 9 0 Figure 3 Figure 2 Inches MM Note 3 2 Dimensions 4 29 109 3 15 80 3 54 90 0 20 5 0 20 5 m Figure 4 Figure 5 Figure 6 4 69 119 0 24 6 uidi Figure 7 Figure 8 Figure 9 Note Inches MM 3 3 Dimensions of Keypad and Keypad Mounting Holes e 56 65 3l 07 95 67 6668 PANEL CONTROL rPRG MODE4 RUN OA OV O Lr niaJ La aia J 49 12 5
65. errite Ring 6KM 221F25X4A1 1 Phase OC1x1pes 7 6KM 221FB0N1A1 10A 240 VAC 200x145x40 118x186 4 12 4 Ferrite Ring 6KM 221F50X4A1 1 1 6KM 221001N1A1 6KM 221001X4A1 EFL 2 2 E9 7 6KM 221002N1A1 23 200x205x40 178x186 M4x12 4 Ferrite Ring 6KM 221002X4A1 OC1x1pes 6KM 221003N1A1 6KM 221003X4A1 EFL 0 75 E9 4 6KM 243FBONTA1 200x145x45 118x186 M4xi2 4 Ferrite Ring 6KM 243F50X4A1 415 VAC OC1x1pes 6KM 243001N1A1 6KM 243001X4A1 EFL 4 0 E9 4 6KM 243002N1A1 12A 200x205x45 178x186 4 12 4 Ferrite Ring 6KM 243002X4A1 OC1x1pes 6KM 243003N1A1 6KM 243003X4A1 6KM 243005N1A1 6KM 243005X4A1 Table 10 1 RFI Filters Dimensions Conforms to EN55011 Class B 10 1 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 1 Check the filter rating label to ensure that the current voltage rating and part number are correct 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 e
66. esettovalueswhichareappropriate AWARNING forthemotorbeingused Themotormaynotoperate correctlyifthesevaluesarenotsetcorrectly whichcould resultinaccidents 000t0999 TORQUE LIMITING RESPONSE At Constant Speed 369 000t0999 TORQUE LIMITING RESPONSE During Acceleration Deceleration 394 i 9 CERE EB I Pe 1 P 4 P Represented by the Hundreds Digit Gain Value Represented by the Tens and Units Digit Time Constant 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 Customer Setting 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
67. ied connected correctly Will the motor run if Keypad RUN key is pressed Set the frequen by pressing V key Has the frequency set signal 0 to 10V or 4 to 20mA Is the wiring been input between Terminals Will the motor run if 13 12 11 and C1 Keypad is connected correctly Is high limiter or frequency set signal below the Set the correct starting frequency Replace the fre frequency quency reference voltage or current Source and check Possible Drive Do the output for ground in failure Contact GE terminals U V W reference circuit Fuji Electric have applied voltage pressed TS Is the wiring to the motor connected properly is he load too eS Has the torque Yes Has the motor Yes Release the 2 boostvalue been been locked lock No correctly set No Failure in Decrease the load or increase crease the torque Drive capacity boost value Motor will not run under these conditions amp BX coast to stop command ON CLOSED 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 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 Are the high limiter F 3
68. input fuses are to be customer supplied and may 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 reverse direction interchange any two of the U V or Wterminal connections 240V Single Phase 1 4 to HP L1 L2 P1 DB U V W E G t 230 amp 480V Three Phase 1 4 to 5 HP Li L2 1 1 JU V W G x Thermal Relay Fuses Rating per TABLE 4 Reference UL power circuit protection requirements TT 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 223F25AA4A1 Optional Figure 4 3 MAIN CIRCUIT TERMINAL LAYOUT 4 3 3 Phase Motor Table 4 Wire Size Recommendations amp Circuit Protection Ratings 240V Single Phase and 230V Three Phase Model Power NEMA 1 6KM 221F25N1A1 6KM 221F50N1A1 6KM 221001N1A1 6KM 221002N1A1 6KM 221003N1A1 6KM 223F25N1A1 6KM 223F50N1A1 6KM 223001N1A1 6KM 223002N1A1 6KM 223003N1A1 6KM 223005N1A1 480V Three Phase 6KM 221F25X4A1 6KM 221F50X4A1 6KM 221001X4A1 6KM 221002X4A1 6KM 221003X4A1 6KM 223F25X4A1 6KM 223F50X4A1 6KM 223001X4A1 6KM 22300
69. ion 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 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 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 Factory Setting 24 Customer Setting F 43 F 44 F 45 F 46 F 47 F 48 F 49 F 50 F 51 Setting 010400 Description 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 se
70. istep 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 Additional 8 steps available with F 43 1 and 44 to 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 8 F 02 1 Stop key on the keypad active F 02 2 Stop key on the keypad inactive 5 9 TABLE 6 Function Codes Function Code Numbers Followed by Function Descriptions Function can be changed while the Drive is operating i i BasicFunctions cont d BasicFunctions cont d BasicFunctions Pade 6 cont d Pade 6 cont d Page 6 Data Protection 2 Multistep Frequency 10 X4 Terminal Function Setting 2 1 Frequency Command Multistep Frequency Setting 8 1 7 Multistep Frequency 0 Multistep Frequency Setting 9 17 17 Operation Command Setting 3 Maximum Frequency Multistep Frequency Setting 4 Base Frequency 1 Multistep Frequency 10 Maximum Output Voltage Setting 5 10 Acceleration Time 1 Multistep Frequency Setting 6 Deceleration Time 1 Multistep Frequency 10 Torque Boost 1 Setting 7 FMA Terminal Voltage S curve Acceleration 11 Adjustment Deceleration
71. k 8 Weak 3 Strong Strong 7 ai voltage d 5 Output frequency f L Manual A 240V is for single phase input only 6 4 F 09 F 10 Setting 85 0 01 Description 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 2 0 FMA terminal output Select the type of signal output from the FMA terminal by means of F 41 FMA terminal function selection MOTOR POLES This sets the number of poles of the motor being used for synchronous speed display 2 2 poles 6 6 poles 10 10 poles 4 4 poles 8 8 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 LINE SPEED DISPLAY COEFFICIENT This sets the display coefficient for displaying the line speed m min Display value m min Output frequency Hz x display coefficient Display Coefficient Setting Step Setting Range 0 01 to 9 99 0 01 10 0 to 200 0 0 1 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 g
72. lections via binary combination Input Function closure between X1 X2 X3 and CM Selection Frequency selections determined using functions F_21 thru F_27 X4 Function Extension _43 0 acceleration deceleration time 2 is selected when 4 is Input 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 Y1 Output Function Outputs one of the following signals depending on setting of F_54 Programmable 0 Drive running RUN 3 Undervoltage stop mode LV 1 Frequency level detection FDT 4 Torque limiting mode TL 2 Frequency equivalence FAR 5 Auto restart mode after momentary power loss IP Allowable load Maximum 27VDC 50mA or less PLC 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 Drive Interface Details 27 MAX Load Output Terminal Y1 50 mA MAX Input Terminal FWD REV X1 X4 BX RST THR DC24 27V 4 6 mA MAX 4 4 7 Input Terminal 23 m Reference Input 13 1 5 Ohms 12 2 WATT 11 C1 44 to 20 mA dc 250 Ohms With PLC Terminal Connection Between PLC and Drive PLC Drive Note Do Not Connect Figure 4 7 DRI
73. m min display de MD eon qe RA dv t ea AN RUN svos eed n eo ee FUNC DATA FUNC DATA es Beg ov D Lx c Bag S Mire foo ca RUN RUN Not effective Not effective Keypad panel Keypad panel operation operation Drive will stop gt Drive will stop Display Hz Display A STOP STOP PRG PRG ERG S Res PRG fod Fest PROGRAM Mode PROGRAM Mode PROGRAM Mode PROGRAM Mode PROGRAM Mode ERES while running 7 gt while running gt while running NE while running gt while running
74. mended 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 Install asurge protector in parallel with any magnetic contactors solenoids relays ortimer coils which are close to the Drive Terminal Label L1 L2 L3 V W TABLE 5 Terminal Name AC Supply Line Input Terminals Drive Output Terminals P DB External Braking Resistor Terminals P1 P 11 12 13 C1 CM FWD REV BX RST DC Reactor Terminals Frequency Setting amp Analog Freq Meter Common Terminal Frequency Setting Voltage Input Frequency Setting Voltage Output Term Frequency Setting Current Input Control Circuit Common Terminal Forward Command Input Terminal Reverse Command Input Terminal Motor Coast To Stop Command Input Terminal Fault Reset Input Terminal A DANGER Terminal Identification Function Function POWER TERMINAL BOARD Connection for 200 230 VAC or 380 480 VAC 3 phase 50 60 Hz L1 amp L2 for single phase input 200 240 VAC 50 60 Hz Connection for 3 phase induction motor 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 Connection
75. mode 2 Changing Function Codes in the RUN Mode See TABLE 6 5 2 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 D STOP Mode Display continually flashes Hz display A display V display r min display m min display FUNC FUNC FUNC FUNC DATA DATA DATA DATA nn Lm Ug 8 drea Y aes T Lgs ala RON 1 29 Cl mm aes STCF ER Ael E beret V L C3
76. nd FWD or REV Closing opening the maintained contact starts stops the Drive Q 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 Total wiring between the Drive and the motor must not exceed the length shown below 200V Series 400V Series Hp 1 4 1 2 12 35 1 2 1 23 5 538 ft 754 ft Function F 12 data F 1220 1 20r3 F12 4 15 1076 ft 243 ft 1076 ft Error in current detection may increase when 8 A specially designed motor is used b A Drive s capacity is 2 Hp ratings or greater than the motor capacity UL CSA Drive Caution Label VOYANT N EST PAS ETEINT SOUS TENSION VOIR LE SCHEMA See diagram on page 4 6 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 WARNING MORE THAN ONE LIVE CIRCUIT SEE DIAGRAM AVERTISSEMENT CET EQUIPEMENT RENFERME PLUSIEURS CIRCUITS SA523154 01 Section 2 DESCRIP
77. o CM jumper required for operation using keypad RUN STOP Figure 4 4 ES DB RESISTOR Not available on 6KM 221F25X1A1 6KM 221F25A4A1 6KM 223F25X1A1 6KM 223F25A4A1 Figure 4 5 DYNAMIC BRAKING RESISTOR CONNECTIONS 4 5 DISCONNECT CIRCUIT Motor Thermal BREAKER verlood Relay a 1 or 3PH gt o 50 60 Hz 230 480 9 04 Q Based on Model selected O O Q Q GROUND FUSE DC REAC OR A CURRENT 13 4T 2 a 12 BRAKING RESISTOR 20 1 2 TO 5 11 DO NOT CONNECT P TO CM EG e e a c z FREQUENCY METER 10V MOVABLE COIL TYPE 10V BRAKING RESISTOR THERMAL SWITCH DIGITAL METER D TE O 0 OFF OREV ALARM RELAY OUTPUT Q O Q Q O PROGRAMMABLE LOGIC CONTROL POWER Q Q Q Q Q Q 5 gt Q Q ANY ADDITIONAL NORMALLY GROUND 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 operation error due to noise interference Never install them inthe same duct or conduit A separation distance of 4 inches or more is recom
78. ocedures step by step SHOCK HAZARD labels may be located on or inside the Drive to alert people that dangerous voltage may be present Refer to Section 1 Safety Precautions for Warnings and Cautions Blank space has been intentionally left at the bottom of each page for the convenience of the user in documenting notes Section 1 2 TABLE OF CONTENTS Title Page SAFETY PRECAUTIONS e eeeeseee 1 1 DESCRIPTION COMPONENT IDENTIFICATION AND SPECIFICATIONS 2 1 General DescriDEIQID cerni nme tore eb e e 2 1 Delivery Inspection Procedures sse 2 1 Nameplate Data d a Pe kara a ER e d 2 1 Drive Keypad Functions and Layout 2 2 Drive e cra Cr e ERO D be ad 2 3 Table 1 Standard Specifications sese 24 Table 2 Drive Dimensions 2 7 Table 3 Drive Ratings Efficiencies and Watts 1 055 2 7 INSTALLATION GUIDELINES enne tnnt 3 1 Installation Enronteht e 3 1 Installation Mounting Clearance sssenm 3 1 DIMENSION 3 2 Dimensions of Keypad MountingHooles sss 34 WIRING PROCEDURES
79. on Installation should be less than 1000 meters 3281 feet elevation not in contact with corrosive gas or oil mist StoredTemperature 20 to 65 C 4 to 149 F AmbientTemperature 10 to 50 C 14 to 122 F remove ventilation covers if temperature is over 40 C 104 Humidity 20 to 95 relative humidity non condensing Vibration 0 6G or less CoolingMethod 1 4 to 1 HP Convection 2 HP and greater Forced air Integral fan Output RatedOutputVoltage 3 Phase 3 Wire 80 240 VAC or 160 480 VAC Can not exceed power supply voltage FrequencyRange 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 15095 for 1 minute duration inverse time characteristic 200 for 0 5 seconds Power Suppl RatedinputACVoltage 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 396 Frequency 5 ControlSystem Sinusoidal PWM TORQUE VECTOR Control Control FrequencySetting Analog 0 02 Hz step at Maximum frequency of 60 Hz Resolution 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 0196 of Maximum frequency 14 to
80. on pattern and the operation level 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 SLIP COMPENSATION 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 10096 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 Factory Setting 13 Rated motor Current Std 4 Pole Motor 0 0 Hz Customer Setting F 69 F 70 F 71 F 72 F 73 Setting i 09 999 999 Description 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 priortoactivationofTorque VectorControl 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 Stan
81. onship between this function and function F 00 Data protection is shown in the table below F 57 F 00 Data changing Edit permi oa Data protection possible oo o wmv EN Dp Yes 1 No 6 20 Factory Setting 0 Hz Customer Setting F 58 F 59 F 60 F 61 F 62 F 63 F 64 Setting 01030 010400 010400 010400 1510400 0 00103600 0 00103600 Description JUMP FREQUENCY Hysteresis JUMP FREQUENCY 1 JUMP FREQUENCY 2 JUMP FREQUENCY 3 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 4 The midpoints for the frequencies Jump frequency 2 to be jumped can be set in steps Jump frequency 3 of 1 Hz Jump a UK Output dump frequency hysteresi 7 y T Amp Y frequency d Jump frequency 3 Frequency f f 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 BASE FREQUENCY 2 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
82. overheating protection is required to be provided in accordance with the Canadian Electrical Code Part 1 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 AWARNING The Drive leakage current to 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 ANY APPLICATIONS REQUIRING OPERATION ABOVE 120 HZ MUST BE APPROVED BY THE MOTOR MANUFACTURER 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 AWARNING Before disassembling disconnect and
83. plete nameplate data IN WARRANTY FAILURE CHECKLIST To assist with warranty troubleshooting the following information is required This data is needed to evaluate the cause in an effort to eliminate any further failures Model No Serial No Start Up Date Failure Date Status When Failure Occurred check one Power Up Running _______ Decel Explanation of Failure Application Information check Yes or No Input Transformer _______ No If Yes KVA L1 Volts L2 Volts L3 Volts Power Factor Correction Capacitors Yes No If Yes Microfarad Other Equipment on Same Power Yes No If Yes what Line Reactor on Input Yes Input Starter Yes Output Starter Yes _ No _ Motor Overloads Yes No Conirol Terminals Used circle if used THR X1 X2 X3 30A 30B 30C RST BX FWD REV C1 11 12 13 RUN RT1 Function Codes Different From Factory Settings Function Code Setting Function Code Setting Failure Message see Section 5 Latest Fault 1 Previous Faults No Message Hz 1 2 V 3 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 A
84. r Middle EE E Sus ELEC Re Unit Cover S o m 3 Top Cover Screw Heat Sink and Mounting Tabs run Main Circuit Teminal Block Step 2 Press Upward at the locations indi cated by the arrows to remove the top cover Figure 4 1 REMOVING THE TOP COVER 4 1 Control Circuit Terminal Block Charge CRG Lamp 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
85. r wattage value less than standard application breaking resistor ACAUTION Do not connect a power supply to the control circuit terminals except 30A B C maximum rating 250 volts 0 3A ac dc ACAUTION lFor 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 ACAUTION Do not use a switch on the output side of the Drive for ON OFF operation ACAUTION Do not connect power factor correcting capacitors on the output side of the Drive ACAUTION 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 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 ACAUTION Do not perform a megger test between the Drive terminals or on the control circuit terminals ACAUTION 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
86. rol power is not supplied the alarm signal will not be retained NOTE2 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 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 Overcurrent during during Overcurrent at acceleration deceleration constant speed Repair Is motor circuit U V W of motor shorted or grounded Yes short circuit No No No and or grounding Reduce the torque boost Yes setting Reduce the No load fluctua Yes tion or usea There is the possibility of Does the load failure in the change Drive with higher capacity Is the deceleration time setting too short for the load Is the torque boost setting correct Can the torque boost setting be reduced Drive or a suddenly noise problem Contact GE Fuji Electric There is a possibility of Is the Drive failure acceleration or a motor time setting too noise problem short for the Contact GE Fuji load Electric Reduce the loa
87. se Connect correctly OH2 Is the connection between THR and Repair the wiring CM correct and or connections Is the alarm function Possible Drive of externally failure or malfunc connected equip tion to electrical ment activating noise Contact GE Fuji Electric Eliminate the cause of the alarm 8 5 6 Overload Overload Protection Overload Protection of Drive Unit of Motor Is the electronic overload character istic correct for the Install an external overload relay in the motor s thermal motor power circuit overload characteristics Is the electronic Set to the correct correctly Is the load too large Possible Drive failure or malfunc tion due to electrical noise Reduce the load or Contact GE Fuji use a Motor and Electric Drive with higher capacity 8 6 7 Memory error keypad communications error CPU error Keypad Communications Memory Error Error CPU Error Display abnormal Replace the defective parts Er4 Erb Turn the power supply Option Communications Option Link Error off Wait until the Error 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 di
88. splay The Drive is operational The Drive failure should be referred to Product Service Contact GE Fuji Electric 8 7 8 Drive output circuit error Are terminals U V and W not yet connected or open Connect or replace the wiring Is BX CM signal ON CLOSED Turn BX CM signal OFF OPEN Was an operation com Do not operate any key and mand input or was the control circuit terminal during STOP key pressed during tuning tuning Is data F 70 and F 71 correct Yes Set the correct data Contact GE Fuji Electric 8 8 9 Motor will not run The motor will not run Is the CHARGE supply circuit CRG Lamp on breaker or contactor been turned on Yes Has the power Turn the power supply circuit breaker or contactor to on Check the display ves 15 the digital Check for the contents and press display indicating Is the voltage of the No the reset switch a protection power terminal after the failure is function operation L1 L2 L3 correct presence of low voltage missing phase improper connection failure input line circuit breaker or AC line corrected contactors When there is no abnormal condition Local or remote L3 Not supplied on 1 phase drives operation continue operation Yes Local Remote Has FWD or Is the wiring Yes Poor contact in REV between FWD or switch or relay command signal REV CM terminals been appl
89. t Clamp Meter Moving lron type ammeter Output Power Electrodynamometer type wattmeter DRIVE 3 Phase To Power Motor Supply L3 not supplied on 1 phase units TYPE OF MEASUREMENT DEVICE MA gt MW 42 ELECTRODYNAMOMETER TYPE WATTTMETER MOVING IRON TYPE VOLTMETER Y ELECTRODYNAMOMETER TYPE WATTTMETER MOVING IRON TYPE VOLTMETER MOVING IRON TYPE AMMETER MOVING IRON TYPE AMMETER Figure 7 2 MEASUREMENT LOCATIONS AND DEVICES EXAMPLE 7 3 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 Display aida Function Explanation tiem Protective Operation OC1 Overcurrent Protects the Drive if During Drive output frequency drops to 0 0 Hz OC2 r ion the Drive output Acceleration Motor coasts to a stop OC3 protectio current momentarily CCP eratio Alarm terminals 30A 30B and 30C exceeds the During are activated overcurrent detection Deceleration Alarm signal is maintained internally Short circuit Die man dis During until alarm reset command is given Ground fault overcurrent resulting from an output phase 50969 to phase or phase to Operation ground short circuit LU Momentary Avoids loss of control of the Drive
90. ted is the same as for linear acceleration and deceleration time G The actual acceleration and deceleration times when a S curve pattern is selected is extended by 1096 when 1 is set or 20 when 2 is set from the times set by F 06 and 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 Customer Setting F 29 F 30 F 31 F3 Factory Setting Description Setting PROTECTION HISTORY FAULT MEMORY The Last 4 drive faults are displayed in order when the y key is pressed Operation Procedure Procedure abd Remarks up 611218 Press the t Brass the T 3 key Press ihe Press hs Contents of the Y A key COMES 5 Frese the Press the Arla Contents of the V key A key EE eso ed Press the Press the Contents of the 6 a fourth last rip LV Mr key Toenis 1 T shows there is no Press the trip history for this 1 Elad i j key 01015 STARTING FREQUENCY 1Hz 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 TORQUE
91. tiometer 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 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 FAR LV TL Auto restart mode after momentary power loss IP Pulse frequency adjustment to 6 kHz maximum Analog 0 to 10 VDC adjustment range of 6 5 to 10 3 VDC 2 5 ITEM ProtectiveFunctions Keypad DriveOperation DriveSetting Datalnitializing DriveFault Charge CRG Lamp LED SPECIFICATION Operation continued Stall prevention Undervoltage Surge input Overcurrent Drive overheating Overvoltage External faults Short circuit for output terminals CPU malfunction Communication error Motor overload Ground fault at start electronic thermal Output wiring not connected Memory error during auto tuning only Digital Display 4 digit LED Output frequency output current output voltage motor speed line speed m min machine speed r min can be displayed 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 Un
92. ttings 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 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 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 through 15 ON CLOSED NOTE These functions are only active when F_43 1 X4 6 17 Factory Setting 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 Customer Setting F 52 F 53 Setting 0 02t05 0 Description FREQUENCY SETTING SIGNAL FILTER This Function Code is used to set the time constant
93. willoperate whenanoperationcommandisgiven eveniftheanalog frequencyiszero 6 13 Customer Setting F 35 Setting 0 00 B o output Description 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 200 b output frequency 100 70 frequency 012 04 0 4 Frequency 10V 20mA 0 4 Frequency setting setti 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 fbias and setting frequency gain at this time can be calculated by the following formulas fi f2 fbias f1 x Vi V1 V2 1000 x f1 2 Gain 100 x V1 V2 fi x V2 f2 x Vi Output v2 f2 Poe frequency uU 100 4a SV 10V setting bias NE vi fi Example If the analog frequency setting voltage is 1 to 5Vdc and the output frequency is weighted to 0 to 100 then Vi ft 2 1 0 V2 f2 5 100 so that IV IV foias 25 and gain 200 6 14 100 Facton Setting 100 076 10V 20mA ng Customer Setting F 36 F
94. y equipment 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 GE Fuji Drives USA Inc 1501 Roanoke Blvd Suite 435 Salem VA 24153 1 540 387 5739 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 9 1 Warranty period is 12 months after installation or 18 months after shipment from the Company whichever occurs first Before calling the number atleftto determine warranty status the Drive serial number will be required This is located on the Drive nameplate If the Drive is still under warranty further information will be required per the In Warranty Failure Checklist shown on page 9 2 of this Instruction Book 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 MOTORS Repairs on motors are generally handled by the motor manufacturer For specific instructions on your motor call the distributor from which it was purchased and be prepared to furnish com

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