AF-3100α SERIES General-purpose High-performance Inverter Maintenance Manual

Transcription

1 AF-3100α SERIES General-purpose High-performance Inverter Maintenance Manual THE AVAILABLE SOLUTION, WORLDWIDE. AF-3100α SERIES Manual

2 INTRODUCTION Thank you for purchasing the SUMITOMO highperformance AF-3100α. The AF3100α provides highprecision speed control from ultra-low to high speed in sensorless vector mode. The AF3100α can provide control to +/-0.2% with a speed range of 120:1 60Hz). Speed control as precise as a DC motor control is possible in sensorless vector operation. An important feature in the complete control of the AF3100α is allowed in three separate modes: Sensorless Vector, Volts/Hertz and Vector Control (closed loop using Pulse Generator Feedback) In addition, high torque at low speed with sensorless vector control selected allows for a maximum of 200% torque and can be obtained over the 120:1 speed range. This is comparable to DC control. The starting torque capacity is a maximum of 250%. High-performance auto tuning is available in this stateof-the-art drive. Just select the auto-tuning function and the motor data are automatically read with the motor operating under optimal conditions. The AF3100α Series allows the user to more easily adjust the performance of the drive with the motor. Please read and observe all safety instructions. Do not make withstand voltage tests on any part of the AF-3100α AC drive. The AF-3100α uses semiconductors that are vulnerable to the high voltages used by withstand testing equipment. During installation, be sure all terminals are tightened to the recommended torque rating. Refer to the instructions detailing torque values. Handle with care to avoid damage to the AC drive. Do not pick up the inverter by the covers; use the heat sink when lifting and transporting the unit. Please keep this manual available for maintenance and inspection procedures. For guidelines on maintenance and inspection, refer to the Inspection of Generalpurpose Inverters prepared by the Japan Electrical Manufacturers Association. TO USERS: Precautions for safe operation of the inverter are shown in this manual, as well as on the inverter. Read the manual carefully before operation of this unit. Precautions shown in this manual and on the inverter describe procedures to be strictly observed to prevent injury to personnel and safe use of the AF-3100α. This manual should be kept near the inverter for reference use. The inverter described in this operation manual is used for variable-speed operation of 3-phase induction motors in a general industry environment. CAUTION The inverter described in this manual is not designed or manufactured for use in equipment or in systems that may cause injury or death to people; always use proper safety measures. Our products are manufactured under stringent quality control. Always install safety devices on your equipment to prevent serious accidents or loss of life when our using motor control products, such as the AF-3100α. Do not use the inverter for any load other than 3- phase induction motors. The AF-3100α is not in an explosion-proof enclosure; therefore, if an explosion-proof motor application is needed, pay special attention to the installation environment. Before using the AF-3100α, carefully read the Operations Manual. Carefully read the manual if the inverter is to be stored on a long-term basis. Installation of the AF-3100α or any electrical device should be installed by a licensed electrician.

3 SAFETY PRECAUTIONS Safety is an important concern when working with any electrical equipment. AC drives operate at dangerous voltage levels and dangerous voltages can be present for several minutes after power is removed. Only persons experienced with the installation, operation and maintenance of AC drives should be allowed to remove the enclosure cover. Failure to follow proper electrical safety procedures could lead to serious injury or loss of life. Therefore, it is important to read and understand the installation, wiring, operation, maintenance, and inspection practices for the AF-3100α. Safety precautions are classified into DANGER and CAUTION in this manual. DANGER CAUTION!DANGER: Improper handling will result in a dangerous condition with possibly serious injury or loss of life. Improper handling will result in a dangerous condition with possibly serious injury. Matters described in observed. Meaning of symbol CAUTION can result in serious injury. As with all warnings, this warning is to be strictly : This symbol indicates danger. The details of danger are described inside the symbol. General caution Risk of electric shock Risk of fire : This symbol indicates caution. The details of caution are indicated inside the symbol. General caution Electric shock Parts rotating Fire Hot : This symbol indicates prohibited operation. The prohibited operation is detailed inside the symbol. Prohibited, general Disassembly prohibited Contact prohibited : This symbol indicates attention. The details of the warning are indicated inside the symbol. General attention demanded Ground 1

4 INSTALLATION WARNINGS CAUTION When HEAVY! is shown, two or more persons are required to move the equipment. When moving the inverter, do not pick up by the enclosure; injury to personnel and/or the unit may result. Only lift using the heat sink. Do not operate an inverter that is damaged or has missing parts. Install the inverter on metal or other nonflammable materials. Mount the inverter according to the weight of the unit listed in this manual. Do not place flammables near the inverter. Prevent foreign objects from entering the unit. This includes any conductive material, dust, corrosive gases or flammable materials. 2

5 WIRING DANGER Use lock-out procedures to insure the power supply is OFF before wiring. Ground the inverter. Proper sizing of protective devices for the AC drive are required. CAUTION Do not connect the output terminals (U, V, and W) to an AC power supply. Verify proper AC input voltage levels exist before installation or operation. Do not connect a resistor directly to the DC terminals (P and N). Torque the terminal screw thread to the specified value. 3

6 ADJUSTMENT AND OPERATION DANGER Install the front cover before turning ON the power. Do not remove the cover when inverter is energized. Follow electrical safety procedures while working on AF-3100α. When the restart-after-fault function or retry function is selected, be prepared for sudden operation of the inverter. Always follow safety procedures to protect personnel from unexpected operation. Ensure the Start signal is OFF before re-setting to prevent unexpected inverter operation. Do not touch; high voltages are present on the terminals of the AC drive while energized; voltages are lethal. Perform installation or maintenance in a dry environment. Provide an independent emergency stop contact for the inverter. Before initial operation the direction of rotation of the motor is undetermined. If the driven machine can be damaged by rotation in the wrong direction, uncouple the motor from the load before attempting to operate the drive. CAUTION Do not connect the output terminals (U, V, and W) to an AC power supply. Verify the rated voltage of the inverter coincides with the voltage of the AC power supply. Do not connect a resistor directly to the DC terminals (P and N). Torque the terminal screw threads to the specified value. 4

7 MAINTENANCE, INSPECTION, AND PARTS REPLACEMENT DANGER Do not remove the covers for approximately 10 minutes after the power is turned OFF; high voltages exist for several minutes after power is removed. Only persons trained to maintain or replace components on electrical equipment should work on the AF-3100α drive. Always disconnect the power to the inverter before beginning inspection of the motor or other electrical equipment. DANGER Do not attempt to repair the inverter. Contact the nearest service office when repair or replacement may be necessary. The inverter should be disposed of as general industrial waste. GENERAL PRECAUTIONS All illustrations in this operation manual show the details of the inverter without covers. When operating the inverter, ensure all covers are in their original position. Always operate the inverter according to the operations manual. 5

8 TABLE OF CONTENTS INTRODUCTION Safety precautions Installation warnings Wiring Adjustment and operation Maintenance, inspection and parts replacement Handling AF-3100α Delivery Software version Inquiry CONSTRUCTION Installation and storage Storage Installation Installation method and space Torquing method of mounting screw threads External installation of heat sink WIRING 4-1. Main circuit wire and fuse selection Wiring precautions , Motor wiring , Details of terminal arrangement Control circuit Terminal functions Standard connection diagram Applied connection diagram OPERATION 5-1. Safety precautions Operation checklist Sensorless vector operation Local operation Remote operation USE OF THE OPERATION UNIT 6-1. OPU Display Changing a parameter function with OPU/keypad , 33 PARAMETER MENUS 7-1. List of parameters Monitor (Display of condition) , Parameter menus TROUBLESHOOTING/MAINTENANCE AND INSPECTION TROUBLESHOOTING 1-1. OPU fault display and correction Troubleshooting Troubleshooting: motor rotation MAINTENANCE AND INSPECTION 2-1. Precautions for maintenance and inspection Inspection items Replacement of parts OPTION 1-1. List of options Guidelines for peripheral equipment Options , 64 AC reactor Electrical noise filter Braking unit/braking resistor Option Cards Relay output card Analog monitor card Pulse generator feedback , 75 Remote control OPU/keypad SPECIFICATIONS 1-1. Specifications: Standard Specifications: Common, control Internal block diagram Outside dimensions , Measurements for external installation of inverter heat sink

9 HANDLING Introduction 1-1. AF-3100α The AF-3100α is a general-purpose high performance inverter used for controlling the speed of a 3-phase induction motor Delivery After unpacking, follow the checklist described below. Adhere to the following guidelines: CAUTION When moving the inverter, do not pick up by the enclosure. Move the inverter by lifting the heat sink. When HEAVY! is shown, two or more persons are required to move the equipment. When the inverter is delivered, is it the one you ordered? (Note 1) Are the following items packed together? Main unit of AF-3100α Operation manual for AF-3100α Options and their operation manuals (When options are ordered.) Any parts damaged during transportation? Example of entry in rating plate (11kW or more) Are screw threads and terminals tightened firmly? Are connectors tightened firmly? Are there any missing connectors? If you find any problems, immediately contact the nearest sales office or the electrical product group in Chesapeake, VA. Note 1: Check the rating plate on respective units to confirm your order. (5.5kW ~ 7.5kW) MODEL No. INPUT OUTPUT AF-3100α AC Drive VER. MAX. AMB. 50 C OL. CAP.150%/1min ENCL. NEMA 1 Suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes. SERIAL No. MASS DATE ROM Type of inverter Input power specifications Rated output Serial No. Date of manufacture AF-3100 α AC Drive MODEL No. VER. INPUT OUTPUT MAX. AMB. 50 C OL. CAP.150%/1min ENCL. OPEN SERIAL No. ROM Suitable for use on a circuit capable of delivering MASS not more than 100,000 RMS symmetrical amperes. Type of inverter Input power specifications Rated output Serial No. A F * * * * U Voltage Code Voltage (V) / 220 / / 400 / 440 / 460 Unit specifications Code Unit Specifications 2 Constant torque type Capacity Code kw Code kw 5A A Fig

10 1-3. Software version The version of the software incorporated in the AF-3100α can be confirmed by monitor parameter M18. When inquiring about the operation specifications of the inverter, please have this number available Inquiry When inquiring about AF-3100α, be prepared to advise of the inverter type (Model No.) and Serial No. If possible, energize the drive to verify the version of software as described above. 8

11 INSTALLATION AND STORAGE 3-1. Storage Store the inverter in a place protected from wind, rain, and direct sunlight. Refer to storage specifications Installation Install the AF-3100α in an environment that satisfies the following conditions: Ambient temperature: -10 to +40 C. (50 C when installed in a panel without a cover) Humidity: 90% or less, any dew condensation is not allowed No vibration No dust, iron chips, corrosive gas, oil mist, explosive gas, or inflammable gas No wind, rain, water, or oil No direct sunlight Environment free from electrical noise 3-3. Installation method and space Installation precautions CAUTION Install the inverter on metal or other nonflammable material. Do not place flammable material near the inverter. Do not hold or pick up by the front cover when attempting to carry the inverter. Prevent foreign objects from entering the unit. This includes any conductive material, dust, corrosive gases or flammable materials. Mount the inverter according to the weight of the unit listed in this manual. Do not operate an inverter that is damaged or has missing parts. 9

12 TORQUING METHOD OF MOUNTING SCREW THREADS CAUTION Refer to the following table when installing the inverter and connecting wires to the terminal block. Nominal dia. of screw thread Torque (N m) / (lb-in) M (0.59) / 6.8 (4.9) M (0.93) / 10.2 (8.3) M (1.37) / 16 (13) M5 2.9 / 26 M6 4.8 / 43 M8 12 / 106 Torque level in parentheses applies to terminal blocks on a printed circuit board and top cover set screw threads. Install the AF-3100α vertically for maximum cooling and heat dissipation. Install the AF-3100α as shown in Fig. 3-1 to provide the proper ventilation space. Ambient temperature Verify the temperature(s) in the surrounding space of the drive, as indicated in Fig. 3-2, do not exceed the allowable temperature range. 150mm or more 50mm or more 50mm or more 50mm 50mm 150mm or more Fig mm Fig

13 3-4. External installation of heat sink External installation of the heat sink, outside of the panel, is allowed for increased heat dissipation. This results in lowering the enclosed panel ambient temperatures. (5.5-11kW) Step 1 Step 2 Step 3 (15kW/200V) Fig (55-75kW/400V) Use an optional bracket for installation of the heat sink outside the panel. Remove this plate.* ➀ Remove the plate from the bottom of the unit. ➁ Install the unit in the same way as shown above. *Remove the screw threads and then remove the plate. Inside of wall Outside of wall Outlet of cooling vent Ventilation for cooling shall not be obstructed. Space: 50mm (1.97) Plate for external installation of heat sink ➀ Remove the standard plate. ➁ Attach the optional plate for external installation of heat sink to both sides of the unit. 3 Install the unit as shown in the steps shown above. CAUTION With the heat sink installed outside the panel, make arrangements for ventilation as shown in Fig Radiation fin Fig Intake ventilation shall not be obstructed! 11

14 WIRING 4-1. Main circuit wire and fuse selection Install input fuses between the 3-phase AC power supply and the input terminals (R, S, and T) of the AF3100α. When a breaker with GF (ground fault) is installed in addition to fuses, select one of the highfrequency resistant types to prevent nuisance tripping. Refer to the table 4-1 below for proper wire and fuse selection. Use the recommended terminals or lugs shown in tables 4-2 and 4-3 on main circuit wires. Table 4-1. Main Circuit Wire and Fuse Selection Voltage 200V 400V Input Fuse Selection Wire Selection (AWG) Rating Applicable Input Output Normal Duty Heavy Duty Input Output Inverter Amps Amps HP kw Bussman Gould Bussman Gould 60 C 75 C 60 C 75 C AF3122-5A5-U FRN-R-40 TR40R FRN-R-45 TR45R AF3122-7A5-U FRN-R-50 TR50R FRN-R-60 TR60R AF U FRN-R-70 TR70R FRN-R-80 TR80R AF U FRN-R-85 TR90R FRN-R-100 TR100R AF3124-5A5-U FRS-R-20 TRS20R FRS-R-25 TRS25R AF3124-7A5-U FRS-R-25 TRS25R FRS-R-30 TRS30R AF U FRS-R-40 TRS40R FRS-R-45 TRS45R AF U FRS-R-50 TRS50R FRS-R-60 TRS60R AF U FRS-R-75 TRS75R FRS-R-85 TRS90R AF U FRS-R-100 TRS100R FRS-R-125 TRS125R AF U FRS-R-125 TRS125R FRS-R-150 TRS150R AF U FRS-R-150 TRS150R FRS-R-175 TRS175R AF U FRS-R-175 TRS175R FRS-R-200 TRS200R 1/0 1/ AF U FRS-R-225 TRS225R FRS-R-275 TRS300R 3/0 3/0 Wire Gauge per UL 508C Table 39.2, Copper. Use only 60/75 Copper Wire. Use Heavy Duty when intermittent load requirements exceed 150%. Table 4-2. Recommended Non-Insulated Crimp-type Terminals Model AWG Manufacturer Series P/N AF U 6 Thomas & Betts Sta-Kon E6-14 AF U 4 Thomas & Betts Sta-Kon F4-14 AF U 10 Thomas & Betts Sta-Kon D8-14 AF U 8 Thomas & Betts Sta-Kon D8-14 AF U 4 Thomas & Betts Sta-Kon F10731 AF U 3 Thomas & Betts Sta-Kon F10731 AF U 1 Thomas & Betts Sta-Kon G2-38 AF U 1 Thomas & Betts Sta-Kon G2-38 AF U 1/0 Thomas & Betts Sta-Kon H973 AF U 3/0 Thomas & Betts Sta-Kon K973 Table 4-3. Recommended Lugs Model AWG Manufacturer Series P/N AF U 1 Thomas & Betts Color-Keyed AF U 1 Thomas & Betts Color-Keyed AF U 1/0 Thomas & Betts Color-Keyed AF U 3/0 Thomas & Betts Color-Keyed

15 4-2. Wiring precautions Carefully read the following suggestions to ensure correct wiring. Follow the National Electric Code or local electrical codes. Safety precautions DANGER Wiring to be installed by a licensed electrician. Verify AC power is disconnected before wiring. High voltages exist for several minutes after removal of power. Wait approximately 10 minutes before attempting to work on the drive. Ground the inverter per instructions in the manual and/or in accordance with the National Electric Code or local electrical codes. Install a circuit breaker/fuse for protection of the inverter in accordance with the National Electric Code or applicable local codes. CAUTION Do not connect the output terminals (U, V, and W) of the drive to the AC power supply; catastrophic equipment failure will result. Do not connect a resistor directly to the DC terminals (P and N). Contact the factory for assistance. Verify the rated voltage of the inverter coincides with the voltage of the AC power supply. Torque the terminal screw thread to the specified value (page 11). 13

16 Additional wiring precautions Do not ground the control circuit terminals COM or BC. Use shielded wire or twisted shielded wire for wiring to the control circuit. Do not run control wiring in the same conduit or wire-way with input or output power wires. Important Note: Configure jumpers S, TX1, TX2 & TX3 for proper short circuit protection. See Note 2 on the AF-3100α connection diagram for settings. The grounding wire must be sized according to the National Electric Code or local electrical codes in effect at the point of installation. Design precautions Input signals to the AF-3100α are low voltage, low current control signals requiring relay contacts rated for low energy, micro-control signal operation. Use goldflashed, silver-plated or other low-resistance contacts. If the start signal input is ON (closed) when a power failure occurs, the inverter will automatically restart when power is reapplied. Fail safe methods include three wire control to the inverter control terminals or installation of a electromagnetic contactor on the inverters input side configured to drop off-line during power failure to prevent unintended starts. Do not apply voltage to the input points (FR, RR, etc.) of the control circuits. These are active low inputs and are not intended for voltage inputs. Form C relay contacts FA and FB are intended to operate in series with a relay or other electrical device. To prevent failure of these contacts do not exceed the current or voltage ratings. Use of a power transfer switch during inverter operation may result in a catastrophic failure of the drive due to a momentary shorting of the contactors. To prevent this possibility, use electrical or mechanical inter-locks for MC1 and MC2. Please refer to Figure Motor wiring Motor circuit wiring Pay special attention to the distance from the motor to the inverter. The longer the wiring run, the higher the voltage drop. Wiring lengths greater than 30m/100ft will affect the performance of the inverter. Installation of an AC line reactor may be necessary. As shown in the table below, decrease the carrier frequency using parameter C13 to prevent the adverse effects from long cable distances. Do not run multiple sets of drive to motor conductors in a common wire way or conduit. This practice may result in inductive coupling of voltage between different sets of motor leads, which can cause equipment damage, and a safety hazard may exist. Power supply Inverter Possible short circuit Fig. 4-1 Wiring distance 60m or less 61 ~ 100m 101m or more Carrier frequency (Parameter C13) 10kHz or less 6kHZ or less 2.5kHz 14

17 Proper wiring practice requires power wiring (AC input power or inverter output) to be kept separate from control circuit wiring. Maintain a minimum separation of 36 in/1m between parallel conduits. If it is necessary for power and control wiring to cross, cross at a 90 angle. Do not place input feeder cables in the same conduit as the motor leads. Control circuit terminal block Main circuit terminal block R S T N P1 P U V W E Control circuit wiring Maximum spacing R S T U V W Main circuit wiring Power supply 3-phase power supply Motor wiring Grounding cable E CAUTION Do not connect the 3-phase input power supply to the inverter output terminals U, V, and W as catastrophic inverter failure will result. Output inverter terminals R, S and T may be wired in any configuration. Verify motor rotation before coupling motor to the load. NOTE: When initially operating a 3-phase AC motor, the direction of rotation is undetermined. If the drive machinery can be damaged by rotation in the wrong direction, uncouple the motor from the load before attempting to operate the drive. 15

18 4-4. Details of terminal arrangement 200 V class 5.5~7.5kW 11~15kW 22~30kW 37~45kW 55~75kW NOTE: 200V class greater than 15kW not available with UL in U.S. Control circuit terminal block (Common to all drives). Terminal block screw diameter on control card (M3.5). 16 +V VRF IRF COM FRQ+ FRQ - UPF DRV OM X1 X2 OM FA FC FB FR RR BC ES MBS BC JOG AD2 BMD BC DFH DFM DFL BC RST

19 400 V class 5.5~7.5kW 11~15kW 22~30kW 37~45kW 55~75kW Control circuit terminal block (Common to all drives). Terminal block screw diameter on control card. (M3.5) +V VRF IRF COM FRQ+ FRQ - UPF DRV OM X1 X2 OM FA FC FB FR RR BC ES MBS BC JOG AD2 BMD BC DFH DFM DFL BC RST 17

20 Supply voltage selection jumpers (Applicable only to 400 V class) When the 400 V class is used for voltages in the 380 V to 460 V range, configure the jumpers as shown below. For the 15 kw unit, change the connector pins 380 V (CN1), V (CN2), and 460 V or greater (CN3) on the IPM (Intelligent Power Module) card. 380V 460V 400/440V S1 TX1 TX2 TX3 380 V Jumper S1-TX1 400/440 V Jumper S1-TX2 460 V Jumper S1-TX3 The AF-3100α requires separate grounding. When more than one AF-3100α is used, ground them as shown in Figures 1 or 2 shown below. The grounding cable in a 3 phase/4 wire system should be used as the grounding conductor between the motor and the drive. Ground the motor to the cable ground and wire the cable ground to terminal E on the inverter. For long cable runs contact the factory for assistance. Refer to NEC and local electric codes for additional wiring guidelines. Use grounding method (1) for the preferred ground method. If method (1) is not possible, use grounding method (2). Grounding method (3) is not recommended. Note: Do not apply external power to these terminals. Control power input If control power is supplied by the inverter power supply, jumper r-r1 and s-s1 on the main control board. Factory settings are jumpered as r-r1 and s-s1. If control power is supplied from an external power supply, remove the r-r1 and s-s1 jumpers and input 230 VAC to terminals r1 and s1 on both the 200 and 400 V models. Inverter Other equipment (1) Preferred grounding...best Inverter Other equipment (2) Common grounding...allowed s s1 r1 r Inverter Other equipment Do not connect voltages exceeding 230 VAC to r1 and s1; otherwise, failure of CAUTION the inverter may result. To verify the external power supply operates, remove the power to the AF-3100α to measure the external control voltage. Reapply power to the inverter. Wiring for the external control power supply requires shielded wire to minimize electrical noise to the unit. Grounding Follow all applicable electrical codes for grounding as specified by National Electric Code or local electrical codes. Size grounding cables sized in accordance with the National Electric Code or local electrical codes. Grounding leads should be as short as possible. Common grounding of the AF-3100α with other equipment, such as welders, etc., is not acceptable. (3) Common grounding...not Allowed (1) Correct grounding (2) Correct grounding (3) Incorrect grounding 18

21 4-5. Control circuit Frequency DC0 ~ 1 ma Frequency adjust 3 kω 2 W Open collector output (MAX 24 VDC 50 ma) Relay output MAX 230 VAC 1 A 30 VDC 1 A Form C COM: Common BC : Sequence input common OM : Open collector output common Forward rotation Reverse rotation External error Coast stop Jogging 2nd acceleration selection B mode Preset speed setting Preset speed setting Preset speed setting Reset Digital output UPF Digital output DRV Digital output 1 Digital output 2 Fault detection N.O. Fault detection Common Fault detection N.C. Fig Note: 1. Do not ground terminals COM, OM, or BC. Use twisted or shielded wire for frequency input signals related terminals +V, VRF, IRF, and COM, as well as for frequency output terminals FRQ+ and FRQ-. Refer to Fig for additional instructions. 2. All control circuit terminals FR through MBS - BC are active low digital inputs; application of voltages to these inputs will result in failure of the inverter. To prevent unintended signals, use shielded wire. ; ;; ; + V VRF COM 3. Use shielded wire for the open collector outputs UPF, DRV, X1 and X2 to OM. Proper polarity connections are necessary to prevent failure of the open collector outputs. 4. When the open collector is used for driving an inductive load (relay coil, etc.), be sure to install a free-wheel diode. Contact the factory if assistance is needed. See Fig DRV, UPF X1, X2 OM 50 ma max + 24 V Fig Free-wheel diode (100 V; 0.1 A or more) Shielding changes not required on end opposite the inverter. Vinyl tape, etc. Fig Inverter Connect shielding to inverter at connection point to inverter. Do not run control circuit wiring in the same conduit or raceway as the power wiring. Maintain maximum separation between control and power circuits in accordance with proper wiring procedures. Use twisted shielded wire for prevention of malfunction due to noise. Ground the shielding as shown in Fig

22 4-6. Terminal functions Kind Terminal Code Name of terminal Function Main Circuit Frequency adjustment input Control circuit (Input signal) Sequence Input Control circuit (Output signal) Monitor Open Collector Contact point output R, S, T AC power input Commercial 3-phase power supply. U, V, W Inverter output 3-phase motor. P, P1 Line reactor Remove the jumpers between terminals P and P1 to allow for connection of the optional DC connection line reactor. P, N Braking unit connection Connection for the Optional Braking Unit Card. P, PR Braking resistor Optional braking resistor connection. The PR terminal is provided in the kw unit. connection E Ground Inverter chassis grounding terminal. TX1, TX2, TX3, S1 Supply voltage selection Supply voltage selection terminals. Only on 460 V class units of 15 kw or above. Control power For inverter supplied control power, connect r-r1 and s-s1, respectively. For externally r, r1, s, s1 selection supplied control power remove the r-r1 and s-s1 jumpers; input 230 VAC power to r1 and s1. (Input 230 VAC to both 230 and 460 V units). The external control circuit terminal block (see note) is on the driver card. +V Power supply for Power supply for the external speed (frequency) potentiometer (variable resistor: 1-5kΩ). the external speed 10 VDC; maximum supplied current 10 ma. potentiometer VRF Frequency adjustment When 0-5, 0-8, or 0-10 VDC is input, the output frequency reaches its maximum at 5 V, 8 V input voltage and 10 V, respectively. Select paramater A 00/12 for 0-5, 8, or 10 V operation. IRF Frequency adjustment 4-20 ma (DC), the output frequency reaches its maximum at 20 ma, minimum at 4mA. current input Input resistance: 250Ω. COM Common for Common terminal for frequency adjustment signals (terminals: +V, VRF, and IRF). analog inputs FR Forward rotation FR-BC contact closed results in forward rotation; deceleration/stop when the contact is open. RR Reverse rotation RR-BC contact closed results in reverse rotation; deceleration/stop when the terminals are open. ES External fault When the contact terminals ES-BC are closed, the inverter faults and an alarm signal is latched and output to FA and FB. To re-start the inverter a reset must be initiated by closing RST-BC. External relays can be used to fault the inverter by closing ES-BC, the fault can be software selected to External Fault (NO) or External Fault (NC). The factory default External Fault (NO). MBS Coast Stop When the contact terminals MBS-BC are closed, a coast stop is initiated. Operation begins from 0 Hz when the MBS-BC is re-opened and the signal FR or RR is closed. When the digital input is set for catch on the fly start, operation from coast stop is allowed. No alarm signals are output. JOG Digital input terminal 1 AD2 Digital input terminal 2 The following functions can be selected: Preset speed selection, JOG selection, 2nd BMD Digital input terminal 3 deceleration selection, B mode selection, local/remote operation command, frequency DFH Digital input terminal 4 command selection, hold selection, frequency increase, frequency decrease, and catch on the DFM Digital input terminal 5 fly function. DFL Digital input terminal 6 RST Alarm reset When the terminals RST-BC are closed, the inverter is reset to allow for normal operation. BC Common Common for digital input signals. FRQ+, FRQ- Frequency counter Depending on the selection (see parameter E02), a 0 to 1 ma DC current is output on terminals output FRQ+ and FRQ-in proportion to the output frequency of the inverter. Digital pulses with the same frequency as the output frequency of the inverter can also be selected for output. Factory default setting is a pulse output frequency at 1 ma for 60 Hz. The input impedance of the meter shall be less than 500Ω. UPF Digital output terminal 1 The following functions can be selected: fault, in-operation, at frequency, DRV Digital output terminal 2 frequency detection 1, frequency detection 2, current detection 1, current detection 2, run signal initiated (FF/RR), under-voltage, thermal alarm, stall Allowable load X1 Digital output terminal 3 operation, retry attempts exceeded, torque detection 1, torque detection 2, DC24V X2 Digital output terminal 4 and zero speed detection function. 50mA MAX OM Common open collector output Common terminal for open collector transistors. FA, FB, FC Error Detect Contact point output Normally Open or Normally Closed Form C contact. Fault: FA-FC closed; FB-FC open Normal: FA-FC open; FB-FC closed Note: kw: Bus bar card 15 kw: IPM card 20 kw or more: Driver card 20 Contact Ratings AC 230V 1A MAX DC 30V 1A MAX

23 4-7. Standard connection diagram kw/200 V class kw/400 V class Resistor Units Braking Unit P N 22 kw or > 400 V class Note 8 PR P N Power supply MCB Optional ACL Noise filter PR R S Note 6 P Braking resistor Note 3 P1 DCL N U Note 6 V Motor IM : Main circuit terminal : Control circuit terminal T W r s r1 AF3100α Note 7 E Note 5 s1 Note 1: Programmable Digital Inputs Forward rotation Reverse rotation External fault Preset speed setting Jogging 2nd acceleration/ deceleration B mode selection Alarm reset Coast stop Frequency adjustment 3 kω 2 W 4-20 ma + COM FR RR ES DFL DFM DFH JOG AD2 BMD RST MBS BC +V VRF COM IRF Note 4 OPU + FRQ FRQ Shielded or twisted shielded wire Twisted wire FA FB FC DRV UPF X1 X2 OM Frequency + FM Fault contact output 230 VAC; 1A or less (At fault: FA-FC closed) 30 VDC; 1A or less (At fault: FB-FC open) Digital output DRV (Factory Setting: "In operation") Digital output UPF (Factory Setting: "Frequency reached") Digital output X1 (Factory Setting: "Thermal alarm") Digital output X2 (Factory Setting: "Stall operation") Common open collector Frequency meter output Meter specification: DC 1 ma F.S. Note 1 Open collector output: 24 V, 50 ma or less Notes 1: Digital inputs can be programmed using parameters F01 to F10. 2: Installed in units with a minimum of kw. 400 V class AC input power voltage selections. 460 V 400/440 V 380 V S1 TX1 TX2 TX3 Jumper: S1-TX1: 380 V S1-TX2: 400/440 V S1-TX3: 460 V 3: Remove jumper if a DC reactor is used. 4: Using parameter F00, the fault output relay may be programmed as External Fault N.C. or External Fault N.O. 5: Inverter and motor must be grounded. 6: Primary circuit terminals with a minimum of 37 kw uses a bus bar. 7: If the control power source has a separate input, remove r-r1 and s-s1 jumpers. Connect the control input voltage at r1 and s1 for both 200 and 400 volt units. 8: For connections of dynamic braking resistor and dynamic braking units, refer to the operations manual for the braking unit and resistor shipped with those units. Follow the connection diagrams in the manual or contact the factory for assistance. A connection is made between P and N on the braking unit and the inverter, while the dynamic braking resistor is connected to P and PR on the braking unit. 21

24 4-8. Applied connection diagram Operation by IRF current signal, 4-20mA DC Example: Terminal DFL is used to switch from IRF (current signal) to VRF (voltage signal) as the Frequency Adjustment Input Power supply MCB FU Tx (Note 4) Manual (Speed setting unit) Automatic (Current signal) AU U V W ACL X Y Z R S T FB P P1 AF-3100α U V W E Grounding IM FC Stop Operation RN RN RN AU FR (Note 1) DFL (Note 3) FRQ+ FRQ + FM Frequency meter 1mA F.S. Frequency setting unit 3kΩ BC +V VRF (Note 2) COM Current signal DC4 20mA + IRF Twisted wire Shielded wire Note 1: Set the parameter A00 to 1: External. Note 2: Set the parameter A12 to 3: VRF 10 V. Note 3: Set the parameter F01 to Frequency command, and parameter F18 to 4: IRF 20 ma. Note 4: Install a step-down transformer when the power supply is in the 400 V class. Operation of separately ventilated motor (with axial fan) TX1 (Note 1) MB THR U V W Axial fan BM Power supply MCB FU THR MB ACL U V W TX2 (Note 2) MB MX X Y Z R S T P P1 AF-3100α U V W E Grounding U-Y V-Z W-X Motor IM T1 Thermostat T2 Grounding Forward rotation Reverse rotation External fault T1 T2 MX FR (Note 4) RR ES (Note 3) BC FRQ+ FRQ + FM Frequency meter 1mA F.S. 3KΩ Frequency adjustment +V VRF (Note 4) COM Twisted wire Shielded wire Note 1: Install a 400/200 V transformer when the power supply is in the 400 V class. A transformer is unnecessary for 400 V axial fans. Note 2: Install a step-down transformer when the power supply is in the 400 V class. Note 3: Set the parameter F00 to (1: NC contact). Note 4: Set the parameter A00 to (1: External), and the parameter A12 to (3: VRF 10 V). 22

25 Positioning up/down operation BR Power supply MCB ACL U X V Y W Z R S T P P1 U V W Br IM LS1 Tx FU (Note 4) Braking unit TB TC Forward rotation Stop LS2 R F Reverse rotation LS4 F R F LS1 R LS3 F R A B Twisted wire Shielded wire F FX R RX DF BR FX RX DF DF FX RX FB FC AF-3100α (Note 6) Relay card (Option) E P N R1A R1B R1C R2A FR R2B RR R2C DFL (Note 3) DFM MBS BC (Note 1) Remove the short bar. Braking unit E1TA TB TC E2 P M1 M2 N PR S1S2 E (Note 2) DBR DBR Braking resistor A B LS2 Forward rotation LS1, LS3 Holding type limit switch Operation pattern Forward rotation LS3 LS4 Note 1: Remove the short bar when the thermal trip signals (TA, TB, and TC) of the braking unit are used. Note 2: Use nonflammable cable for wiring the braking resistor. Note 3: In frequency setting, the parameter B00 is for slow speed setting and the parameter B01 is for high speed setting. Note 4: Install a step-down transformer when the power supply is the 400 V class. Note 5: Set the parameter E01 to 400 Hz and the parameter E25 to 3, and adjust the brake releasing timing by E00. The parameter E00 is usually set to 1-2. Note 6: Use the optional relay card. External control power input Power supply MCB MC ACL U X V Y W Z R S T P P1 U V W IM Note 1: Control power AC200V/ 220V MCB r r1 s s1 FB (Note 3) E Manual Automatic Stop Operation RN MC AU RN FC AF-3100α Current signal DC4 20mA + Speed adjustment 3kΩ RN AU FR DFL BC +V VRF (Note 2) COM IRF Twisted wire Shielded wire Note 1: If the power supply is in the 400 V class, the control power specification is 200/220 VAC. An 400 VAC power supply cannot be used. Note 2: Set the parameter A12 to 3: VRF 10 V. Note 3: When external control power input is used, remove the jumpers r-r1 and s-s1, and then input the external control power. 23

26 Preset speeds (16) Power supply MCB ACL U X V Y W Z R S T P P1 U V W IM Preset speed by external input signal Forward rotation Reverse rotation External fault Preset speed 0 Preset speed 1 Preset speed 2 Preset speed 3 FR RR ES DFL DFM DFH JOG AD2 AF-3100α Parameter setting Preset speed 0 F01=0 Preset speed 1 F02=1 Preset speed 2 F03=2 Preset speed 3 F04=3 A01= * Hz E Frequency setting A01 B00 B01 B02 B03 B04 B05 B06 Preset speed 0 DFL Preset speed 1 DFM Preset speed 2 DFH Preset speed 3 JOG BMD A12=0 B Reset Coast stop RST MBS BC Twisted wire Shielded wire B22 B23 B24 B25 B26 B B : Selected terminal to BC closed. 0 : Selected terminal to BC open. Brake motor operation (electromagnetic contactor on input power supply) BR Power supply MCB Tx Note 2 FU ON OFF MC Forward MC Stop rotation F R F MC R Reverse rotation F R ACL U X V Y W Z MC F FX R RX BR R S T FB FC P P1 AF-3100α U V W E Br IM FRQ+ + FRQ- FM - meter 1mA F.S. Forward rotation Brake Operation pattern Forward rotation Brake Twisted wire Shielded wire FX RX FX RX Reset +V FR (Note 1) VRF COM RR MBS RST Speed adjustment unit 3kΩ Note 1: Set the parameter A12 to 3: VRF 10 V. Note 2: Install a step-down transformer if the power supply is in the 400 V class. BC 24

27 Operation of motor with brake (electromagnetic contactor/braking unit on power supply side) BR Power supply MCB Tx (Note 4) FU ON OFF TB TC MC Braking unit Forward MC Stop rotation R F F R Twisted wire Shielded wire Reverse rotation R MC F ACL U X V Y W Z MC F FX R RX BX BR FX RX BX Reset R S T FB FC R1A R1C FR RR MBS RST BC P (Note 3) Relay card (Option) P1 AF-3100α U V W E P (Note 6) N E1 P N PR Br IM (Note 1) Remove jumper. Braking unit TATB TC E2 M1 M2 S1S2 E (Note 2) DBR DBR Braking resistor FRQ+ + FM FRQ- - +V VRF COM (Note 5) Speed adjustment unit 3kΩ Frequency meter 1mA F.S. Brake Forward rotation Operation pattern Brake Note 1: Remove the jumper if the thermal trip signals (TA, TB, and TC) of the braking unit are used. Note 2: Use nonflammable cable for wiring the braking resistor. Note 3: Set the parameter E25 to 1. (Changing the function of terminals R1A and R1C during operation.) Note 4: Install a step-down transformer if the input power is 460 V. Note 5: Set the parameter A12 to 3: VRF 10 V. Note 6: Connect a braking resistor to the terminals P and PR of the 15 kw or less/200 V class and 11 kw or less/400 V class, and set 0 to the parameter C03 and the operating rate to the parameter C04. 25

28 OPERATION 5-1. Safety precautions DANGER Do not operate unless in a dry environment. Do not touch any component of the inverter with power applied. Some components are at DC bus potential after input power is removed for several seconds. If the inverter has a run signal, the inverter will restart upon RESET. Always open run contacts before reseting inverter. Always install the front cover before applying AC power. Do not remove the cover with power applied. Provide a separate, independent emergency stop contact for the inverter. Verify the driven load can be safely operated; if not, ensure the motor is uncoupled from the connected load. Note: When initially operating a 3-phase AC motor, the direction of rotation is undetermined. If the driven machinery can be damaged by rotation in the wrong direction, uncouple the motor from the load before attempting to operate the drive. CAUTION Do not touch the heatsink or braking resistor; temperatures in excess of 300 C can be present. Verify the speed ranges of the inverter match the allowable speeds of the connected motor. Use an external motor brake as necessary. Do not touch the cooling fan. 26

29 5-2. Operation Checklist 5-3. Sensorless Vector Operation When installation and wiring are completed, verify the following checklist before applying power: Are the AC input power connections (R, S, and T) and motor connections (U, V, and W) wired correctly? Are the jumper settings for the control power supply correct (r1,r,s1,s)? If an external power supply is used, are the jumpers removed and input connections to r1 and s1 correct? Are the output terminals (U, V, and W) connected in the correct phase order? Verify motor rotation before operating inverter. Verify no short circuit exists in the motor cable. Are wire connectors securely tightened? Is all mounting hardware (such as screws) securely tightened? Is the wiring and logic of the external control devices verified and tested for proper operation? Has the operation of the motor and load been verified for safe operation? Is the AC input supply voltage and voltage rating of the inverter confirmed? (400 V class unit: Are the supply voltage jumpers properly configured? (Refer to S, TX1, TX2 and TX3) Applying power Apply power with the inverter in the OFF position and confirm there are no faults. Should a fault exist, immediately remove the power and check the wiring of the inverter. If there is no fault, the READY lamp (green) on the OPU/keypad will illuminate. The inverter is ready to run. Trial operation Verify that the driven load can be safely operated or, if not, that the motor is uncoupled from the connected load. Note: When initially operating a 3-phase AC motor, the direction of rotation is undetermined. If the driven machinery can be damaged by rotation in the wrong direction, uncouple the motor from the load before attempting to operate the drive. The operation unit (OPU/keypad) permits selection of local or remote operation modes. Respective operation modes are explained below; however, only the OPU mode numbers are shown here. For programming the inverter by using the OPU, refer to Section 6. How to use the operation unit. Unless the necessary parameters are set correctly, the sensorless vector operation may not perform as expected. Set the following motor parameters as shown below: (Refer to parameter table Menu C) Menu C09: Number of motor poles Menu C10: Type of motor Menu C11: Motor capacity Menu C12: Control method selection to 1: Sensorless Menu settings for motor cable selection. If the motor cable exceeds 10 m (33 ft.) the resistance of the cable increases; motor terminal voltage is reduced resulting in less developed torque in the motor. To prevent these losses, configure the motor wiring parameters as follows: Motor cable distance (Menu Parameters C14 and C15) if the motor cable is less than 10m/33 ft - no parameter changes are necessary if the motor cable equals 10m/33 ft - parameter C14 is ignored if motor cable greater than 10m/33 ft - configure C14 cable size and C15 cable distance Proper sizing of motor cables should be selected in accordance with the National Electric Code (NEC) and/or local electrical codes. Typically size the cable for a calculated voltage drop of less than 2% of the rated output voltage. Refer to the NEC or local electrical codes for sizing guidelines. Setting the carrier frequency. For long cable runs refer to the chart shown in Section 4-3. Improper setting of the carrier frequency will affect the inverters performance with possible adverse effects from harmonics, reflected waves and voltage drops. The carrier frequency must be carefully selected as shown on page 14. * If the carrier frequency is improperly set for long cable runs, sensorless vector operation may not produce expected performance. * Sensorless operation permits operation of one motor with one inverter. In this mode, two or more motors cannot be operated by one inverter. When operation of more than one motor is desired, configure C11 to 0: V/Hz to select Volts/Hertz operation. Line voltage drop = 3x Line resistance (mω/3) x Wiring distance (m) x Current (A) (V) 1000 Table 9 of the NEC 27

30 Local operation (Operation with OPU/keypad) The use of the OPU/keypad, in local mode, is recommended during installation. This will assist in configuring and testing of the inverter. The inverter is factory preset for local operation from the OPU. The following example shows the use of the OPU/keypad. Operation procedure Apply power Set FF or RR in the Open/OFF position when external control logic is used for operation. Apply AC input power. Always press the down arrow to go to the next step. M Hz Output frequency READY ALARM LOCAL READY ON Local operation selection Verify the operation mode (A00) of the OPU to Local (0). (Local:0 is the factory default.) A 0 0 Panel: 0 Operation mode READY ALARM LOCAL LOCAL ON Preparation for operation Verify the jogging frequency parameter B13 is configured to 5 Hz. (If not, set to 5 Hz.) M00 Jog frequency 05.00Hz Jogging operation selection Press the JOG key to select jogging operation. JOG ON Jogging operation Press FWD or REV for jogging operation of the motor with forward or reverse rotation. Press the JOG key again, and the Jogging mode changes to the normal operation mode. FWD or REV is ON while the key is being pressed. JOG OFF Operation selection Operation Verify the internal frequency settings of parameter A01 is 10 Hz and the acceleration time parameter A04 and deceleration time parameter A05 are configured for 10 sec. (If not, please enter the suggested values.) Press FWD or REV and the forward or reverse motor rotation begins with the acceleration time in parameter A04*. A Hz Acceleration time A sec Jog frequency A sec Deceleration time FWD or REV ON Stop Press the STOP key and the inverter stops in relation to the deceleration time of parameter A05*. FED or REV OFF Note: The light blinks during deceleration. * A04 and A05 are deceleration times for the frequency set by parameter B15 (60 Hz is factory default). The acceleration time up to 10 Hz is 10 x 10/60 = 1.7 sec. 28

31 Remote operation (Operation with remote control logic) External relay logic and contacts are connected to the control terminal for remote operation. Operation procedure Apply power Set FF or RR in the Open/OFF position when external control logic is used for operation. Apply AC input power. M Hz Output frequency READY ALARM LOCAL READY ON Remote operation selection Set the operation mode of the OPU/keypad parameter A00 to 1:External. Configure the frequency command selection parameter A12. See parameter table for selections. Configure the OPU/keypad to display M00 Output frequency. Refer to Section 6-3 for additional information. A 0 0 Ext.: 1 Operation command selection READY ALARM LOCAL LOCAL OFF A12 VRF 5V:1 Frequency command selection M Hz Forward Operation To select forward rotation close the contacts for FR- BC. Gradually increase the frequency command from 0 V and observe motor operation and rotation. Output frequency M Hz Output frequency FWD OFF Gradually lower the speed command to 0 V, verify the motor decelerates and stops. M Hz Output frequency Reverse operation Open the FR-BC contacts and close the RR-BC contacts to operate the motor in REVERSE. The motor will rotate in reverse. A sec Acceleration time A sec Deceleration time REV ON Stop Open the RR-BC section and the motor decelerates and stops. OFF If the inverter and motor were safely operated, the inverter can operate in normal operating modes. 29

32 USE OF THE OPERATION UNIT 6-1. OPU Display Data/Menu Easy to read LCD display. Two lines, 16 Characters (English and Japanese). This key is used for changing the position of the data/menu cursor. READY (Green) Set AF-3100α is ready for operation when illuminated. After setting respective data, press this key and the display values are written to memory. ALARM (Red) Cursor When illuminated a fault condition exists. This key is used to move the cursor to the digit to be changed. LOCAL (Green) Up / Down AF-3100α is controlled by the OPU/keypad when illuminated. This key is used to change the operation frequency, name of parameter, and data. : Increase : Decrease Forward Rotation Reverse Rotation JOG STOP Forward operation start key. The start key is pressed, run lamp turns ON; OFF when STOP is pressed and blinks during deceleration. Reverse operation START key. Start key is pressed, run lamp turns ON; OFF when STOP is pressed and blinks during deceleration. JOG mode selection key. Pressing this key illuminates the ON light, press again and the light goes off. Under normal conditions, operation stops when this key is pressed. If STOP is pressed under fault conditions, the ALARM lamp illuminates and the inverter operation is reset. * If using the remote OPU removed from the main unit of the inverter, remote operation option is required. 30

33 6-2. Display Characters or numerals highlighted by the cursor can be changed on the OPU. Parameter Menu (Line one, left side) Menu display area Press menu key. Move the cursor to line one, left side, using left arrow key and press the Up key and Down key. Change the menu as follows: When Down key is used F 0 0 E 0 0 D 0 0 C 0 0 B 0 0 A 0 0 M 0 0 When Up key is used Menu number area (Line one, left side, 2nd & 3rd characters) Parameter number Move the cursor to the 2nd and 3rd character from the left side, line one by pressing the right arrow key and press the Up key and Down key. Change the numerical value at the position of the cursor. Data area (Line one, left side, 4th character forward) Monitored value and preset value display area M (monitor) shows the monitored value. (The cursor cannot be moved, and the monitored value cannot be changed.) Menus A-F show the preset parameters. (The cursor cannot be moved, and parameters cannot be changed.) Note: Data exceeding the parameter range cannot be saved to memory. (Line two) Comment area Comments on the functions of M (monitor) and A-F (functions) are shown in English. Display in KANA characters is possible. Monitor Display menu M 0 0~ The monitor mode displays parameters such as speed, current, faults, etc. A 0 0~ Menu A (Basic parameters) Used for setting basic parameters. B 0 0~ Menu B (Frequency related parameters) Used for setting frequency related parameters. C 0 0~ Menu C (Control related parameters) Used for setting motor control related parameters. D 0 0~ Menu D (B mode parameters) Used for setting B mode related parameters. E 0 0~ Menu E (Monitor related parameters) Used for setting monitor related parameters) F 0 0~ Menu F (Special parameters) Used for setting special parameters. 31

34 6-3. Example: Changing a parameter function with OPU/keypad. Change the preset frequency of the inverter from 10 Hz to 20 Hz in local mode. Apply power. M 00 Output frequency Hz To change the frequency adjustment parameter, display parameter A 0 1. The cursor is in the menu area. Press the Up key to change the menu M 0 0 to A 0 0. (Press the Up key.) To set the frequency command parameter to A 0 1, move the cursor to the lower digit of the menu number. (Press the Right shift key twice.) To select the desired menu number A 0 1, increase by +1 by pressing the Up key. (Press the Up key.) A 00 Panel: 0 Operation command selection A00 Panel: 0 Operation command selection A Hz Frequency setting Change data in parameter A 0 1. To change the parameter data of A 0 1 from 10 Hz to 20 Hz, press the data/menu key to move to the DATA area from the MENU area. A Hz Frequency setting Move the cursor to the position under the 1 of Hz. (Press the Left shift key three times.) A Hz Frequency setting Change Hz to Hz. (Press the Up key.) A Hz Frequency setting To save the new data in parameter A 0 1, press the Set key. When the Set key is pressed, Setting end appears on line two of the display. After several seconds, the OPU/keypad displays the original Frequency setting. A01 Setting end 20.00Hz NOTE: To save the DATA, the Set key must be pressed; otherwise, the data will not be saved. A Hz Frequency setting 32

35 The parameter menu operation frequency. A 0 1 permits direct setting of the To change the parameter menu A 0 1, press the data/menu key to move from the menu area to the data area. A Hz Frequency setting Move the cursor to the position under the 1 of Hz. (Press the Left shift key three times.) A Hz Frequency setting Direct selection When the Up key is being pressed, the frequency increases. To decrease the frequency press the Down key A Hz Frequency setting Note: If a stop command is issued before the data has been saved by pressing the Set key, this data will not be saved to memory. Loss of input power will also prevent the new settings from being saved unless the Set key has been pressed. To prevent loss of data, always press the Set key. When the Set key is pressed, Setting end appears on line two and the original comment Frequency setting is displayed. A Hz Setting end A Hz Frequency setting Unless the Set key be saved to memory. is pressed, the new data will not 33

36 PARAMETER MENUS 7-1. List of parameters Basic parameters Frequency adjustment related parameters Menu Function Display Available Choices Setting Unit A B Factory Default 00 Operation command mode Operation command selection 0: Local; 1: Terminal 0: Local 01 Frequency adjustment Frequency adjustment 0.00~400.00Hz 0.01Hz 10.00Hz 02 Lower limit frequency Lower Limit frequency 0.00~120.00Hz 0.01Hz 0:00Hz 03 Upper limit frequency Upper limit frequency 0.50~400.00Hz 0.01Hz Hz 04 1st acceleration time Acceleration time 0.1~3000.0sec 0.1sec 10.0sec 05 1st deceleration time Deceleration time 0.1~ sec 0.1sec 10.0sec 06 1st acceleration/deceleration mode Acceleration/deceleration time 0: Linear acceleration; 1: S-Curve acceleration 0: Linear acceleration 07 1st S-Curve time S-Curve time 0.0~3.0sec 0.1sec 0.5sec 0: Constant torque 08 V/Hz pattern selection V/Hz pattern selection 1: Decreasing torque 0: Constant torque 2: Broken-line V/Hz 09 Boost voltage setting Manual torque boost 0.0~30.0% 0.1% 3.0% Base frequency setting Base frequency 1.00~400.00Hz 0.01Hz 60.00Hz 11 Base frequency/voltage setting Base voltage 0.0~230.0 (460.0) V 0.1V ( ): For 460V Class 0: Local 1: VRF 5V 12 Frequency command selection Frequency command selection 2: VRF 8V, 3: VRF 10V 0: Local 4: IRF 200mA Command standard frequency Command standard frequency 1.00~400.00Hz 0.01Hz 60.00Hz 14 Intermediate frequency Intermediate frequency 0.00~400.00Hz 0.01Hz 6.00Hz 15 Intermediate voltage Intermediate voltage 0.0~230.0 (460.0) V 0.1V 30.0(60.0)V 0: FWD/REV provided 16 Boost selection Boost selection 1: REV not provided; 2: FWD provided 3: Automatic 0: FWD/REV provided 00 1st frequency setting 1st frequency setting 0.00~400.00Hz 0.01Hz 20.00Hz 01 2nd frequency setting 2nd frequency setting 0.00~400.00Hz 0.01Hz 30.00Hz 02 3rd frequency setting 3rd frequency setting 0.00~400.00Hz 0.01Hz 40.00Hz 03 4th frequency setting 4th frequency setting 0.00~400.00Hz 0.01Hz 0.00Hz 04 5th frequency setting 5th frequency setting 0.00~400.00Hz 0.01Hz 0.00Hz 05 6th frequency setting 6th frequency setting 0.00~400.00Hz 0.01Hz 0.00Hz 06 7th frequency setting 7th frequency setting 0.00~400.00Hz 0.01Hz 0.00Hz st jump start frequency 1st jump frequency start 0.00~400.00Hz 0.01Hz 0.00Hz 08 1st jump end frequency 1st jump frequency end 0.00~400.00Hz 0.01Hz 0.00Hz 09 2nd jump start frequency 2nd jump frequency start 0.00~400.00Hz 0.01Hz 0.00Hz 10 2nd jump end frequency 2nd jump frequency end 0.00~400.00Hz 0.01Hz 0.00Hz 11 3rd jump start frequency 3rd jump frequency start 0.00~400.00Hz 0.01Hz 0.00Hz 12 3rd jump end frequency 3rd jump frequency end 0.00~400.00Hz 0.01Hz 0.00Hz 13 Jogging frequency setting Jogging frequency 0.00~20.00Hz 0.01Hz 5.00Hz 14 Start frequency setting Start frequency 0.00~60.00Hz 0.01Hz 0.50Hz 15 Acceleration frequency Acceleration frequency 1.00~ Hz 0.01Hz 60.00Hz 16 Frequeny bias Frequency bias -30.0~0.0~+30.0% 0.1% 0.0% 17 2nd acceleration time 2nd acceleration time 0.1~3000sec 0.1sec 30.0 sec 18 2nd deceleration time 2nd deceleration time 0.1~3000sec 0.1sec 30.0sec 19 2nd acceleration/deceleration mode 2nd acceleration/deceleration mode 0: Linear acceleration; 1: S-Curve acceleration 0: Linear acceleration time 20 2nd S-Curve time 2nd S-Curve time 0.0~3.0sec 0.1sec 0.5sec 21 8th frequency setting 8th frequency setting 0.00~400.00Hz 0.01Hz 0.00Hz 22 9th frequency setting 9th frequency setting 0.00~400.00Hz 0.01Hz 0.00Hz 23 10th frequency setting 10th frequency setting 0.00~400.00Hz 0.01Hz 0.00Hz 24 11th frequency setting 11th frequency setting 0.00~400.00Hz 0.01Hz 0.00Hz 25 12th frequency setting 12th frequency setting 0.00~400.00Hz 0.01Hz 0.00Hz 26 13th frequency setting 13th frequency setting 0.00~400.00Hz 0.01Hz 0.00Hz 27 14th frequency setting 14th frequency setting 0.00~400.00Hz 0.01Hz 0.00Hz 28 15th frequency setting 15th frequency setting 0.00~400.00Hz 0.01Hz 0.00Hz Ref. pg

37 Menu Function Display Available Choices Setting Unit Factory Default Ref. pg. 00 DC braking frequency DC braking frequency 0.00~10.00Hz 0.01Hz 0.50Hz 01 DC braking voltage DC braking voltage 0.0~30.0% 0.1% 0.0% 02 DC braking time DC braking time 0.0~10.0sec 0.1sec 0.0sec 03 Overvoltage stall prevention Overvoltage stall prevention 0: Not provided; 1: Provided 0: Not provided Regenerative braking rate Regenerative braking rate 0.0~30.0% 0.1% 0.0% 05 Stall prevention level at (constant speed) Stall prevention (constant speed) 0.0~200.0% 0.1% 160.0% 06 Stall prevention level (accel/decel) Stall prevention (Acceleration/deceleration) 0.0~200.0% 0.1% 160.0% 07 Constant output stall prevention compensation gain Stall compensation gain 0.0~100.0% 0.1% 100.0% 08 Motor rated current (Electronic thermal relay) Electronic thermal relay 0.1 ~ Inverter rated current 0.1A Inverter rated current 09 Number of motor poles Number of motor poles 0:4P, 1: 6P 0: 4P 0: General-purpose motor 1 1: General-purpose motor 2 2: General-purpose motor 3 0: General 10 Motor type setting Motor type 3: AF motor 1; 4: AF motor 2 purpose motor 1 See parameter 5: AF motor 3 200V/60Hz C12, page 47. 6: Explosion-proof motor 1 (400V/60Hz) 7: Explosion-proof motor 2 8: Explosion-proof motor 3 0: 2.2kW, 1: 3.7kW 2: 5.5kW, 3: 7.5kW C 11 Motor rated watts Motor rated watts 4: 11kW, 5: 15kW 6: 22kW, 7: 30kW *kw 41 8: 37kW, 9: 45kW 10: 55kW, 11: 75kW 12 Control method selection Control selection 0: V/Hz; 1: Sensorless 2: PG level V/Hz 13 Carrier frequency Carrier frequency 2.5Hz~*14 5kHz 0.5kHz * 14 Motor wiring cable dia. (Note) Cable diameter 3.5~325mm 2 0: 3.5m 2 15 Motor wiring cable length (Note) Cable length 10~1500m 1m 10m 16 High start torque control selection High start torque 0: Not provided; 1: Provided 0: Not provided 17 Energy saving control selection Energy saving 0: Not provided; 1: Provided 0: Not provided 18 Droop control gain Droop gain 0.0~50.0% 0.1% 0.0% 0: Provided; 1: FWD only provided 19 Slip compensation Slip compensation 2: REV only provided 3: FWD/REV not provided 0: FWD/REV provided 4: (future) 20 Motor rated current Tuning current 0.1~409.6A 0.1A * 21 Motor rated voltage Tuning voltage 0.1~230.0 (460.0) V 0.1V (400.0) V 22 Motor rated frequency Tuning frequency 50.00~120.00Hz 0.01Hz 60.00Hz Motor rated speed (rpm) Tuning speed (rpm) ~3600.0rpm 0.1rpm 0: End 24 Auto tuning selection Auto tuning selection 1: Resistance only 0: End 2: Full tuning (motor rotates) 00 B mode acceleration time Acceleration time B 0.1~3000.0sec 0.1sec 30.0sec 01 B mode deceleration time Deceleration time B 0.1~3000.0sec 0.1sec 30.0sec 02 B mode acceleration/deceleration time Accel/decel B mode 0: Linear acceleration; 1-S-Curve acceleration 0: Linear acceleration 03 B mode S-Curve time S-Curve time B 0.0~3.0sec 0.1sec 0.0sec 0: Low torque B mode V/Hz pattern selection V/Hz pattern selection B 1: Low limit torque 2: Broken-lineV/Hz 2: Break-point V/Hz 05 B mode boost voltage setting Manual torque boost B 0.0~30.0% 0.1% 3.0% B mode base frequency setting Base frequency B 1.00~400.00Hz 0.01Hz 60.00Hz 07 B mode base voltage setting Base voltage B 0.0~230.0 (460.0) V 0.1V (400.0) V 43 D B mode constant-speed stall 08 prevention level Stall prevention B 0.0~200.0% 0.1% 160.0% 09 B mode accel/decel stall prevention level Stall prevention B 0.0~200.0% 0.1% 160.0% B mode constant output stall prevention compensation gain Stall compensation gain B 0.0~100.0% 0.1% 100.0% 11 B mode intermediate frequency Intermediate frequency B 0.00~400.00Hz 0.01Hz 6.00Hz B mode intermediate voltage Intermediate voltage B 0.0~230.0 (460.0) V 0.1V 30.0 (60.0)V 0: FWD/REV provided; 1:REV not provided 13 B mode boost selection Boost selection B 2: FWD not provided; 3: Automatic 0:FWD/REV PROVIDED 44 Note: The menus C14 and C15 are displayed and can be set only when the control method selection C12 is set to 1: Sensorless. *: Differs according to the rated capacity. Control related parameters Motor B mode related parameters 35

38 Monitor related parameters Menu Function Display Available Choices Setting Unit E Note: Display and setting of E19-E24 are possible when the analog monitor card is installed. (Refer to the section Option Cards ) Display and setting of E25-E28 are possible when the relay card is installed. (Refer to the section Option Cards ) Display and setting of E29-E35 are possible when the PG card is installed. (Refer to the section Option Cards. ) 36 Factory Default 00 Output frequency detection 1 Frequency detection ~400.00Hz 0.01Hz 60.00Hz 01 Output frequency detection width 1 Frequency detection width ~400.00Hz 0.01Hz Hz 02 Frequency counter Frequency meter selection 0: Analog 1; 1: Analog 2 0: Analog output selection 2: Digital 1; 3: Digital 2 03 Frequency counter scale Frequency meter scale 1.00~400.00Hz 0.01Hz 60.00Hz Frequency counter correction Frequency meter correction -30.0~+30.0% 0.1% 0.0% 05 Custom display mode unit Custom display mode 0: No unit, 1: rpm 1: rpm 2: m/min 06 Custom display mode multiplier Custom display multiplier 0.00~ : Fault; 1: In operation 2: At Frequency 3: Frequency 1 4: Frequency 2 5: Current 1; 6 Current 2 7: FR/RR ON (RUN) 07 Digital output selection (X1) Functional terminal selection (XI) 8: Under-voltage 9: Thermal alarm 9: Thermal alarm 10: Stalling 46 11: Retry over 12: Torque detection 1 13: Torque detection 2 14: 0 speed 15: User alarm 08 Digital output selection (X2) Functional terminal selection (X2) Same as above 10: Stalling 09 Output frequency detection 2 Frequency detection 2 0.0~400.00Hz 0.01Hz 50.00Hz 10 Output frequeny detection width 2 Frequency detection width 2 0.0~400.00Hz 0.01Hz Hz 11 Current detection 1 Current detection 1 0.0~200.0% 0.1% 100.0% 12 Current detection 2 Current detection 2 0.0~200.0% 0.1% 150% 13 Instantaneous stop/start selection Instantaneous stop/start 0: Not provided; 1; Provided 0: Not provided Number of retry attempts Number of retry attempts 0~3 times 0 times 15 Retry wait time Retry wait time 0.0~10.0sec 0.1sec 1.0 sec 16 Write selection Write selection 0: enabled; 1: disabled 0: Possible 17 Fault clear Fault clear 0: Execute 18 Factory parameter reset Preset value initialization 0: Execute 0: Output frequency 1: Frequency command 19 Analog monitor AM1 selection Analog monitor AM1 2: Output current 3: Output voltage 0: Frequency 4: Overload rate; 5: Motor torque 6: Frequency 2 20 Analog monitor AM2 selection Analog monitor AM2 Same as above 2: Current 21 Analog monitor AM1 gain Monitor AM1 gain 0.0~200.0% 0..1% 100.0% 22 Analog monitor AM2 gain Monitor AM2 gain 0.0~200.0% 0.1% 100.0% 23 Analog monitor AM1 offset Monitor AM1 offset 0.0~100.0% 0.1% 0.0% 24 Analog monitor AM2 offset Monitor AM2 offset 0.0~100.0% 0.1% 0.0% 0: Fault; 1: In operation 47 2: At Frequency 3: Frequency 1 4: Frequency 2 5: Current 1 6: Current 2 7: FR/RR ON 25 Relay 1 output selection Relay 1 selection 8: Under-voltage 0: Fault 9: Thermal alarm 10: Stalling 11: Retry over 12: Torque detection 1 13: Torque detection 2 14: 0 speed 15: User alarm 26 Relay 2 output selection Relay 2 selection Same as above 0: Fault 27 Relay 1 output delay time Relay 1 delay time 0.0~10.0sec 0.1 sec 0.0 sec 28 Relay 2 output delay time Relay 2 delay time 0.0~10.0sec 0.1 sec 0.0 set Ref. pg. 45

39 Special parameters Menu Function Display Available Choices Setting Unit F 00 ES selection ES selection 0: N.O. contact; 1: N.C. contact Factory Default 0: N.O. (normally open) 0: Preset 0; 1: Preset 1 2: Preset 2; 3: Preset 3 4: JOG selection 5: Acceleration/deceleration 2 01 DFL selection DFL selection 6: B mode selection 7: Operation command 0: Preset 0 8: Frequency command 9: Hold selection 10: FRQ up; 11: FRQ down 12: Catch on the Fly DFM selection DFM selection Same as above 1: Preset 1 03 DFH selection DFH selection Same as above 2: Preset 2 04 JOG selection JOG selection Same as above 4: JOG selection 05 AD2 selection AD2 selection Same as above 5: Accel/Decel 06 BMD selection BMD selection Same as above 6: B mode selection 07 JOG acceleration time JOG acceleration time 0.1~3000; 0.1 sec 0.1sec 0.1sec 08 JOG deceleration time JOG deceleration time 0.1~3000; 0.1 sec 0.1sec 0.1sec 09 DRV selection DRV selection Same as E07/08 1: In operation 10 UPF selection UPF selection Same as E07/08 2: Frequency reaching 11 At Frequency (UPF) limit settings At Frequency limit 0.0~100.0% 0.1% 5.0% 12 Torque detection level 1 Torque detect level 1 0.0~200.0% 0.1% 100.0% 13 Torque detection level 2 Torque detect level 2 0.0~200.0% 0.1% 150.0% 0: FWD/REV 14 Permissible motor rotation Rotation permission selection 1: FWD only 0: FWD/REV 2: REV only 15 Permissible motor rotation Rotation direction selection 0: Ordinary 0: Ordinary 1: FWD < > REV 16 Display language selection Language selection 0: Japanese; 1: English 1: English 17 Operation command mode 2 selection Operation command 2 0: Local; 1: Ext. 0: Local 0: Local; 1: VRF 5V 18 Frequency command 2 selection Frequency command 2 2: VRF 8V; 3: VRF 10V 0: Local 4: IRF 20mA 19 Monitor menu selection Monitor menu M00~M19 M00 20 Accel/decel jump frequency (start) At frequency accel jump (begin) 0.00~400.00Hz 0.01Hz Hz 21 Accel/decel jump frequency (end) At frequency accel jump (end) 0.00~400.00Hz 0.01Hz Hz 22 Accel/decel time jump freq gain At frequency acceleration gain 0.1~ User alarm time User alarm time 0~30000hr 1hr 30000hr 24 DRV terminal output delay time DRV delay time 0.0~10.0sec 0.1sec 0.0sec 25 UPF terminal output delay time UPF delay time 0.0~10.0sec 0.1sec 0.0sec 26 X1 terminal output delay time X1 delay time 0.0~10.0sec 0.1sec 0.0sec 27 X2 terminal output delay time X2 delay time 0.0~10.0sec 0.1sec 0.0sec 0: Normal operation 28 Torque detect 1 Torque detect 1 1: Slow speed only 2: Fault during operation 0: Normal operation 3: Slow speed fault only 29 Torque detect 2 Torque detect 2 Same as above 0: Normal operation Ref. pg

40 7-2. Monitor (Display of condition) The monitor mode is used to display real time parameters such as, drive configuration, faults, digital input status, output parameters and more. Using the selections in parameter F19, monitor mode selections can be configured as shown below: M00: Output frequency The inverter output frequency is displayed. M01: Output voltage The inverter output voltage is displayed. M02: Output current The inverter output current is displayed. M03: Electronic thermal relay load factor The electronic thermal relay load factor for rated current (see parameter C08) is displayed. When this value exceeds 85% of rated current, the alarm lamp begins to blink. At 100% the inverter will fault. While running, if the current is less than rated current (set by parameter C08) 0% is displayed. M04: Custom display mode The display unit is set by the parameter E05 while the custom mulitplier is set by the parameter E06. The value obtained by multiplying the output frequency by the custom mulitplier set by E6 is displayed with units selected by parameter E05. Examples of custom display modes are shown below. The motor speed (rpm) and conveyor speed can be displayed. M05: Fault history 1 M06: Fault history 2 M07: Fault history 3 M08: Fault history 4 M09: Fault history 5 Fault histories are displayed. Fault history 1 shows the latest fault. The content of the fault histories is saved in non-volatile memory. M10: Torque monitor The output torque of the motor is displayed in percent (%). Parameters C09, C10, and C11 must be properly set for correct torque display. Large fluctuations in torque can be expected if using V/Hz control (C12: Control selection; V/Hz: 0) or during low speed operation. M11: VRF monitor Voltage input to terminal VRF (Frequency Adjust signal). M12: IRF monitor Current input to terminal IRF (Frequency Adjust signal) M13: Digital Input Monitor Mode This mode is used to confirm the status of the digital inputs. When the digital inputs to the terminal(s) are connected to common through a contact, a 1 (one) will be displayed; and conversely, if the digital input to the terminal is open a 0 (zero) will be displayed. All digital inputs are active low. The order of display is shown below. E05:0 M 0 4 Custom display mode FR RR ES MBS JOG AD2 E05:1 M 0 4 r p m Custom display mode M Digital input contact monitor E05:2 M 0 4 m / m i n Custom display mode BMD DFH DFM DFL RST 38

41 M14: Digital Output Monitor Mode The status of the multifunctional digital output terminals (open collector transistors) is displayed. This mode is used to confirm the status of the digital outputs. Terminal OM is the common. If the digital outputs are ON, terminals DRV, UPF, X1 and X2 are at common potential or a 0. If the digital outputs are OFF the terminals are in a high impedance state. UPF DRV X1 X2 M Digital output status monitor M15: DC bus voltage The DC bus voltage of the inverter is displayed. M16: Command frequency The command frequency is displayed. M17: Cumulative operation time The cumulative inverter operation time is displayed. This can be used as maintenance guidelines for changing cooling fans, filters and other maintenance items. M18: ROM version The inverter software version is displayed. Drive capabilities may be enhanced or parameters may change in different versions of operation software. The software version can be useful when discussing drive functions with the factory. If calling the factory, please be prepared to provide the inverters software version. M19: Double monitor Both output frequency and output current are displayed. Line one will display the output frequency and the second line will display the output current. 39

42 7-3. Parameter menus Menu A - Basic parameters Operation command mode Output frequency A03 Upper limit frequency A00: Operation command mode The operation command mode (Local: 0; Ext.: 1) is selected. Local: 0 Operation is carried out by means of the FWD, REV, JOG, and STOP keys on the OPU. Ext.: 1 Inverter operation is set by digital input signal(s) to FR/RR and/or JOG. If there is an analog input change (VRF verses IRF) and operation command mode 2 is selected, A00 setting becomes invalid, and F17 setting becomes valid. Example: When A00 = 0, F07 = 1, and F01 = 7 DFL-BC open: Operation by local key DFL-BC closed: Operation Forward-FR, Reverse-RR, or JOG. Operation frequency adjustment A01: Frequency adjustment CAUTION Frequency adjustment is allowed to 400 Hz. Confirm the allowable speed range of the motor and connected machine before adjusting the frequency. A02 Lower limit frequency 1st acceleration time setting Frequency setting A04: 1st acceleration time A05: 1st deceleration time Parameter A04 is the acceleration time for the frequency to increase from 0 Hz to the target frequency preset by parameter B15 (acceleration/deceleration frequency), as shown in the graph below. Parameter A05 is the deceleration time for the frequency to decrease from the target frequency to 0 Hz. A second acceleration/deceleration time can be selected by a digital input. Refer to B17/B18 (2nd time setting) and F01-F06 (Digital input terminal selection setting) for details. B15 Output frequency The base frequency is set by A01. Local operation of the selected frequency command is by parameter A12: 0 (local). Digital inputs can be used for selecting one of sixteen (16) preset speeds, in addition to the base frequency command. Upper/lower frequency limit setting A04 A05 Time A02: Lower frequency limit setting A03: Upper frequency limit setting The upper/lower output frequency limits are set. When the upper frequency limit and the lower frequency limit are equal, inverter operation is at that frequency. A02 greater > than A03 is an invalid setting. With an operation command input, operation is at the lower frequency limit (inclusive of 0 Hz). 40

43 Acceleration/deceleration mode A06: 1st acceleration/deceleration mode A07: 1st S-Curve time A06: This mode is selected for the 1st acceleration/deceleration parameter. Linear acceleration: 0 In this pattern, the present frequency is linearly accelerated/decelerated to the desired operation frequency. S-curve acceleration: 1 The present frequency is accelerated/decelerated in the shape of an S-curve to the desired operation frequency. This pattern is effective in alleviating the shock due to starting and stopping. The linear portion of the S-curve acceleration/deceleration is the same as the linear acceleration/deceleration time; the total acceleration/deceleration time will be increased by the S-curve time. Operation frequency Linear time A04 Letter-S time A07 A08: The V/Hz pattern is set. Constant torque: 0 For constant torque load such as conveyors, etc. A11 Base voltage Output voltage A10 Base frequency Output frequency Variable torque: 1 For variable torque loads such as fans, pumps, etc. Output voltage Linear acceleration Letter-S acceleration A11 Base voltage Time *Same applies to deceleration. V/Hz pattern A08: V/Hz pattern A10: Base frequency setting A11: Base voltage setting A14: Intermediate frequency A15: Intermediate frequency/voltage If the B mode is selected by a digital input, the B mode related parameters D07, D11, and D12 become valid. If sensorless control (C12: Control method) is selected these parameters are not used. CAUTION When the intermediate frequency is excessively high, motor instability, or inverter tripping from an overloaded motor may cause faults; in addition, other faults may occur. Refer to the motor rating nameplate to set proper intermediate frequency/ voltage. Care is required when setting the base frequency and base voltage. A10 Base frequency Output frequency Intermediate V/Hz: 2 The user s original V/Hz pattern can be configured by setting the intermediate frequency and voltage as shown below. A11 Base voltage A15 Intermediate voltage Output voltage A14 A10 Intermediate base frequency frequency Output frequency 41

44 Torque boost A09: Boost voltage The boost voltage is configured by means of the ratio percentage (%) to the base frequency/voltage. Boost selection, parameter A16, can be configured for automatic boost as well as FWD/REV, FWD or REV only. Caution must be used in this selection. A16: Boost selection Parameters D05 (B Mode Boost Voltage) and D13 (B Mode Boost selection) are valid when B Mode is selected by a digital input. When sensorless control is selected this parameter is not used. A16: FWD/REV provided: 0 A09 Boost voltage becomes valid for both forward and reverse rotation. Output voltage A11 Output voltage A09 A10 Reverse rotation Forward rotation Output frequency Automatic: 3 Irrespective of A09, the boost voltage is automatically controlled according to the load. This is effective for a load with large friction losses. Since the exciting current (corresponding to the magnetic flux) is maintained constant by this control, parameters C09-C11 must be configured correctly. A11 Output voltage Heavy load A11 0V A09 Forward/reverse rotation A10 Output frequency Light load Output frequency REV not provided: 1 A09 Boost voltage becomes invalid during reverse rotation (boost voltage: 0). This is effective when the load is in the regenerative state during reverse rotation. FWD not provided: 2 A09 Boost voltage becomes invalid during forward rotation (boost voltage: 0). This is effective when the load is in the regenerative state during forward rotation. 42 A11 Output voltage A09 A10 Forward rotation Reverse rotation Output frequency Frequency command A10 A12: Frequency command selection A13: Frequency command basic frequency CAUTION Frequency adjustment is allowable to 400 Hz. Confirm the allowable frequency range of the motor and associated machinery before adjusting the frequency. Injury to personnel and equipment damage may result. Assume the input frequency command is from VRF (0-10V). Parameter F01, DFL terminal function is configured as #8 (frequency command); parameter F18, the frequency command selection is configured as 4: IRF 4-20mA. When the digital input DFL is closed, the input frequency command is changed from VRF to IRF. Example: When the setting is A12 = 3, F18 = 4, and F01 = 8 DFL-BC open: Frequency command by 0-10 VDC DFL-BC closed: Frequency command by 4-20 ma (DC) A12: Frequency command Local: 0 The value in parameter A01 is the output frequency.

45 VRF 5V: 1 When the input voltage to the frequency adjustment input terminal VRF is 5 V, the maximum frequency is set by parameter A13. VRF 8V: 2 When the input voltage to the frequency adjustment input terminal VRF is 8 V, the maximum frequency is set by parameter A13. VRF 10V: 3 When the input voltage to the frequency adjustment input terminal VRF is 10 V, the maximum frequency is set by parameter A13. IRF 20 ma: 4 When the input current to the frequency adjustment input terminal IRF is 20 ma, the maximum frequency is set by parameter A13. If the input current is less than 4 ma, the minimum frequency is 0. A13: Command basic frequency The maximum frequency is selected by parameter A12. Menu B (Frequency related parameters) Preset frequency settings B00: 1st frequency setting B01: 2nd frequency setting B02: 3rd frequency setting B03: 4th frequency setting B04: 5th frequency setting B05: 6th frequency setting B06: 7th frequency setting B21: 8th frequency setting B22: 9th frequency setting B23: 10th frequency setting B24: 11th frequency setting B25: 12th frequency setting B26: 13th frequency setting B27: 14th frequency setting B28: 15th frequency setting CAUTION Frequency adjustment is allowable to 400 Hz. Confirm the allowable frequency range of the motor and associated machinery before adjusting the frequency parameters. Injury to personnel and equipment damage may result. One of sixteen preset frequencies may be selected by closing a combination of digital inputs configured for preset speed selection. Refer to F01-F06 for digital input configuration. The corresponding parameter selection between the digital input configuration and the preset frequency is show in the table below. Preset Preset Preset Preset Note A01 or external analog B B B B B B B B B B B B B B B Note: Selected by A12 0 implies connected to common. As shown above, 16 preset frequencies are allowed. Jump frequency configuration B07: 1st jump start frequency B08: 1st jump end frequency B09: 2nd jump start frequency B10: 2nd jump end frequency B11: 3rd jump start frequency B12: 3rd jump end frequency Jump frequencies are chosen to avoid resonance or instabilities of machinery. Jump frequencies are not allowed during acceleration or deceleration. 43

46 Output frequency Output voltage B12 B11 B10 B09 B08 B07 Jumping range Input frequency signal A13 B16 (%) 0V 4mA Bias + Bias 0 Bias 5V, 8V, 10V, 20mA Frequency setting command If the frequency is set within the jump frequency range shown in the figure above, the -mark is the set frequency. Jog frequency B13: Jog frequency While running forward or reverse the jog mode is not allowed. If jog mode is accepted, the JOG lamp on the OPU is illuminated. The jog acceleration time is configured by parameters F07 and F08. Start frequency B14: Start frequency The start frequency is the initial output frequency given as input start signal. The start/run signal will be ignored if a command frequency is given that is lower than the start frequency. While running, if the command frequency is less than the start frequency, the inverter will decelerate the motor and stop. 2nd acceleration/deceleration time setting B17: 2nd Acceleration time B18: 2nd Deceleration time The 2nd acceleration/deceleration time is selected by means of a configurable digital input selection. The 2nd acceleration/deceleration parameters are set by B19 and B20. Refer to parameters F01-F06 (digital input configuration) for 2nd acceleration/deceleration configuration. B15 Output frequency Acceleration/deceleration standard frequency B17 B18 Time B15: Acceleration/deceleration frequency setting The acceleration/deceleration frequency is the target frequency for the inverter, as shown in the graph, for the acceleration time of parameters A04 (1st accel time), B17 (2nd accel time) and D00 (B-mode accel time). And it is the deceleration time for parameters A05 (1st decel time), B18 (2nd decel time) and D01 (B-mode decel time). This parameter sets the desired output frequency. Frequency bias B16: Frequency bias setting With this parameter, a bias may be added (or subtracted) to the input frequency adjustment signals VRF and IRF as shown in the following figure. The percent value in parameter B16 is added to parameter A13 Command frequency. 2nd acceleration/deceleration mode B19: 2nd acceleration/deceleration mode B20: 2nd S-curve time B19: The 2nd acceleration/deceleration mode is valid when selected by a digital input. This digital input must be configured for acceleration/deceleration 2. 44

47 Output frequency *The same applies to deceleration. Menu C (Control related parameters) DC brake setting C00: DC braking frequency C01: DC braking voltage C02: DC braking time Linear acceleration S-curve acceleration CAUTION The DC brake cannot be used as a holding brake for extended perionds of time; in addition, the brake will not energize during a power failure. Holding brakes must be provided separately. The C02 parameter for DC braking torque affects the time and frequency during a deceleration to stop. Positioning accuracy can be improved by appropriately setting parameter C02. If the frequency command is lower than the value in parameter C00 the inverter will not start. Output frequency C00 DC braking voltage Linear time B17 S-curve time B20 C02 Time Time C03: Not provided: 0 The built-in dynamic braking transistor-resistor functions with C03 set to 0 and the over-voltage stall prevention is deactivated. If an external braking unit is connected, paramter C03 must be set to 0. Provided: 1 The overvoltage stall prevention is active with parameter C03 set to 1. This prevents operation of the built-in dynamic breaking transistor. C04: Regenerative braking rate The AF3100α provides a built-in transistor for regenerative braking in the kw range for the 200 V class and kw range for the 400 V class. A braking resistor can be connected externally, if necessary. C04: This parameter is used to prevent over heating of the dynamic breaking resistor by setting the effective duty cycle. This value should be less than the rated effective duty cycle of the braking resistor. If this parameter value is exceeded, the internal braking transistor is deactivated. For a duty cycle rate greater than 30% or if an over-voltage condition exists, use an external braking unit to prevent damage to the inverter. This setting does not apply when the inverter is not equipped with an internal braking transistor or if a braking unit is used. Stall prevention level C05: Constant speed stall prevention level C06: Acceleration/deceleration stall prevention level C07: Constant output stall prevention compensation gain Parameter C07 is used to improve the acceleration/ deceleration performance above base frequency with constant speed output. With the level set to 100% (factory setting), the current limit level will not be decreased above base frequency. If the setting is 0%, the current limit level is decreased at the rate of (Base frequency)/(output frequency). Stall prevention level C05 C06 C07: When setting is 100% C01 Time Regenerative braking C03: Overvoltage stall prevention Base frequency C07: When setting is 0% Output frequency 45

48 Electronic thermal relay C08: Motor rated current (electronic thermal relay) The rated current of the inverter is factory preset. An overload fault occurs if the current is 150% of the preset current for one minute. This overloaded condition can be monitored by the electronic thermal relay load factor set by M03. When a general-purpose motor is selected by parameter C10, the current is decreased according to the heat characteristics of the general-purpose motor. If the output current exceeds 150% of the rated current of the inverter, the electronic thermal relay operates according to the i 2 t characteristic; if the current exceeds 180% of the rated current, an overload fault occurs in 0.5 second. Selection of motor and sensorless control C09: Number of motor poles C10: Motor type C11: Motor capacity C12: Control method These parameters must be set correctly for sensorless control or for automatic boosting. The configuration method for C10 is shown below. Setting Type of Motor 230V class 460V class General-purpose motor 1 General-purpose motor 2 General-purpose motor 3 230V/60Hz 230V/50Hz 230V/60Hz 460V/60Hz 460V/50Hz 460V/60Hz 3 AF motor 1 200V/60Hz 400/60Hz 4 AF motor 2 200V/50Hz 400/50Hz 5 AF motor 3 200V/60Hz 440/60Hz Explosion-proof motor 1 Explosion-proof motor 2 Explosion-proof motor 3 230V/60Hz 230V/50Hz 230V/60Hz 460/60Hz 400V/60Hz 460/60Hz The following conditions must be satisfied for satisfactory performance in sensorless control or automatic boosting mode. An auto-tune must be done before operating the inverter. The motor and inverter capacity must be equal or not exceed +/- two motor sizes. The number of motor poles shall be 4 pole or 6 pole. One inverter should operate only one motor; consult the factory if multiple motors are used. The cable length from the inverter to the motor shall be less than 10 m / 33 ft. If the cable length exceeds 10 m / 33 ft, configure C14 and C15 or perform an auto-tune to ensure satisfactory performance. Since slip compensation is performed during operation in sensorless control mode, the preset frequency will be different from the output frequency. When the B mode is selected by the digital input terminal, the V/Hz control in the B mode is selected instead of sensorless control. Carrier frequency C13: Carrier frequency The PWM (pulse width modulation) carrier frequency is configurable. If there is a long distance between the inverter and motor, decrease the carrier frequency to prevent undesirable harmonic effects such as leakage currents and coupling to other circuits. However, lower carrier frequencies increase motor noise but reduce harmonics. Setting range: 30 kw or less khz 37 kw or less khz C14: Wiring cable diameter C15: Wiring cable length High starting torque control C16: High starting torque control When this parameter is set to Provided, the starting torque can be increased to approximately 250% with sensorless control. However, speed variances in the low-speed area may increase. Energy-saving control selection C17: Energy-saving control When this parameter is set to 1: Provided, energysaving control is active. This control is effective for fan and pump applications. Satisfactory energy-savings cannot be expected for machines that are accelerating and decelerating frequently or for those with heavy loads applied; this parameter will not correctly function under these conditions. Droop control C18: Droop control gain Configure the droop rate of the output frequency with respect to the base frequency during constant torque operation of a motor. Droop control will decrease the frequency according to the load. This function is effective for coordination of multiple motors in a process line. 46

49 Droop gain = (Droop frequency/base frequency) * 100 (%) Slip compensation C19: Slip compensation selection If sensorless control is selected, slip compensation is conducted as usual, but can be enabled or disabled selectively by choosing 0, 1, 2, or 3. Setting 0 Details of slip compensation Slip compensation for both forward and reverse rotation 1 Slip compensation only for forward rotation 2 Slip compensation only for reverse rotation 3 4 Auto-tune Droop characteristics at base frequency Load torque Rated torque Large droop gain No slip compensation for both forward and reverse rotation No slip compensation only during regenerative operation C20: Motor current C21: Motor voltage C22: Motor base frequency C23: Motor rated speed C24: Auto-tuning selection Droop frequency Small droop gain Base frequency Output frequency For automatic boosting and sensorless control, an electric constant is needed for the motor. The autotuning function automatically measures this constant of the motor. Setting Details of setting 0 No auto-tune 1 Only the wiring resistance alone is tuned. The motor will not rotate. 2 The motor constant is tuned. The motor rotates. Before auto-tuning, set the following: Parameters C09-C11 must be set correctly. Set parameters C20-C23 to the rated values as shown on the motor nameplate. Begin an auto-tune using parameter C24. The system begins the autotune mode and the READY lamp on the OPU blinks. Press the FWD or REV key on the OPU, and the autotune begins. If the auto-tune is completed with incorrect parameter settings, reset parameters C09- C11 to the factory preset values. Set parameter C12 to sensorless: 1 ; this completes the auto-tune procedure. Menu D - Motor B parameters The AF3100α is provided with a B mode (multi-motor mode) to select a V/Hz pattern and acceleration/ deceleration times for second motor; Motor B. B mode acceleration/deceleration time D00: B mode acceleration time D01: B mode deceleration time Parameter D00 is the B mode acceleration time necessary for the frequency to increase from 0 Hz to the frequency set by parameter B15 (acceleration/ deceleration standard frequency). Parameter D01 is the B mode deceleration time necessary for the frequency to decrease from the acceleration/ deceleration standard frequency to 0 Hz. If the 2nd acceleration/deceleration is selected by a digital input, the 2nd acceleration/deceleration time is given priority. CAUTION During an auto-tune, exercise proper care if the motor is connected to a machine. Parameter C24 allows for auto-tuning with motor rotation or without motor rotation. If necessary de-couple the motor shaft if damage to the machine may occur; otherwise, if coupled, ensure the motor shaft will not rotate during the auto-tuning procedure. 47

50 B15 Output frequency CAUTION If an excessively large intermediate frequency/ voltage is entered, problems such as motor instability, inverter tripping due to over-current or other faults may occur. Carefully check the motor nameplate and ratings before setting parameter D12. Constant torque: 0 D00 D01 Time Useful for constant torque loads (conveyors etc.). Output voltage B mode acceleration/deceleration mode D07 D02: B mode acceleration/deceleration mode D02: The B mode acceleration/deceleration time is active when the B mode acceleration/ deceleration mode is selected. Refer to A06 and A07 (1st acceleration/deceleration mode) for details. D03: B mode S-curve time D06 Output frequency Output frequency Linear time D00 S-curve time D03 Decreasing torque: 1 Useful for decreasing torque loads (pump, fan, etc.). Linear acceleration S-curve acceleration D07 Output voltage Time *The same applies to deceleration. B mode V/Hz pattern D04: B mode V/Hz pattern selection D04: The V/Hz pattern is set when the B mode is selected by a digital input. D06: B mode base frequency D07: B mode base voltage D11: B mode intermediate frequency D12: B mode intermediate frequency/voltage Note: D04, D06, D07, D11, and D12 are not related to sensorless control. These functions are used exclusively by the V/Hz operation. D06 Output frequency 48

51 Broken-line V/Hz: 2 The following graph shows the intermediate frequency can be set by parameters D11 and D12. D07 Output voltage Forward rotation Output voltage Reverse rotation D07 D05 D12 Output frequency D06 Output frequency FWD not provided: 2 D11 B mode torque boost D06 The boost voltage of D05 becomes invalid (boost voltage: 0) during forward rotation. This configuration is useful for up/down loads that regenerate during forward rotation. D05: B mode boost voltage The boost voltage is set by the percent of base voltage with a selection 0.0% to 30% of base voltage. See the following graph. D13: B mode boost selection D07 Output voltage Reverse rotation Forward rotation FWD/REV provided: 0 The boost voltage of D05 becomes valid for both forward and reverse rotation. D05 Output frequency Output voltage D06 D07 Auto: 3 D05 D06 Frequency The boost voltage is automatically controlled according to the load irrespective of parameter D05. This setting is useful for a large frictional load. The stator exciting current (corresponding to magnetic flux) is kept constant; parameters C09-C11 must be set correctly. If a motor with a current rating during normal operation is different from that in the B mode, do not set parameter D13 to Auto: 3. REV not provided: 1 The boost voltage of D05 is invalid during reverse rotation. This configuration is useful for up/down loads that regenerate during reverse rotation. D07 Output voltage Heavy load Light load Output frequency D06 49

52 B mode stall prevention level D08: B mode constant speed stall prevention level Output frequency D09: B mode acceleration/deceleration stall prevention level E01 E10 D10: B mode constant output stall prevention compensation gain Parameter D10 is used to improve the acceleration/ deceleration performance above base frequency in the constant horsepower (HP) area. If the setting is 100% (factory preset), the current limit level will not be decreased in the constant HP area. If the setting is 0%, the level is decreased at the rate of Base frequency/output frequency. E00,E09 Output signal H L H L Frequency counter output H Time Stall prevention level D08 D09 Base frequency D10: 0% D10: 100% Menu E (Monitor related parameters) Frequency detection Output frequency E00: Output frequency detection 1 E01: Output frequency detection 1 detection width E09: Output frequency detection 2 E10: Output frequency detection 2 detection width The digital output goes low when the frequency exceeds the value set by E00 and E09. The frequency detection width set by parameters E01 and E10, respectively, determines the upper limit of the output detection. The digital output goes high at the frequency of the sum of E00 + E01 and E09 + E10. E02: Frequency output selection E03: Frequency counter scale E04: Frequency counter correction The output terminals for the frequency counter are FRQ+ and FRQ-. When the analog output is configured, the output is 1 ma DC at the frequency set by parameter E03. When a digital output is selected by parameter E02, the digital pulse (12 volt peak value) is the same frequency as the inverter output frequency. Setting Details of setting 0 Analog, not including slip compensation 1 Analog, including slip compensation 2 Digital, including slip compensation 3 Digital, not including slip compensation The frequency counter output can be scaled within the range of -30 to +30%. Custom display mode E05: Custom display mode unit E06: Custom display mode multiplier Using monitor screen M04, motor speed (rpm), conveyor speed, and other custom speed operations may be displayed. The speed display units can be selected according to parameter E05. Parameter E06 applies a multiplier to motor speed to convert speed to other engineering units as selected by parameter E05. Since the output frequency is the default setting, the displayed values are those shown on the next page. 50

53 (Displayed value) = (E06) x (Output frequency) Example: Motor speed (rpm) Set values as follows.... 4P motor: E06 = 30 6P motor: E06 = 20 Output current E11 E12 E05 Setting M04 display 0: No unit 0: No unit is displayed 1: rpm Speed (rpm) is displayed 2: m/min Speed (m/min) is displayed Output signal H L H L H Time Digital output X1 and X2 setting E07: Digital output selection X1 E08: Digital output selection X2 The details of the digital output open collector transistors are configured as follows: Setting Details of setting 0 Inverter fault output 1 In-operation output 2 At Frequency output See F11. 3 Frequency detection 1 See E00 and E01. 4 Frequency detection 2 See E09 and E10. 5 Current detection 1 See E11. 6 Current detection 2 See E12. 7 Start contact CLOSED (FR and RR) 8 Under-voltage 9 Electronic thermal relay pre-alarm (85%) 10 Stall 11 Retry times attempts See E Torque detection 1 See F Torque detection 2 See F Zero speed detection 15 User alarm F23 Current detection E11: Current detection 1 E12: Current detection 2 When the output current exceeds the preset current values in parameter E11 and E12, the digital output goes low. Auto restart E13: Instantaneous stop/restart selection E14: Number of retry attempts E15: Retry wait time CAUTION When the instantaneous stop/start is set to Provided: 1 or the number of retry attempts is set to any value other than 0, the system will suddenly restart when the fault is removed. The machine should always be designed to ensure operational safety. Parameter E13, Instantaneous stop/start selection, permits an automatic restart if the parameter value is set to 1 and is inactive if the parameter value is set to 0. This parameter will allow automatic restarts after a temporary under-voltage condition for the input voltage supply. There are no limits to the number of restarts due to this condition. When E13 is set to 1, a temporary under-voltage condition is not regarded as a fault and the fault relay contacts FA (N.O.) and FB (N.C.) are not affected. Faults subject to the retry attempts set by E14 and E15 are over-voltage and over-current. If the number of retry attempts are exceeded, an error is generated and the inverter faults; however, faults are not output during restarts and retry attempts due to instantaneous under-voltage and over-current. Parameter E15, retry wait time, will affect the inverter after an instantaneous fault. Parameter E15, retry wait time, should be set to allow the conditions that caused the fault to be cleared. If this time is set too short, over-current, overload, or other faults may occur; attempt to set at an optimal value. Under normal operating conditions, factory presets may not need to be changed. 51

54 Write selection E16: Write selection Write protection for parameters other than E16 is set. If set, other parameters cannot be changed. However, the analog monitor for motor torque can only be used in sensorless vector mode. Example: The graph shows the monitor output for the command frequency with parameter A13 setting at 60 Hz; E21 and E22 values are 0. Fault clear Output voltage E17: Fault clear The history of faults displayed by M05-M09 is cleared. 10V Gain: 200% Gain: 100% 100% Gain: 50% Parameter reset to factory values 5V 50% E18: Parameter reset to factory values All parameters are reset to the factory preset values. The history of faults and cumulative run time are not reset. Analog monitor output signal selection E19: Analog monitor AM1 output selection E20: Analog monitor AM2 output selection Choices for E19 and E20: 0: Output frequency 1: Frequency 2: Output current 3: Output voltage 4: Percent overload 5: Motor torque 6: Output frequency 2 Analog monitor output signal gain control E21: Analog monitor AM1 gain E22: Analog monitor AM2 gain Control range: 0-200% The initial gain is 100%. (Vout equals Vin) The standard values for 0 to 10 VDC output of various signals at the gain of 100% are as follows: 0: Output frequency.... Standard frequency (parameter A13) 1: Frequency setting.... Standard frequency (parameter A13) 2: Output current Rated current of inverter 3: Output voltage Rated base voltage of inverter 4: Overload rate When the electronic thermal relay trip level is 100% or greater 5: Motor torque Rated torque of the motor 6: Output frequency 2.. Command frequency (A13) Example: When the gain is set to 50%, the output is 10 V x 0.5 = 5 V. The upper limit of the output voltage is +10 V. 0 30Hz Parameter B15 60Hz E23: Analog monitor AM1 offset E24: Analog monitor AM2 offset Controls the magnitude of the analog monitor output signal. E23: The offset value for signal AM1. E24: The offset value for signal AM2. With an initial value of 0% the range can be adjusted from 0-100% with increments of 0.01 V/0.1%. Only positive adjustments are allowed. E25: RY1 output selection E26: RY2 output selection For specifications of the relay output card refer to page 73 of this manual. Relays RV1 and RV2 are in addition to the open collector outputs. E27: Relay 1 output delay time E28: Relay 2 output delay time The contact output is delayed by the time in parameters E27 and E Hz Analog monitor output signal gain control Relay outputs Relay 1(RY1) and Relay 2(RY2) Relay output delay time Output frequency 52

55 Menu F Special parameters ES terminal configuration F00: ES terminal configuration Selects the relay logic for the input terminal ES-External fault input. 0: normally open contact is the factory preset. Selecting a 1 configures the relay as a normally closed contact. Setting Details of setting 0: Normally open contact Fault is generated if ES-BC is closed 1: Normally closed contact Fault is generated if ES-BS is open Digital input terminal configuration F01: DFL terminal configuration F02: DFM terminal configuration F03: DFH terminal configuration F04: JOG terminal configuration F05: AD2 terminal configuration F06: BMD terminal configuration These parameters configure the digital inputs DFL, DFM, DFH, JOG, AD2, and BMD. Setting Details of setting 0 Preset speed 0 Refer to Menu B. 1 Preset speed 1 Refer to Menu B. 2 Preset speed 2 Refer to Menu B. 3 Preset speed 3 Refer to Menu B. 4 JOG function Note 1 5 Acceleration/deceleration 2 function Note 2 6 B mode function Refer to Menu D. 7 8 Operation Input selection (OPU/external) Refer to A00/F17. Input frequency selection (VRF or IRF) Refer to A12/F17. 9 Hold selection Note 3 10 Frequency increase Note 4 11 Frequency decrease Note 4 12 Catch on the fly restart Note 5 Note 1: The jogging mode can be selected only when the inverter is stopped. After the inverter is started by closing FRQ Up or FRQ Down, the jog mode is latched and continues even if the jog contact is opened. Jog mode is unlatched upon return to the stop position. The jogging frequency is set by parameter B13, and the acceleration/deceleration time is set by parameter F07 and F08. Note 2: This parameter can be set irrespective of whether the inverter is at rest or in operation. The 2nd acceleration/deceleration time is set by parameters B17 and B18. Top priority is given to this acceleration/ deceleration mode except during a jogging condition. Note 3: This is set for 3-wire operation. When the hold input is selected, the digital input FR or RR is latched. Note 4: This is used to increase/decrease the frequency by a digital input. Frequency is increased or decreased as long as the contact point is closed. Note 5: Catch on the fly input. If the contact is closed, the speed is detected and an algorithm is begun to match the speed of the motor to the inverter. If the speed of rotation is low, a 0 speed restart may be conducted. Jogging acceleration/deceleration time F07: Jogging acceleration time F08: Jogging deceleration time Parameter F07 sets the time necessary for the frequency to increase from 0 Hz to parameter B15 (acceleration frequency), while parameter F08 sets the time necessary for the frequency to decrease from the command frequency to 0 Hz. B15 Output frequency F07 F08 Time 53

56 Digital outputs DRV and UPF F09: Digital output DRV F10: Digital output UPF The digital outputs are open collector transistors and can be configured the same as parameters E07 and E08. Setting 0 Inverter fault output 1 In-operation output Details of setting 2 At frequency output See F11. 3 Frequency detection 1 See E00 and E01. 4 Frequency detection 2 See E09 and E10. 5 Current detection 1 See E11. 6 Current detection 2 See E12. 7 Start contact closed 8 Under-voltage 9 Electronic thermal relay pre-alarm (85%) 10 Stalling 11 Retry attempts See E Torque detection 1 See F Torque detection 2 See F Speed detection Torque detection F12: Torque detection level 1 F13: Torque detection level 2 In cases where the torque detection is selected for a digital output, the output signal level goes low when the calculated torque exceeds the preset torque value. Again, see the following graph. Output signal Calculated torque F12 F13 H L H L H Time At Frequency F11: At frequency width setting In cases where the at frequency is selected by the digital output parameters E07, E08, F09, or F10, the output signal level goes low when the output frequency reaches the commanded frequency. The operating width of this output signal is set as a percentage of the command frequency and operates as shown in the following graph. Output frequency Command frequency F11 Time Output signal H L H OFF ON OFF 54

57 Permissible motor rotations F14: Permissible motor rotation The direction of motor rotation is selected. Setting Details of setting 0 Both forward and reverse rotation 1 Only forward rotation. Reverse rotation prohibited. 2 Only reverse rotation. Forward rotation prohibited. Auto shift accel/decel F20: Auto shift accel/decel start frequency F21: Auto shift accel/decel stop frequency F22: Auto shift accel/decel rate multiplier The acceleration/deceleration time can be changed within the preset frequency range. The ratio to the present acceleration/deceleration is set by parameter F22. See the following graph. Direction of rotation F15: Direction of motor rotation The direction of motor rotation can be changed with respect to the operation command. This function is used to change the direction of motor rotation after completion of the wiring between the motor and inverter. Output frequency F21 F20 Acceleration/deceleration control range Language selection F16: Parameter display language selection The language for the operation unit (OPU) display can be selected as Japanese: 0 or English: 1. Operation command mode 2 F17: Operation command mode 2 selection A digital input configured for operation command mode 2 (see parameter F01) provides the signal to change the operational input to mode 2. Parameter F17 is used to select the operation command with 0: local and 1: external. This allows the user to switch from external control to OPU/keypad control (or vice versa) with a digital input. Frequency command 2 F18: Frequency command 2 A digital input configured for frequency command 2 (see parameter F01) provides the signal to change the frequency reference according to parameter F18. Parameter F18 is used to select the frequency command reference. If a preset speed is selected by a digital input, priority is given to the preset speed command. Refer to A12: Frequency command for details. Monitor menu selection setting F19: Monitor menu selection Upon power up, parameter F19 selects the monitor menu that appears on the OPU/keypad. M00, Output frequency, is the factory preset. See Section I-7-2 for additional details. User alarm time F23: User alarm time The system will enter the user alarm state, and the alarm lamp on the OPU/keypad will blink when the configured value in parameter F23 exceeds the monitor display (M17-Cumulative operation time). This alarm reminds users to perform routine or scheduled maintenance to include cleaning the heat sink, and fan and of the inverter. In addition, this timer may indicate routine maintenance on the reducer directly coupled to the motor is needed. User alarm signals may be used to activate alarm lights or relays if the user alarm is configured for a digital output and wired to external devices. Digital output delay times F24: DRV digital output delay time F25: UPF digital output delay time F26: X1 digital output delay time F27: X2 digital output delay time These functions can be used to adjust the delay time to release a brake by using frequency detection, current detection or torque detection. Torque detection selection F28: Torque Detection 1 F29: Torque Detection 2 Time 55

58 TROUBLESHOOTING/MAINTENANCE AND INSPECTION DANGER Only qualified persons should attempt to inspect or repair the inverter. Do not alter, attempt repair or replace unauthorized parts in the inverter. Delay inspection of the inverter until approximately 10 minutes has passed. Potentially lethal voltages exist in the drive and may remain at dangerous levels for several minutes after the power is removed. Before attempting to service this controller, wait until the bus charged lamp goes out and measure the DC bus voltage to insure that it is zero. Check the DC voltage between P and N and confirm that it is less than 45 V OPU fault display and correction The AF3100α AC drive incorporates a number of features to assist in troubleshooting the inverter. Problems can result from the operation of drive protective circuits resulting in a fault trip, improper configuration of analog or digital inputs, improper drive connections or failure of external devices controlling the drive. The AF3100α inverters have the capabilities to help detect and correct some of the above conditions. Please refer to the following table for assistance in determining the problem. Display on OPU Check point Correction Over-current (Acceleration) Is the acceleration time too fast? Increase the acceleration time or increase the inverter Is the torque boost setting too large? capacity. Over-current Decrease the torque boost setting. (During acceleration) Is the output (U, V, and W) short-circuited or grounded? Correct the short-circuited or grounded condition. Over-current Is there a sudden load fluctuation? Decrease the load fluctuation or increase the inverter (Constant speed) Is the load too large? capacity. Decrease the load or increase the inverter capacity. Over-current (During constant-speed operation) Is an output (U, V, and W) short-circuited or grounded? Correct the short-circuited or grounded section. Over-current Is the deceleration time too fast? Increase the deceleration time or increase the inverter (Deceleration) Is the output (U, V, and W) short-circuited or grounded? capacity. Correct the short-circuited or grounded conductors. Over-current (During deceleration) Output short circuit Is the motor or cable short-circuited? Correct the short-circuited section. Output short circuit Grounding over-current Short circuit due to defective motor or cable? Correct the grounded section. Output-side grounding over-current Over-voltage Is the deceleration too fast? Decrease the deceleration time. Is the moment of inertia of the load too large? Use a braking resistor. Is there an overhauling condition from the load side? Decrease the supply voltage to within the specification Regenerative over-voltage Is the input supply voltage too high? range. Under-voltage Is there a power failure or supply voltage fluctuation? Restart operation. Are there any loads, requiring a large starting current, Examine the power supply system. Under-voltage-Insufficient connected to the same power supply system? power supply voltage External thermal Is an external fault signal (thermal relay, etc.) connected If not connected, short-circuit the terminals ES-BC to terminals ES-BC? (parameter F00: Normally closed contact). Is the fault signal from the connected equipment Remove the fault of the connected equipment. (External fault input) operating? Overload Is the setting of the electric thermal relay correct? Set an appropriate level. Is the type of motor set correctly? Set the correct type of motor. Overload Is the torque boost setting too large? Make the torque boost setting smaller. (Electronic thermal relay) Is the load too large? Decrease the load or increase the inverter capacity. Heat sink over temperature Is the cooling fan working? Change the cooling fan. Are the cooling air vents open? Clean the vents and/or remove any obstacles Is the ambient temperature too high? Cool the ambient environmental temperature. Radiation fin overheating Is the load too large? Decrease the load or increase the inverter capacity. 56

59 1.2 Troubleshooting Name of protective function Details Display (Operation unit) If the current exceeds approximately 200% for more than During acceleration Over-current (acceleration) Over-current 0.5 second of the rated current, a fault will occur. Probable During constantspeed operation Over-current (constant speed) protection causes include a high impact load during acceleration/deceleration or an overload condition during constant-speed operation. Fault results in a coast stop. During deceleration Over-current (deceleration) A fault occurs when the inverter DC bus voltage exceeds approximately 395 Regenerative volts for the 200 volt class and 790 volts for the 400 volt class. Regenerative over-voltage energy during deceleration of the motor charges the DC bus above limits Over-voltage prevention causing a fault alarm. A surge in the power supply system may also cause this fault. A fault results in a coast stop. The electronic thermal relay of the inverter detects an overload Overload prevention by means of the output current. If the current exceeds 100% (Electronic thermal of the rated current but less than 200%, the protective circuit relay) operates according to the thermal protection characteristics of Overload the inverter. A fault will occur resulting in a coast stop. Note: Multi-motor connections require individual thermal relays for each motor. (Overload rating: 60 seconds, 0.5 second) A fault occurs if a power failure to the inverters AC input Under-voltage voltage is longer than 15 milliseconds; or the DC link voltage prevention drops 20% (approximately 200 volts or less) for the 200 Volt class inverter or 15% (approximately 400 volts or less) for Under-voltage the 400 Volt class. The fault results in a coast stop. Ground fault A fault occurs if any phase is grounded (shorted to ground) or overcurrent if a current is detected in the ground circuit. The fault results Ground-fault overcurrent prevention in a coast stop. Output short circuit A fault occurs if any phase is short circuited (phase to phase, Output short circuit (IPM error) prevention phase to ground). The fault results in a coast stop. Note 1 Heatsink over This fault indicates the internal drive heatsink temperature Heat sink overheating (IPM temperature has been exceeded. The fault results in an alarm. error) Note 1 Closing the control terminals ES-BC causes an external fault External resulting in a coast stop. The input can be selected as a N.O. fault (normally open) or N.C. (normally closed) contact using parameter F00. A system reset is required to return the External thermal inverter to normal run status. Retry Number of retry attempts after a fault has been exceeded: attempts operation is not allowed. Note 2 A phase or motor lead between the inverter and motor is U-phase open Open phase detection open. The open phase in question will be displayed on the V-phase open OPU/keypad. Operation will be prohibited. W-phase open 3-phase unbalanced A fault occurs if there are unbalanced phase currents from detection the inverter to the motor. The fault results in a coast stop. 3-phase unbalance If the output current exceeds the value in parameter C06 Acceleration (Stall prevention level during accel/decel), acceleration/ deceleration is decreased until current reaches the limit set by parameter C06. Current limit stall prevention Constantspeed operation Deceleration Note 1: IMP error is displayed for units of 1.15 kw or less. Note 2: The details of the fault are displayed. If the output current exceeds the value in parameter C05 (Stall prevention level at constant speed), the inverter output frequency is decreased until the output current is within limits set by parameter C05; the preset frequency is resumed. Excessive DC bus voltage is present due to regeneration (exceeding the braking capacity). The deceleration frequency is slowed to prevent a DC bus over-voltage fault; deceleration is resumed upon the decrease in the DC bus voltage. Current limit stall prevention is also active due to over-current during decel. The current level can be set by parameter C06. 57

60 1-3. Troubleshooting Motor rotation Symptoms Possible cause Detailed Troubleshooting The motor does not run at all. Correct power is not applied. (1) Inspection of main circuit Is the power supplied within specifications? Is the motor wired correctly? The wiring is incorrect. Inspection of input signal Is there an input start signal? Are both forward and reverse rotation start signals input simultaneously? Is the frequency adjustment signal zero? Are terminals ES-BC connected (parameter F00 = 1)? Are terminals MBS-BC connected? Incorrect parameter settings. Oversized load. Inspection of parameter Is the parameter A01 setting zero when A12 operation command mode setting is 0? Are the frequency settings for various operation functions (preset speed, etc.) zero? Is the upper limit frequency zero? Inspection of load Is the load too heavy? Is the motor/shaft in a bind? The inverter protection function 1-2. OPU error display and correction is active. The rating and type of the motor used Conduct auto-tuning. (Refer to p. 47.) with sensorless control do not match Select C12 V/Hz control for motors where sensorless control the inverter parameters. is applicable. Set the parameters C09 ~ C11 of the inverter for motors where sensorless control applies. Conduct auto-tuning. (Refer to p. 47.) The motor runs in reverse. Phase sequence of the output (1) Inspection of main circuit terminals U, V, and W. Command signal is incorrect. Inspection of input signal Acceleration or deceleration The acceleration/deceleration time (1) Inspection of acceleration/deceleration time is not smooth. is incorrect. The inverter is undersized for the Inspection of load load. Excessively large torque boost Inspection of torque boost The rating and type of the motor used with sensorless control do Conduct auto-tuning. Refer to page 47. not match the inverter parameters. Select C12 V/Hz control for motors not applicable to sensorless control. Correctly set the parameters C09 ~ C11 of the inverter for motors applicable to sensorless control. Motor rotation varies Loading changes (1) Inspection of load during operation. Noise (2) Inspection of frequency adjustment signal The rating and type of the motor Conduct auto-tuning. Refer to page 47. used with sensorless control does Select C12 not match the inverter parameters. V/Hz control for motors where sensorless control is not applicable. Correctly set the parameters C09 ~ C11 of the inverter for motors applicable to sensorless control. 58

61 2. Inspection and Maintenance Always inspect the AF3100α drives upon receipt to insure that no shipping damage has occurred. If damage is suspected, contact the freight carrier immediately to file a damage claim. Also, contact your local Sumitomo Machinery Corp. of America (SMA) representative or distributor to receive a Return Material Authorization number if inspection indicates damage to the drive. Attempting to install or operate a drive which has been damaged may create a safety hazard. Preventative maintenance should include removal of dust or build-up of other materials from the heat sink, ensuring proper ventilation of the drive to prevent exceeding the rated ambient temperature of the inverter Precautions for maintenance and inspection DANGER Do not allow personnel that are not trained or qualified to maintain, perform inspection or install replacement parts; otherwise, electric shock or injury may result. Do not alter or repair the inverter; otherwise, electric shock or injury may result. Allow a minimum of 10 minutes or more after the power is turned OFF before beginning inspection; otherwise, electric shock will result Inspection items Daily inspection Check the motor during operation for the following: Is the motor operating as expected? Is the inverter within environmental specifications? Is there adequate cooling for the system? Is there any abnormal vibration or sound? Is there any overheating or discoloration of the inverter wiring? Periodical inspection The following must be checked periodically: Inspection period Every 6 months Every year Inspection item Terminal block connections and mounting bolts Inspect wiring and crimp-style terminals for corrosion or loose connections Inspect the condition of the external relay contactors and their contacts Removal of dust from the printed circuit cards, cooling fins, etc. by using compressed air that is dry and clean Confirm that replacement parts are available Note: To check the conductivity of the control circuit, use a volt-ohm meter using the high resistance range. Do not use a megger to test control circuits. 59

62 2-3. Replacement of parts Parts should be returned to our factory for inspection. They will be replaced or repaired as determined by the factory. The following parts are expected to deteriorate over a period of time, leading to the deterioration of inverter performance and possible failure; therefore, it is necessary to perform preventive maintenance. Name of parts Cooling fan DC Bus Capacitor Standard replacement period 2-3 years 5 years Method of replacement/others Replacement with a new cooling fan (Determined upon investigation) Replacement with a new capacitor (Determined upon investigation) Relays Determined upon investigation Remarks The service life of the cooling fan used for AF-3100α is approximately 20,000 hours (continuous operation at 40 C). However, the actual life is subject to the ambient temperature, etc. Use the specified fan; contact Sumitomo for replacement part number. The service life of the capacitor used for AF-3100α is approximately 35,000 hours (continuous operation at 40 C). However, the actual life is subject to the loading condition, ambient temperature, etc. As a method to check the proper time for parts replacement, the cumulative operation time can be displayed by the monitor M17 (Cumulative operation time display). 60

63 OPTION 1-1. List of options (Mounting Position) Power supply DC reactor Control unit and control resistor Circuit breaker for wiring Electromagnetic contactor AC reactor for improvement of power factor LC-type noise filter Zero-phase reactor Capacitive (XY) filter Zero-phase rector P1 P N R S T Inverter (AF-3100α) U V W Separate installation type Built-in option Name Type Use & specifications Remote control box Operator station OS-II Frequency counter (0-100%) Forward/reverse rotation command Frequency adjustment Frequency adjustment unit VR-01 Potentiometer for frequency adjustment 3 kω, 2W With scale plate and knob Frequency counter for % speed indication % speed indicator DCF-12N 0-100% display, 50 divisions 1 mamp DC full scale AC ammeter ACF-12N Inverter output current detection Combination with detection CT Surge arrestor Y122CA006 Surge arrestor for electromagnetic contactor Y220CA058~057 AC reactor (200V) Reduce the effects of long motor leads Y220CA085~095 For each voltage and capacity (400V) LC noise filter XY noise filter HF type 3XYHB (X480AC185) High attenuation filter on the inverter input side For each voltage and capacity Capacitive filter on the inverter input side Common to all capacities Zero-phase reactor RC9129 Installed on the inverter input/output side (X480AC192) Zero-phase reactor/common to all capacities Braking unit Braking unit DU type For each voltage, capacity, and braking specification Braking resistor QZG and QRZG types Consult Factory Used for inverter output signal from the relay Relay output card CF contact point (CF ) Contact rating: 230 VAC, 1 A 30 VDC, 1 A Internal parameter output via analog output Analog monitor card CD signal of the inverter CF VDC Resolution: 11 bits Note 1: For details, refer to the standard connection diagram page 16 and page 22. Motor IM 61

64 GUIDELINES FOR PERIPHERAL EQUIPMENT Circuit breaker Install a circuit breaker on the power supply side of the inverter for protection of the wiring. Refer to the National Electric Code or any local electric codes for proper sizing requirements. Refer to the table on page 13 for standard selection. Primary-side contactor An electromagnetic contactor (MC) can be used on the primary side of the inverter, but do not use the contactor to start/stop the inverter. If the contactor opens and removes power to the inverter, the motor will coast to a stop. If a DBR, dynamic braking resistor with braking unit, is used in conjunction with an MC, install proper controls to remove the MC from the circuit when the thermal relay contact of the braking unit is activated. That is, do not open the MC during a dynamic breaking operation. Secondary-side electromagnetic contactor If an electromagnetic contactor is installed between the inverter and motor, do not open/close the contactor during operation of the inverter. Using a contactor between the inverter and the motor is not recommended. Thermal relay An electronic thermal relay is incorporated in the inverter. If multiple motors are operated with one inverter, individual thermal relays must be installed for each motor. A value set for 1.1 times the rated motor current at 60 Hz operation of the motor is recommended for the operating current of the thermal relay. Power factor correction Installation of power factor correction equipment is not recommended on the input or output side of the inverter. RFI interference High frequency signals due to harmonics from the inverter circuit may cause interference with control wiring or communication equipment (AM wave) used near the inverter. Installation of an LC filter, capacitive filter, and zero-phase reactor is recommended to minimize the effects. Wiring practices 1. Long cable lengths from the inverter to the motor will produce a significant voltage drop across the cable. This voltage drop will affect the generated torque of the motor. Properly size the cable according to the National Electric Code or local electric codes. 2. Control wiring between the remote frequency/ speed potentiometer and the inverter should be less than 30 meters. Use twisted and shielded wiring installed in conduit separate from the motor wiring. Follow established wiring practices per the National Electric Code or any local electric codes. Do not run control wiring in the same conduit or wire-way with input or output AC power wires. Maintain a minimum separation of 36 inches (1 meter) between parallel conduits carrying input power or motor leads and conduits carrying control wires. If it is necessary for power and control wiring to cross, cross at a 90 angle and maintain as much separation as possible. 3. Conductors from the inverter output to the motor must be run in metallic conduit or covered metal wire-way to minimize radiated electrical interference which could affect nearby electronic devices or cause interference in communication devices. Conduit must be properly grounded. In some installations with sensitive electronic equipment, it may be necessary to use shielded cable for the motor conductors. Do not run leads from multiple drives to multiple motors in the same conduit. 4. Do not run motor leads in the same conduit as input power leads. Switching noise on the motor leads will be coupled into the AC line. 62

65 1-2. Options Operator station OS-II (UF ) (Frequency counter scale: 0-100%) Power supply MCB ACL U X V Y W Z R S T P P1 AF-3100α U V W IM φ OS-II Operator station E 25 C L Location of mounting hole Frequency meter + SP FM SN FRQ+ FRQ OPERATOR STATION Mounting hole 2-φ5.5 Forward rotation 5 Frequency adjust 3kΩ Reverse rotation FR RR BC +V VRF COM 100 Twisted wire Shielded wire Frequency adjustment potentiometer: VR-01; 3 kω; 2 W (VR01) % speed indicator: DCF-12N [1 ma F.S.] 0-100%; 50 divisions (X525AA014) φ ± ± ±1.5 Panel cut 50 ± ± ±0.5 φ30 Bakelite plate (0.8t) φ25 Mounting panel Control: 3 kω; 2 W φ9.5 Drilling of panel holes φ85 M4 (M5) Terminal screw thread M4 mounting bolt 5 45 ± ± ±1 φ87 45 ± ±0.5 4-φ5 hole Surge arrestor: Y122CA006 When the electromagnetic contactor (MC) is turned OFF, a large voltage transient is generated in the MC coil. This voltage transient may cause damage to the equipment connected to the same power supply system as the MC coil. To prevent damage to other components from this voltage transient install a surge arrestor across the MC coil. 20 ±1 32 ±1 White Red ±15 UL1015 AWG ± ±

66 AC ammeter: ACF-12N The CT (current transformer) detects the current of the secondary side of the inverter. Low frequency output from the inverter may cause large errors ±1 50 ± ±1.5 Panel cut 50 ± ± ± φ85 M4 (M5) Terminal screw thread 5 45 ± ± ±1 φ87 45 ± ± M4 mounting bolt ACF-12N 4-φ5 hole M5 thread 75 M5 thread 60 M6 thread E 110 φ Rating plate ± ± COMA-15 COM COM COM COM E = φ26 E = φ30 Combination of AC ammeter (ACF-12N) and current transformer Motor Capacity (kw) 200V class 400V class Meter CT Number of Meter CT Rated Max. primary Rated Max. current scale Type through current scale (A) (A) holes (A) (A) Type Number of primary through holes COM /5A COMA-15 20/5A COM /5A COMA-15 30/5A COM /5A COM /5A COM /5A COM /5A COM /5A COM /5A COM /5A COM /5A COM /5A COM /5A COM /5A COM /5A COM /5A COM /5A COM /5A 1 Construction of current transformer (CT) COMA-15 type: Totally molded current transformer with primary winding COM type: Totally molded current transformer of a round through window type COM type: Totally molded current transformer of a round through window type Install the CT on the output side of the inverter. 64

67 AC REACTOR (Installation) Install an AC reactor on the primary side if the inverter installation conditions are as follows: The power transformer rating exceeds 500 kva. If the rated transformer current exceeds 30 times the inverter current, a large peak current will be applied to the input rectifier section leading to possible failure of the inverter. To prevent damage from these peak AC currents, an AC line reactor must be installed. Pay particular attention with the larger capacity inverters due to the frequent operation with large transformers in series with the inverters. Unexpected changes in the supply voltage may be encountered. Example: If power factor correction capacitors are suddenly applied to the input power supply on the high voltage side of the power system. Phase control equipment is installed in the same power supply system as the inverter. The supply voltage is unbalanced. Power factor correction capacitors are installed in the power supply system supplying the inverter. Power factor correction of the power supply is necessary. Installation of an AC reactor will improve the power factor power system. Harmonic frequency suppression is required. T D1 ±5 D2 ±5 D1 ±20 D2 ±5 T D1 ±5 D2 ±5 T H1 ±5 H H1 ±5 H1 ±5 H A W ±5 4-Gφ Fig. 1 B D1 D2 A W ±5 4-Gφ Fig. 2 B T D1 D2 A W ±5 4-Gφ Fig. 3 B T Connection H1 H2 H1 H2 A W B 4 Gφ A 4 Gφ W Fig. 4 Fig. 5 Fig. 6 B 200V series 400V series Applicable Specifications capacity Item No. Weight Insula- Current (A) L (mh) Y220CA- W D1 D2 H1 H2 A B G T (kw) (kg) tion Figure M5 3.9 F M6 4.4 F M6 5.4 F M6 7.2 F M8 8.6 F M F M F M F M F 4 Applicable Specifications capacity Item No. Weight Insula- Current (A) L (mh) Y220CA- W D1 D2 H1 H2 A B G T (kw) (kg) tion Figure M4 4.2 B M5 4.4 B M5 5.5 F M6 6.3 F M6 9.0 F M F M F M F M F M10 31 F 4 65

68 ELECTRICAL NOISE FILTER Input/output filter The input/output filters are installed to reduce the electrical noise level from the inverter and prevent adverse electronic effects to peripheral equipment. The standard input-side filters are the LC-type filters, zero-phase reactor, and capacitive (XY) filter; while the standard output-side filter is the zero-phase reactor. LC filter: Attenuates most electrical noise from the inverter. Zero-phase reactor: Effective at lowering the electrical noise transmitted from the input power source. Capacitive filter: Effectively lowers the noise level in the AM radio frequency band. Capacitive filter (XY filter) (Made by Okaya Denki Sangyo) (Applicable type): Common to all capacities; 200/400 V common 3XYHB , X480AC185 Power supply MCB Minimum wiring length Black Black Black Yellow/Green Capacitive filter 3XYHB R S T E Inverter Connections Connect directly to the inverter input power supply terminals. The connections should be as short as possible. Ensure correct grounding. Grounding resistance: 100 ohms or less. This unit cannot be used on the inverter output terminals ± 1.0 φ ± ± ± mm 31.0 Soldering UL-1015AWG18 Black and yellow/green 4.5 Zero-phase reactor: RC9129 (Made by Soshin Denki) X480AC192 7x14 slot 180±2 160± φ Connections Can be used on both inverter input power supply and output (motor) power supply side. Wind the three wires of the respective phases from the input or output side three times (4 turns or more) in the same direction. If winding the wires three times (4 turns or more) is not possible because the wire is too large, install two or more zero-phase reactors beside each other to reduce the number of turns. Ensure the gap between the cable and core is as small as possible ±2 Wire size (Note) 14mm 2 or less 14~30mm 2 22mm 2 Number of winding times (turns) 3 times (4T) Once (2T) Through (1T) Qty. 1 pc 2 pcs 4 pcs Winding method Note: The size of wire may differ according to the type (i.e., insulation, AWG) of wire used. LC filter (High attenuation filter made by Soshin Denki) Contact our company for the general-purpose filter, outputside LC filter, and filters (installed on the output side) that conform to various standards (VCCI, FCC, and VDE). 66 List of LC filters Applicable motor 200V input side Weight Outline Weight Outline (kg) drawing 400V input side (kw) (kg) drawing 5.5 HF3030A-FS 3.5 HF3015C-FS HF3040A-FS 4.5 Fig. 1 HF3020C-FS 3.0 Fig HF3060A-FS 13 HF3030C-FS HF3080A-FS 22 Fig. 2 HF3040C-FS 4.5 Fig HF3150A-FS 52 HF3060C-FS HF3150A-FS 52 Fig. 3 HF3080C-FS HF3200A-FS 62 HF30100C-FS 30 Fig HF3200A-FS 62 HF30150C-FS HF3300A-FS 69 HF3150C-FS 52 Fig HF3200C-FS 62

69 Outline drawing of LC filter Dimensions (mm) Part name A B C D E F G H HF3030A-FS HF3040A-FS HF3060A-FS (Unit: mm) Part name J K L M N P Q HF3030A-FS 35 R2.75; length 7 φ M5 HF3040A-FS 40 M4 30 R3.25; length 8 φ 6.5 HF3060A-FS M6 50 Fig. 1 H ±1.5 J ±1.5 K ±1.5 4 L A ±1.5 B ±7.5 C ±1 D ±1.5 4 M Q ±1.5 G ±1 F ±1 E ±1.5 Grounding terminal Input terminal Metal case Rating plate Output terminal 2 P 3 N Fig ± ± ± ±1.5 6 M ± ± ±1 230 ± ±1 99 ±1 10 φ6.5 Fig φ6.5 Input terminal Metal case Rating plate Output terminal 3 M12 Grounding terminal 2 M6 120 ±2 250 ± ±1 290 ±2 145 ±1 145 ±1 145 ±1 145 ±1 620 ±2 710 ± ±2 100 ± ±1 Fig ± ± ±1.5 2 R2.75 Length ± ± ±1 210 ±1.5 2 φ ±1 80 ±1 110 ±1.5 Grounding terminal 2 M4 Input terminal Metal case 3 M4 Rating plate Output terminal 3 M4 67

70 Fig. 5 H ±1.5 J ±1.5 K ±1.5 4 L A ±1.5 B ±7.5 C ±1 D ±1.5 4 M Q ±1 G ±1 F ±1 E ±1.5 Grounding terminal 2 P Grounding terminal 2 P Input terminal Rating plate Output terminal 3 N Part name Dimensions (Unit: mm) A B C D E F G H J K L M N P Q HF3030C-FS M5 30 HF3040C-FS R3.75; length 8 φ 6.5 M4 HF3060C-FS M6 50 Fig. 6 E ±1.5 M ±1.5 L ±1.5 K ±1.5 Metal case Rating plate Output terminal Grounding terminal H J A ±7.5 B ±1.5 C ±1 D ±1.5 Part name F ±1 G ±1 10 N Input terminal Dimensions (Unit: mm) A B C D E F G H J K L M N P Q HF3080C-FS φ 6.5 M10 M4 HF3100C-FS M12 Fig φ6.5 Input terminal Metal case Rating plate Output terminal 3 M12 Grounding terminal 2 M6 Power supply E R S T E Inverter 145 ±1 145 ±1 145 ±1 145 ±1 620 ±2 710 ± ±2 250 ± ±1 290 ±2 100 ± ±1 200 ±2 Shortest wiring Connections Install the filter between the power supply and inverter input terminal. The line connecting the inverter and filter should be as short as possible. Grounding wire should be as large as possible. Ensure correct grounding. The input line filter and the output line filter should be separated. The filter cannot be installed on the inverter output side. 68

71 BRAKING UNIT/BRAKING RESISTOR Selection table Braking torque: 100% Type Motor Operation rate: 4% ED max. Operation rate: 10% ED max. Voltage of capacity Braking time: 7 sec. max. Braking time: 15 sec. max inverter (kw) Braking unit Braking resistor ** Braking unit Braking resistor ** Type Qty Type Qty Type Qty Type Qty AF3122-5A5 5.5 * QRZG500-18Ω 1 * QRZG500-10Ω 2 AF3122-7A5 7.5 * QRZG500-18Ω 1 * QRZG500-10Ω 2 AF * QRZG Ω 3 * QRZG Ω 3 AF3122-5A5 15 * QRZG Ω 3 * QRZG Ω 4 200V 18.5 DU-207S 1 QRZG Ω 3 DU-203S 1 QRZG Ω 5 AF class 22 DU-207S 1 QRZG Ω 3 DU-204S 1 QRZG Ω 6 AF DU-208S 1 QRZG Ω 4 DU-205S 1 QRZG Ω 8 AF DU-208S 1 QRZG Ω 4 DU-203S 2 QRZG500.16Ω 5x2 AF DU-207S 2 QRZG Ω 3x2 DU-204S 2 QRZG Ω 6x2 AF DU-207S 2 QRZG Ω 3x DU-205S 2 QRZG Ω 8x2 AF3124-5A5 5.5 AF3124-7A5 7.5 * QZG300-30Ω 2 * QRZG500-30Ω 2 AF * QRZG500-18Ω 3 * QRZG500-18Ω 3 AF DS-401S 1 QRZG500-10Ω 3 DU-402S 1 QRZG500-10Ω 4 400V 18.5 DU-401S 1 QRZG500-10Ω 3 DU-403S 1 QRZG Ω 6 AF class 22 DU-408S 1 QRZG Ω 3 DU-403S 1 QRZG Ω 6 AF DU-409S 1 QRZG Ω 4 DU-404S 1 QRZG Ω 8 AF DU-409S 1 QRZG Ω 4 DU-405S 1 QRZG Ω 10 AF DU-410S 1 QRZG Ω 5 DU-406S 1 QRZG Ω 12 AF DU-410S 1 QRZG Ω 6 DU-407S 1 QRZG Ω 16 AF DU-409S 2 QRZG Ω 4x2 DU-405S 2 QRZG Ω 10x2 * A braking resistor is incorporated into the inverter; therefore, a braking unit is unnecessary. Set parameters C03 and C04 if a braking unit is used and the operating rate of the braking resistor. ** Connect resistors in series. Wire Size (Terminal P/PR/N) Type of braking unit Wire Type of braking unit Wire DU-201S DU-401S 2mm 2 DU-202S 3.5mm 2 DU-402S 200V DU-203S DU-403S 3.5mm 2 class DU-204S 5.5mm 2 DU-404S DU-205S 8mm 2 400V DU-405S DU-207S class DU-406S 5.5mm 2 DU-208S 3.5mm 2 DU-407S 8mm 2 DU-408S 2mm 2 DU-409S DU-410S 3.5mm 2 Size of wire (terminal P/PR) for AF3122-5A5, 7A5, 011, and 015 is xxx. Size of wire (terminal P/PR) for AF3124-5A5, 7A5, and 011 is xxx. 60Hz Output frequency 0 Operating rate %ED = X 100 tb tc Operating rate %ED tb tc tb tc = Braking time (sec) = Repeating cycle (sec) Time Notes: The maximum temperature of the braking resistor is approx. 150 C. Heat-resistant wire is required. Optional Dynamic Braking resistors must be mounted in an area where heat build-up from the resistors will not raise the ambient temperature above the inverters rating. The maximum wire length shall be 5 meters (16 ft). Use twisted wire. Improper connection of P, N, and PR will lead to failure of the inverter and braking unit. Make sure that the same terminal codes are connected. Heavy-duty cycle operation of the resistors can result in resistor temperatures in excess of 300 C. The resistors must not be located near any flammable material or mounted on a surface which could be damaged by radiated heat in this temperature range. Severe burns may result from contact with the resistors in addition to possible electric shock. 69

72 Connection diagram of braking unit/braking resistor ➀ One braking unit ➁ Two braking units Inverter Inverter P N P N Braking resistor Braking resistor Braking resistor PR E P N E1 Jumper PR E P N E1 Jumper PR E P N E1 Jumper Master TA TB TC Master TA TB TC Master TA TB TC M1 M2 E2 S1 S2 M1 M2 E2 S1 S2 M1 M2 E2 S1 S2 Installation of jumper pin DBM DBM DBM DBM DBM DBM DBS DBS DBS DBS DBS DBS 460V 230V 460V 230V 460V 230V 400/440V 380V 200/220V 400/440V 380V 200/220V 400/440V 380V 200/220V Jumper Jumper Jumper The above examples show jumper installation when the inverter supply voltage is 200/220 V and 400/440 V. Precautions 1. Remove the jumpers from E1-TA and E2-TC if thermal relay output terminals TA, TB, and TC are used in external circuits. 2. When two or more braking units are used, switch the jumpers from the master (DBM) to the slave (DBS), and vice-versa. If one braking unit is used set the jumper in the master (DBM) configuration. The original setting is DBM. If the power supply is 230 VAC for the 200 V class or 380 V/460 V for the 400 V class, properly configure the jumpers for the applied voltage. Original settings are 200/220 V for the 200 V class and 400/440 V for the 400 V class. 3. If two braking units are used, connect the P and N terminals from the braking units to the P and N terminals on the inverter. 4. The wiring distance between the inverter and braking unit must be less than or equal to 5 meters (16 ft) and the distance between the braking unit and braking resistor shall also be less than 5 m (16 ft.). Wiring to be twisted. When two or more braking units are used, use twisted wire for M1, M2, S1 and S2. 5. Do not locate near flammable material as the temperature rise of the braking resistor may exceed 150 C. 6. Install the braking resistor in a well-ventilated area. 7. Incorrect connection of terminals P, N, and PR will result in failure of the inverter and braking unit. 8. When resistors other than those specified are connected, the braking unit may inadvertently fail. 9. Do not touch terminals or jumper pins if the charge lamp is lit even after the power is turned OFF. 70

73 Dimensions of braking unit Mounting hole (4 M5Bolt) Size of terminal screw thread Main Control Type circuit circuit Weight terminal terminal DU- P, PR, N M1~E2 201S, 202S 207S, 208S 401S, 402S 403S, 404S M4 408S, 409S 410S M3 203S, 204S 205S, 206S 405S, 406S M6 407S 3kg Dimensions of braking unit QRZG500 type QZG300 type φ5 φ φ ± ±

74 Higher harmonic control YES Start Calculation of equivalent capacity Is the equivalent capacity within the limit? Calculation of higher harmonic current The equivalent capacity is calculated by converting the capacity of the user s higher harmonic generator into the capacity of a 6-pulse converter and totaling the capacity of each equipment. The following formula is used for calculation. Po = KiPi Po: Equivalent capacity (conversion into 6-pulse converter) Ki: Conversion factor (Table 1) Pi: Rated capacity (kva) (Table 2) i: Type of conversion circuit Table 1 Conversion factor Table 2 Rated capacity AF-3100α Conversion Relay input capacity Pi (kva) factor Capacity of motor 200V 400V Without K31 = reactor With reactor K32 = (AC side) With reactor K33 = (DC side) With reactor K34 = 1.4 (AC/DC sides) Table 3 Limit of equivalent capacity 6.6kV 22/23kV 66kV Limit Equivalent capacity: 50 kva Equivalent capacity: 300 kva Equivalent capacity: 2,000 kva n-th degree higher harmonic current (A) = Basic wave input current (A) of higher harmonic generator x Qty of n-th degree higher harmonic (%) x Max. qty of operation/100 Basic wave input current (A) of higher harmonic generator (Table 4) Qty of n-th degree higher harmonic (%) (Table 5) Max. operation rate The capacity ratio at which the capacity of the operating equipment becomes maximum with respect to the total capacity of higher harmonic generators The operation rate is 0.5 when intermittent operation continues at the rated capacity and operating time of 1/2. The average value corresponding to the condition of operation when there is a load change in 30 minutes. Table 4 Basic input current Motor Basic input current (A) Capacity 200V 400V OK YES Is it within the guideline? NO Measures: Reactor, etc. Table 5 Qty of generated n-th degree higher harmonic Unit: % Degree 5th degree 7th degree 11th degree 13th degree 17th degree 19th degree 23rd degree 25th degree Without reactor With reactor (AC side) With reactor (DC side) With reactor (AC/DC sides) Table 6 Upper limit of higher harmonic current per kw contact power Unit: A/kW Incoming Order Voltage 5th degree 7th degree 11th degree 13th degree 17th degree 19th degree 23rd degree 25th degree 6.6kV kV kV kV Calculated n-th degree higher harmonic current < Upper limit on n-th degree higher harmonic current 72

75 Option Cards: Only one option card can be used. 1. Relay output card Part Number: CF Function: The open collector output signal is converted into the dry contact signal. Parameters E25 and E26 can be used. Contact rating: 230 VAC, 1A; 30 VDC, 1A Relay to output Terminal block Details of detection RY1 RY2 R1C R1B R1A R2C R2B R2A Output selected by relay 1 output selection (E25) Output selected by relay 2 output selection (E26) 2. Analog monitor card Part Number: CF Function: Two signals for output are selected from among the following: output frequency, frequency adjustment, output current, output voltage, and motor torque. Output signal: (1) Analog output: 0-10 VDC Resolution... 5 mv/10 V Error... Within ± 1% (Motor torque: Within ± 20%) Max. output current... 3 ma Selection of output signal: The analog signals output to AM1-COM (Parameter E19) and AM2-COM (Parameter E20) are selected as follows: Setting Signal Description Signal Level 10 V DC = 100% gain 0 Output frequency Standard frequency (Parameter A13 setting) 1 Command frequency Standard frequency (Parameter A13 setting) 2 Output current Rated current for inverter 3 Output voltage Base frequency/voltage 4 Overload rate Electronic thermal trip level 5 Motor torque When motor is 100% loaded 6 Output speed (rpm) Standard frequency (Parameter A13 setting) Internal block diagram D/A COM AM2 COM AM1 If this option is selected, E19 and E24 are automatically added to the parameter menu. Menu Function Setting range Setting for shipment E19 Selection of output signal from terminals AM1 and COM 0~6 0 (Output frequency) E20 Selection of output signal from terminals AM2 and COM 0~6 0 (Output frequency) E21 Gain control for the signal selected for output AM1 0~200% 100% E22 Gain control for the signal selected for output AM2 0~200% 100% E23 Offset control for the signal selected for AM1 0~100% 0% E24 Offset control for the signal selected for AM2 0~100% 0% Recommended wiring: twisted, shielded wire. 73

76 3. Pulse Generator (PG) Feedback Option If this option is mounted, E29 through E35 are automatically added to the parameter menu. Type: Indication: Function: CF Allows the AF3100α to operate in the vector mode with feedback from the Pulse Generator (PG). The PG card installs in the AF3100α. Analog Out (0-10 volts) AM1 Com AM2 CN2 Com CN4 PG Feedback Card CN3 B- B+ A- A+ B- B+ A- A+ CM V CN1 To CN2 AF3100α Note: For Analyog Output Signal parameters (E19 to E24) refer to the AF3100a Maintenance Manual or the AF3100a Catalog Parameters E19 through E24 allow programming the output signals AM1 and AM2. Line Driver Output shielded cable PG Parameter Function Range Factory Setting E29 PG Pulse Count 100 ~ E30 PG Standard Phase Selection 0 or 1 0 E31 Speed Proportional Gian 0.0 ~ 500% 100% E32 Speed Integral Gain 0.0 ~ 500% 100% E33 Disturbance Observer Gain 0.0 ~ 100% 70% E34 Disturbance Observer 0.01 ~ 9.99 seconds 0.05 Compensation Time E35 % Torque Limit Command 0: Panel, 1:0-5V; 0-8V, 2: 0-0 (see parameter C05) 8V; 3: 0-10V, 4: 0-20ma Settings for Analog Monitor Output Signals for AM1 and AM2. Refer to parameters E19 and E20. Setting Signal Description Signal Level 10 V DC = 100% gain 0 Output frequency Full Scale w/gain = 100% Vout + 10 Volts 1 Command frequency Command Frequency 2 Output current Rated Current for Inverter 3 Output voltage Base Frequency Voltage 4 Overload rate Electronic Thermal Trip 5 Motor torque 100% motor load 6 Output speed (rpm) Standard frequency command PG Card Relay Card Analog Card 74

77 The parameter menu automatically adds E19-E24 if the optional analog monitor card is used. Analog monitor output signal selection E 1 9 E 2 0 E 1 9 Analog monitor AM1 (0-5) Analog monitor AM2 (0-5) The signal configured for analog output AM1 is selected from the list below: Available Selections: 0: Output frequency 1: Frequency setting 2: Output current 3: Output voltage 4: Overload rate 5: Motor torque E 2 0 The signal configured for analog output AM2 is selected from the list below: Output voltage 10 V Gain: 200% Gain: 100% 100% Gain: 50% 5 V 50% 0 30 Hz B15 setting 60 Hz 120 Hz Output frequency Gain control for the analog output signal. E 2 1 E 2 2 Monitor AM1 gain 0-200% Monitor AM2 gain 0-200% The magnitude of the analog monitor output signal is controlled. The signal gain for AM1 or parameter E21 is limited to 200%. The signal gain for AM2 or parameter E22 is limited to 200%. Control range: 0-200% Initial setting: 100% The output voltages for the following signals with a gain of 100% are shown as follows: 0: Output frequency... Standard frequency (Parameter B15 setting) 1: Frequency setting... Standard frequency (Parameter B15 setting) 2: Output current... Rated current of inverter 3: Output voltage... Base voltage 4: Overload rate... When the trip level of electronic thermal relay is 100% 5: Motor torque... When the motor is 100% loaded Example of action: Monitor output for the output frequency when the B15 setting is 60 Hz and E21 and E22 are set to 0. When the gain is 50%, 10 V x 50%/100% = 5 V is output. The upper limit of the output voltage is +10 V. The motor torque can be used only during sensorless operation. Offset control for analog monitor output signal E 2 3 E 2 4 Monitor AM1 offset (0-100%) Monitor AM2 offset (0-100%) The magnitude of the analog monitor output is controlled. E 2 3 E 2 4 The signal offset value for AM1 is limited to 100%. The signal offset value for AM2 is limited to 100%. The control range is 0-100% at the rate of 0.01V/0.1%. Control is possible only in the positive direction. 75

78 (WARNING) MAKE SURE POWER LINE IS TURNED OFF BEFORE REMOVING OPERATOR STATION. Remote control OPU/keypad. Optional When placing an order, if necessary, specify the remote control OPU. Built-in RS-232C-IC card Flat cable OPU with built-in RS-232C Connector The operation unit (OPU) shown in the photo can be panel mounted on the enclosure door. Knockout dimensions for front mounting MOUNTING HOLES (2-M4 BOLTS) Knockout dimensions for front mounting READY ALARM LOCAL FWD RUN REV DATA MENU SELECT JOG SET RESET STOP MAX R

79 SPECIFICATIONS 200V class Braking Torque Power Supply Output Type AF3122 AF3122 AF3122 AF3122-5A5-U -7A5-U -011-U -015-U Applicable motor output (kw) Rated capacity (kva) Note Rated current (A) Rated overload current Note 2 150% 1 min; 200% 0.5 sec Rated voltage (V) Note 3 3-phase; 200~230V Phase/voltage/frequency 3-phase; 200~220V/50Hz, 200~230V/60Hz Voltage & frequency variance Voltage: -15% and +10% Frequency: ±5% Required power capacity (kva) Note Standard Approx. 10% If option is used Type Braking resistor Torque 150% or greater, short duty cycle Protective construction Open Note 6 NEMA1 Cooling method Forced air cooling Approx. weight (kg) Note Note 1: Rated output voltage is 220 V. 2: The ratio (%) to the rated current of the inverter. 3: The maximum output voltage will not exceed the supply voltage. Any desired voltage smaller than the supply voltage can be set. 4: If an AC line reactor (AC/DC: option) is used. 5: The braking torque and the operation rate are subject to the braking unit and braking resistor used. 6: UL Approved in open chassis only (enclosure same as all other models). 400V class Braking Torque Power Supply Output Type AF3124 AF3124 AF3124 AF3124 AF3124 AF3124 AF3124 AF3124 AF3124 AF3124-5A5-U -7A5-U -011-U -015-U -022-U -030-U -037-U -045-U -055-U -075-U Applicable motor output (kw) Rated capacity (kva) Note Rated current (A) Rated overload current Note 2 Rated voltage (V) Note 3 Phase/voltage/frequency 150% 1 min; 200% 0.5 sec 3-phase; 380/V, 400~440V and 460V 3-phase; 380Vand 400~420V/50Hz; 400~440V and 460V/60Hz Voltage & frequency variance Voltage: Within -15% and +10% Frequency: Within ±5% Required power capacity (kva) Note Standard Approx. 10% If option is used Type Braking resistor Braking resistor and braking unit Torque 150% or greater, short duty cycle 100% or greater Note 5 Protective construction Open Note 6 NEMA 1 Cooling method Forced air cooling Approx. weight (kg) Note 1: The rated output voltage is 440 V. 2: The ratio (%) to the rated current of the inverter. 3: The maximum output voltage will not exceed the supply voltage. Any desired voltage smaller than the supply voltage can be set. 4: If an AC line reactor (AC/DC: option) is used. 5: The braking torque and the operation rate are subject to the braking unit and braking resistor used. 6: UL Approved in open chassis only (enclosure same as all other models). 77

80 COMMON SPECIFICATIONS 1-a. Control 1-b. Control method Control Display Environment Control method Sensorless flux vector, V/Hz, closed loop vector Output frequency range 0~400.00Hz Frequency adjustment resolution 0.01 Hz: Digital setting 1/1000 of max. output frequency: Analog setting Frequency accuracy 0.01% of preset frequency: Digital setting Within ± 0.5 % of max. frequency (25 ± 10 C) Carrier frequency Variable: The maximum carrier frequency decreases for 30 kw or greater. Voltage/frequency characteristics Three separate V/Hz patterns are possible. Torque boosting Manual boosting (variable: 0-30%), automatic boosting, and sensorless speed control (automatic tuning) DC braking Variable braking frequency start, Hz; operation time, 0-10 sec; operation voltage, 0-30%. Acceleration/deceleration time 0.1-3,000 sec; selection of linear or S Curve; 1st and 2nd settings Frequency Digital Digital operation unit adjustment signal Analog DC 0~5V, 0~8V, 0~10V, 4~20mA Stall prevention Variable: 0-200% (Factory preset at 160%) Starting torque 200% or greater if sensorless control is selected. Speed variance rate ± 0.2% or less. The load is 0-100% when sensorless control is selected. Trip-less operation Current limit during constant speed operation, current limit during acceleration/deceleration, overvoltage stall prevention, instantaneous overcurrent limit function, and instantaneous stop restart function Coast stop, external fault, FWD, REV rotation, external wiring. The following digital inputs are programmable. Note 1: Operation input signal Preset speed selection, JOG selection, 2nd acceleration/deceleration selection, B mode selection (See Note 2), operation command selection, frequency command selection, hold selection, frequency increase, frequency decrease, and catch on the fly start Fault output via contacts FA and FB The following open collector outputs (See Note 3): Output signal Inverter fault output FA and FB, in operation, at frequency, frequency detection 1, frequency detection 2, current detection 1, current detection 2, start contact point ON, under-voltage, electronic thermal pre-alarm, stalling, retry attempt, torque detection 1, torque detection 2, zero speed detection, and user alarm Operation function Upper/lower limit frequency setting, jump frequency, frequency bias, and instantaneous stop restart operation Output frequency, output voltage, output current, overload rate, custom display (display converted Condition of operation motor/load shaft speed (rpm) and line speed with unit indication), torque monitor, VRF monitor, IRF monitor, input/output contact point monitor, DC bus voltage, command frequency, cumulative operation time, ROM version, and two line display, such as output frequency and output current Preset information Display of parameter and data Fault display Upon a protective function (fault) the details are displayed. Up to four preceding errors can be displayed. Suggested locaton Indoor. There shall be no corrosion, toxicity, inflammable gas, dust, or oil mist. Ambient temperature -10 to +40 C (+ 50 C when installed inside the panel Note 4) Storage temperature -10 C ~ + 60 C Ambient humidity 90% RH or less (Dew condensation not allowed) Altitude 1000 m or less above sea level Vibration 0.6 G or less (As per JIS C0911) Note 1: Six out of eleven functions can be selected by setting parameters. 2: In addition to normal operation, the functions of acceleration/deceleration, V/Hz pattern, boost, and stall prevention can be changed. It is advantageous when two motors with different capacities are controlled by one inverter. 3: Four out of 15 functions can be selected by setting the appropriate parameters. 4: The maximum allowable temperature of 50 C can be achieved by removing the front cover if the equipment is installed inside an enclosure. 5: The base is the speed (rpm) at the base frequency. 78

81 1-2. Internal block diagram Note 3 MCB ACL U X R Converter R P1 P N Inverter U Motor Power supply V W Y Z S T + C V W IM Note 4 Selection of supply voltage for 400 V class FAN S1 TX1 TX2 200 V class TX3 Control power + 24 V CHARGE Voltage detection Current detection Gate drive circuit E Grounding Grounding Forward rotation Reverse rotation FR RR PWM circuit Protective circuit Note 1: Digital input DFL DFM DFH JOG AD2 CPU ROM FRQ* FRQ* (Meter specification: DC 1 ma F.S.) Frequency counter DCF 12N + - FM Note 5 External fault Alarm reset Coast Frequency adjust VR 01 3 kω 3 2 DC 0 ~ 10 V 1 4 ~ 20 ma + COM - BMD ES RST MBS BC + V VRF COM IRF + 10 V OPU Operation unit Output signal circuit AR + 5 V FA FB FC DRV UPF X1 X2 OM Error contact point output 230 VAC; 1 A max. 30 VDC; 1 A max. When an error occurs: FA-FC closed FB-FC open Note 2: Digital output Open collector common (Open collector output: 24 V, 50 ma max.) Twisted line Shielded line Option Note 1: 13 kinds of input functions can be allotted individually by setting parameters. Note 2: 15 kinds of input functions can be allotted individually by setting parameters. Note 3: Remove the short bar when a DC reactor is connected. Note 4: The 200 V class has no TX1, TX2, and TX3 terminals. Supply voltage is preset as follows: S1-TX1 short circuit for 380 V, S1-TX2 short circuit for 400/440 V, and S1-TX3 short circuit for 460 V. Note 5: The setting can be changed to B contact point input by setting the parameter. *1: 13 separate functions can be programmed. *2: 15 separate functions can be programmed. *3: Remove the jumper if a DC reactor is connected. *4: The 200 V class has no TX1, TX2, and TX3 terminals. Supply voltage is preset as follows: S1-TX1 short circuit for 380 V, S1-TX2 short circuit for 400/440 V, and S1-TX3 short circuit for 460 V. *5: The setting can be programmed to a normally closed relay. 79

82 FWD READY ALARM LOCAL RUN REV (WARNING) MAKE SURE POWER LINE IS TURNED OFF BEFORE REMOVING OPERATOR STATION. DATA SET MENU SELECT JOG RESET STOP FWD READY ALARM LOCAL RUN REV (WARNING) MAKE SURE POWER LINE IS TURNED OFF BEFORE REMOVING OPERATOR STATION. DATA SET MENU SELECT JOG RESET STOP FWD READY ALARM LOCAL RUN REV (WARNING) MAKE SURE POWER LINE IS TURNED OFF BEFORE REMOVING OPERATOR STATION. DATA SET MENU SELECT JOG RESET STOP 1-3. Outside dimensions 5.5, 7.5kW 200V/400V 15kW 200V/400V 4 ø10.0 (0.39) 10 (0.39) 330 (12.99) 372 (14.65) 380 (14.96) 400 (15.75) 7 (0.28) 7 (.028) 12 (0.47) 180 (7.09) 12 (0.47) 204 (8.03) 16 (0.63) 201 (7.91) 66 (2.60) 21 (0.83) 190 (7.48) 232 (9.13) 21 (0.83) 10 (0.39) 123 (4.84) 241 (9.49) 6 ø32.0 (1.26) 4 M8 22, 30kW 400V (18.11) (23.23) (24.35) (10.24) (12.20) 65 (2.56) (4.96) (10.63) 3 ø62 (2.44) ø44 (1.73) Dimensions in mm (inch) 80

83 FWD READY ALARM LOCAL RUN REV (WARNING) MAKE SURE POWER LINE IS TURNED OFF BEFORE REMOVING OPERATOR STATION. DATA SET MENU SELECT JOG RESET STOP FWD READY ALARM LOCAL RUN REV (WARNING) MAKE SURE POWER LINE IS TURNED OFF BEFORE REMOVING OPERATOR STATION. DATA SET MENU SELECT JOG RESET STOP 37, 45kW 400V 4 M8 Numbers in ( ) = inches 140 (5.51) 640 (25.20) 845 (33.27) 330 (12.99) 376 (14.80) 275 (10.83) 118 (4.65) 439 (17.28) 4 M10 6 ø50 (1.97) 55, 75kW 400V (7.58) (28.15) (29.13) (39.76) (15.75) (19.88) (22.52) (11.73) (5.17) ø52 (1.73) 6 ø52 (2.05) OPTIONAL BRACKET (5.11) (20.87) (21.77) 81

84 1-4. Measurements for external installation of inverter heat sink AF-3100α 5.5~7.5kW/ V AF-3100α 11~15kW/ V (12.40) (12.99) (14.37) (14.96) (7.09) (7.80) 6.0 (.236) (7.48) (9.25) AF-3100α 22~30kW/400V AF-3100α 37~45kW/400V (7.28) (17.17) (18.11) (7.28) (23.82) (7.28) (10.24) (12.44) AF-3100α 55k~75kW/400V (14.96) (15.75) (8.46) (8.46) (27.17) 12.5 (0.49) (8.46) 10.0 (0.39) (20.08) (20.79) 82

85 NOTES 83

86 NOTES 84

87 Headquarters and Manufacturing Sumitomo Machinery Corporation of America 4200 Holland Boulevard, Chesapeake, VA (757) FAX: (757) Toll Free: SM-CYCLO ( ) ISO 9001 C E R T I E D IF North American Regional Offices Stocking & Assembly Facilities Mid-West 175 West Lake Drive Glendale Heights, IL (630) FAX: (630) West 2375 Railroad Street Corona, CA (909) FAX: (909) Southwest 1420 Halsey Way #130 Carrollton, TX (972) FAX: (972) Northeast 501 Office Center Dr., Suite 260 Ft. Washington, PA (215) FAX: (215) Teterboro 7 Malcolm Avenue Teterboro, NJ (201) FAX: (201) Southeast 4200 Holland Boulevard Chesapeake, VA (757) FAX: (757) Canadian Stocking & Assembly Facilities Toronto (East) SM-CYCLO OF CANADA, LTD. 870 A Equestrian Court Oakville, Ontario, Canada L6L 6L7 (905) FAX: (905) British Columbia (West) SM-CYCLO OF CANADA, LTD. 740 Chester Road, Annacis Island, Delta B.C., Canada V3M 6J1 (604) FAX: (604) Montreal SM-CYCLO OF CANADA, LTD. 226 Migneron Street St. Laurent, Quebec, Canada H4T 1Y7 (514) FAX: (514) Mexico Monterrey SM-CYCLO DE MEXICO, S.A. DE C.V. Calle C No. 506A Parque Industrial Almacentro Apodaca, N.L., Mexico Tel.: /8 FAX: Central & South America Sales, Engineering, Stocking & Assembly Brazil SM-CYCLO REDUTORES DO BRASIL LTDA. Av. Dr. Ulysses Guimarães, Diadema São Paulo, Brazil Tel.: FAX: Chile SM-CYCLO DE CHILE LTDA. Napoleon 3565, Of. 510 Las Condes - Santiago, Chile Tel.: FAX:

88 SPEED REDUCER GEARMOTOR SHAFT MOUNTED GEARMOTOR BEVEL GEARMOTOR SM-CYCLO Concentric LOW RATIO PLANETARY SM-CYCLO Concentric PRECISION CYCLO SM-HELICAL BUDDYBOX Parallel Offset SM-BEVEL BUDDYBOX Right Angle SUMITOMO QuaDelta PROGRAM Providing THE AVAILABLE SOLUTION, WORLDWIDE SM-CYCLO Concentric Concentric ALL DRIVES GEAR BOXES MOTORS CONTROLLERS MECHANICAL VARIABLE SPEED ELECTRICAL VARIABLE SPEED ALL TYPES CONCENTRIC PARALLEL OFFSET RIGHT ANGLE ALL SPEEDS CONSTANT SPEED MECHANICAL VS ELECTRICAL VS SM-BEIER AF-3100α AC Drive NTAC-2000 AC Drive WORLD- WIDE THE AMERICAS ASIA EUROPE HELICAL GEAR REDUCER SHAFT MOUNT SPEED REDUCER Power Transmission Products 4200 Holland Blvd., Chesapeake, VA (757) FAX: (757) Toll Free: SM-CYCLO Web: DISTRIBUTED BY: ISO 9001 C ER T IE D IF PARAMAX Parallel Offset & Right Angle SM-SHAFT MOUNT Parallel Offset DOUBLE SHAFT MOUNT ENVELOPING WORM SPEED GEAR REDUCER SHAFT MOUNT GEARMOTOR SPEED REDUCER WORM GEARMOTOR PARTS & SERVICE SM-HEDCON SM-SHAFT MOUNT Right Parallel Angle Offset SM-HYPONIC SM-SHAFT MOUNT Right Parallel Angle Offset SM-ULYSSES Right Angle WORLDWIDE