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Hitachi SJ100 SERIES Service Manual

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SJ100 SERIES
SERVICE MANUAL
(ADJUSTMENT AND MAINTENANCE)
Model:
European Version
SJ100-002NFE to SJ100-022NFE
SJ100-004HFE to SJ100-075HFE
US Version
SJ100-002NFU to SJ100-022NFU
SJ100-004HFU to SJ100-075HFU
SJ100-037LFU
Japanese Version
SJ100-002LFR to SJ100-037LFR
SJ100-004HFR to SJ100-075HFR
After reading this manual, keep it at hand for future reference
Hitachi, Ltd.
HITACHI INVERTER
Tokyo Japan
NBS585XA

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  • Page 1 HITACHI INVERTER SJ100 SERIES SERVICE MANUAL (ADJUSTMENT AND MAINTENANCE) Model: European Version SJ100-002NFE to SJ100-022NFE SJ100-004HFE to SJ100-075HFE US Version SJ100-002NFU to SJ100-022NFU SJ100-004HFU to SJ100-075HFU SJ100-037LFU Japanese Version SJ100-002LFR to SJ100-037LFR SJ100-004HFR to SJ100-075HFR After reading this manual, keep it at hand for future reference NBS585XA Hitachi, Ltd.

  • Page 2: Table Of Contents

    INDEX 1. Pre-operation Check 1-1. Check inverter model and Manufacturing number 1-2. Check inverter parameter and motor specification 2. Measurement of The Internal Voltage Supply 3. Trouble Shoot 3-1. Error messages - Possible Cause and Remedy 3-2. Analysis of Various Operating Problems That Do Not Trigger an Trip Message 3-3.
  • Page 3 Revisions Revision history table Revision contents Date of issue Manual No.

  • Page 4: Pre-Operation Check

    Output/Sortie: 1-360Hz 200-240V 7.1 A MFG No. 78H T1129670060 Date: 9708 Hitachi, Ltd. NE16452-6 MADE IN JAPAN You can find these information from the specification label which attached at the side cover of the unit. (1) Description of the model name.

  • Page 5: Check Inverter Parameter And Motor Specification

    1.2 Check Inverter parameter and motor specification. [1] Inverter specifications. (1) Inverter specifications (Monitor mode) Display Function name Category Screen display Initial Remarks order Code display Output frequency monitor Monitor Output current monitor Monitor Running direction monitor Monitor Feedback data of PID Monitor control monitor Intelligent input terminal...
  • Page 6 (3) Inverter specifications (Extended function mode : A group) Display Function name Category Screen display Initial Remarks Order Code display A20 - A35 Multi-speed 1 to 16 Note 1 Jogging frequency Stop mode of jogging Torque boost mode A241 Torque boost mode(2 setting) Level of manual torque boost...
  • Page 7 (4) Inverter specifications (Extended function mode : B group) Display Function name Category Screen display Initial Remarks Order Code display Selection of restart mode Allowable UV time Retry waiting time Electronic thermal level note note note Rated current of each inverter Electronic thermal level B212 note...
  • Page 8 (5) Inverter specifications (Extended function mode : C group) Display Function name Category Screen display Initial Remarks Order Code display Input terminal 1 assign Input terminal 2 assign Input terminal 3 assign Input terminal 4 assign Input terminal 5 assign Input terminal 6 assign Input terminal 1 condition Input terminal 2 condition...
  • Page 9 (6) Inverter specifications (Extended function mode : H group) Display Function name Catego Screen display Initial Remarks Order Code display Auto tuning setting Motor data selection Motor data selection(2 H202 setting) Motor capacity setting Motor capacity setting(2 H203 setting) Motor poles setting Motor poles setting(2 setting) H204...
  • Page 10 [2] Motor specifications. Output voltage Output frequency Motor MFG number Motor output Rated current Amps Motor poles Rated voltage Motor rated rpm Rated frequency Starting current Amps [3] Load conditions Equipment name Torque characteristics Acceleration time Required torque Deceleration time Load inertia (J) Variable speed range Hz to...

  • Page 11: Measurement Of The Internal Voltage Supply

    2. Measurement of the Internal Voltage Supply There are PV5L, PV24L and NV12L internal DC voltage supplies. These supplies are isolated from the main high voltage portion. And it is not possible to measure DC voltages at the non isolated portion. Please make measurements for above mentioned voltages for the isolated portion.

  • Page 12: Trouble Shoot

    3. Trouble Shoot 3-1. Error Messages - Possible Cause and Remedy: (1) Over current 1 (E 01, E 02, E 03, E 04) Phenomena: Over current (CT or Rsh;gate driver IC) for each condition. E 01 : Over current during constant speed operation. E 02 : Over current during deceleration.
  • Page 13 Specimen ; “CO FBE4 01 0000” ; under normal; 0Hz “CO FBE4 15 0203” ; under over.C trip “CO FBE4 15 C203” ; under OC.Drive trip. “CO FBE4 15 4103” ; under OC.Accel trip “FBE4” or “FBE2” is 1 byte data, the data is hex data. Example “4103”; “03” has no meaning. Resolve “41”h bit by bit, “41”h ->...
  • Page 14 (4) Over voltage (E 07) Phenomena: Over voltage at DC bus line of the frequency inverter. Cause: Mains voltage too high, mains voltage fluctuation or rapid mains voltage return (choke energy leads to voltage increase). Remedy: Make sure that mains voltage is within tolerance limits. Cause: In case SJ100 is used in combination with a regenerative braking unit(ISPM)/ resistor but the regenerative braking unit(ISPM)/resistor does not function.
  • Page 15 Cause: Re-power up the frequency inverter short time after power off. It is necessary to keep several seconds after power off to memorize the current data at EEPROM. If this time is too short, this storage performance cannot be done and leads to EEPROM error.
  • Page 16 Cause: Component itself is defect. Remedy: Replace ISPM (in case of E 11) or I/O board board (in case of E 12). (9) External Trip (E 12) Phenomena: Trip due to have inputted an external signal to “EXT” input terminal of the frequency inverter.
  • Page 17 (13) Over temperature (E 21) Phenomena: Temperature sensor which located close to IGBT inside ISPM shows a too high temperature. Cause: Ventilator blocked. (for models which has ventilator.) Remedy: Check ventilator Cause: The frequency inverter does not get enough cooling air. Remedy: Check cabinet ventilation, air filters, and ventilation openings in the cabinet.

  • Page 18: Analysis Of Various Operating Problems That Do Not Trigger An Trip Message

    3-2. Analysis of Various Operating Problems That Do Not Trigger an Trip message. Problem Possible cause Remedy The motor does not start Mode of frequency command [A01] Check each mode again and/or Run command [A02] is not proper Incorrect power supply condition Check that the power supply is within its specification Inverter is in trip mode...

  • Page 19: How To Initialize The Data (Factory Setting)

    3-3. How to Initialize the Data (FACTORY SETTING) 1. Select the mode of initialization data to which you want to initialize by [b85]. Japanese version data -----> Set “00” and store EU version data -----> Set “01” and store US version data ----->...

  • Page 20: Error Message Comparison

    3-4. Error Message comparison Digital Panel DOP / DRW Contents Over current while constant speed OC. Drive driving (CT or gate driver IC) Over current while deceleration (CT or OC. Decel gate driver IC) Over current while acceleration (CT or OC.

  • Page 21: Other Displays

    3-5. Other Displays Digital Panel Contents - Reset terminal is ON - During initialization (such as at power-on) - Voltage is within UV level - Power OFF - During retry mode - During initialization as EU settings - During initialization as US settings - During initialization as Japanese settings - Erasing trip histories - Copying with DRW,DRW-2...

  • Page 22: Ambient Condition Of The Frequency Inverter (Temperature, Altitude)

    4. Ambient Condition of the Frequency Inverter 4-1. Required Derating in case of 50deg, 55deg of Ambient Temperature Inverter ratings can be influenced by many factors. You can find in this section, the relation between ambient temperature and output current (%) and carrier frequency. Standard ratings in 40 degree C Top cover removed condition in 50 degree C max.
  • Page 23 SJ100-037LF(U) SJ100-022NFE(U) 100% 100% Carrier frequency [kHz] Carrier frequency [kHz] SJ100-007HFE(U) SJ100-004HFE(U) 100% 100% Carrier frequency [kHz] Carrier frequency [kHz] SJ100-022HFE(U) SJ100-015HFE(U) 100% 100% Carrier frequency [kHz] Carrier frequency [kHz]...
  • Page 24 SJ100-040HFE(U) 100% Carrier frequency [kHz] SJ100-055LFU SJ100-075LFU 100% 100% Carrier frequency [kHz] Carrier frequency [kHz] SJ100-055HFE(U) SJ100-075HFE(U) 100% 100% Carrier frequency [kHz] Carrier frequency [kHz]...

  • Page 25: Required Derating Toward Altitude

    4-2. Required derating toward altitude 100% 1000 2000 3000 4000 Altitude [m] Example of calculation SJ100-007NFE (4 Amps) is installed at 2000m of altitude and 16kHz of carrier frequency. Required derating of output frequency of this case will be as follows. 4 [Amps] * 90% * 95% = 3.4 [Amps] Carrier frequency derating Altitude frequency derating...

  • Page 26: Level Of Each Detection

    5. Level of Each Detection 5-1. DC Bus Voltage Detection Characteristics Frequency inverter has several detection characteristics for DC bus voltage as followings. [1] 200V class DC bus voltage [Vdc] Over voltage level 395V +- 20V BRD on/off level 370V +-20V Actual DC bus voltage Under voltage...
  • Page 27 [2] 400V class DC bus voltage [Vdc] Over voltage level 790V +- 40V BRD on/off level 740V+-40V Actual DC bus voltage Under voltage recovering level 440V +- 20V Under voltage level 380V +- 20V Trip Trip Trip Reset Display Over During Under example of...

  • Page 28: Output Current Detection Characteristics

    5-2. Output Current Detection Characteristics Frequency inverter has several detection characteristics for output current to protect IGBT from break down, or to protect motor from over heat. [1] Over current Frequency inverter shuts off the output instantaneously when output current exceeds to 220%(190) of its rated current.

  • Page 29: Motor Temperature Detection (Ptc)

    5-3. Motor Temperature Detection (PTC) Frequency inverter has a motor temperature sensor input (PTC input : PTC resistor). When the resistance value is more than 3k ohm +-10%, the frequency inverter trips with “E35”. Motor SJ100 inverter PTC thermistor 5(PTC) Except Japanese version 5-4.

  • Page 30: Measurement & Replacement Of Subassemblies

    6. Measurement & Replacement of Subassemblies 6-1. Insulation Measurement For SJ100 inverter, do not perform insulation measurements , otherwise MOV will be damaged. (MOV; between R(L1)-G, S(L2)-G, T(L3)-G) 6.2. Power Components Measurements. When checking the power components, the following procedure is recommended: Clear voltage Wait for capacitors discharge Check capacitors for neutrality...
  • Page 31 [3] Rectifier Measurement (Ll) (L2) (L3) Main circuit of SJ100 This is to measure 6 rectifiers of the input side. Resistance Measurement Allowable Value From R(Ll) S(L2) 50kohm or more S(L2) R(Ll) S(L2) T(L3) T(L3) S(L2) R(L1) T(L3) R(Ll) S(L2) R(Ll) T(L3) T(L3)
  • Page 32 [4] IGBT Measurement Resistance Measurement Allowable Value From 50kohm or more 50 ohm or less 50 ohm or less DC current detecting resistor (shunt resistor) 50kohm or more (Order of mili ohm) If the result is out of its spec, replace the unit. Please note that this cannot cover 100% to find IGBT failure because if the power devices in failure, sometimes you can find the failure in components while they are activated.

  • Page 33: Maintenance And Inspection Procedure

    7. Maintenance and Inspection Procedure 7-1. Precautions (1) Maintenance and Inspection Precautions Be sure to check the followings before starting maintenance and inspection because there is a danger of electrical shock. Display on the digital operation panel and POWER indication has been turned OFF. The voltage between + and - is 15Vdc or lower.
  • Page 34 When there is no motor connected to the inverter, please use additional resistor like Fig. 7-2. There will be a voltage at output terminal even the frequency command is naught due to the leakage current of the semiconductor devices. Frequency Inverter 220kohm Fundamental wave...
  • Page 35 Table 7-1 Measuring Instruments Item Instruments Type of Instrument Remarks Supply voltage and E Moving iron type voltmeter or Fundamental wave L1-L2 L2-L3 L3-L1 effective value Rectifier type voltmeter Supply current and I Moving iron type ammeter Total effective value Supply power and W Electrodynamics wattmeter...

  • Page 36: Maintenance Of Parts

    7-3. Maintenance of Parts (1) Maintenance of printed circuit board (I/O board) Printed circuit boards are maintenance free under normal applications except ALARAM relay (hardware). However, in case which maintenance and inspection are necessary, pay attention to the prevention of damage caused by static electricity as shown below. * Prevent damage caused by static electricity MCU and LSI on the printed circuit board can be destroyed by static electricity.

  • Page 37: Daily Inspection And Periodical Inspection

    8. Daily Inspection and Periodical Inspection Inspection Item Contents Cycle Method Criteria Standard Instruments point replacement daily periodic period " Overall Ambient Check ambient temperature, Ambient temperature Thermometer Environment humidity, dust, corrosive gas, oil mist, : -10deg to 40deg, etc. no icing "...
  • Page 38 Inspection Item Contents Cycle Method Criteria Standard Instruments point replacement daily periodic period " Control circuit Operation check Check the balance of the output Measure the Within 2% of voltage next voltage of each phase to phase output voltage difference between each page without motor.

  • Page 39: Image Block Diagram

    U(T1) S(L2) V(T2) T(L3) Tr BR W(T3) CONVERTER I/O BLOCK POWER SUPPLY (I/O board) OPERATION PANEL WITH POTEN TIO METER HITACHI DETECT V,I DRIV E CIRCUIT SERIAL COMMUNICATION ISORATION COMMUNICATION PORT TERMINALS EEPROM USER INTERFACE REMORT OPERATOR EMC DIRECTIVE COMPLIANT WITH DEDICATED NOISE FILTER(OPTION) Note;...

  • Page 41: Spare Parts List

    10-1. Spare Parts list Class Parts Code DWG.No. Parts Name Remarks Quantity 254858 2T004556 1 Key PAD (HITACHI) For all models SJ100-002-007LFR 254857 2T004372 4 Front case (S) SJ100-002-005NFE SJ100-002,004NFU 254855 1T001784 4 Front case (L) SJ100-015-075LFR SJ100-007-022NFE SJ100-007-022NFU SJ100-037-075LFU SJ100-004-075HFR SJ100-004-075HFE;HFU...
  • Page 42 1T001858 4 Case (LL) SJ100-055,075LFU;HFE;HFU,LFR,HFR SJ100-002-007LFR 254862 4T013417 4 Rear cover (S) SJ100-002-005NFE SJ100-002,004NFU 254860 3T015700 4 Rear cover (L) SJ100-015-037LFR SJ100-007-022NFE SJ100-007-022NFU SJ100-037LFU SJ100-004-037HFR SJ100-004-040HFE;HFU 3T016368 4 Rear cover (LL) SJ100-055,075LFU;HFE;HFU,LFR,HFR 254861 3T015710 4 Condensor cover (L) SJ100-037LFR SJ100-015,022NFE SJ100-015,022NFU SJ100-037LFU ,037HFR SJ100-030,040HFE...
  • Page 43 3T016873 3 ISPM (without PCB2) SJ100-015LFR;NFE;NFU 3T016874 3 ISPM (without PCB2) SJ100-022LFR;NFE;NFU 3T016875 3 ISPM (without PCB2) SJ100-037LFR;LFU 3T017100 2 ISPM (without PCB2) SJ100-055LFR;LFU 3T017101 2 ISPM (without PCB2) SJ100-075LFR;LFU 3T016876 2 ISPM (without PCB2) SJ100-004HFR;HFE;HFU 3T016877 2 ISPM (without PCB2) SJ100-007HFR;HFE;HFU 3T016878 2 ISPM (without PCB2)
  • Page 44 CB470 Capacitor board SJ100-037HFR,030HFE SJ100-040HFE,HFU CB68X4H Capacitor board SJ100-055HFR,HFE,HFU CB68X6H Capacitor board SJ100-075HFR,HFE;HFU SJCB180A PCB2 SJ100-002LFR SJCB330A PCB2 SJ100-004LFR SJCB680A PCB2 SJ100-007LFR SJCB470B2 PCB2 SJ100-015LFR SJCB680B2 PCB2 SJ100-022LFR;011NFE SJCB2330A PCB2 SJ100-002NFE;NFU SJCB2680A PCB2 SJ100-004NFE;NFU, 005NFE SJCB560B2 PCB2 SJ100-007NFE;NFU SJCB470B2T PCB2 SJ100-015NFE;NFU, 037LFR;LFU SJCB680B2T PCB2...
  • Page 45 Note No.10 4T013337 3 is usable for 4T01337 4. The difference is the length. No.13 The copper bar is used between ISPM and heatsink. C/H version is applied US version except key pad/knob/cover/case etc. This spare parts list will be changed without notice. To get latest spare parts list, please contact to sales office. This service manual may not be revised if the spare parts list was revised.
  • Page 46 Parts name Quantity Keypad Front case (L) Key cover Volume knob Top cover (S) Case (S) Rear cover (S) ISPM – IO cable (S) ISPM I/O board PCB2 SJ100-002NFE 002NFU 004NFE 004NFU 005NFE...
  • Page 47 Parts name Quantity Keypad Front case (L) Key cover Volume knob Top cover (L) Case (M) Rear cover (L) ISPM – IO cable (L) ISPM I/O board PCB2 SJ100-004HFE 004HFU 007NFE 007NFU 011NFE...
  • Page 48 Parts name Quantity Keypad Front case (L) Key cover Volume knob Top cover (L) Case (M) Rear cover (L) Cooling fan (L) ISPM – IO cable (L) ISPM I/O board PCB2 SJ100-007HFE 007HFU 015HFE 015HFU 022HFE 022HFU...
  • Page 49 Parts name Quantity Keypad Front case (L) Key cover Volume knob Top cover (L) Case (L) Rear cover (L) Condensor cover ISPM – IO cable (L) ISPM I/O board Capacitor board PCB2 SJ100-015NFE 015NFU...
  • Page 50 Parts name Quantity Keypad Front case (L) Key cover Volume knob Top cover (L) Case (L) Rear cover (L) Condensor cover Cooling fan (L) ISPM – IO cable (L) ISPM I/O board Capacitor board PCB2 SJ100-022NFE 022NFU 030HFE 037LFU 040HFE 040HFU...
  • Page 51 Parts name Quantity Keypad Front case (L) Key cover Volume knob Top cover (LL) Case (LL) Rear cover (LL) Condensor cover (LL) Cooling fan (S) ISPM – IO cable (L) ISPM I/O board Capacitor board PCB2 SJ100-055LFU 055HFU 075HFU 055HFE 075HFE 055LFE...
  • Page 52 Parts name Quantity Keypad Front case (L) Key cover Volume knob Top cover (LL) Case (LL) Rear cover (LL) Condensor cover (LL) Cooling fan (S) ISPM – IO cable (L) ISPM I/O board Capacitor board PCB2 SJ100-075LFU 075LFE...

  • Page 53: I/O Board Compatibility

    10-2. I/O board compatibility V: available - : not available board evision Name “R ” SJ100EUL "C","D","H" SJ100EUL "E","F","G","H" SJ100075EUL "A" SJ100L "C","D","H" SJ100075L "A" Note; "SJ100xxxEUx" ; "SOURCE type" on the control terminal(different from SINK). "SJ100xxxL" ; "SINK type" on the control terminal.(different from SOURCE) kW setup is not necessary such as J100 , J300 series for I/O board if I/O board was replaced.
  • Page 54 10-3. O,OI terminal adjustment procedure If you need the fine adjustment with out F31 IN EX%S, IN EX%E function(DOP/DRW), or A group A13,A14 function (on standard panel), refer to following procedure. At first, stop the SJ100, and erase the INV trip (error) to change parameters. O terminal adjustment Supply the DC10 [V] and if the freq.

  • Page 55: Kw Setup Procedure

    10-4. kW setup procedure To set up kW, we advise you not to use DOP/DRW !, use only standard panel. Meaning set C91 "01" ; Debug on set C94 "D000" ; kW address set C95 "xx" ; kW code set B84 "01" ;...
  • Page 75 End of page...

This manual is also suitable for:

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