Hitachi WJ200 Series

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6−1

Troubleshooting

and Maintenance

In This Chapter… page

- Troubleshooting ............................................................................... 2

- Monitoring Trip Events, History, & Conditions .............................. 8

- Restoring Factory Default Settings .............................................. 14

- Maintenance and Inspection ......................................................... 15

- Warranty ......................................................................................... 22

Main Page

Default Chapter2
- Caution When Using Safe Stop Function2
- Definitions and Symbols2
- Hazardous High Voltage2
Safety Messages2
- General Precautions - Read These First3
- Index to Warnings and Cautions in this Manual5
- General Warnings and Cautions11
- Revisions19
- Contact Information20
- Getting Started21
Chapter 1 : Getting Started22
Introduction22
- Main Features22
- Inverter Specification Label23
- Model-Specific Tables for 200V and 400V Class Inverters24
WJ200 Inverter Specifications24
- General Specifications28
- Derating Curves31
Introduction to Variable-Frequency Drives38
- The Purpose of Motor Speed Control for Industry38
- What Is an Inverter38
- Inverter Input and Three-Phase Power39
- Torque and Constant Volts/Hertz Operation39
- Inverter Output to the Motor40
- Braking41
- Intelligent Functions and Parameters41
- Velocity Profiles42
Frequently Asked Questions43
- Inverter Mounting and Installation46
Chapter 2 : Inverter Mounting and Installation47
- Main Physical Features47
- Orientation to Inverter Features47
  - Unpacking and Inspection47
  - Power Wiring Access48
- Basic System Description49
- Step-By-Step Basic Installation51
- Powerup Test68
- Using the Front Panel Keypad70
Choosing a Programming Device83
- Introduction of Inverter Programming83
Chapter 3 : Configuring Drive Parameters84
Using the Keypad Devices84
- Control Algorithms85
- Operational Modes85
- Run Mode Edit85
- Dual Rating Selection86
- “D” Group: Monitoring Functions88
- Trip Event and History Monitoring90
- Local Monitoring with Keypad Connected91
- “F” Group: Main Profile Parameters92
- “A” Group: Standard Functions93
- Run Command Source Setting94
- Basic Parameter Settings96
- Analog Input Settings97
- Ezsq Related Settings99
- Multi-Speed and Jog Frequency Setting100
- Jog Frequency102
- Torque Control Algorithms103
- Manual Torque Boost105
- Voltage Compensation Gain and Slip Compensation Gain105
- Voltage Gain105
- DC Braking (DB) Settings107
- Frequency-Related Functions109
- Jump Frequencies110
- Acceleration Stop/Deceleration Stop111
- PID Control112
- PID Loop Configuration114
- PID Sleep Function115
- Automatic Voltage Regulation (AVR) Function116
- Energy Savings Mode / Optional Accel/Decel117
- Second Acceleration and Deceleration Functions118
- Accel/Decel119
- A131 Curve Constant (Swelling)120
- A150~A153 Curvature of EL-S-Curve120
- Acceleration / Deceleration Pattern Summary120
- Additional Analog Input Settings121
- Analog Input Calculate Function122
- Add Frequency123
- Input Range Settings124
- Automatic Restart Mode125
- B" Group: Fine Tuning Functions125
  - Active Frequency Matching Restart128
  - Electronic Thermal Overload Alarm Setting129
  - Electronic Thermal Characteristic130
  - Electronic Thermal Characteristic Curve130
  - Electronic Thermal Warning Output131
  - Current Limitation Related Functions132
  - Over-Current Trip Suppression132
  - Overload Restriction132
  - Software Lock Mode134
  - Motor Cable Length Parameter135
  - Rotation Restriction Related Parameters136
  - Run/Power on Warning Time136
  - Reduced Voltage Start137
  - Display Related Parameters138
  - Basic Display Mode139
  - Data Comparison Display Mode139
  - User Setting Display Mode139
  - Automatic User Parameter Registration142
  - User Parameter Registration142
  - Analog Voltage Input Mode143
  - Quadrant-Specific Setting Mode143
  - Terminal-Switching Mode143
  - Torque Limit Function143
  - Controlled Stop Operation at Power Loss145
  - Window Comparator, Analog Disconnection148
  - Ambient Temperature Setting149
  - Watt-Hour Related149
  - Carrier Frequency (PWM) Related150
  - Miscellaneous Settings151
  - Stop Mode / Restart Mode Configuration153
  - Brake Control Function Related156
  - DC Bus AVR (Automatic Voltage Regulation) for Deceleration Settings159
  - Inverter Mode Setting160
  - STO (Safe Torque Off) Setting160
  - Password Function162
  - How to Authenticate Password163
  - How to Change Password163
  - How to Delete Password163
- C" Group: Intelligent Terminal Functions164
  - Intelligent Input Terminal Overview165
  - Input Function Summary Table166
  - Output Terminal Configuration170
  - Output Function Summary Table172
  - Low Load Detection Parameters175
  - Frequency Arrival Output176
  - Output Function Adjustment Parameters176
  - Overload Warning Output176
  - PID FBV Output176
  - Network Communications Settings179
  - Analog Input Signal Calibration Settings180
  - Miscellaneous Functions181
  - Analog Output Calibration Related Functions182
  - Output Logic and Timing183
  - Other Functions184
  - “H” Group: Motor Constants Functions185
  - Motor Constants Selection187
- Sensorless Vector Control188
- Auto-Tuning Function189
  - Off-Line Auto-Tuning Procedure (with Motor Rotation)191
  - Option Card Error192
  - “P” Group: Other Parameters192
  - Encoder (Pulse Train Input) Related Settings193
  - Torque Command Related Settings194
- Simple Positioning195
  - 2-Phase Pulse Input195
  - Single Phase Pulse Input196
  - Simple Positioning Setting197
  - Multistage Position Switching Function (CP1/CP2/CP3)200
  - Speed/Positioning Switching Function (SPD)201
  - Homing Function202
  - Ezsq User Parameter Related Settings203
  - Operations and Monitoring204
  - Caution Messages for Operating Procedures205
Chapter 4 : Operations and Monitoring205
Introduction205
- Warning Messages for Operating Procedures206
Connecting to Plcs and Other Devices207
- Example Wiring Diagram208
Control Logic Signal Specifications209
- Wiring Sample of Control Logic Terminal (Source Logic)210
- Sink/Source Logic of Intelligent Input Terminals211
- Wire Size for Control and Relay Terminals211
- How to Connect?212
- Recommended Ferrule212
- Intelligent Inputs213
Intelligent Terminal Listing213
- Intelligent Outputs214
Using Intelligent Input Terminals215
- Forward Run/Stop and Reverse Run/Stop Commands219
- Multi-Speed Select ~Binary Operation220
- Programming Using the CF Switches221
- Standard Keypad Programming221
- Jogging Command222
- External Signal for DC Braking223
- Set Second Motor, Special Set224
- Two Stage Acceleration and Deceleration225
- Free-Run Stop226
- External Trip227
- Unattended Start Protection228
- Commercial Power Source Switchover229
- Software Lock230
- Analog Input Current/Voltage Select231
- Reset Inverter232
- Thermistor Thermal Protection233
- Three-Wire Interface Operation234
- PID ON/OFF and PID Clear235
- Remote Control up and down Functions236
- Force Operation from Digital Operator238
- Overload Restriction Source Changeover240
- Brake Confirmation241
- Torque Limit Switch241
- LAD Cancellation242
- Pulse Counter Clear243
- Add Frequency Enable244
- Force Terminal Mode245
- Permission for Torque Command Input245
- Clearance of Cumulative Power Data246
- General Purpose Input247
- Analog Command Hold248
- Multistage-Position Switch249
- Limit Signal of Homing, Trigger Signal of Zero-Return250
- Speed/Position Changeover251
- Executing Ezsq Program252
- Retain Output Frequency252
- Safe Stop Related Signals252
- Display Limitation253
- Permission of Run Command253
- Rotation Direction Detection253
- Sinking Outputs, Open Collector254
Using Intelligent Output Terminals254
- Internal Relay Output255
- Output Signal ON/OFF Delay Function256
- Run Signal257
- Frequency Arrival Signals258
- Overload Advance Notice Signal260
- Output Deviation for PID Control261
- Alarm Signal262
- Over Torque Signal264
- Undervoltage Signal265
- Torque Limited Signal266
- Running Time and Power on Time over Signal267
- Electronic Thermal Warning Signal Output268
- External Brake Related Output Signals269
- Zero Hz Speed Detection Signal270
- Speed Deviation Excessive Signal271
- Positioning Completion Signal272
- Analog Input Disconnect Detect273
- PID Second Stage Output274
- Communication Signal Disconnect Detect277
- Logic Output Function278
- Lifetime Warning Output Function279
- Starting Contact Signal280
- Heat Sink Overheat Warning281
- General Input282
- Low Load Detection Signal282
- Inverter Ready Signal283
- Forward Rotation, Reverse Rotation Signals284
- Major Failure Signal285
- Window Comparator for Analog Inputs286
- Frequency Command Source, Run Command Source287
- 2Nd Motor Selection288
- STO (Safe Torque Off) Performance Monitor289
- Analog Input Operation290
- Pulse Train Input Operation292
- Analog Output Operation293
Safe Stop Function295
Chapter 5: Inverter System Accessories296
- Component Description296
- Introduction296
Chapter 6 Troubleshooting and Maintenance300
- General Precautions and Notes301
- Inspection Items301
Troubleshooting301
- Inverter Does Not Power up302
- Motor Does Not Start302
- Troubleshooting Tips302
- A Part of Function Codes Is Not Displayed303
- Inverter Doesn't Respond to Changes in Frequency Setting from Operator303
- Motor Does Not Accelerate to Command Speed303
- Operator (Keypad) Does Not Respond303
- Motor Rotates Reverse Direction with Forward Command304
- Motor Rotates Reverse Direction with RUN Key of Keypad304
- Overcurrent Trip304
- Parameter Data Does Not Change304
- Over Voltage Trip (E07)305
- Overload Trip (E05)305
- Sound Noise of Motor or Machine305
- Thermistor Error Trip (E35)305
- DC Braking Doesn’t Work306
- If Cable to Operator Is Disconnected, Inveter will Trip or Stop306
- No Response over Modbus Communication306
- Under-Voltage Error306
- Error Codes307
- Fault Detection and Clearing307
Monitoring Trip Events, History, & Conditions307
- Warning Codes310
- Trip History and Inverter Status312
Restoring Factory Default Settings313
- Daily and Yearly Inspection Chart314
Maintenance and Inspection314
- Megger Test315
- IGBT Test Method316
- General Inverter Electrical Measurements317
- Inverter Output Voltage Measurement Techniques319
- Capacitor Life Curves320
Warranty321
Appendix A: Glossary and Bibliography322
- Glossary and Bibliography322
- Connecting the Inverter to Modbus330
- Modbus Network Communications330
- Network Protocol Reference330
Appendix B: Modbus Network Communications331
Introduction331
Connecting the Inverter to Modbus332
- Inverter Parameter Setup333
Network Protocol Reference334
- Transmission Procedure334
- Message Configuration: Query335
- Error Check336
- Header and Trailer (Silent Interval)336
- Message Configuration: Response337
- Normal Response337
- Transmission Time Required337
- No Response Occurs338
- Explanation of Function Codes339
- Read Holding Register [03H]340
- Write in Coil [05H]341
- Write in Holding Register [06H]342
- Loopback Test [08H]343
- Write in Coils [0Fh]344
- Write in Holding Registers [10H]345
- Write in Holding Registers [17H]346
- Exception Response347
- Store New Register Data (ENTER Command)348
- Ezcom (Peer-To-Peer Communication)349
- Modbus Coil List353
Modbus Data Listing353
- Modbus Holding Registers355
- List of Inverter Trip Factors358
- List of Registers (Monitoring)359
Appendix C: Drive Parameter Setting Tables382
- Introduction382
- Main Profile Parameters383
- Parameter Settings for Keypad Entry383

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