AF-3100 SERIES

General-purpose High-performance Inverter Maintenance Manual

THE AVAILABLE SOLUTION, WORLDWIDE.

AF-3100 SERIES
Manual 00.000.00.000

INTRODUCTION
Thank you for purchasing the SUMITOMO highperformance AF-3100. The AF3100 provides highprecision speed control from ultra-low to high speed in sensorless vector mode. The AF3100 can provide control to +/-0.2% with a speed range of 120:1 (maximum @ 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 AF3100 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 AF3100 Series allows the user to more easily adjust the performance of the drive with the motor. 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-3100. This manual should be kept near the inverter for reference use. Please read and observe all safety instructions. Do not make withstand voltage tests on any part of the AF-3100 AC drive. The AF-3100 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:
The inverter described in this operation manual is used for variable-speed operation of 3-phase induction motors in a general industry environment. Do not use the inverter for any load other than 3phase induction motors. The AF-3100 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-3100, 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-3100 or any electrical device should be installed by a licensed electrician.

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-3100.

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-3100.

Safety precautions are classified into DANGER and CAUTION in this manual. !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.
CAUTION can result in serious injury. As with all warnings, this warning is to be strictly

DANGER CAUTION
Matters described in observed. Meaning of symbol

: 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

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.

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.

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-3100.

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.

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-3100 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.

TABLE OF CONTENTS
INTRODUCTION Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Installation warnings . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adjustment and operation . . . . . . . . . . . . . . . . . . . . . . 4 Maintenance, inspection and parts replacement . . . . 5 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1-1. AF-3100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1-2. Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1-3. Software version . . . . . . . . . . . . . . . . . . . . . . . . 8 1-4. Inquiry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CONSTRUCTION Installation and storage . . . . . . . . . . . . . . . . . . . . . . . 9 3-1. Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3-2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3-3. Installation method and space . . . . . . . . . . . . . . 9 Torquing method of mounting screw threads . . 10 3-4. External installation of heat sink . . . . . . . . . . . . 11 OPTION WIRING 4-1. Main circuit wire and fuse selection . . . . . . . . . . 12 4-2. Wiring precautions . . . . . . . . . . . . . . . . . . . 13, 14 4-3. Motor wiring . . . . . . . . . . . . . . . . . . . . . . . . 14, 15 4-4. Details of terminal arrangement . . . . . . . . . . 16-18 4-5. Control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4-6. Terminal functions . . . . . . . . . . . . . . . . . . . . . . 20 4-7. Standard connection diagram . . . . . . . . . . . . . . 21 4-8. Applied connection diagram . . . . . . . . . . . . 22-25 OPERATION 5-1. Safety precautions . . . . . . . . . . . . . . . . . . . . . . 26 5-2. Operation checklist . . . . . . . . . . . . . . . . . . . . . . 27 5-3. Sensorless vector operation . . . . . . . . . . . . . . . 27 Local operation . . . . . . . . . . . . . . . . . . . . . . . . . 28 Remote operation . . . . . . . . . . . . . . . . . . . . . . . 29 USE OF THE OPERATION UNIT 6-1. OPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 6-2. Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 SPECIFICATIONS 1-1. Specifications: Standard . . . . . . . . . . . . . . . . . . 77 Specifications: Common, control . . . . . . . . . . . . 78 1-2. Internal block diagram . . . . . . . . . . . . . . . . . . . . 79 1-3. Outside dimensions . . . . . . . . . . . . . . . . . . . 80, 81 1-4. Measurements for external installation of inverter heat sink . . . . . . . . . . . . . . . . . . . . . . . . 82 1-1. List of options . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Guidelines for peripheral equipment . . . . . . . . . 62 1-2. Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63, 64 AC reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Electrical noise filter . . . . . . . . . . . . . . . . . . . 66-68 Braking unit/braking resistor . . . . . . . . . . . . . 69-72 Option Cards Relay output card . . . . . . . . . . . . . . . . . . . . . . . . 73 Analog monitor card . . . . . . . . . . . . . . . . . . . . . . 73 Pulse generator feedback . . . . . . . . . . . . . . 74, 75 Remote control OPU/keypad . . . . . . . . . . . . . . . 76 TROUBLESHOOTING/MAINTENANCE AND INSPECTION TROUBLESHOOTING 1-1. OPU fault display and correction . . . . . . . . . . . 56 1-2. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 57 1-3. Troubleshooting: motor rotation . . . . . . . . . . . . . 58 MAINTENANCE AND INSPECTION 2-1. Precautions for maintenance and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 59 2-2. Inspection items . . . . . . . . . . . . . . . . . . . . . . . . . 59 2-3. Replacement of parts . . . . . . . . . . . . . . . . . . . . 60 PARAMETER MENUS 7-1. List of parameters . . . . . . . . . . . . . . . . . . . . 34-37 7-2. Monitor (Display of condition) . . . . . . . . . . . 38, 39 7-3. Parameter menus . . . . . . . . . . . . . . . . . . . . . 40-55 6-3. Changing a parameter function with OPU/keypad . . . . . . . . . . . . . 32, 33

HANDLING
Introduction 1-1. AF-3100
The AF-3100 is a general-purpose high performance inverter used for controlling the speed of a 3-phase induction motor.

1-2. 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-3100 Operation manual for AF-3100 Options and their operation manuals (When options are ordered.) Any parts damaged during transportation? Example of entry in rating plate

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.

(11kW or more)
AF-3100 AC Drive
MODEL No. INPUT OUTPUT
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.

(5.5kW ~ 7.5kW)
Type of inverter Input power specifications Rated output
MODEL No. INPUT OUTPUT SERIAL No. AF-3100 AC Drive VER.

VER.

Type of inverter Input power specifications Rated output Serial No.

MAX. AMB. 50 C OL. CAP.150%/1min ENCL. OPEN

ROM

MASS

Suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes.

SERIAL No. DATE

MASS ROM

Serial No. Date of manufacture

A F 3 1 2

Voltage

* * *U
Capacity Voltage (V) 200 / 220 / 230 380 / 400 / 440 / 460 Code 5A5 7A5 011 015 022 kW 5.5 7.5 11 15 22 Code 030 037 045 055 075 kW 30 37 45 55 75

Code 2 4 Unit specifications Code 2

Unit Specifications Constant torque type Fig. 1-1

1-3. Software version

The version of the software incorporated in the AF-3100 can be confirmed by monitor parameter M18. When inquiring about the operation specifications of the inverter, please have this number available.

1-4. Inquiry
When inquiring about AF-3100, 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.

INSTALLATION AND STORAGE

3-1. Storage
Store the inverter in a place protected from wind, rain, and direct sunlight. Refer to storage specifications. 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

3-2. Installation
Install the AF-3100 in an environment that satisfies the following conditions: Ambient temperature: -10 to +40C. (50C when installed in a panel without a cover) Humidity: 90% or less, any dew condensation is not allowed

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.

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 M3 M3.5 M4 M5 M6 M8

Torque (Nm) / (lb-in) 0.77 (0.59) / 6.8 (4.9) 1.15 (0.93) / 10.2 (8.3) 1.76 (1.37) / 16 (13) 2.9 / 26 4.8 / 43 12 / 106

Torque level in parentheses applies to terminal blocks on a printed circuit board and top cover set screw threads.

Install the AF-3100 vertically for maximum cooling and heat dissipation. Install the AF-3100 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. 3-1

50mm Fig. 3-2

10

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

Fig. 3-4-1

(55-75kW/400V)
Use an optional bracket for installation of the heat sink outside the panel.

(15kW/200V)

Remove this plate.*

Remove the plate from the bottom of the unit. Install the unit in the same way as shown above. *Remove the screw threads and then remove the plate.

Plate for external installation of heat sink

Remove the standard plate. Attach the optional plate for external installation of heat sink to both sides of the unit. z Install the unit as shown in the steps shown above.

Inside of wall

Outside of wall

Outlet of cooling vent Ventilation for cooling shall not be obstructed.

CAUTION
Space: 50mm (1.97)

With the heat sink installed outside the panel, make arrangements for ventilation as shown in Fig.3-4-2.

Fig. 3-4-2
Radiation fin Intake ventilation shall not be obstructed!

11

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 AF3100. When a breaker with GF (ground fault) is installed in addition to fuses, select one of the highTable 4-1. Main Circuit Wire and Fuse Selection
Voltage Rating HP 7.5 10 15 20 7.5 10 15 20 30 40 50 60 75 100 kW 5.5 7.5 11 15 5.5 7.5 11 15 22 30 37 45 55 75 Applicable Inverter AF3122-5A5-U AF3122-7A5-U AF3122-011-U AF3122-015-U AF3124-5A5-U AF3124-7A5-U AF3124-011-U AF3124-015-U AF3124-022-U AF3124-030-U AF3124-037-U AF3124-045-U AF3124-055-U AF3124-075-U Input Output Amps Amps 24 32 44 56 13 16 24 32 48 64 80 96 112 150 24 32 44 56 13 16 24 32 48 64 80 96 112 150 Input Fuse Selection Normal Duty Heavy Duty Bussman Gould Bussman Gould FRN-R-40 TR40R FRN-R-45 TR45R FRN-R-50 TR50R FRN-R-60 TR60R FRN-R-70 TR70R FRN-R-80 TR80R FRN-R-85 TR90R FRN-R-100 TR100R FRS-R-20 TRS20R FRS-R-25 TRS25R FRS-R-25 TRS25R FRS-R-30 TRS30R FRS-R-40 TRS40R FRS-R-45 TRS45R FRS-R-50 TRS50R FRS-R-60 TRS60R FRS-R-75 TRS75R FRS-R-85 TRS90R FRS-R-100 TRS100R FRS-R-125 TRS125R FRS-R-125 TRS125R FRS-R-150 TRS150R FRS-R-150 TRS150R FRS-R-175 TRS175R FRS-R-175 TRS175R FRS-R-200 TRS200R FRS-R-225 TRS225R FRS-R-275 TRS300R Wire Selection (AWG) Input Output 60C 75C 60C 75C 10 10 10 10 8 8 8 8 6 6 6 6 4 4 4 4 12 12 12 12 12 12 12 12 10 10 10 10 8 8 8 8 4 6 4 6 3 4 3 4 1 3 1 3 1 1 1/0 1/0 3/0 3/0

frequency 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.

200V

400V

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 AF3122-011-U AF3122-015-U AF3124-011-U AF3124-015-U AF3124-022-U AF3124-030-U AF3124-037-U AF3124-045-U AF3124-055-U AF3124-075-U AWG 6 4 10 8 4 3 1 1 1/0 3/0 Manufacturer Thomas & Betts Thomas & Betts Thomas & Betts Thomas & Betts Thomas & Betts Thomas & Betts Thomas & Betts Thomas & Betts Thomas & Betts Thomas & Betts Series Sta-Kon Sta-Kon Sta-Kon Sta-Kon Sta-Kon Sta-Kon Sta-Kon Sta-Kon Sta-Kon Sta-Kon P/N E6-14 F4-14 D8-14 D8-14 F10731 F10731 G2-38 G2-38 H973 K973

Table 4-3. Recommended Lugs

Model AF3124-037-U AF3124-045-U AF3124-055-U AF3124-075-U AWG 1 1 1/0 3/0 Manufacturer Thomas & Betts Thomas & Betts Thomas & Betts Thomas & Betts Series Color-Keyed Color-Keyed Color-Keyed Color-Keyed P/N 71010 71010 71014 71014

12

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

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-3100 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-3100 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 4-1.
Wiring distance Carrier frequency (Parameter C13)

4-3. 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

Possible short circuit Inverter

Fig. 4-1

60m or less 10kHz or less

61 ~ 100m 6kHZ or less

101m or more 2.5kHz

14

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 W

Control circuit wiring

Maximum spacing R S T U V

Main circuit wiring Power supply 3-phase power supply

Motor wiring

Grounding cable

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

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). +V VRF IRF COM FRQ+ FRQ- UPF DRV OM X1 X2 OM FA FC FB FR 16 RR BC ES MBS BC JOG AD2 BMD BC DFH DFM DFL BC RST

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

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), 400-440 V (CN2), and 460 V or greater (CN3) on the IPM (Intelligent Power Module) card. 460V 400/440V 380V S1 TX1 TX2 TX3 380 V Jumper S1-TX1 400/440 V Jumper S1-TX2 460 V Jumper S1-TX3

The AF-3100 requires separate grounding. When more than one AF-3100 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. s s1 r1 r

Inverter

Other equipment

Inverter

Other equipment

(1) Preferred grounding...Best

(2) Common grounding...Allowed

Inverter

Other equipment

CAUTION

Do not connect voltages exceeding 230 VAC to r1 and s1; otherwise, failure of the inverter may result.

(3) Common grounding...Not Allowed

To verify the external power supply operates, remove the power to the AF-3100 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-3100 with other equipment, such as welders, etc., is not acceptable.

(1) Correct grounding

(2) Correct grounding

(3) Incorrect grounding

18

4-5. Control circuit

Frequency DC0 ~ 1 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 Fault detection N.O. Fault detection Common Preset speed setting Fault detection N.C. Reset

Frequency adjust

3 k 2 W

Open collector output (MAX 24 VDC 50 mA)

Digital output DRV

Digital output UPF

Digital output 1

Digital output 2 Preset speed setting

Preset speed setting

Forward rotation

Reverse rotation

External error

Coast stop

2nd acceleration selection

Jogging

B mode

Fig. 4-5-1

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. 4-5-2 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.

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. 4-5-3.

; ;

Shielding changes not required on end opposite the inverter.

;; ;; ;;

DRV, UPF X1, X2 OM

50 mA max

+ 24 V
Free-wheel diode (100 V; 0.1 A or more)

+V VRF COM
Connect shielding to inverter at connection point to inverter.

Fig. 4-5-3

Inverter

Vinyl tape, etc.

Fig. 4-5-2

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. 4-5-2. 19

4-6. Terminal functions

Kind Terminal Code Name of terminal R, S, T AC power input U, V, W Inverter output Line reactor P, P1 connection P, N Braking unit connection Braking resistor P, PR connection E Ground TX1, TX2, TX3, S1 Supply voltage selection Control power selection r, r1, s, s1 Main Circuit Frequency adjustment input +V Power supply for the external speed potentiometer Frequency adjustment input voltage Frequency adjustment current input Common for analog inputs Forward rotation Reverse rotation External fault Function Commercial 3-phase power supply. 3-phase motor. Remove the jumpers between terminals P and P1 to allow for connection of the optional DC line reactor. Connection for the Optional Braking Unit Card. Optional braking resistor connection. The PR terminal is provided in the 5.5-15 kW unit. Inverter chassis grounding terminal. Supply voltage selection terminals. Only on 460 V class units of 15 kW or above. For inverter supplied control power, connect r-r1 and s-s1, respectively. For externally 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. Power supply for the external speed (frequency) potentiometer (variable resistor: 1-5k). 10 VDC; maximum supplied current 10 mA. When 0-5, 0-8, or 0-10 VDC is input, the output frequency reaches its maximum at 5 V, 8 V and 10 V, respectively. Select paramater A 00/12 for 0-5, 8, or 10 V operation. 4-20 mA (DC), the output frequency reaches its maximum at 20 mA, minimum at 4mA. Input resistance: 250. Common terminal for frequency adjustment signals (terminals: +V, VRF, and IRF). FR-BC contact closed results in forward rotation; deceleration/stop when the contact is open. RR-BC contact closed results in reverse rotation; deceleration/stop when the terminals are open. 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). 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. The following functions can be selected: Preset speed selection, JOG selection, 2nd deceleration selection, B mode selection, local/remote operation command, frequency command selection, hold selection, frequency increase, frequency decrease, and catch on the fly function.

VRF IRF COM FR

Control circuit (Input signal) Sequence Input

RR ES

MBS

Coast Stop

Contact point output Open Collector

Control circuit (Output signal) Monitor

JOG AD2 BMD DFH DFM DFL RST BC FRQ+, FRQ-

Digital input terminal 1 Digital input terminal 2 Digital input terminal 3 Digital input terminal 4 Digital input terminal 5 Digital input terminal 6 Alarm reset Common Frequency counter output

UPF DRV X1 X2 OM FA, FB, FC

When the terminals RST-BC are closed, the inverter is reset to allow for normal operation. Common for digital input signals. Depending on the selection (see parameter E02), a 0 to 1 mA DC current is output on terminals 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 500. Digital output terminal 1 The following functions can be selected: fault, in-operation, at frequency, Digital output terminal 2 frequency detection 1, frequency detection 2, current detection 1, current Allowable load detection 2, run signal initiated (FF/RR), under-voltage, thermal alarm, stall Digital output terminal 3 operation, retry attempts exceeded, torque detection 1, torque detection 2, DC24V 50mA MAX Digital output terminal 4 and zero speed detection function. Common open collector output Common terminal for open collector transistors. Error Detect Contact point output Normally Open or Normally Closed Form C contact. Fault: FA-FC closed; FB-FC open Contact Ratings Normal: FA-FC open; FB-FC closed AC 230V 1A MAX DC 30V 1A MAX

Note: 5.5-11 kW: Bus bar card 15 kW: IPM card 20 kW or more: Driver card

20

4-7. Standard connection diagram

5.5-15 kW/200 V class 5.5-75 kW/400 V class
Braking Unit
Resistor Units

22 kW or > 400 V class

Note 8
N N

PR

Braking resistor

: Main circuit terminal : Control circuit terminal

Optional
MCB ACL Noise filter PR R P

Note 3

DCL
P1 N U Note 6 V W

Motor
IM

Power supply

S Note 6 T

r s r1 s1

AF3100
Note 7

E Note 5

Forward rotation Reverse rotation External fault Preset speed setting

Note 1:

FR RR

FRQ+

Frequency meter output Frequency Meter specification: DC 1 mA F.S.

+ FM

FRQ ES Note 4 DFL DFM FA DFH FB FC

Programmable Digital Inputs

Jogging
2nd acceleration/ deceleration

JOG AD2 BMD RST MBS BC OPU

Fault contact output 230 VAC; 1A or less (At fault: FA-FC closed) 30 VDC; 1A or less (At fault: FB-FC open)

B mode selection Alarm reset Coast stop

DRV UPF X1

Frequency adjustment 3 k 2W
+ 4-20 mA COM

+V VRF COM

X2

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")

Note 1

Open collector output: 24 V, 50 mA or less

OM IRF

Common open collector

Notes 1: Digital inputs can be programmed using parameters F01 to F10. 2: Installed in units with a minimum of 400 V @ 11 kW. 400 V class AC input power voltage selections. 460 V 400/440 V 380 V Jumper: S1-TX1: 380 V S1-TX2: 400/440 V S1-TX3: 460 V

Shielded or twisted shielded wire Twisted wire

S1 TX1 TX2 TX3

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

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
MCB U Power supply FU Tx (Note 4) Manual (Speed setting unit) AU Automatic (Current signal) FB FC Stop Operation RN RN RN AU FR (Note 1) DFL (Note 3) BC +V VRF (Note 2) COM IRF
Twisted wire Shielded wire

ACL X Y Z R S T V W

P1 U V W IM

AF-3100
E Grounding

FRQ+

+ FM

FRQ

Frequency meter 1mA F.S.

Frequency setting unit 3k Current signal + DC420mA

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 Axial fan V BM W

MCB U Power supply TX2 (Note 2) THR MB V W FU

ACL X Y Z R S T P P1 U V W U-Y V-Z W-X Motor IM

E MB Grounding

T1 Thermostat T2

AF-3100
MX FR (Note 4) RR T1 T2 MX ES (Note 3) BC FRQ Grounding

Forward rotation Reverse rotation External fault

FRQ+

+ FM Frequency meter 1mA F.S.

3K 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

Positioning up/down operation

BR

MCB Power supply

U V W

ACL X Y Z

Br R S T P P1 U V W IM LS1 LS2 Forward rotation

Tx FU (Note 4) Braking unit TB TC Forward rotation LS2 Stop F Reverse rotation LS4 F R F R F R BR A B FX RX DF Twisted wire Shielded wire FX DF RX FR RR DFL (Note 3) DFM MBS BC LS1 LS3 FB FC R F FX R RX

Forward rotation LS1, LS3 (Note 1) Remove the short bar.

Holding type limit switch

LS4

AF-3100
P N

Braking unit Operation pattern

LS3

E1TA TB TC E2 P M1 M2 N PR S1S2 E (Note 2)

DF

(Note 6) Relay card (Option) R1A R1B R1C R2A R2B R2C

DBR DBR Braking resistor A B

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

MCB Power supply MC U V W ACL X Y Z R S T r r1 s s1 FB MC Manual Automatic Stop Operation RN RN RN AU FR DFL BC Speed adjustment 3k AU FC (Note 3) P P1 U V W IM

MCB Note 1: Control power AC200V/ 220V

AF-3100

+V VRF (Note 2) COM Twisted wire IRF

Current signal + DC420mA

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

Preset speeds (16)

MCB Power supply ACL U V W X Y Z R S T P P1 U V W IM

Preset speed by external input signal Frequency setting A01 Preset speed 0 DFL 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 Preset speed 1 DFM 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 Preset speed 2 DFH 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 Preset speed 3 JOG 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1

AF-3100
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 BMD Reset Coast stop RST MBS BC Parameter setting Preset speed 0 Preset speed 1 Preset speed 2 Preset speed 3 F01=0 F02=1 F03=2 F04=3 A01= Hz * A12=0

B00 B01 B02 B03 B04 B05 B06 B21 B22 B23 B24 B25
Twisted wire Shielded wire

B26 B27 B28

1 : Selected terminal to BC closed. 0 : Selected terminal to BC open.

Brake motor operation (electromagnetic contactor on input power supply)

BR

MCB Power supply Tx Note 2

MC U V

ACL X Y Z R S T P P1 U V W

Br

IM Brake Brake

FU OFF

FB ON MC MC Forward rotation F Reverse rotation F R FC

Forward rotation

Forward rotation Operation pattern

MC

Stop

F FX R RX

AF-3100
FRQ+ FRQ+ Frequency FM meter - 1mA F.S.

F R BR

FX Twisted wire Shielded wire FX RX RX FR RR Reset MBS RST BC

+V (Note 1) VRF COM

Speed adjustment unit 3k

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.

24

Operation of motor with brake (electromagnetic contactor/braking unit on power supply side)
BR

MCB Power supply Tx (Note 4) FU OFF ON MC MC Stop TB TC

MC U V W

ACL X Y Z

Br R S T P P1 U V W IM Brake Forward rotation Brake (Note 1) Remove jumper. Braking unit Operation pattern

FB FC MC

Braking unit
Forward rotation

AF-3100
F FX P (Note 6) N

F
Reverse rotation

E1 TA TB TC E2 P M1 M2 N PR S1S2 E

F R

R RX (Note 2) BX BR (Note 3) Relay card (Option) R1A R1C FX RX FR RR +V VRF COM FRQ(Note 5) DBR DBR Braking resistor FRQ+ FM + Frequency meter 1mA F.S. -

Twisted wire Shielded wire

BX Reset

Speed adjustment unit 3k

MBS RST BC

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

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

5-2. Operation Checklist

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.

5-3. Sensorless Vector Operation

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 (m/3) x Wiring distance (m) x Current (A) (V) 1000 Table 9 of the NEC 27

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. M00 000.00Hz Output frequency READY ALARM LOCAL A00 Operation mode READY ALARM LOCAL LOCAL ON Panel: 0 READY ON

Local operation selection

Verify the operation mode (A00) of the OPU to Local (0). (Local:0 is the factory default.)

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

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.)

A01

010.00Hz

Acceleration time A04 Jog frequency A05 0010.00sec 0010.00sec

Operation

Press FWD or REV and the forward or reverse motor rotation begins with the acceleration time in parameter A04*.

Deceleration time

FWD or REV ON

FED or REV OFF

Stop

Press the STOP key and the inverter stops in relation to the deceleration time of parameter A05*.

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

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. M00 000.000Hz Output frequency READY ALARM LOCAL 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. A12 A00 Ext.: 1 READY ON

Operation command selection READY ALARM LOCAL VRF 5V:1 LOCAL OFF

Frequency command selection M00 000.00Hz

Forward Operation

To select forward rotation close the contacts for FRBC. Gradually increase the frequency command from 0 V and observe motor operation and rotation.

Output frequency M00 060.00Hz

Output frequency

FWD OFF

Gradually lower the speed command to 0 V, verify the motor decelerates and stops.

M00

060.00Hz

Output frequency A04 0010.00sec

Acceleration time A05 0010.00sec

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.

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

USE OF THE OPERATION UNIT

6-1. OPU Display
Easy to read LCD display. Two lines, 16 Characters (English and Japanese).

Data/Menu
This key is used for changing the position of the data/menu cursor.

READY (Green)
AF-3100 is ready for operation when illuminated.

Set
After setting respective data, press this key and the display values are written to memory.

ALARM (Red)
When illuminated a fault condition exists.

Cursor
This key is used to move the cursor to the digit to be changed.

LOCAL (Green)
AF-3100 is controlled by the OPU/keypad when illuminated.

Up / Down
This key is used to change the operation frequency, name of parameter, and data. : Increase : Decrease

Forward Rotation
Forward operation start key. The start key is pressed, run lamp turns ON; OFF when STOP is pressed and blinks during deceleration.

Reverse Rotation
Reverse operation START key. Start key is pressed, run lamp turns ON; OFF when STOP is pressed and blinks during deceleration.

JOG
JOG mode selection key. Pressing this key illuminates the ON light, press again and the light goes off.

STOP
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

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 v and Down key w . Change the menu as follows:

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 v and Down key v . Change the numerical value at the position of the cursor.

F 0 0
w When Down key is used w v

E 0 0
w v

v When Up key is used

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.

D 0 0
w v

C 0 0
w v

Display menu
Monitor

B 0 0
w v

M 0 0

~ ~ ~ ~ ~ ~ ~

The monitor mode displays parameters such as speed, current, faults, etc.

A 0 0
w v

Menu A
(Basic parameters)

A 0 0

M 0 0

Used for setting basic parameters.

Menu B
(Frequency related parameters)

B 0 0

Used for setting frequency related parameters.

Menu C
(Control related parameters)

C 0 0

Used for setting motor control related parameters.

Menu D
(B mode parameters)

D 0 0

Used for setting B mode related parameters.

Comment area
(Line two) Comments on the functions of M (monitor) and A-F (functions) are shown in English. Display in KANA characters is possible.

Menu E
(Monitor related parameters)

E 0 0

Used for setting monitor related parameters)

Menu F
(Special parameters)

F 0 0

Used for setting special parameters.

31

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.
M00 000.00Hz

Output frequency

To change the frequency adjustment parameter, display parameter A 0 1 .

A00 Panel: 0

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 .) 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. Move the cursor to the position under the 1 of 10.00 Hz. (Press the Left shift key three times.)

Operation command selection

A00

Panel: 0

Operation command selection

A01

10.00Hz

Frequency setting

A01

10.00Hz

Frequency setting

A01

10.00Hz

Frequency setting

Change 10.00 Hz to 20.00 Hz. (Press the Up key

.)

A01

20.00Hz

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. NOTE: To save the DATA, the Set key must be pressed; otherwise, the data will not be saved.

A01 Setting end

20.00Hz

A01

20.00Hz

Frequency setting

32

The parameter menu A 0 1 permits direct setting of the operation frequency. To change the parameter menu A 0 1 , press the data/menu key to move from the menu area to the data area. Move the cursor to the position under the 1 of 10.00 Hz. (Press the Left shift key three times.)
A01 10.00Hz

Frequency setting

A01

10.00Hz

Frequency setting

Direct selection When the Up key is being pressed, the frequency increases. To decrease the frequency press the Down key 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. Unless the Set key be saved to memory. is pressed, the new data will not
A01 50.00Hz

Frequency setting

A01 Setting end

50.00Hz

A01

50.00Hz

Frequency setting

33

PARAMETER MENUS
7-1. List of parameters
Menu 00 01 02 03 04 05 06 07 08 Function Operation command mode Frequency adjustment Lower limit frequency Upper limit frequency 1st acceleration time 1st deceleration time 1st acceleration/deceleration mode 1st S-Curve time V/Hz pattern selection Boost voltage setting Base frequency setting Base frequency/voltage setting Frequency command selection Command standard frequency Intermediate frequency Intermediate voltage Boost selection 1st frequency setting 2nd frequency setting 3rd frequency setting 4th frequency setting 5th frequency setting 6th frequency setting 7th frequency setting 1st jump start frequency 1st jump end frequency 2nd jump start frequency 2nd jump end frequency 3rd jump start frequency 3rd jump end frequency Jogging frequency setting Start frequency setting Acceleration frequency Frequeny bias 2nd acceleration time 2nd deceleration time 2nd acceleration/deceleration mode 2nd S-Curve time 8th frequency setting 9th frequency setting 10th frequency setting 11th frequency setting 12th frequency setting 13th frequency setting 14th frequency setting 15th frequency setting Display Operation command selection Frequency adjustment Lower Limit frequency Upper limit frequency Acceleration time Deceleration time Acceleration/deceleration time S-Curve time V/Hz pattern selection Manual torque boost Base frequency Base voltage Frequency command selection Command standard frequency Intermediate frequency Intermediate voltage Boost selection 1st frequency setting 2nd frequency setting 3rd frequency setting 4th frequency setting 5th frequency setting 6th frequency setting 7th frequency setting 1st jump frequency start 1st jump frequency end 2nd jump frequency start 2nd jump frequency end 3rd jump frequency start 3rd jump frequency end Jogging frequency Start frequency Acceleration frequency Frequency bias 2nd acceleration time 2nd deceleration time 2nd acceleration/deceleration mode 2nd S-Curve time 8th frequency setting 9th frequency setting 10th frequency setting 11th frequency setting 12th frequency setting 13th frequency setting 14th frequency setting 15th frequency setting Available Choices 0: Local; 1: Terminal 0.00~400.00Hz 0.00~120.00Hz 0.50~400.00Hz 0.1~3000.0sec 0.1~3000.0 sec
0: Linear acceleration; 1: S-Curve acceleration

Setting Unit 0.01Hz 0.01Hz 0.01Hz 0.1sec 0.1sec

Factory Default 0: Local 10.00Hz 0:00Hz 120.00Hz 10.0sec 10.0sec

0: Linear acceleration

Ref. pg.

35

Basic parameters

A
09 10 11 12 13 14 15 16 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

0.0~3.0sec 0: Constant torque 1: Decreasing torque 2: Broken-line V/Hz 0.0~30.0% 1.00~400.00Hz 0.0~230.0 (460.0) V 0: Local 1: VRF 5V 2: VRF 8V, 3: VRF 10V 4: IRF 200mA 1.00~400.00Hz 0.00~400.00Hz 0.0~230.0 (460.0) V 0: FWD/REV provided
1: REV not provided; 2: FWD provided

0.1sec 0.1% 0.01Hz 0.1V 0.01Hz 0.01Hz 0.1V 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.1% 0.1sec 0.1sec 0.1sec 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz 0.01Hz

0.5sec 36 0: Constant torque 3.0% 60.00Hz ( ): For 460V Class 0: Local 60.00Hz 6.00Hz 30.0(60.0)V 0: FWD/REV provided 20.00Hz 30.00Hz 40.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 5.00Hz 0.50Hz 60.00Hz 0.0% 30.0 sec 30.0sec
0: Linear acceleration time

37 36

37

36 37

Frequency adjustment related parameters

3: Automatic 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~20.00Hz 0.00~60.00Hz 1.00~400.00 Hz -30.0~0.0~+30.0% 0.1~3000sec 0.1~3000sec
0: Linear acceleration; 1: S-Curve acceleration

38

39

0.0~3.0sec 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz 0.00~400.00Hz

0.5sec 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz 0.00Hz

38

34

Menu 00 01 02 03 04 05 06 07 08 09

Function DC braking frequency DC braking voltage DC braking time Overvoltage stall prevention Regenerative braking rate

Display

Available Choices 0.00~10.00Hz 0.0~30.0% 0.0~10.0sec 0: Not provided; 1: Provided 0.0~30.0% 0.0~200.0% 0.0~200.0% 0.0~100.0% 0.1 ~ Inverter rated current 0:4P, 1: 6P 0: General-purpose motor 1 1: General-purpose motor 2 2: General-purpose motor 3 3: AF motor 1; 4: AF motor 2 5: AF motor 3 6: Explosion-proof motor 1 7: Explosion-proof motor 2 8: Explosion-proof motor 3 0: 2.2kW, 1: 3.7kW 2: 5.5kW, 3: 7.5kW 4: 11kW, 5: 15kW 6: 22kW, 7: 30kW 8: 37kW, 9: 45kW 10: 55kW, 11: 75kW 0: V/Hz; 1: Sensorless 2: PG level 2.5Hz~*14 5kHz 3.5~325mm2 10~1500m 0: Not provided; 1: Provided 0: Not provided; 1: Provided 0.0~50.0% 0: Provided; 1: FWD only provided 2: REV only provided 3: FWD/REV not provided 4: (future) 0.1~409.6A 0.1~230.0 (460.0) V 50.00~120.00Hz 1000.0~3600.0rpm 0: End 1: Resistance only 2: Full tuning (motor rotates) 0.1~3000.0sec 0.1~3000.0sec
0: Linear acceleration; 1-S-Curve acceleration

Setting Unit 0.01Hz 0.1% 0.1sec 0.1% 0.1% 0.1% 0.1% 0.1A

DC braking frequency DC braking voltage DC braking time Overvoltage stall prevention Regenerative braking rate Stall prevention level at (constant speed) Stall prevention (constant speed) Stall prevention level (accel/decel) Stall prevention (Acceleration/deceleration) Constant output stall prevention Stall compensation gain compensation gain Motor rated current (Electronic thermal relay) Electronic thermal relay Number of motor poles Number of motor poles

Factory Default 0.50Hz 0.0% 0.0sec 0: Not provided 0.0% 160.0% 160.0% 100.0% Inverter rated current 0: 4P 0: General purpose motor 1 200V/60Hz (400V/60Hz)

Ref. pg.

40

Control related parameters

10

Motor type setting

Motor type See parameter C12, page 47.

11

Motor rated watts

Motor rated watts

*kW

41

12 13 14 15 16 17 18 19 20 21 22 23 24 00 01 02 03 04 05 06 07

Control method selection Carrier frequency Motor wiring cable dia. (Note) Motor wiring cable length (Note) High start torque control selection Energy saving control selection Droop control gain Slip compensation Motor rated current Motor rated voltage Motor rated frequency Motor rated speed (rpm) Auto tuning selection B mode acceleration time B mode deceleration time
B mode acceleration/deceleration time

Control selection Carrier frequency Cable diameter Cable length High start torque Energy saving Droop gain Slip compensation Tuning current Tuning voltage Tuning frequency Tuning speed (rpm) Auto tuning selection Acceleration time B Deceleration time B Accel/decel B mode S-Curve time B V/Hz pattern selection B Manual torque boost B Base frequency B Base voltage B Stall prevention B Stall prevention B Stall compensation gain B Intermediate frequency B Intermediate voltage B Boost selection B

0.5kHz 1m 0.1% 0.1A 0.1V 0.01Hz 0.1rpm 0.1sec 0.1sec 0.1sec 0.1% 0.01Hz 0.1V 0.1% 0.1% 0.1% 0.01Hz 0.1V

V/Hz * 0: 3.5m2 10m 0: Not provided 0: Not provided 0.0% 0: FWD/REV provided * 200.0 (400.0) V 60.00Hz 0: End 30.0sec 30.0sec
0: Linear acceleration

42

Motor B mode related parameters

B mode S-Curve time B mode V/Hz pattern selection B mode boost voltage setting B mode base frequency setting B mode base voltage setting B mode constant-speed stall prevention level B mode accel/decel stall prevention level B mode constant output stall prevention compensation gain B mode intermediate frequency B mode intermediate voltage B mode boost selection

0.0~3.0sec 0: Low torque 1: Low limit torque 2: Break-point V/Hz 0.0~30.0% 1.00~400.00Hz 0.0~230.0 (460.0) V 0.0~200.0% 0.0~200.0% 0.0~100.0% 0.00~400.00Hz 0.0~230.0 (460.0) V
0: FWD/REV provided; 1:REV not provided 2: FWD not provided; 3: Automatic

0.0sec 43 2: Broken-lineV/Hz 3.0% 60.00Hz 200.0 (400.0) V 160.0% 160.0% 100.0% 6.00Hz 30.0 (60.0)V 0:FWD/REV PROVIDED 43 44 45 44 43

08 09 10 11 12 13

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.

35

Menu 00 01 02 03 04 05 06

Function Output frequency detection 1 Output frequency detection width 1 Frequency counter output selection Frequency counter scale Frequency counter correction Custom display mode unit Custom display mode multiplier

Display Frequency detection 1 Frequency detection width 1 Frequency meter selection

Available Choices 0.00~400.00Hz

Setting Unit 0.01Hz 0.01Hz 0.01Hz 0.1% 0.01

Factory Default 60.00Hz 400.00Hz 0: Analog 60.00Hz 0.0% 1: rpm 1.00

Ref. pg.

07

Digital output selection (X1)

0.00~400.00Hz 0: Analog 1; 1: Analog 2 2: Digital 1; 3: Digital 2 Frequency meter scale 1.00~400.00Hz Frequency meter correction -30.0~+30.0% Custom display mode 0: No unit, 1: rpm 2: m/min Custom display multiplier 0.00~99.99 0: Fault; 1: In operation 2: At Frequency 3: Frequency 1 4: Frequency 2 5: Current 1; 6 Current 2 7: FR/RR ON (RUN) Functional terminal selection (XI) 8: Under-voltage 9: Thermal alarm 10: Stalling 11: Retry over 12: Torque detection 1 13: Torque detection 2 14: 0 speed 15: User alarm Same as above 0.0~400.00Hz 0.0~400.00Hz 0.0~200.0% 0.0~200.0% 0: Not provided; 1; Provided 0~3 times 0.0~10.0sec 0: enabled; 1: disabled 0: Output frequency 1: Frequency command 2: Output current 3: Output voltage 4: Overload rate; 5: Motor torque 6: Frequency 2 Same as above 0.0~200.0% 0.0~200.0% 0.0~100.0% 0.0~100.0% 0: Fault; 1: In operation 2: At Frequency 3: Frequency 1 4: Frequency 2 5: Current 1 6: Current 2 7: FR/RR ON 8: Under-voltage 9: Thermal alarm 10: Stalling 11: Retry over 12: Torque detection 1 13: Torque detection 2 14: 0 speed 15: User alarm Same as above 0.0~10.0sec 0.0~10.0sec

45

9: Thermal alarm 46

Monitor related parameters

08 09 10 11 12 13 14 15 16 17 18

Digital output selection (X2) Output frequency detection 2 Output frequeny detection width 2 Current detection 1 Current detection 2 Instantaneous stop/start selection Number of retry attempts Retry wait time Write selection Fault clear Factory parameter reset

Functional terminal selection (X2) Frequency detection 2 Frequency detection width 2 Current detection 1 Current detection 2 Instantaneous stop/start Number of retry attempts Retry wait time Write selection Fault clear Preset value initialization

0.01Hz 0.01Hz 0.1% 0.1% 0.1sec

10: Stalling 50.00Hz 400.00Hz 100.0% 150% 0: Not provided 0 times 1.0 sec 0: Possible 0: Execute 0: Execute

45

46

19

Analog monitor AM1 selection

Analog monitor AM1

0: Frequency

20 21 22 23 24

Analog monitor AM2 selection Analog monitor AM1 gain Analog monitor AM2 gain Analog monitor AM1 offset Analog monitor AM2 offset

Analog monitor AM2 Monitor AM1 gain Monitor AM2 gain Monitor AM1 offset Monitor AM2 offset

0..1% 0.1% 0.1% 0.1%

2: Current 100.0% 100.0% 0.0% 0.0% 47

25

Relay 1 output selection

Relay 1 selection

0: Fault

26 27 28

Relay 2 output selection Relay 1 output delay time Relay 2 output delay time

Relay 2 selection Relay 1 delay time Relay 2 delay time

0.1 sec 0.1 sec

0: Fault 0.0 sec 0.0 set

36

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.)

Menu 00

Function ES selection

Display ES selection

Available Choices 0: N.O. contact; 1: N.C. contact 0: Preset 0; 1: Preset 1 2: Preset 2; 3: Preset 3 4: JOG selection 5: Acceleration/deceleration 2 6: B mode selection 7: Operation command 8: Frequency command 9: Hold selection 10: FRQ up; 11: FRQ down 12: Catch on the Fly Same as above Same as above Same as above Same as above Same as above 0.1~3000; 0.1 sec 0.1~3000; 0.1 sec Same as E07/08 Same as E07/08 0.0~100.0% 0.0~200.0% 0.0~200.0% 0: FWD/REV 1: FWD only 2: REV only 0: Ordinary 1: FWD < > REV 0: Japanese; 1: English 0: Local; 1: Ext. 0: Local; 1: VRF 5V 2: VRF 8V; 3: VRF 10V 4: IRF 20mA M00~M19 0.00~400.00Hz 0.00~400.00Hz 0.1~10.0 0~30000hr 0.0~10.0sec 0.0~10.0sec 0.0~10.0sec 0.0~10.0sec 0: Normal operation 1: Slow speed only 2: Fault during operation 3: Slow speed fault only Same as above

Setting Unit

Factory Default 0: N.O. (normally open)

Ref. pg.

01

DFL selection

DFL selection

0: Preset 0

48 0.1sec 0.1sec 0.1% 0.1% 0.1% 0.01Hz 0.01Hz 0.1 1hr 0.1sec 0.1sec 0.1sec 0.1sec 1: Preset 1 2: Preset 2 4: JOG selection 5: Accel/Decel 6: B mode selection 0.1sec 0.1sec 1: In operation 2: Frequency reaching 5.0% 100.0% 150.0% 0: FWD/REV 0: Ordinary 1: English 0: Local 0: Local M00 400.00Hz 400.00Hz 1.0 30000hr 0.0sec 0.0sec 0.0sec 0.0sec 0: Normal operation 0: Normal operation 50

02 03 04 05 06 07 08 09

DFM selection DFH selection JOG selection AD2 selection BMD selection JOG acceleration time JOG deceleration time DRV selection UPF selection

DFM selection DFH selection JOG selection AD2 selection BMD selection JOG acceleration time JOG deceleration time DRV selection UPF selection

Special parameters

10

49

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

At Frequency (UPF) limit settings At Frequency limit Torque detection level 1 Torque detect level 1 Torque detection level 2 Torque detect level 2 Permissible motor rotation Permissible motor rotation Display language selection Operation command mode 2 selection Rotation permission selection Rotation direction selection Language selection Operation command 2

Frequency command 2 selection Frequency command 2 Monitor menu selection Accel/decel jump frequency (start) Accel/decel jump frequency (end) Accel/decel time jump freq gain User alarm time DRV terminal output delay time UPF terminal output delay time X1 terminal output delay time X2 terminal output delay time Torque detect 1 Torque detect 2 Monitor menu At frequency accel jump (begin) At frequency accel jump (end) At frequency acceleration gain User alarm time DRV delay time UPF delay time X1 delay time X2 delay time Torque detect 1 Torque detect 2

37

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 1 3 0 0 0 0 0 0 0 0 0 0 0 Digital input contact monitor

E05:2
M 0 4 m / m i n Custom display mode BMD DFH DFM DFL RST

38

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

M14 0 0 0 0 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

7-3. Parameter menus

Menu A - Basic parameters Operation command mode 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 1st acceleration time 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.
A02 Lower limit frequency Output frequency A03 Upper limit frequency

Frequency setting

CAUTION
Frequency adjustment is allowed to 400 Hz. Confirm the allowable speed range of the motor and connected machine before adjusting the 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.
Time Output frequency B15

Upper/lower frequency limit setting 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).

A04

A05

40

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.
Output voltage A11 Base voltage

Output frequency A10 Base 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. Output frequency

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.

A10 Base frequency

Intermediate V/Hz: 2 The users original V/Hz pattern can be configured by setting the intermediate frequency and voltage as shown below.
Output voltage A11 Base voltage

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.
A15 Intermediate voltage A14 A10 Intermediate base frequency frequency Output frequency

41

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 A11 A11

Output voltage Reverse rotation

Forward rotation

A09 Output frequency

A10

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.
Output voltage Heavy load

Forward/reverse rotation

Light load

A09 0V Output frequency Output frequency A10

A10

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.
Output voltage Forward rotation A11

Frequency command 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.

Reverse rotation

A09 Output frequency A10

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)

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

A12: Frequency command Local: 0 The value in parameter A01 is the output frequency.

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

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 0 Note A01 or external analog B00 B01 B02 B03 B04 B05 B06 B21 B22 B23 B24 B25 B26 B27 B28 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 Preset 1 0 0 1 1 0 0 1 1 0 0 1 1 0 0 1 1 Preset 2 0 0 0 0 1 1 1 1 0 0 0 0 1 1 1 1 Preset 3 0 0 0 0 0 0 0 0 1 1 1 1 1 1 1 1

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.

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.

43

Output frequency B12 B11 B10 B09 B08 B07

Output voltage

A13

Bias +

5 5
Jumping range

B16 (%)

Bias 0 Bias Frequency setting command 0V 4mA

Input frequency signal

5V, 8V, 10V, 20mA

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. Acceleration/deceleration standard frequency 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. 44

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.
Output frequency B15

Time B17 B18

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.

Output frequency Linear time B17 S-curve time B20

Linear acceleration S-curve acceleration

Time *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

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

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 AF3100 provides a built-in transistor for regenerative braking in the 5.5-15 kW range for the 200 V class and 5.5-15 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 C07: When setting is 100%

C00 Time DC braking voltage C02

C05 C06

C01 Time

Regenerative braking C03: Overvoltage stall prevention

C07: When setting is 0% Output frequency

Base frequency

45

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 2t 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 0 1 2 3 4 5 6 7 8 Type of Motor General-purpose motor 1 General-purpose motor 2 General-purpose motor 3 AF motor 1 AF motor 2 AF motor 3 Explosion-proof motor 1 Explosion-proof motor 2 Explosion-proof motor 3 230V class 230V/60Hz 230V/50Hz 230V/60Hz 200V/60Hz 200V/50Hz 200V/60Hz 230V/60Hz 230V/50Hz 230V/60Hz 460V class 460V/60Hz 460V/50Hz 460V/60Hz 400/60Hz 400/50Hz 440/60Hz 460/60Hz 400V/60Hz 460/60Hz

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 ... 2.5-14.5 kHz 37 kW or less ... 2.5-10.0 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.

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.

46

Droop gain = (Droop frequency/Base frequency) * 100 (%)

Droop characteristics at base frequency Load torque

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 No auto-tune Only the wiring resistance alone is tuned. The motor will not rotate. The motor constant is tuned. The motor rotates. 0 1 2

Rated torque

Small droop gain

Large droop gain

Before auto-tuning, set the following:

Droop frequency Output frequency

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 C09C11 to the factory preset values. Set parameter C12 to sensorless: 1; this completes the auto-tune procedure. Menu D - Motor B parameters The AF3100 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.

Base frequency

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 1 2 3 4 Details of slip compensation Slip compensation for both forward and reverse rotation Slip compensation only for forward rotation Slip compensation only for reverse rotation No slip compensation for both forward and reverse rotation No slip compensation only during regenerative operation

Auto-tune C20: Motor current C21: Motor voltage C22: Motor base frequency C23: Motor rated speed C24: Auto-tuning selection

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

Output frequency B15

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
Time

Useful for constant torque loads (conveyors etc.).

Output voltage D07

D00

D01

B mode acceleration/deceleration mode 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 Decreasing torque: 1
S-curve time D03 D06

Output frequency

Output frequency Linear time D00

Useful for decreasing torque loads (pump, fan, etc.).

Output voltage

Linear acceleration S-curve acceleration D07

Time *The same applies to deceleration. Output frequency

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

48

Broken-line V/Hz: 2 The following graph shows the intermediate frequency can be set by parameters D11 and D12.
Output voltage D07 D07

Output voltage

Forward rotation

Reverse rotation

D05 Output frequency D12 D06 Output frequency D11 D06

FWD not provided: 2 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.
Output voltage Reverse rotation D07

B mode torque boost 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 FWD/REV provided: 0 The boost voltage of D05 becomes valid for both forward and reverse rotation.
Output voltage D07

Forward rotation

D05 Output frequency D06

Auto: 3 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.
Output voltage

D05 Frequency

D06 Heavy load D07

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.

Light load

Output frequency

D06

49

B mode stall prevention level

Output frequency

D08: B mode constant speed stall prevention level D09: B mode acceleration/deceleration stall prevention level 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.
Stall prevention level D08 D09 E00,E09 Time E01 E10

Output signal

Frequency counter output 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.

D10: 100%

D10: 0% Output frequency Base frequency

Setting 0 1 2 3

Details of setting Analog, not including slip compensation Analog, including slip compensation Digital, including slip compensation Digital, not including slip compensation

Menu E (Monitor related parameters) Frequency detection 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.

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

(Displayed value) = (E06) x (Output frequency) Example: Motor speed (rpm) Set values as follows. ... 4P motor: E06 = 30 6P motor: E06 = 20
E05 Setting 0: No unit 1: rpm 2: m/min M04 display 0: No unit is displayed Speed (rpm) is displayed Speed (m/min) is displayed
Time Output current E11 E12

Output signal

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 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Details of setting Inverter fault output In-operation output At Frequency output See F11. Frequency detection 1 See E00 and E01. Frequency detection 2 See E09 and E10. Current detection 1 See E11. Current detection 2 See E12. Start contact CLOSED (FR and RR) Under-voltage Electronic thermal relay pre-alarm (85%) Stall Retry times attempts See E14. Torque detection 1 See F12. Torque detection 2 See F13. Zero speed detection User alarm F23

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.

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.

51

Write selection E16: Write selection Write protection for parameters other than E16 is set. If set, other parameters cannot be changed. Fault clear E17: Fault clear The history of faults displayed by M05-M09 is cleared. Parameter reset to factory values 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. 52

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.
Output voltage 10V Gain: 200% 5V 100% Gain: 100% Gain: 50%

50%

0 30Hz Parameter B15 60Hz

Output frequency 120Hz

Analog monitor output signal gain control 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. Relay outputs Relay 1(RY1) and Relay 2(RY2) 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. Relay output delay time E27: Relay 1 output delay time E28: Relay 2 output delay time The contact output is delayed by the time in parameters E27 and E28.

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 0: Normally open contact 1: Normally closed contact Details of setting Fault is generated if ES-BC is closed Fault is generated if ES-BS is open

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

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 0 1 2 3 4 5 6 7 8 9 10 11 12 Details of setting Preset speed 0 Refer to Menu B. Preset speed 1 Refer to Menu B. Preset speed 2 Refer to Menu B. Preset speed 3 Refer to Menu B. JOG function Note 1 Acceleration/deceleration 2 function Note 2 B mode function Refer to Menu D. Operation Input selection (OPU/external) Refer to A00/F17. Input frequency selection (VRF or IRF) Refer to A12/F17. Hold selection Note 3 Frequency increase Note 4 Frequency decrease Note 4 Catch on the fly restart Note 5

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.

Output frequency

B15

Time F07 F08

53

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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Details of setting Inverter fault output In-operation output At frequency output See F11. Frequency detection 1 See E00 and E01. Frequency detection 2 See E09 and E10. Current detection 1 See E11. Current detection 2 See E12. Start contact closed Under-voltage Electronic thermal relay pre-alarm (85%) Stalling Retry attempts See E14. Torque detection 1 See F12. Torque detection 2 See F13. 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.

Calculated torque F12 F13

Time

Output signal

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 OFF

L ON

H OFF

54

Permissible motor rotations F14: Permissible motor rotation The direction of motor rotation is selected.
Setting 0 1 2 Details of setting Both forward and reverse rotation Only forward rotation. Reverse rotation prohibited. 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.
Output frequency

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. Language selection
Time F21 Acceleration/deceleration control range F20

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

55

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.

1-1. OPU fault display and correction

The AF3100 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
Display on OPU Over-current (Acceleration) Over-current (During acceleration) Over-current (Constant speed) Over-current (During constant-speed operation) Over-current (Deceleration) Over-current (During deceleration) Output short circuit Output short circuit Grounding over-current Output-side grounding over-current Over-voltage Check point Is the acceleration time too fast? Is the torque boost setting too large?

connections or failure of external devices controlling the drive. The AF3100 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.

Is the output (U, V, and W) short-circuited or grounded? Is there a sudden load fluctuation? Is the load too large? Is an output (U, V, and W) short-circuited or grounded? Is the deceleration time too fast? Is the output (U, V, and W) short-circuited or grounded?

Correction Increase the acceleration time or increase the inverter capacity. Decrease the torque boost setting. Correct the short-circuited or grounded condition. Decrease the load fluctuation or increase the inverter capacity. Decrease the load or increase the inverter capacity. Correct the short-circuited or grounded section. Increase the deceleration time or increase the inverter capacity. Correct the short-circuited or grounded conductors. Correct the short-circuited section. Correct the grounded section.

Is the motor or cable short-circuited? Short circuit due to defective motor or cable?

Is the deceleration too fast? Is the moment of inertia of the load too large? Is there an overhauling condition from the load side? Is the input supply voltage too high? Is there a power failure or supply voltage fluctuation? Are there any loads, requiring a large starting current, connected to the same power supply system? Is an external fault signal (thermal relay, etc.) connected to terminals ES-BC? Is the fault signal from the connected equipment operating? Is the setting of the electric thermal relay correct? Is the type of motor set correctly? Is the torque boost setting too large? Is the load too large? Is the cooling fan working? Are the cooling air vents open? Is the ambient temperature too high? Is the load too large?

Decrease the deceleration time. Use a braking resistor. Decrease the supply voltage to within the specification range. Restart operation. Examine the power supply system. If not connected, short-circuit the terminals ES-BC (parameter F00: Normally closed contact). Remove the fault of the connected equipment. Set an appropriate level. Set the correct type of motor. Make the torque boost setting smaller. Decrease the load or increase the inverter capacity. Change the cooling fan. Clean the vents and/or remove any obstacles Cool the ambient environmental temperature. Decrease the load or increase the inverter capacity.

Regenerative over-voltage Under-voltage Under-voltage-Insufficient power supply voltage External thermal (External fault input) Overload Overload (Electronic thermal relay) Heat sink over temperature Radiation fin overheating

56

1.2 Troubleshooting
Name of protective function Over-current protection Details If the current exceeds approximately 200% for more than During acceleration 0.5 second of the rated current, a fault will occur. Probable During constantcauses include a high impact load during acceleration/decelspeed operation eration or an overload condition during constant-speed During deceleration operation. Fault results in a coast stop. A fault occurs when the inverter DC bus voltage exceeds approximately 395 volts for the 200 volt class and 790 volts for the 400 volt class. Regenerative energy during deceleration of the motor charges the DC bus above limits 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 by means of the output current. If the current exceeds 100% of the rated current but less than 200%, the protective circuit operates according to the thermal protection characteristics of the inverter. A fault will occur resulting in a coast stop. Note: Multi-motor connections require individual thermal relays for each motor. (Overload rating: 150% @ 60 seconds, 200% @ 0.5 second) A fault occurs if a power failure to the inverters AC input voltage is longer than 15 milliseconds; or the DC link voltage drops 20% (approximately 200 volts or less) for the 200 Volt class inverter or 15% (approximately 400 volts or less) for the 400 Volt class. The fault results in a coast stop. A fault occurs if any phase is grounded (shorted to ground) or if a current is detected in the ground circuit. The fault results in a coast stop. A fault occurs if any phase is short circuited (phase to phase, phase to ground). The fault results in a coast stop. This fault indicates the internal drive heatsink temperature has been exceeded. The fault results in an alarm. Closing the control terminals ES-BC causes an external fault resulting in a coast stop. The input can be selected as a N.O. (normally open) or N.C. (normally closed) contact using parameter F00. A system reset is required to return the inverter to normal run status. Number of retry attempts after a fault has been exceeded: operation is not allowed. A phase or motor lead between the inverter and motor is open. The open phase in question will be displayed on the OPU/keypad. Operation will be prohibited. A fault occurs if there are unbalanced phase currents from the inverter to the motor. The fault results in a coast stop. If the output current exceeds the value in parameter C06 (Stall prevention level during accel/decel), acceleration/ deceleration is decreased until current reaches the limit set by parameter C06. 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. Display (Operation unit) Over-current (acceleration) Over-current (constant speed) Over-current (deceleration)

Regenerative over-voltage prevention

Over-voltage

Overload prevention (Electronic thermal relay)

Overload

Under-voltage prevention Ground fault overcurrent prevention Output short circuit prevention Heatsink over temperature External fault Retry attempts Open phase detection 3-phase unbalanced detection Acceleration

Under-voltage

Ground-fault overcurrent Output short circuit (IPM error) Note 1 Heat sink overheating (IPM error) Note 1

External thermal

Note 2 U-phase open V-phase open W-phase open 3-phase unbalance

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.

57

1-3. Troubleshooting
Motor rotation
Symptoms The motor does not run at all. Possible cause Correct power is not applied. Detailed Troubleshooting (1) Inspection of main circuit Is the power supplied within specifications? The wiring is incorrect. Is the motor wired correctly? 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. 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? Oversized load. Inspection of load Is the load too heavy? Is the motor/shaft in a bind? The inverter protection function is active. The rating and type of the motor used with sensorless control do not match the inverter parameters. 1-2. OPU error display and correction Conduct auto-tuning. (Refer to p. 47.) Select C12 is applicable. V/Hz control for motors where sensorless control of the inverter for motors

Set the parameters C09 ~ C11 where sensorless control applies. Conduct auto-tuning. (Refer to p. 47.) The motor runs in reverse. Phase sequence of the output terminals U, V, and W. Command signal is incorrect. Acceleration or deceleration is not smooth. The acceleration/deceleration time is incorrect. The inverter is undersized for the load. Excessively large torque boost The rating and type of the motor used with sensorless control do not match the inverter parameters. (1) Inspection of main circuit

Inspection of input signal (1) Inspection of acceleration/deceleration time Inspection of load Inspection of torque boost Conduct auto-tuning. Refer to page 47. 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 during operation.

Loading changes Noise The rating and type of the motor used with sensorless control does not match the inverter parameters.

(1) Inspection of load (2) Inspection of frequency adjustment signal Conduct auto-tuning. Refer to page 47. Select C12 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

2. Inspection and Maintenance

Always inspect the AF3100 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 2-1. Precautions for maintenance and inspection

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.

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.

2-2. 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 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

Every year

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

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 Standard replacement period Method of replacement/others Remarks The service life of the cooling fan used for AF-3100 is approximately 20,000 hours (continuous operation at 40C). 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-3100 is approximately 35,000 hours (continuous operation at 40C). However, the actual life is subject to the loading condition, ambient temperature, etc.

Cooling fan

2-3 years

Replacement with a new cooling fan (Determined upon investigation)

DC Bus Capacitor

5 years

Replacement with a new capacitor (Determined upon investigation) Determined upon investigation

Relays

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

OPTION
1-1. List of options
(Mounting Position)
Power supply Operator station OS-II Name Type Use & specifications Remote control box Frequency counter (0-100%) Forward/reverse rotation command Frequency adjustment Potentiometer for frequency adjustment 3 k, 2W With scale plate and knob Frequency counter for % speed indication 0-100% display, 50 divisions 1 mAmp DC full scale Inverter output current detection Combination with detection CT Surge arrestor for electromagnetic contactor Reduce the effects of long motor leads For each voltage and capacity High attenuation filter on the inverter input side For each voltage and capacity Capacitive filter on the inverter input side Common to all capacities Installed on the inverter input/output side Zero-phase reactor/common to all capacities Braking unit For each voltage, capacity, and braking specification Consult Factory Used for inverter output signal from the relay contact point Contact rating: 230 VAC, 1 A 30 VDC, 1 A Internal parameter output via analog output signal of the inverter 0-10 VDC Resolution: 11 bits

Circuit breaker for wiring

Frequency adjustment unit

VR-01

Separate installation type

Electromagnetic contactor

% speed indicator

DCF-12N

AC reactor for improvement of power factor

AC ammeter Surge arrestor

ACF-12N Y122CA006 Y220CA058~057 (200V) Y220CA085~095 (400V) HF type 3XYHB-105104 (X480AC185) RC9129 (X480AC192) DU type QZG and QRZG types CF3100-50101 (CF310051-01)

LC-type noise filter

AC reactor

Zero-phase reactor

LC noise filter XY noise filter

Capacitive (XY) filter R P1 S T

Zero-phase reactor

Braking unit
DC reactor P Control unit and control resistor N Inverter (AF-3100)

Braking resistor

Built-in option

Relay output card

Analog monitor card

CD3100-50100 CF310050-01

Zero-phase rector

Note 1: For details, refer to the standard connection diagram page 16 and page 22.

Motor

IM

61

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

1-2. Options
Operator station OS-II (UF10005-01) (Frequency counter scale: 0-100%)
MCB Power supply ACL U V W X Y Z R S T P P1 U V W IM

AF-3100

80

24

OS-II Operator station Frequency meter + SP FM

25

FRQ+ FRQ

C L

Location of mounting hole

SN Forward rotation 5 Reverse rotation 7 RR 6

OPERATOR STATION

21

FR

182

140

BC

Mounting hole 2-5.5 21

Frequency adjust 3k

17 18 19

+V VRF COM

100

Twisted wire

Shielded wire

Frequency adjustment potentiometer: VR-01; 3 k; 2 W (VR01)

15 24

% speed indicator: DCF-12N [1 mA F.S.] 0-100%; 50 divisions (X525AA014)

40 30

50

60 70 80 90

3 50 12

12.5 31.5 111 0.5 10

Panel cut 500.5 1201.5 500.5 500.5 500.5

30

25

20 10 0 100

5 450.5 350.5 1001

85

Bakelite plate (0.8t) Mounting panel

50 Control: 3 k; 2 W

M4 mounting bolt

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.
White Red 1015 201 32
1 0 250+10

UL1015 AWG13

350.5

Drilling of panel holes

M4 (M5) Terminal screw thread

450.5

9.5

4-5 hole

1.8 6 17.51 10

16

17.51

4.5 10 14

63

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.
12.5 31.5 111 0.5 10 500.5 1201.5 Panel cut

500.5

500.5

500.5

5 450.5 350.5 1 100

140

M4 (M5) Terminal screw thread

85

80 85

M4 mounting bolt

ACF-12N
M5 thread M6 thread
E 75 M5 thread 60

2
601

65

84 100

1.6

10

8 42

841 100

101 96

Rating plate

110

8 42

COMA-15

COM-15-26 COM-15-30

COM-15-26 COM-15-30

E = 26 E = 30

Combination of AC ammeter (ACF-12N) and current transformer

Motor Capacity (kW) Meter Rated current (A) 5 5 5 5 5 5 5 5 5 Max. scale (A) 50 50 75 100 150 200 250 300 400 200V class CT Type COM-15-26 COM-15-26 COM-15-26 50/5A 50/5A 75/5A Number of primary through holes 3 3 2 2 1 1 1 1 1 Meter Rated current (A) 5 5 5 5 5 5 5 5 5 5 Max. scale (A) 20 30 50 50 75 100 150 150 200 250 COMA-15 COMA-15 400V class CT Type 20/5A 30/5A Number of primary through holes 3 3 2 2 1 1 1 1

5.5 7.5 11 15 22 30 37 45 55 75

COM-15-26 50/5A COM-15-26 50/5A COM-15-26 75/5A COM-15-30 100/5A COM-15-26 150/5A COM-15-26 150/5A COM-15-30 200/5A COM-15-30 250/5A

COM-15-36 100/5A COM-15-26 150/5A COM-15-30 200/5A COM-15-30 250/5A COM-15-30 300/5A COM-15-30 400/5A

Construction of current transformer (CT) COMA-15 type: Totally molded current transformer with primary winding COM-15-26 type: Totally molded current transformer of a round through window type COM-15-30 type: Totally molded current transformer of a round through window type Install the CT on the output side of the inverter.

64

350.5
4-5 hole

450.5

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.
T D1 5 D2 5

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.
D1 20 D2 5 T D1 5 D2 5

T H1 5 H1 5 B A W 5 H2 +10 25

H1 5

H2

+10 25

A W 5

B 4-G

A W 5

4-G

4-G

Fig. 1
D1 D2

Fig. 2
T D1 D2

Fig. 3

T H2

Connection
H1

H1

H2

A 4G W

A 4G W

Fig. 4 Item No. Y220CA058 059 060 061 063 064 065 066 067 Item No. Y220CA085 086 087 088 090 091 092 093 094 095 W 155 155 155 185 185 185 220 220 220 W 155 155 155 185 185 185 185 220 220 260 D1 45 45 50 60 53 60 130 140 150 D1 45 45 50 53 60 60 70 60 75 145 D2 40 40 45 55 48 55 55 65 65 D2 40 40 45 48 55 55 60 55 65 85 H1 150 150 150 175 175 175 205 205 205 H1 150 150 150 175 175 175 175 205 205 235

Fig. 5 H2 180 185 185 215 220 230 240 240 H2 175 175 180 210 215 215 220 250 265 270 A 80 80 80 80 80 80 90 90 90 A 80 80 80 80 80 80 80 90 90 90 B 50 50 55 65 65 80 85 100 100 B 50 50 55 65 80 80 95 85 100 145 G 5 5 5 6 6 6 7 7 7 G 5 5 5 6 6 6 6 7 7 11

Fig. 6 T M5 M6 M6 M6 M8 M10 M10 M10 M12 T M4 M5 M5 M6 M6 M6 M8 M8 M10 M10 Weight Insula- Figure (kg) tion 3.9 4.4 5.4 7.2 8.6 10.5 13.0 16.0 19.0 F F F F F F F F F

Applicable Specifications capacity Current (A) L (mH) (kW) 5.5 24 0.5 7.5 33 0.4 11 47 0.3 15 63 0.2 22 92 0.15 30 130 0.1 37 155 0.08 45 190 0.07 55 220 0.06 Applicable Specifications capacity Current (A) L (mH) (kW) 5.5 13 2.0 7.5 17 1.5 11 25 1.0 15 33 0.7 22 48 0.5 30 66 0.4 37 80 0.3 45 100 0.25 55 120 0.21 75 160 0.15

200V series

2 4

Weight Insula- Figure (kg) tion 4.2 4.4 5.5 6.3 9.0 11.0 12.0 14.0 17.0 31 B B F F F F F F F F

400V series

3 5 4

65

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-105104, X480AC185
MCB R Power supply S
1.0

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.
22 12 4.3 11.0 31.0
1.0

5.5

Soldering UL-1015AWG18 Black and yellow/green 10 2 300mm 47.0

T Minimum wiring length Black Black Black Yellow/Green 3XYHB 105104 E

Inverter

Capacitive filter

55.0

1.0

Zero-phase reactor: RC9129 (Made by Soshin Denki) X480AC192 Connections 1802 Can be used on both inverter input power supply and output (motor) power 1601 7 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 7x14 slot times (4 turns or more) is not possible because the wire is too large, install two 130 or more zero-phase reactors beside each other to reduce the number of turns. 85 Ensure the gap between the cable and core is as small as possible.
31.5
Number of winding times (turns)

Wire size (Note) 14mm2 or less 3 times (4T) Qty. 1 pc Winding method

14~30mm2 Once (2T) 2 pcs

22mm2 Through (1T) 4 pcs

35 80 832

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).

List of LC filters
Applicable motor 200V input side (kW) 5.5 HF3030A-FS 7.5 HF3040A-FS 11 HF3060A-FS 15 HF3080A-FS 22 HF3150A-FS 30 HF3150A-FS 37 HF3200A-FS 45 HF3200A-FS 55 HF3300A-FS 75 Weight (kg) 3.5 4.5 13 22 52 52 62 62 69 Outline drawing Fig. 1 Fig. 2 Fig. 3 400V input side HF3015C-FS HF3020C-FS HF3030C-FS HF3040C-FS HF3060C-FS HF3080C-FS HF30100C-FS HF30150C-FS HF3150C-FS HF3200C-FS Weight (kg) 3.0 3.0 3.5 4.5 13 22 30 52 52 62 Outline drawing Fig. 4 Fig. 5 Fig. 6 Fig. 7

66

4.5

Outline drawing of LC filter

Part name Dimensions (mm) C D E F 230 210 110 80 320 285 120 90 520 490 160 130 Part name HF3030A-FS HF3040A-FS HF3060A-FS J 35 40 50 K 12 15 (Unit: mm) L R2.75; length 7 R3.25; length 8 M 5.5 6.5 N M5 M6 P M4 Q 30 50

A HF3030A-FS 274 HF3040A-FS 355 HF3060A-FS 550 Fig. 1

H1.5 J1.5 1.5 K 4L

B 258 330 544

G 60 70 90

H 70 80 100

A1.5 B7.5 C1 D1.5

4M

Q1.5

G1 F1 E1.5

601.5

Grounding terminal 2P

Input terminal Metal case

Rating plate Output terminal 3N

4501.5

201.5 1201.5

Fig. 2

6M10

110 3107.5 2701.5 2501 2301.5

25

1181

991

106.5

Fig. 3
106.5 Input terminal Metal case Rating plate Output terminal 3M12 Grounding terminal 2M6

1202 2501.5 2701

2902

1451

1451 1451 6202 7107.5

1451 1001.5 2002

251

Fig. 4
701.5 351.5 121.5 2R2.75 Length 7 2741.5 248.57.5 2301 2101.5

25.5

Grounding terminal 2M4

Input terminal Metal case 3M4

Rating plate Output terminal 3M4

601 801 1101.5

67

Fig. 5

H1.5 J1.5 K1.5 4L

A1.5 B7.5 C1 D1.5

4M

Grounding terminal 2P

Grounding terminal Input terminal Rating plate Output terminal 2P 3N

Part name

B 330 544

C 320 520

D 285 490

E 120 160

F 90 130

Dimensions (Unit: mm) G H J K 70 90 80 100

M1.5

L R3.75; length 8

G1 F1 E1.5

Q1

M 6.5

N M5 M6

P M4

Q 30 50

HF3030C-FS 355 HF3040C-FS HF3060C-FS 550 Fig. 6

40 50

12 15

E1.5

Metal case

Rating plate

Output terminal

L1.5 K1.5

Grounding terminal

H A7.5 B1.5 C1 D1.5

F1 G1 Input terminal

10N

A HF3080C-FS 310 HF3100C-FS 345 Fig. 7

Input terminal

Part name

B 270 290

C 250 270

D 230 250

E 450 480

F 118 115

Dimensions (Unit: mm) G H J K 99 120 110 25 115 150

L 60 75

M 20

P M10 6.5 M12

Q M4
1 4 5 E 6 R S Inverter T E Shortest wiring

Metal case

Rating plate

106.5 Output terminal 3M12

Grounding terminal 2M6

Power supply

2 3

1451

1451
2

1451 620 7107.5

1451 1001.5 2002

251

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

1202 2501.5 2701 2902

BRAKING UNIT/BRAKING RESISTOR

Selection table
Braking torque: 100% Voltage Type of inverter AF3122-5A5 AF3122-7A5 AF3122-015 AF3122-5A5 200V class AF3122-022 AF3122-030 AF3122-037 AF3122-045 AF3122-055 AF3124-5A5 AF3124-7A5 AF3124-011 AF3124-015 400V class AF3124-022 AF3124-030 AF3124-037 AF3124-045 AF3124-055 AF3124-075 Motor capacity (kW) 5.5 7.5 11 15 18.5 22 30 37 45 55 5.5 7.5 11 15 18.5 22 30 37 45 55 75 Operation rate: 4% ED max. Braking time: 7 sec. max. Braking unit Type * * * * DU-207S DU-207S DU-208S DU-208S DU-207S DU-207S * * DS-401S DU-401S DU-408S DU-409S DU-409S DU-410S DU-410S DU-409S Qty 1 1 1 1 2 2 1 1 1 1 1 1 1 2 Braking resistor ** Type QRZG500-18 QRZG500-18 QRZG500-4.5 QRZG500-2.5 QRZG500-2.5 QRZG500-1.6 QRZG500-1.1 QRZG500-1.1 QRZG500-1.6 QRZG500-1.6 QZG300-30 QRZG500-18 QRZG500-10 QRZG500-10 QRZG500-4.5 QRZG500-4.5 QRZG500-2.5 QRZG500-1.6 QRZG500-1.6 QRZG500-2.5 Qty 1 1 3 3 3 3 4 4 3x2 3x 2 3 3 3 3 4 4 5 6 4x2 Operation rate: 10% ED max. Braking time: 15 sec. max Braking unit Type * * * * DU-203S DU-204S DU-205S DU-203S DU-204S DU-205S * * DU-402S DU-403S DU-403S DU-404S DU-405S DU-406S DU-407S DU-405S Qty 1 1 1 2 2 2 1 1 1 1 1 1 1 2 Braking resistor ** Type QRZG500-10 QRZG500-10 QRZG500-4.5 QRZG500-2.5 QRZG500-1.6 QRZG500-1.1 QRZG500-0.6 QRZG500.16 QRZG500-1.1 QRZG500-0.6 QRZG500-30 QRZG500-18 QRZG500-10 QRZG500-4.5 QRZG500-4.5 QRZG500-2.5 QRZG500-1.6 QRZG500-1.1 QRZG500-0.6 QRZG500-1.6 Qty 2 2 3 4 5 6 8 5x2 6x2 8x2 2 3 4 6 6 8 10 12 16 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 DU-201S DU-202S 200V DU-203S class DU-204S DU-205S DU-207S DU-208S Wire 3.5mm2 5.5mm2 8mm2 3.5mm2 Type of braking unit DU-401S DU-402S DU-403S DU-404S 400V DU-405S class DU-406S DU-407S DU-408S DU-409S DU-410S Wire 2mm2 3.5mm2
60Hz Output frequency

Operating rate %ED

5.5mm2 8mm2 2mm2 3.5mm2

tB tC
Operating rate %ED =

Time

tB tC

X 100

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.

tB = Braking time (sec) tC = Repeating cycle (sec)

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 300C. 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.

Notes: The maximum temperature of the braking resistor is approx. 150C. 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

69

Connection diagram of braking unit/braking resistor

One braking unit

Inverter

Two braking units

Inverter

Braking resistor

Braking resistor

Braking resistor

PR E Master

N E1 TA TB TC E2 S1 S2

Jumper

PR E Master

N E1 TA TB TC E2 S1 S2

Jumper

PR E Master

N E1 TA TB TC E2 S1 S2

Jumper

M1 M2

M1 M2

M1 M2

Installation of jumper pin DBM DBS 460V 400/440V 380V DBM DBS 230V 200/220V DBM DBS 460V 400/440V 380V DBM DBS 230V 200/220V DBM DBS 460V 400/440V 380V DBM DBS 230V 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 150C. 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

Dimensions of braking unit

Mounting hole (4M5Bolt)

Size of terminal screw thread

225 240

213

Type DU-s s s s s 201S, 202S 207S, 208S 401S, 402S 403S, 404S 408S, 409S 410S 203S, 204S 205S, 206S 405S, 406S 407S

Main circuit terminal P, PR, N

Control circuit terminal M1~E2

Weight

M4 M3 3kg

60 100

169 178

M6

Dimensions of braking unit QRZG500 type

5

QZG300 type
5 57

40

84

40

355 381

10 40

2742 309 3352

10 40

79

71

Higher harmonic control

Start
The equivalent capacity is calculated by converting the capacity of the users 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
AF-3100 Without reactor With reactor (AC side) Conversion factor K31 = 3.4 K32 = 1.8 K33 = 1.8 K34 = 1.4

Calculation of equivalent capacity

Table 2 Rated capacity

Capacity of motor 5.5 7.5 11 15 22 30 37 45 55 75 Relay input capacity Pi (kVA) 200V 400V 6.77 6.77 9.07 9.07 13.1 13.1 17.6 17.6 25.9 25.9 34.7 34.7 42.8 42.8 52.1 52.1 63.7 63.7 87.2

YES

Is the equivalent capacity within the limit?

With reactor (DC side) With reactor (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

Calculation of higher harmonic current

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 5.5 19.1 9.55 7.5 25.6 12.8 11 36.9 18.5 15 49.8 24.9 22 73.1 36.6 30 98.0 49.0 37 121 60.4 45 147 73.5 55 180 89.9 75 123

Table 5 Qty of generated n-th degree higher harmonic

Degree Without reactor With reactor (AC side) With reactor (DC side) With reactor (AC/DC sides) 5th degree 65 38 30 28 41 14.5 13 9.1 8.5 7.4 8.4 7.2 7.7 3.4 5.0 4.1 4.3 3.2 4.7 3.2 3.1 1.9 3.2 2.4 2.6 1.7 3.0 1.6

Unit: %
1.8 1.3 2.2 1.4

7th degree 11th degree 13th degree 17th degree 19th degree 23rd degree 25th degree

YES

Is it within the guideline? NO

Table 6 Upper limit of higher harmonic current per kW contact power

Incoming Voltage 6.6kV 22kV 33kV 66kV Order 5th degree 3.5 1.8 1.2 0.59

Unit: A/kW

7th degree 11th degree 13th degree 17th degree 19th degree 23rd degree 25th degree 2.5 1.3 0.86 0.42 1.6 0.82 0.55 0.27 1.3 0.69 0.46 0.23 1.0 0.53 0.35 0.17 0.90 0.47 0.32 0.16 0.76 0.39 0.26 0.13 0.70 0.36 0.24 0.12

OK

Measures: Reactor, etc.

Calculated n-th degree higher harmonic current < Upper limit on n-th degree higher harmonic current

72

Option Cards: Only one option card can be used. 1. Relay output card
Part Number: CF310051-01
Relay to output RY1 Terminal block
R1C R1B R1A R2C

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

Details of detection Output selected by relay 1 output selection (E25) Output selected by relay 2 output selection (E26)

RY2

R2B R2A

2. Analog monitor card

Part Number: CF310050-01 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
Setting 0 1 2 3 4 5 6 Signal Description Output frequency Command frequency Output current Output voltage Overload rate Motor torque Output speed (rpm)

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:

Signal Level 10 V DC = 100% gain Standard frequency (Parameter A13 setting) Standard frequency (Parameter A13 setting) Rated current for inverter Base frequency/voltage Electronic thermal trip level When motor is 100% loaded Standard frequency (Parameter A13 setting)

Internal block diagram

COM AM2 D/A COM AM1

If this option is selected, E19 and E24 are automatically added to the parameter menu.
Menu E19 E20 E21 E22 E23 E24 Function Selection of output signal from terminals AM1 and COM Selection of output signal from terminals AM2 and COM Gain control for the signal selected for output AM1 Gain control for the signal selected for output AM2 Offset control for the signal selected for AM1 Offset control for the signal selected for AM2 Setting range 0~6 0~6 0~200% 0~200% 0~100% 0~100% Setting for shipment 0 (Output frequency) 0 (Output frequency) 100% 100% 0% 0%

Recommended wiring: twisted, shielded wire.

73

3. Pulse Generator (PG) Feedback Option

If this option is mounted, E29 through E35 are automatically added to the parameter menu. Type: Indication: Function: Allows the AF3100 to operate in the vector mode with feedback from the Pulse Generator (PG). The PG card installs in the AF3100. CF31057-01
AM1 Com AM2 Com

PG Feedback Card
CN2 CN1 CN4
B- B+ A- A+ B-

Analog Out (0-10 volts)

CN3
B+ A- A+ CM V

To CN2 AF3100

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. Parameter E29 E30 E31 E32 E33 E34 E35 Function PG Pulse Count PG Standard Phase Selection Speed Proportional Gian Speed Integral Gain Disturbance Observer Gain Disturbance Observer Compensation Time % Torque Limit Command (see parameter C05)

Line Driver Output

shielded cable

PG

Range 100 ~ 5000 0 or 1 0.0 ~ 500% 0.0 ~ 500% 0.0 ~ 100% 0.01 ~ 9.99 seconds 0: Panel, 1:0-5V; 0-8V, 2: 08V; 3: 0-10V, 4: 0-20ma

Factory Setting 1024 0 100% 100% 70% 0.05 0

Settings for Analog Monitor Output Signals for AM1 and AM2. Refer to parameters E19 and E20.
Setting 0 1 2 3 4 5 6 Signal Description Output frequency Command frequency Output current Output voltage Overload rate Motor torque Output speed (rpm) Signal Level 10 V DC = 100% gain Full Scale w/gain = 100% Vout + 10 Volts Command Frequency Rated Current for Inverter Base Frequency Voltage Electronic Thermal Trip 100% motor load Standard frequency command

PG Card

Relay Card

Analog Card

74

The parameter menu automatically adds E19-E24 if the optional analog monitor card is used. Analog monitor output signal selection E 1 9 Analog monitor AM1 (0-5) E 2 0 Analog monitor AM2 (0-5) E 1 9 The signal configured for analog output AM1 is selected from the list below: E 2 0 The signal configured for analog output AM2 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

Output voltage 10 V Gain: 200% 5V 100% Gain: 100% Gain: 50%

50%

0 30 Hz B15 setting 60 Hz

Output frequency 120 Hz

Gain control for the analog output signal. E 2 1 Monitor AM1 gain 0-200% E 2 2 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 Monitor AM1 offset (0-100%) E 2 4 Monitor AM2 offset (0-100%) The magnitude of the analog monitor output is controlled. The signal offset value for AM1 is limited to E 2 3 100%. E 2 4 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

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

149.0

159.0

(WARNING) MAKE SURE POWER LINE IS TURNED OFF BEFORE REMOVING OPERATOR STATION.

140.5 4-R10 71.5 18.0 23.0 25.0 76.0

DATA MENU

SET

RUN

SELECT

RESET

FWD

REV

JOG

STOP

76.0 90.0

MAX 17.0

29.0

76

13.6

8.8

149.0

SPECIFICATIONS
200V class
Type Applicable motor output (kW) Rated capacity (kVA) Note 1 Rated current (A) Rated overload current Note 2 Rated voltage (V) Note 3 Phase/voltage/frequency Voltage & frequency variance Required power capacity (kVA) Note 4 Standard Type If option is used Torque Protective construction Cooling method Approx. weight (kg) Note 6 AF3122 -5A5-U 5.5 10 24 AF3122 AF3122 -7A5-U -011-U 7.5 11 13 18 32 44 150% 1 min; 200% 0.5 sec 3-phase; 200~230V 3-phase; 200~220V/50Hz, 200~230V/60Hz Voltage: -15% and +10% Frequency: 5% 7.6 10 15 Approx. 10% Braking resistor 150% or greater, short duty cycle Open Note 6 NEMA1 Forced air cooling 9 9 11 16 AF3122 -015-U 15 24 56

Braking Torque Power Supply

Output

20

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
Type Applicable motor output (kW) Rated capacity (kVA) Note 1 Rated current (A) Rated overload current Note 2 Rated voltage (V) Note 3 Phase/voltage/frequency Voltage & frequency variance Required power capacity (kVA) Note 4 Standard Type If option is used Torque Protective construction Cooling method Approx. weight (kg) 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 5.5 7.5 11 15 22 30 37 45 55 75 10 13 19 24 36 48 61 73 86 115 13 16 24 32 48 64 80 96 112 150 150% 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: Within -15% and +10% Frequency: Within 5% 7.6 9.9 14 19 29 39 48 58 71 98 Approx. 10% Braking resistor Braking resistor and braking unit 150% or greater, short duty cycle 100% or greater Note 5 Open Note 6 NEMA 1 Forced air cooling 9 9 11 16 26 32 45 45 58 65

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).

Braking Torque Power Supply

Output

77

COMMON SPECIFICATIONS
1-a. Control 1-b. Control method
Control method Output frequency range Frequency adjustment resolution Frequency accuracy Carrier frequency Voltage/frequency characteristics Torque boosting DC braking Acceleration/deceleration time Digital Frequency adjustment signal Analog Stall prevention Starting torque Speed variance rate Trip-less operation Sensorless flux vector, V/Hz, closed loop vector 0~400.00Hz 0.01 Hz: Digital setting 1/1000 of max. output frequency: Analog setting 0.01% of preset frequency: Digital setting Within 0.5 % of max. frequency (25 10C) Variable: 2.5-14.45 The maximum carrier frequency decreases for 30 kW or greater. Three separate V/Hz patterns are possible. Manual boosting (variable: 0-30%), automatic boosting, and sensorless speed control (automatic tuning) Variable braking frequency start, 0.5-10 Hz; operation time, 0-10 sec; operation voltage, 0-30%. 0.1-3,000 sec; selection of linear or S Curve; 1st and 2nd settings Digital operation unit DC 0~5V, 0~8V, 0~10V, 4~20mA Variable: 0-200% (Factory preset at 160%) 200% or greater if sensorless control is selected. 0.2% or less. The load is 0-100% when sensorless control is selected. 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: 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): 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 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 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 Display of parameter and data Upon a protective function (fault) the details are displayed. Up to four preceding errors can be displayed. Indoor. There shall be no corrosion, toxicity, inflammable gas, dust, or oil mist. -10 to +40C (+ 50C when installed inside the panel Note 4) -10C ~ + 60C 90% RH or less (Dew condensation not allowed) 1000 m or less above sea level 0.6 G or less (As per JIS C0911)

Control Display

Operation input signal

Output signal

Operation function

Condition of operation Preset information Fault display Suggested locaton Ambient temperature Storage temperature Ambient humidity Altitude Vibration

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 50C 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

Environment

1-2. Internal block diagram

Note 3

ACL MCB
U V W X Y Z R S T S1
Note 4 Selection of supply voltage for 400 V class FAN Converter

P1

N Inverter U Motor

Power supply

+
C

V W

IM

CHARGE Grounding

TX1 TX2 TX3

200 V class Voltage detection Control power FR + 24 V Current detection Gate drive circuit E

Grounding

Forward rotation Reverse rotation RR DFL DFM DFH Note 1: Digital input

PWM circuit

Protective circuit
(Meter specification: DC 1 mA F.S.) Frequency counter DCF 12N +

CPU
FRQ*

JOG AD2 BMD Note 5 ES RST

ROM

FM
FRQ* -

FA FB AR Error contact point output 230 VAC; 1 A max. 30 VDC; 1 A max. When an error occurs: FA-FC closed FB-FC open

External fault Alarm reset Coast

FC

MBS BC +5V OPU Operation unit DRV

Frequency adjust VR 01 3 k 3 2 1 DC 0 ~ 10 V +V VRF COM

+ 10 V

Output signal circuit

UPF X1 X2 OM Open collector common (Open collector output: 24 V, 50 mA max.) Note 2: Digital output

4 ~ 20 mA + COM -

IRF

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: *2: *3: *4:

13 separate functions can be programmed. 15 separate functions can be programmed. Remove the jumper if a DC reactor is connected. 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

1-3. Outside dimensions

5.5, 7.5kW 200V/400V 15kW 200V/400V
410.0 (0.39) 10 (0.39) 380 (14.96) 21 (0.83) 10 (0.39) 400 (15.75)

READY ALARM LOCAL

(WARNING) MAKE SURE POWER LINE IS TURNED OFF BEFORE REMOVING OPERATOR STATION.

D AT A MENU

SET

READY ALARM LOCAL

330 (12.99)

372 (14.65)

(WARNING) MAKE SURE POWER LINE IS TURNED OFF BEFORE REMOVING OPERATOR STATION.

DATA MENU

SET

RUN

SELECT

RESET

FWD

REV

JOG

STOP

RUN

SELECT

RESET

FWD

REV

JOG

STOP

7 (0.28) 7 (.028) 12 (0.47) 180 (7 .09) 204 (8.03) 12 (0.47) 16 (0.63) 201 (7 .91) 66 (2.60) 21 (0.83) 190 (7 .48) 232 (9.13) 123 (4.84) 241 (9.49)

632.0 (1.26)

4M8

22, 30kW 400V

R EAD Y AL AR M L O C AL

(WARNING) MAKE SURE POWER LINE IS TURNED OFF BEFORE REMOVING OPERATOR STATION.

D AT A MENU

SET

RUN

SELECT

RESET

FWD

REV

JOG

STOP

65 (2.56)

460.0 (18.1 1) 590.0 (23.23) 618.5 (24.35)

260.0 (10.24) 310.0 (12.20)

126.0 (4.96) 270.0 (10.63)

Dimensions in mm (inch)
44 (1.73) 362 (2.44)

80

37, 45kW 400V

4M8

Numbers in (
READY ALARM LOCAL
(WARNING) MAKE SURE POWER LINE IS TURNED OFF BEFORE REMOVING OPERATOR STATION.

) = inches

DATA MENU

SET

RUN

SELECT

RESET

FWD

REV

JOG

STOP

640 (25.20) 140 (5.51)

845 (33.27)

330 (12.99) 376 (14.80) 439 (17 .28)

1 (4.65) 18 275 (10.83)

4M10

650 (1.97)

715.0 (28.15) 740.0 (29.13) 192.5 (7 .58)

55, 75kW 400V

R EAD Y AL AR M L OC AL
(WARNING) MAKE SURE POWER LINE IS TURNED OFF BEFORE REMOVING OPERATOR STATION.

D ATA MENU

SET

RUN

SELECT

RESET

FWD

REV

JOG

STOP

1010.0 (39.76)

400.0 (15.75) 505.0 (19.88) 572.0 (22.52)

297 (1 .9 1.73) 131.4 (5.17)

52 (1.73)

652 (2.05)

OPTIONAL BRACKET

129.8 (5.1 1)

530.0 (20.87) 553.0 (21.77)

81

1-4. Measurements for external installation of inverter heat sink

AF-3100 5.5~7.5kW/200-400V AF-3100 11~15kW/200-400V

315.0 (12.40) 330.0 (12.99)

180.0 (7.09) 198.0 (7.80)

6.0 (.236)

190.0 (7.48) 235.0 (9.25)

AF-3100 22~30kW/400V

AF-3100 37~45kW/400V

185.0 (7.28) 380.0 (14.96) 400.0 (15.75) 12.5 (0.49) 185.0 (7.28) 185.0 (7.28)

365.0 (14.37) 380.0 (14.96) 690.0 (27.17) 460.0 (18.11) 605.0 (23.82)

260.0 (10.24) 316.0 (12.44)

AF-3100 55k~75kW/400V

510.0 (20.08) 528.0 (20.79)

82

10.0 (0.39)

215.0 (8.46)

215.0 (8.46)

215.0 (8.46)

436.0 (17.17)

NOTES

83

NOTES

84

Sumitomo Machinery Corporation of America R T IFI 4200 Holland Boulevard, Chesapeake, VA 23323 (757) 485-3355 FAX: (757) 485-3075 Toll Free: 1-800-SM-CYCLO (762-9256) www.smcyclo.com e-mail: smcamktg@series2000.com
CE

IS

Headquarters and Manufacturing

O 90

North American Regional Offices Stocking & Assembly Facilities

Mid-West 175 West Lake Drive Glendale Heights, IL 60139 (630) 752-0200 FAX: (630) 752-0208 West 2375 Railroad Street Corona, CA 91720 (909) 340-4100 FAX: (909) 340-4108 Southwest 1420 Halsey Way #130 Carrollton, TX 75007 (972) 323-9600 FAX: (972) 323-9308 Northeast 501 Office Center Dr., Suite 260 Ft. Washington, PA 19034 (215) 653-0560 FAX: (215) 653-0181 Teterboro 7 Malcolm Avenue Teterboro, NJ 07608 (201) 288-3366 FAX: (201) 288-8843 Southeast 4200 Holland Boulevard Chesapeake, VA 23323 (757) 485-3355 FAX: (757) 487-3193

Mexico
Monterrey SM-CYCLO DE MEXICO, S.A. DE C.V. Calle C No. 506A Parque Industrial Almacentro Apodaca, N.L., Mexico 66600 Tel.: 011-52-8-369-3697/8 FAX: 011-52-8-369-3699

Canadian Stocking & Assembly Facilities

Toronto (East) SM-CYCLO OF CANADA, LTD. 870 A Equestrian Court Oakville, Ontario, Canada L6L 6L7 (905) 469-1050 FAX: (905) 469-1055 British Columbia (West) SM-CYCLO OF CANADA, LTD. 740 Chester Road, Annacis Island, Delta B.C., Canada V3M 6J1 (604) 525-5403 FAX: (604) 525-0879 Montreal SM-CYCLO OF CANADA, LTD. 226 Migneron Street St. Laurent, Quebec, Canada H4T 1Y7 (514) 340-1300 FAX: (514) 340-1343

Central & South America Sales, Engineering, Stocking & Assembly

Brazil SM-CYCLO REDUTORES DO BRASIL LTDA. Av. Dr. Ulysses Guimares, 3533 09990-080 Diadema So Paulo, Brazil Tel.: 011-55-11-445-4388 FAX: 011-55-11-456-2922 Chile SM-CYCLO DE CHILE LTDA. Napoleon 3565, Of. 510 Las Condes - Santiago, Chile Tel.: 011-56-2-203-7300 FAX: 011-56-2-203-7195

01

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

v
SM-CYCLO Concentric MECHANICAL VARIABLE SPEED

GEAR BOXES

Concentric ELECTRICAL VARIABLE SPEED

ALL DRIVES ALL TYPES ALL SPEEDS

v

v v v v

MOTORS

CONTROLLERS CONCENTRIC RIGHT ANGLE

PARALLEL OFFSET

v CONSTANT SPEED v MECHANICAL VS v ELECTRICAL VS v

THE AMERICAS

SM-BEIER HELICAL GEAR REDUCER

AF-3100 AC Drive

NTAC-2000 AC Drive

WORLDWIDE

v v

ASIA

EUROPE

SHAFT MOUNT SPEED REDUCER

Power T ransmission Products

4200 Holland Blvd., Chesapeake, VA 23323 (757) 485-3355 FAX: (757) 485-3075 Toll Free: 1-800-SM-CYCLO Web: http://www.smcyclo.com E-mail: smcamktg@series2000.com
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DISTRIBUTED BY:

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SM-SHAFT MOUNT Parallel Offset SHAFT MOUNT GEARMOTOR SPEED REDUCER WORM GEARMOTOR PARTS & SERVICE

SM-HEDCON SM-SHAFT MOUNT Right Angle Parallel Offset

SM-HYPONIC SM-SHAFT MOUNT Right Angle Parallel Offset

SM-ULYSSES Right Angle

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01

CE