Troubleshooting And Maintenance 6 - Free Download PDF

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Troubleshootingand MaintenanceIn This Chapter.6page— Troubleshooting . 2— Monitoring Trip Events, History, & Conditions. 5— Restoring Factory Default Settings . 9— Maintenance and Inspection . 10— Warranty . 18

6–2TroubleshootingTroubleshootingSafety Messages Please read the following safety messages before troubleshooting or performing maintenanceon the inverter and motor system.WARNING: Wait at least five (5) minutes after turning OFF the input power supply beforeperforming maintenance or an inspection. Otherwise, there is the danger of electric shock.WARNING: Make sure that only qualified personnel will perform maintenance, inspection,and part replacement. Before starting to work, remove any metallic objects from your person(wristwatch, bracelet, etc.). Be sure to use tools with insulated handles. Otherwise, there is adanger of electric shock and/or injury to personnel.WARNING: Never remove connectors by pulling on its wire leads (wires for cooling fan andlogic P.C. board). Otherwise, there is danger of fire due to wire breakage and/or injury topersonnel.General Precautions and Notes Always keep the unit clean so that dust or other foreign matter does not enter the inverter. Take special care to avoid breaking wires or making connection mistakes. Firmly connect terminals and connectors. Keep electronic equipment away from moisture and oil. Dust, steel filings and other foreignmatter can damage the inverter, causing unexpected accidents, so take special care.Inspection ItemsThis chapter provides instructions or checklists for these inspection items: Daily inspection Periodic inspection (approximately once a year)Troubleshootingand Maintenance Insulation resistance test

SJ300 InverterTroubleshootingTipsThe table below lists typical symptoms and the corresponding solution(s).Symptom/conditionThe motorwill not run.6–3The inverteroutputs U, V, Ware not supplyingvoltage.Probable CauseSolution Is the frequency command sourceA001 parameter setting correct? Is the Run command source A002parameter setting correct? Make sure the parametersetting A001 is correct. Make sure the parametersetting A002 is correct. Is power being supplied to terminals[R], [S], and [T] ([L1], [L2], and[L3])? If so, the POWER lamp shouldbe ON. Check terminals [R], [S], and[T] ([L1], [L2], and [L3]), then[U], [V], and [W] ([T1], [T2],and [T3]). Turn ON the power supply orcheck fuses. Is there an error code EXX.Xdisplayed? Press the Func. key and determine the error type. Eliminatethe error cause, then clear theerror (Reset). Are the signals to the intelligent inputterminals correct? Is the Run Command active? Is the [FW] terminal (or [RV])connected to P24 (via switch, etc.) Verify the terminal functionsfor C001 - C008 are correct. Turn ON Run commandenable. Supply 24V to [FW] or [RV]terminal, if configured. Has the frequency setting for F001been set greater than zero? Are the control circuit terminals [H],[O], and [L] connected to the potentiometer? Set the parameter for F001 to asafe, non-zero value. If the potentiometer is thefrequency setting source, verifyvoltage at [O] 0V. Is the RS (reset) function or FRS (free- Turn OFF the command(s).run stop) function ON?Inverter outputs Is the motor load too heavy?U, V, W aresupplying voltage. Are the connections of output terminals [U/T1], [V/T2], and [W/T3]correct? Is the phase sequence of the motorforward or reverse with respect to[U/T1],[V/T2], and [W/T3]? Make connections according tothe phase sequence of themotor. In general:FWD U-V-W, and REV UW-V. Are the control terminals [FW] and[RV] wired correctly? Is parameter F004 properly set? Use terminal [FW] for forward,and [RV] for reverse. Set motor direction in F004.Troubleshootingand MaintenanceThe direction of the motor isreversed. Reduce load or test the motorindependently of the load.

6–4TroubleshootingSymptom/conditionThe motor speed will not reach thetarget frequency (desired speed).Probable CauseSolution If using the analog input, is therecurrent or voltage at [O] or [OI]? Check the wiring. Check the potentiometer orsignal generating device. Is the load too heavy? Reduce the load. Heavy loads activate theoverload restriction feature(reduces output as needed). Is the inverter internally limiting theoutput frequency? Check max frequency setting(A004) Check frequency upper limitsetting (A061) If using analog inputs, checktheir settings (A101– A104)or (A111–A114), or (A011–A014) Is the load fluctuation too great?The rotation is unstable.The RPM of the motor does notmatch the inverter outputfrequency setting.Troubleshootingand MaintenanceA parameterwill notchange afteran edit(reverts to oldsetting). Is the supply voltage unstable? Is the problem occurring at a particularfrequency? Increase the motor capacity(both inverter and motor). Fix power supply problem. Change the output frequencyslightly, or use the jumpfrequency setting to skip theproblem frequency. Is the maximum frequency setting Verify the V/F settings matchA004 correct?motor specifications. Does the monitor function D001 Make sure all scaling (such asdisplay the expected output frequency?A011 to A014) is properly set.True for certainparameters Is the inverter in Run Mode? Someparameters cannot be edited duringRun Mode. Put inverter in Stop Mode(press the Stop/reset key). Thenedit the parameter.True for allparameters If you’re using the [SFT] intelligentinput (software lock function)—is the[SFT] input ON? Change the state of the SFTinput, and check the B031parameter (SFT mode).

SJ300 Inverter6–5Monitoring Trip Events, History, & ConditionsFault Detectionand ClearingThe microprocessor in the inverter detects aSTOPvariety of fault conditions and captures the event,RESETrecording it in a history table. The inverter outputRunStopRUNturns OFF, or “trips” similar to the way a circuitbreaker trips due to an over-current condition.STOPMost faults occur when the motor is running (referRESETFaultto the diagram to the right). However, the inverterTripcould have an internal fault and trip in Stop Mode.FaultIn either case, you can clear the fault by pressingthe Stop/Reset key. Additionally, you can clear theinverter’s cumulative trip history by performing the procedure “Restoring Factory DefaultSettings” on page 6–9 (setting B 84 00 will clear the trip history but leave inverter settingsintact).Error StatusCodesThe conditions at the time of an error provide important clues to help you understand the cause.The SJ300 inverter displays a “status at trip point” digit to the right of the decimal point forsome error codes. For example, E07.2 means Error 7 occurred and the inverter status wascondition # “2” when the error occurred.StatusCodes---.0---.1---.2---.3---.4Error CodesInverter StatusResetStopDecelerationConstant -.9Inverter Statusf0 stopStartingDC brakingOverload restrictionAuto-tuningAn error code will appear on the display automatically when a fault causes the inverter to trip.The following table lists the cause associated with the error.ErrorCodeNameProbable Cause(s)Over current event while atconstant speedE02Over current event duringdecelerationE03Over current event duringaccelerationThe dual-voltage motor is wired incorrectly.Over current event duringother conditionsDC braking power(A054) is set too high, or acurrent transformer error occurred, or a noisesource induced the error.E04The inverter output was short-circuited, or themotor shaft is locked or has a heavy load. Theseconditions cause excessive current for the inverter,so the inverter output is turned OFF.Note: The SJ300 will over current trip atnominally 200% of rated current for models up to–550xxx;nominally 180% of rated current for models–750xxx to –1500xxx.Troubleshootingand MaintenanceE01

6–6Monitoring Trip Events, History, & ConditionsErrorCodeProbable Cause(s)E05Overload protectionWhen a motor overload is detected by theelectronic thermal function, the inverter trips andturns OFF its output.E06Braking resistor overloadWhen the regenerative braking resistor exceedsthe usage time allowance or usage ratio, theinverter trips and turns OFF its output to themotor.E07Over voltage protectionWhen the DC bus voltage exceeds a threshold, dueto regenerative energy from the motor.E08EEPROM errorWhen the built-in EEPROM memory hasproblems due to noise or excessive temperature,the inverter trips and turns OFF its output to themotor.E09Under-voltage errorA decrease of internal DC bus voltage below athreshold results in a control circuit fault. Thiscondition can also generate excessive motor heator cause low torque. The inverter trips and turnsOFF its output.CT (current transformer)errorIf a strong source of electrical interference is closeto the inverter or a fault occurs in a built-in CT(current transformer), the inverter trips and turnsits output OFF.E11CPU errorA malfunction in the built-in CPU has occurred,so the inverter trips and turns OFF its output to themotor.E12External tripA signal on an intelligent input terminal configured as EXT has occurred. The inverter trips andturns OFF the output to the motor.E13USPWhen the Unattended Start Protection (USP) isenabled, an error occurred when power is appliedwhile a Run signal is present. The inverter tripsand does not go into Run Mode until the error iscleared.E14Ground faultThe inverter is protected by the detection ofground faults between the inverter output and themotor during powerup tests. This feature protectsthe inverter, and does not protect humans.E15Input over-voltageWhen the input voltage is higher than the specifiedvalue, it is detected 60 seconds after powerup andthe inverter trips and turns OFF its output.E16Instantaneous power failureWhen the input power is removed for more than15ms, the inverter trips and the output to the motorturns OFF. If the power failure duration exceedsthe duration set in parameter B002, it is considered a power failure. When input power isrestored, the inverter restarts if the Run signal ispresent, depending on the restart condition.E21Inverter thermal tripWhen the inverter internal temperature is abovethe threshold, the thermal sensor in the invertermodule detects the excessive temperature of thepower devices and trips, turning the inverteroutput OFF.E10Troubleshootingand MaintenanceName

SJ300 InverterErrorCodeE23Name6–7Probable Cause(s)Gate array errorAn internal inverter error has occurred in communications between the CPU and gate array IC.Phase failure detectionOne of three lines of the 3-phase power is missing.IGBT errorWhen an instantaneous over-current conditionoccurs on any IGBT (output transistor) device, theinverter alarm trips. then it turns the outputs OFFin order to protect the circuitry.E35ThermistorWhen a thermistor is connected to terminals[THM] and [CM1] and the inverter has sensed thetemperature is too high, the inverter trips and turnsOFF the output.E36Brake errorWhen the inverter releases the brake and cannotdetect whether the external brake is ON or OFFwithin the waiting time (set by parameter B024),the inverter trips and turns OFF the output to themotor.––––Under-voltage (brownout)with output shutoffDue to low input voltage, the inverter turns itsoutput OFF and tries to restart. If it fails to restart,then the alarm trips to record the under-voltageerror event.E6XExpansion card #1connection errorE7XExpansion card #2connection errorAn error has occurred in an expansion card or atits connecting terminals. Please refer to themanual for the expansion card for additionaldetails.E24E30NOTE: If an EEPROM error (E08) occurs, be sure to confirm the parameter data values arestill correct.Troubleshootingand Maintenance

6–8Monitoring Trip Events, History, & ConditionsTrip History andInverter StatusWe recommend that you first find the cause of the fault before attempting clearing it. When afault occurs, the inverter stores important performance data at the moment of the fault. Toaccess the data, use the monitor functions (Dxxx) and select D081 for details about the presentfault (En). The previous five faults are stored in D081 to D086, with D (En-1 to En-5). Each errorshifts D081–D085 to D082–D086, and writes the new error to D081.The following Monitor Menu map shows how to access the error codes. When fault(s) exist,you can review their details by first selecting the proper function: D081 is most recent, andD086 is the oldest.Monitor Menu22d 0861d 081Trip History21d 082FUNC.No errorErrorexists?NoYesCurrent TripConditionsE 0 7.2Error Code16 0.00Output frequency attrip point14.00Motor current attrip point12 7 0.0DC bus voltage attrip pointTroubleshootingand Maintenance115118Cumulative inverteroperation timeat trip pointCumulative powerON time at trip point1FUNC.FUNC.2

SJ300 Inverter6–9Restoring Factory Default SettingsYou can restore all inverter parameters to the original factory (default) settings for the intendedcountry of use. After initializing the inverter, use the powerup test in Chapter 2 to get the motorrunning again. To initialize the inverter, follow the steps below.No.Action1Use the FUNC. , 1 , and 2 keys tonavigate to the “B” Group.2345Press theFUNC.Displaykey.Press and hold the 1 key until - Press theFUNC.b - -“B” Group selectedb 001First “B” parameter selectedb 085Country code for initialization selected02key.Func./Parameter00 Japan, 01 Europe,02 U.S.Confirm the country code is correct. Do not change it unless you are absolutely surethe power input voltage range and frequency match the country code setting.To change the country code, press 1 or 2 to set; STR to store.67891011key.b 085Country code for initialization selectedPress the 2 key.b 084Initialization function selectedPress thePress thekey.Press the STR key.Press and hold theFUNC. ,1Holding the keys above, press andSTOPRESET(STOP) key for 3 sec.FUNC.00 initialization disabled,clear trip history only0101 enable initializationb 084Initialization now enabled torestore all defaultsb 084First part of special keysequence, the “B” is flashing.b 084Final part of special keysequence, “B084” is flashing,1, and2STOP0 eu0USADefault parameter countrycode shown during initialization process (left-most character displays alternatingpattern)RESET,keys together.Initialization is complete.d 01Function code for outputfrequency monitor shownorNOTE: Initialization cannot be performed with a remote operator panel. Disconnect the deviceand use the inverter’s front panel keypad.Troubleshootingand MaintenanceWhen the b 084 display functionbegins blinking, release the14, and00keys. Do not let release yet.hold the13FUNC.Press the 1 key.212FUNC.

6–10Maintenance and InspectionMaintenance and InspectionMonthly andYearly InspectionChartItem InspectedCheck for.InspectionCycleMonthOverallTroubleshootingand MaintenanceMaincircuitControlcircuitInspection tures& humidity Thermometer,hygrometerAmbient temperaturebetween -10 to 50 C,non-condensingMajor devicesAbnormalvibration,noise Visual and auralStable environment forelectronic controlsPower supplyvoltageVoltage tolerance Digital volt meter,measure betweeninverter terminals[L1], [L2], [L3]200V class:200 to 240V 50/60 Hz400V class:380 to 460V 50/60 HzGroundInsulationAdequateresistance Megger test500VDC, reading of 5Mohms or greater, see nextsection for test detailsMountingNo loosescrews Torque wrenchM3: 0.5 – 0.6 NmM4: 0.98 – 1.3 NmM5: 1.5 – 2.0 NmComponentsOverheating Thermal trip eventsNo trip eventsHousingDirt, dust VisualVacuum dust and dirtTerminal blockSecureconnections VisualNo ualNo abnormalitiesRelay(s)Chattering AuralSingle click whenswitching ON or OFFResistorsCracks ordiscoloring VisualUse Ohm meter to checkbraking resistorsCooling fanNoise Power down,manually rotateRotation must be smoothDust VisualVacuum to cleanVisualNo abnormalities OverallNo odor,discoloring,corrosionCapacitorNo leaks ordeformation VisualUndistorted appearanceLegibility VisualAll LED segments workDisplay LEDsNote 1: The life of a capacitor is affected by the ambient temperature. See “Capacitor LifeCurve” on page 6–12.Note 2: The inverter must be cleaned periodically. If dust accumulates on the fan and heatsink, it can cause overheating of the inverter.

SJ300 InverterMegger Test6–11The megger is a piece of test equipment that uses a high voltage to determine if an insulationdegradation has occurred. For inverters, it is important that the power terminals be isolatedfrom the Earth GND terminal via the proper amount of insulation.The circuit diagram below shows the inverter wiring for performing the megger test. Just followthe steps to perform the test:1. Remove power from the inverter and wait at least 5 minutes before proceeding.2. Open the front housing panel to access the power wiring.3. Remove all wires to terminals [R, S, T, PD, P, N, RB, U, V, and W]. Most importantly, theinput power and motor wires will be disconnected from the inverter.4. Remove the jumper at connector J61. It is located on the main circuit board beside thepower terminals.5. Use a bare wire and short terminals [R, S, T, PD, P, N, RB, U, V, and W] together as shownin the diagram.6. Connect the megger to the inverter Earth GND and to the shorted power terminals as shown.Then perform the megger test at 500 VDC and verify 5MΩ or greater resistance.Add testjumper wireDisconnectpower sourceSJ300L1RUL2SVL3TWDisconnectmotor wiresMotorPMegger, 500VDCJ61PDRBDisconnect jumper atJ61 before performingthe megger testNEarthGND7. After completing the test, disconnect the megger from the inverter.8. Reconnect the jumper at connector J61 as before.CAUTION: Do not connect the megger to any control circuit terminals such as intelligent I/O,analog terminals, etc. Doing so could cause damage to the inverter.CAUTION: Never test the withstand voltage (HIPOT) on the inverter. The inverter has a surgeprotector between the main circuit terminals above and the chassis ground.Troubleshootingand Maintenance9. Reconnect the original wires to terminals [R, S, T, PD, P, N, RB, U, V, and W].

6–12Maintenance and InspectionSpare partsWe recommend that you stock spare parts to reduce down time, including parts listed below:QuantityPart descriptionCapacitorLife CurveSymbolNotesUsedSpareCooling fanFAN1, 2, 3. (dependson model)1 or 2Fan unit at top of housingin all modelsAuxiliary cooling fanFAN0 or 1. (dependson model)0 or 1–150Lxx, –185Lxx, and–220Lxx modelsCapacitor bankCB11All modelsThe DC bus inside the inverter uses a large capacitor as shown in the diagram below. Thecapacitor handles high voltage and current as it smooths the power for use by the inverter. So,any degradation of the capacitor will affect the performance of the inverter. The capacitor bankin SJ300 series inverters is replaceable. This section will show you how to replace it in the field.Variable-frequency DrivePowerInputL1/RConverterInverterInternal DC BusMotor L2/SU/T1RectifierV/T2L3/TW/T3–Capacitor life is reduced in higher ambient temperatures, as the graph below demonstrates. Besure to keep the ambient temperature at acceptable levels, and perform maintenance inspectionson the fan, heat sink, and other components. If the inverter is installed on a cabinet, the ambienttemperature is the temperature inside the cabinet.Troubleshootingand MaintenanceCapacitor Life CurveAmbienttemperature, C5012 hrs / day operation24 hrs / day operation403020012345678910Years

SJ300 InverterCapacitorReplacement6–13The capacitor bank consists of an assembly that slides out of the SJ300 uni

Troubleshooting Troubleshooting and Maintenance 6–2 Troubleshooting Safety Messages Please read the following safety messages before troubleshooting or performing maintenance on the inverter and motor system. WARNING: Wait at least five (5) minutes after turning OFF the input power supply before performing maintenance or an inspection.