Saftronics FP5/GP5 Series Technical Manual Download Page 71

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Maintenance and Inspection

This chapter describes basic maintenance and inspection procedures for the FP5/GP5.

7.1

Periodic Inspector........................................................... 64

7.2

Parts Replacement Schedule (Guidelines) ................... 64

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Summary of Contents for FP5/GP5 Series

Page 1: ...FP5 GP5 TECHNICAL MANUAL efesotomasyon com Control Techniques emerson saftronics ac drive servo motor...

Page 2: ...efesotomasyon com Control Techniques emerson saftronics ac drive servo motor...

Page 3: ...ds removed in order to describe detail with more clarity Make sure all covers and shields are replaced before operating this product This manual may be modified when necessary because of improvement o...

Page 4: ...lation CAUTION Page When moving the unit lift the cabinet by the base never lift by the front cover Otherwise the main unit may be dropped causing damage to the unit 6 Mount the Inverter on nonflammab...

Page 5: ...rter or the load since it may restart suddenly after being stopped Construct machine system so as to assure safety for personnel even if the Inverter should restart Failure to observe this can result...

Page 6: ...gerous 64 Only authorized personnel should be permitted to perform maintenance inspections or parts replacement Remove all metal objects watches bracelets etc before operation Use tools that are insul...

Page 7: ...ontrol Circuit Terminals 21 3 3 2 Wiring the Control Circuit Terminals 22 3 3 3 Precautions on Control Circuit Wiring 22 3 4 Wiring Inspection 22 4 Operation 23 4 1 Operation Mode Selection 25 4 2 Tes...

Page 8: ...ut Signals n040 n041 55 6 6 Setting Operation Conditions 56 6 6 1 Torque Compensation Gain n067 56 6 7 Motor Protection 57 6 7 1 Motor Overload Detection 57 6 8 PID Control 58 6 8 1 Intended Value Set...

Page 9: ...pect the inverter after delivery to the user 1 1 Inspection Checkpoints 2 1 1 1 Receiving Checkpoints 2 1 1 2 Checking the Nameplate Data 2 1 2 Identifying the Parts 2 efesotomasyon com Control Techni...

Page 10: ...meplate on the side of the FP5 GP5 See below Are any parts damaged Visually check the exterior and verify that there was no damage during transport Is hardware properly seated and securely tightened R...

Page 11: ...Inc Specification Designation For special specifications a spec sheet number appears on the nameplate Figure 3 Specification Designation 1 2 Identifying the Parts Figure 4 Configuration of FP5 GP5 efe...

Page 12: ...Chapter 1 Receiving Firmware S2011 and S3012 Revision 1 9 98 4 Saftronics Inc NOTES efesotomasyon com Control Techniques emerson saftronics ac drive servo motor...

Page 13: ...moving and Replacing the Digital Operator 6 2 1 1 Removing the Digital Operator 6 2 1 2 Replacing the Digital Operator 6 2 2 Removing and Replacing the Front Cover 7 2 3 Choosing a Location to Mount t...

Page 14: ...ove and replace the Digital Operator as follows 2 1 1 Removing the Digital Operator To remove the Digital Operator from the front cover push the Digital Operator lever in the direction shown by arrow...

Page 15: ...placing the Digital Operator 2 3 Choosing a Location to Mount the Inverter To ensure proper performance and long operating life follow the recommendations below when choosing a location for installing...

Page 16: ...less 3 When installing the models of 200V 400V 30kW or more equipped with eyebolts extra spacing will be required on either side For detailed dimensions contact your Saftronics representative 4 For th...

Page 17: ...r Main Circuit Output 12 3 2 3 Grounding 12 3 2 4 Functions of Main Circuit Terminals 13 3 2 5 Main Circuit Configuration 15 3 2 6 Parts Required for Wiring 17 3 3 Wiring the Control Circuit 21 3 3 1...

Page 18: ...e AC power supply voltage Failure to observe this can result in personal injury or fire Do not perform a withstand voltage test of the Inverter It may cause semi conductor elements to be damaged To co...

Page 19: ...by Fuji Electric Co Ltd manufactured in or after 1984 Installation of Magnetic Contactor Inverters can be used without a Magnetic Contactor MC installed at the power supply side When the main circuit...

Page 20: ...not connect a Magnetic Starter or MC to the output circuit If the load is connected while the Inverter is running the Inverter overcurrent protective circuit operates because of inrush current Install...

Page 21: ...e functions of the main circuit terminals Wire according to each terminal function Table 3 200 V Class Terminal Functions Models FP5 GP5 23P7 to 27P5 2011 to 2015 2018 to 2075 Max Applicable Motor Out...

Page 22: ...supply Main circuit input power supply L11 R1 L21 S1 L31 T1 Main circuit input power supply T1 U T2 V T3 W Inverter output B1 B2 Braking Resistor Unit 1 Braking Unit 3 2 DC Reactor 1 2 DC bus terminal...

Page 23: ...GP52015 FP5 GP52018 to FP5 GP52022 FP5 GP52030 to FP5 GP52075 The wiring has been completed at the factory prior to shipping When installing a DC Reactor option on models of 15kW or below remove the...

Page 24: ...54045 FP5 GP54055 to FP5 GP54160 FP5 GP54185 to FP5 GP54300 The wiring has been completed at the factory prior to shipping When installing a DC Reactor option on models of 15kW or below remove the sho...

Page 25: ...T2 U V W 3 30 2018 M8 6 14 L1 L2 L3 R S T L11 L21 L31 R1 S1 T1 T1 T2 T3 U V W 2 38 2022 M8 6 14 L1 L2 L3 R S T L11 L21 L31 T1 T2 T3 U V W M10 4 0 100 2030 M8 4 22 L1 L2 L3 R S T L11 L21 L31 T1 T2 T3...

Page 26: ...2 B1 B2 T1 T2 T3 U V W 44P0 M4 2 5 5 L1 L2 L3 R S T 1 2 B1 B2 T1 T2 T3 U V W 45P5 M4 12 10 3 5 5 5 L1 L2 L3 R S T 1 2 B1 B2 T1 T2 T3 U V W 47P5 M5 8 6 5 5 L1 L2 L3 R S T 1 2 B1 B2 T1 T2 T3 U V W M5 8...

Page 27: ...T L11 L21 L31 R1 S1 T11 T1 T2 T3 U V W M12 4 0 x 2P 100 x 2P 4160 M8 1 50 L1 L2 L3 R S T 1 3 T1 T2 T3 U V W M16 650MCM x 2P 325 x 2P M8 1 50 4185 r l1 s 200 l2 200 s 400 l2 400 M4 20 10 0 5 5 5 L1 L2...

Page 28: ...8 M6 14 6 6 14 M8 14 8 M6 14 6 4 22 M8 14 8 3 2 30 38 M8 38 8 M8 60 8 1 1 0 50 60 M10 60 10 3 0 80 80 10 4 0 100 M10 100 10 4 0 100 100 12 300MCM 150 150 12 400MCM 200 M12 200 12 M12 x 2 325 12 650MC...

Page 29: ...og command 15 V power supply 15 V Allowable current 20 mA maximum FV Frequency reference input voltage 0 to 10 V 100 0 to 10 V 20 k FI Frequency reference input current 4 to 20 mA 100 n042 0 FV effect...

Page 30: ...rroneous operation caused by noise interference Use twisted shielded or twisted pair shielded wire for the control circuit line and connect the shielded sheath to the Inverter Terminal G See Figure 12...

Page 31: ...4 2 Test Run Checkpoints 26 4 3 Setting the Line Voltage Using Jumper For 400V Class 18 5kW and Above 26 4 4 Test Run 27 4 4 1 Digital Operator Display at Power Up 27 4 4 2 Operation Check Points 2 4...

Page 32: ...rve this can result in personal injury CAUTION Never touch the heatsink or discharging resistor since the temperature is very high Failure to observe this can result in harmful burns to the body Since...

Page 33: ...hod Selection SEQ LED Reference Selection REF LED 0 Operation by RUN command from Digital Operator OFF Master frequency reference from Digital Operator OFF 1 Operation by RUN command from control circ...

Page 34: ...and terminal connections are correct o No short circuit caused by wire clippings o Screw type terminals are securely tightened o Motor is securely mounted o All items are correctly earthed grounded 4...

Page 35: ...for operation turn ON the power supply Verify that the Inverter powers up properly If any problems are found turn OFF the power supply immediately The Digital Operator display illuminates as shown bel...

Page 36: ...ital Operator The diagram below shows a typical operation pattern using the Digital Operator Figure 15 Operation Sequence by Digital Operator Table 10 Typical Operation by Digital Operator Description...

Page 37: ...equency monitor display 60 0 Fref Reverse Run Select reverse run fo F R Press 3 times Switch to rev by pressing eu F R Write in set value eu F R Select output frequency monitor display 60 0 Fout Press...

Page 38: ...uency reference voltage 60 0 Fref current by control circuit Terminal FV For reference voltage 10V or FI and verify the input value by the Digital Operator Output Frequency Display Select output frequ...

Page 39: ...Simple Data Setting This chapter describes simple data setting 5 1 Digital Operator Key Description 32 5 2 LED Description 32 efesotomasyon com Control Techniques emerson saftronics ac drive servo mot...

Page 40: ...e Fgain Frequency reference gain Disable Fbias Frequency reference bias Disable FLA Motor rated current Disable PID PID selection Disable kWsav Energy Saving selection Disable PRGM Constant number dat...

Page 41: ...command selection Fo Montr Monitor selection U 01 Accel Acceleration time 10 0 Decel Deceleration time 10 0 During run Press ENTER key to display the monitor value Vmtr Motor rated voltage 200 0 V F...

Page 42: ...Chapter 5 Simple Data Setting Firmware S2011 and S3012 Revision 1 9 98 34 Saftronics Inc NOTES efesotomasyon com Control Techniques emerson saftronics ac drive servo motor...

Page 43: ...3 14 Using Frequency Meter of Ammeter n048 46 6 3 15 Calibrating Frequency Meter of Ammeter n049 46 6 3 16 Reducing Motor Noise or Leakage Current n050 47 6 4 Selecting Stopping Method 48 6 4 1 Selec...

Page 44: ...Constant that can be read 0 Constant write disable n001 n001 to n108 1 Factory setting n001 to n034 n001 to n108 2 n001 to n049 n001 to n108 3 n001 to n108 n001 to n108 4 5 Not used disabled 8 Initia...

Page 45: ...Torque 2 5 120 Hz D Variable Torque 3 6 Variable Torque Characteristics 60 Hz Variable Torque 4 7 High Speed Operation 180 Hz E 1 Consider the following items as the conditions for selecting a V f pat...

Page 46: ...ass the value is twice that of 200 V class Increasing the voltage of the V f pattern increases motor torque but an excessive increase may cause the following Inverter malfunction because of motor over...

Page 47: ...to S6 Then input a FWD or REV RUN command Operation is enabled at the jog frequency set in n029 When multi step speed references 1 or 2 are input simultaneously with the jog frequency reference the jo...

Page 48: ...12 Maximum output frequency 100 Factory setting 100 Frequency Reference Bias n047 The frequency reference at the analog input value of 0 V 4 mA can be set in units of 1 n012 Maximum output frequency 1...

Page 49: ...When deceleration to stop is selected n004 0 Figure 25 Timing Diagram of Accel Decel Time Adjustment By setting multi function contact input selection n035 n036 n037 n038 or n039 to 12 accel decel tim...

Page 50: ...loss When 2 is selected operation restarts if power supply voltage reaches its normal level No fault signal is output 6 3 8 Soft Start Characteristics n023 To prevent shock during machine starting and...

Page 51: ...d operation continues after operation 3 Detected during constant speed running and Inverter output is shut OFF during detection 4 Detected during running and Inverter output is shut OFF during detecti...

Page 52: ...ction Level Frequency Detection Output Frequency Frequency Detection Level Set n040 or n041 to 5 Figure 30 Frequency Detection Example Fout Freq Detection Level 6 3 11 Jump Frequencies n058 to n060 Th...

Page 53: ...ected Power supply is turned OFF 6 3 13 Operating Coasting Motor without Trip To operate coasting motor without trip use the Speed Search command or DC Injection Braking at start Speed Search Command...

Page 54: ...cy Meter of Ammeter n048 Selects to output either output frequency or output current to analog output Terminals AM AC for monitoring Setting Analog Monitor Output Item 0 Output frequency 10 V maximum...

Page 55: ...verter output transistor switching frequency carrier frequency Setting Carrier Frequency kHz Metallic Noise from Motor Noise and Current Leakage 1 2 5 Higher Smaller 2 5 0 3 8 0 4 10 0 5 12 5 6 15 0 N...

Page 56: ...the deceleration rate determined by the time set to decel time 1 n020 and DC Injection Braking is applied immediately before stop If the decel time is short or the load inertia is large an overvoltag...

Page 57: ...9 Example of Stopping Method Coast to Stop w Timer 2 Operation is disabled while the motor decelerates after a STOP command is given A RUN command is accepted but operation does not start until the mo...

Page 58: ...52 7 Fast stop Decelerates to stop by decel time 2 n022 when fast stop is input 8 Master frequency reference input level selection Master frequency reference input level voltage input at open current...

Page 59: ...n002 to 3 Open Run by frequency reference from control circuit Terminals FV FI and RUN command from control circuit Terminals S1 S2 Closed Run by frequency reference and RUN command from the Digital O...

Page 60: ...ld at less than 100ms Figure 44 Sample of Hold Selection Analog Reference UP DOWN Command Setting n039 25 With the FWD or REV RUN command entered accel decel is enabled by inputting the UP or DOWN sig...

Page 61: ...is input while running by the UP DOWN command the jog command has priority Loop Test Setting 26 Checks operation in the serial I F circuit If a fault occurs the Digital Operator displays CE Procedure...

Page 62: ...unction contact inputs To retain the held frequency reference at power OFF set constant n044 to 0 Setting Description 0 Hold reference retained in frequency reference 1 constant n025 1 Not retained Op...

Page 63: ...1 Timer function 52 12 Automatic restart Closed during fault retry operation 13 OL pre alarm Outputs an alarm before Inverter and motor overload protection are enabled Pre alarm level is 150 for 48 se...

Page 64: ...operation as well as during acceleration The required torque is calculated by the Inverter Output voltage Torque compensation gain n067 5 Required torque Operation Figure 48 Torque Characteristics Nor...

Page 65: ...d When operating several motors with one Inverter install a Thermal Overload Relay on each motor In this case set constant n033 to 0 Standard Motor and Inverter Motor Induction motors are classified a...

Page 66: ...gnal 0 to 10 V can be used Control circuit Terminal FI current signal Set auxiliary analog input selection n043 to 1 Control circuit Terminal FI voltage signal Set auxiliary analog input selection n04...

Page 67: ...8 Sets the output voltage lower limit If the voltage reference value calculated in the Energy Saving Control mode is smaller than the specified lower limit this lower limit value is output as the volt...

Page 68: ...ave which receives the command from the master executes the function and returns the response to the master 6 10 1 Communication Specifications Interface RS 485 Communication interface card SI K2 P mu...

Page 69: ...hundredth digit of 0 01 Hz of the received frequency reference is rounded off internally When 30000 100 in units of 0 1 is selected the value is rounded off in the same way MEMOBUS Slave Address n106...

Page 70: ...Chapter 6 Programming Features Firmware S2011 and S3012 Revision 1 9 98 62 Saftronics Inc NOTES efesotomasyon com Control Techniques emerson saftronics ac drive servo motor...

Page 71: ...his chapter describes basic maintenance and inspection procedures for the FP5 GP5 7 1 Periodic Inspector 64 7 2 Parts Replacement Schedule Guidelines 64 efesotomasyon com Control Techniques emerson sa...

Page 72: ...n guide Before servicing turn OFF AC main circuit power and be sure that the CHARGE LED is OFF Table 18 Periodic Inspection Component Check Corrective Action Loose screws Tighten External Terminals Un...

Page 73: ...tents caused by motor machine malfunctions and the corrective actions to be taken 8 1 Fault Diagnosis and Corrective Actions 66 8 2 Alarm Display and Explanation 69 8 3 Motor Faults and Corrective Act...

Page 74: ...e problem contact your Saftronics representative immediately To restart turn ON the reset input signal or press the RESET key or shut OFF the main circuit power supply once to reset the stop status To...

Page 75: ...nverter and motor is not damaged P U F Main circuit fault PUF The direct current circuit fuse is blown The output transistors were damaged Check for damaged transistor load side short circuit groundin...

Page 76: ...Actions for verification change of the constant Braking transistor failure The braking transistor has failed Replace the Inverter H Braking Resistor Unit overheat The Braking Resistor Unit temperatur...

Page 77: ...BUS transmission waiting Under condition of n002 operation method selection 4 the Inverter has not received the normal data from serial communication after power ON Refer to 8 1 Fault Diagnosis and Co...

Page 78: ...t Input the correct the set value Wiring of Terminals T1 T2 and T3 U V and W correct Match wiring to the phase order of the motor leads T1 T2 and T3 U V and W Motor rotation reverses FWD and REV wirin...

Page 79: ...9 Specifications This chapter describes the specifications of the FP5 GP5 Inverter 9 1 Standard Specifications 72 efesotomasyon com Control Techniques emerson saftronics ac drive servo motor...

Page 80: ...eristics Number of V f Patterns 15 preset V f patterns 1 custom V f with voltage limit 1 custom without voltage limit Motor Overload Protection Protected by electronic Thermal Overload Relay Instantan...

Page 81: ...umber of V f Patterns 15 preset V f patterns 1 custom V f with voltage limit 1 custom without voltage limit Motor Overload Protection Protected by electronic Thermal Overload Relay Instantaneous Overc...

Page 82: ...t and Braking Resistor Control Characteristics Number of V f Patterns 15 preset V f patterns 1 custom V f with voltage limit 1 custom without voltage limit Motor Overload Protection Protected by elect...

Page 83: ...10 Dimensions The following chapter describes the dimensions of the FP5 GP5 10 1 Dimensions 76 efesotomasyon com Control Techniques emerson saftronics ac drive servo motor...

Page 84: ...with the top and bottom covers removed Figure 52 Dimensions of FP5 GP5 The following figure shows the mounting dimensions of 400V 185 to 300kW Maximum Applicable Motor Output kW W1 W2 W3 W4 W5 W6 185...

Page 85: ...895 15 0 135 580 1290 400 445 895 270 145 M12 0 55 1 1 140 280 160 126 266 7 0 3 140 280 160 126 266 7 0 3 M5 1 5 4 4 2 2 3 7 4 0 140 280 180 126 266 7 0 4 5 140 280 180 126 266 7 0 4 5 M5 5 5 7 5 20...

Page 86: ...Chapter 10 Dimensions Firmware S2011 and S3012 Revision 1 9 98 78 Saftronics Inc NOTES efesotomasyon com Control Techniques emerson saftronics ac drive servo motor...

Page 87: ...Diagram This chapter describes the connection diagrams for the GP5 11 1 Braking Resistor Unit 80 11 2 Braking Unit and Braking Resistor Unit 81 efesotomasyon com Control Techniques emerson saftronics...

Page 88: ...200V class When installing a DC Reactor option remove the common bar between 1 and 2 terminals provided as standard and connect a DC Reactor with the terminals When using the Thermal Overload Relay se...

Page 89: ...onnect a DC Reactor with the terminals When using the Thermal Overload Relay set constant n070 to 0 Stall Prevention selection during decel is disabled If it is not changed the Inverter may not stop w...

Page 90: ...Chapter 11 Typical Connection Diagram Firmware S2011 and S3012 Revision 1 9 98 82 Saftronics Inc NOTES efesotomasyon com Control Techniques emerson saftronics ac drive servo motor...

Page 91: ...12 Constant List This chapter lists the constants for the FP5 GP5 12 1 Constant List 84 efesotomasyon com Control Techniques emerson saftronics ac drive servo motor...

Page 92: ...ey function 0 STOP key is effective when operated from Digital Operator 1 STOP key is always effective 1 n009 Frequency reference setting method from Digital Operator 0 ENTER key not used 1 ENTER key...

Page 93: ...1 Setting Characteristics 0 No protection 1 Standard motor time constant 8 minutes 2 Standard motor time constant 5 minutes 3 Inverter motor time constant 8 minutes 4 Inverter motor time constant 5 mi...

Page 94: ...erence retained in frequency reference 1 constant n025 1 Not retained 0 n045 Operation method for freq ref loss detection 0 No detection 1 Continue to run at 80 previous ref 0 n046 Frequency reference...

Page 95: ...acceleration Unit 1 Setting range 30 to 200 When level is set to 200 Stall Prevention during acceleration is disabled kVA dependent n072 Stall Prevention level during running Unit 1 Setting range 30 t...

Page 96: ...y time PID Unit 0 1 seconds Setting range 0 0 to 25 5 seconds 1 0 seconds n095 Energy Saving selection same as kWsav LED 0 Energy Saving is disabled 1 Energy Saving is enabled 0 n096 Energy Saving gai...

Page 97: ...lection Unit 0 1Hz Setting range 0 0 to 25 5Hz 2 0Hz n114 Function selection at LOCAL REMOTE switching 0 At LOCAL REMOTE switching restart is enabled after stop command is input 1 At LOCAL REMOTE swit...

Page 98: ...Chapter 12 Constant List Firmware S2011 and S3012 Revision 1 9 98 90 Saftronics Inc NOTES efesotomasyon com Control Techniques emerson saftronics ac drive servo motor...

Page 99: ...r Monitor Display This chapter describes the monitor displays of the Digital Operator of the FP5 GP5 13 1 Digital Operator Monitor Display 92 efesotomasyon com Control Techniques emerson saftronics ac...

Page 100: ...1000 A and above kWout Output voltage Output voltage can be monitored in units of 0 1 kW 1 kW for 1000 k and above F R FWD REV RUN command FWD REV RUN command can be set monitored Setting enabled dur...

Page 101: ...econds 1 seconds for 1000 sec and above Decel Deceleration time 1 Deceleration time 1 n020 can be set read in units of 0 1 seconds 1 seconds for 1000 sec and above Vmtr Motor rated voltage Motor rated...

Page 102: ...Chapter 13 Digital Operator Monitor Display Firmware S2011 and S3012 Revision 1 9 98 94 Saftronics Inc NOTES efesotomasyon com Control Techniques emerson saftronics ac drive servo motor...

Page 103: ...or overheat function 87 DC injection braking at start 46 DC injection braking current 49 87 DC injection braking time at start 8 DC injection braking time at stop 49 87 DC reactor 11 13 14 deceleratio...

Page 104: ...ster frequency reference 10 maximum applicable motor output 3 70 maximum output frequency 84 maximum output voltage 70 maximum voltage 84 maximum voltage output frequency 84 MC fault 66 middle frequen...

Page 105: ...REMOTE 25 reverse run 10 reverse run prohibit 38 84 S s curve selection 87 selecting stopping method 48 sequence common 10 sequence control input common 21 sequence input signal 21 sequence output sig...

Page 106: ...V f data setting error 68 V f pattern selection 84 93 V f reduction level during speed search 86 vibration 70 voltage limit of tuning 59 88 W wire size 17 18 19 withstand voltage test iii 10 efesotoma...

Page 107: ...efesotomasyon com Control Techniques emerson saftronics ac drive servo motor...

Page 108: ...arkway Fort Myers Florida 33905 l Telephone 941 693 7200 l Fax 941 693 2431 Web Address http www saftronics com REV 1 9 98 P N 027 2042 1998 efesotomasyon com Control Techniques emerson saftronics ac...

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