HITACHI frequency converter Cs-H100 series

HITACHI frequency converter Cs-H100 series

1. Overview

The Hitachi Cs-H100 series frequency converter is a high-performance universal frequency converter designed for the global industrial market, aimed at providing precise and reliable speed and torque control for three-phase asynchronous motors and synchronous motors. This series of products is designed to be compact and powerful, covering not only basic V/F control to high-performance sensorless vector control, but also integrating rich application functions such as built-in PID, simple PLC, swing frequency control, and master-slave control, which can meet the diverse needs of general loads such as fans and water pumps, as well as complex processes such as textile and lifting.

2、 Core specifications and technical features

2.1 Product specifications and models

The Cs-H100 series covers a wide power range to meet the needs of different loads. According to the power specifications, it is mainly divided into two categories:

Single phase 220V model (CsH100- □□□ SF): power range from 0.4kW to 4.0kW, suitable for low-power civilian or commercial applications.

Three phase 380V model (CsH100- □□□ HF (S)): with a power range of 0.75kW to 22kW, it is the main model for industrial applications.

The naming of the product model clearly identifies the voltage level, power, and series. For example, CsH100-022SF represents a single-phase 220V, 2.2kW frequency converter.

2.2 Control mode and performance

The core of Cs-H100 lies in its flexible control mode selection, which is set through parameter [F0-03: Control Mode]:

V/F control: Suitable for situations where dynamic response requirements are not high, such as fans and pumps. By setting the multi-point V/F curve 【 F2-00 】 and torque boosting 【 F2-01 】 function, the torque output of the motor can be optimized at different frequencies.

Speed sensorless vector control: This is the highlight feature of Cs-H100, which achieves high-performance control of motor speed and torque without the need for an encoder through an accurate motor parameter model. It has excellent speed dynamic response and low-frequency torque characteristics, especially suitable for applications such as lifting, hoisting, high-precision machining machinery with severe load changes or requiring high starting torque.

2.3 Environmental Requirements and Installation

To ensure the long-term stable operation of the frequency converter, the manual imposes strict requirements on the installation environment:

Environmental temperature: The operating temperature range is -10 ℃ to+50 ℃. When the temperature exceeds 40 ℃, the frequency converter must be downgraded or the carrier frequency must be reduced [F0-26].

Installation space: The frequency converter must be installed vertically on a non combustible metal wall, and ensure that there is a heat dissipation space of more than 10cm in all directions. When installing multiple frequency converters up and down, it is necessary to install insulation deflectors to prevent heat accumulation.

Altitude: It can be fully used below an altitude of 1000 meters. After exceeding 1000 meters, the quota must be reduced by 1% for every 100 meters increase. The maximum usage altitude should not exceed 2000 meters.

3、 Installation, wiring, and electrical design

3.1 Safety first wiring principle

In the "About Wiring" section of the manual, prominent "Danger" and "Caution" labels are used to emphasize the core position of safe operation:

Power off operation: Wiring work can only be carried out after confirming that the input power is completely cut off.

Reliable grounding: It must be reliably grounded as required to prevent electric shock and fire.

Professional operation: Wiring operations must be carried out by qualified electrical professionals.

Correct connection: It is strictly prohibited to connect the power cord to the output terminals (U, V, W) of the frequency converter, and ensure that the power supply voltage is within the specified input voltage range.

3.2 Detailed explanation of main circuit and control circuit

The manual provides detailed instructions on the terminal layout and functions of different power range models.

Main circuit terminal:

R. S, T (L, N): Main power input terminal.

U. V, W: Output terminal of frequency converter, connected to motor.

P (+), PB: External braking resistor connection terminal. The manual provides a detailed selection table for braking resistors and warns that the selected resistor value must not be less than the minimum value in the table, otherwise it may damage the built-in braking unit.

P(+), (-): External brake unit connection terminal.

G: Grounding terminal.

Control circuit terminal:

Digital Input (DI): Supports multifunctional input and can allocate 53 different functions such as forward and reverse rotation, multi-stage speed, fault reset, etc. [F5-00~F5-05]. Models of 11kW and above support switching between NPN/PNP bipolar inputs.

Analog Input (AI): Supports 0~10V voltage or 0~20mA current input, and can be flexibly configured as a 2-point straight line or multi-point curve through jumper wires and parameters [F5-45] to adapt to different sensor signals.

Digital output (DO): open collector or relay output, programmable for various signals such as operation indication, frequency arrival, fault output, etc. [F6-00~F6-02].

485 communication interface: standard configuration, supports Modbus RTU protocol, can achieve network control with upper computer (such as PLC).

3.3 Recommended wire diameter and peripheral equipment

The manual provides a detailed recommended wire diameter table, specifying the selection criteria for wire diameters of air switches (MCCBs), contactors (MCs), power lines, and control lines based on the inverter model. At the same time, various optional accessories are recommended for different application scenarios, such as:

Input/output reactor: used to suppress high-order harmonics, improve power factor, and compensate for voltage drops caused by long cables.

Various filters: used to reduce the conducted and radiated interference generated by frequency converters, ensuring the normal operation of peripheral equipment.

Braking resistor/unit: used to consume regenerative energy and increase braking torque when the motor decelerates or lowers heavy objects.

4、 Operation and Running

4.1 Operator and Parameter Structure

The operator design of Cs-H100 is intuitive and easy to use. Models with 7.5kW and below come standard with a non removable LED operator, while models with 11kW and above come standard with an external LED knob operator and an optional LCD operator with parameter copying function. The indicator lights on the operator (RUN, L/D/C, FWD/REV, TUNE/TC) can clearly display the current operating status, control mode, direction, and faults of the frequency converter.

The parameters of the frequency converter adopt a three-level menu structure (parameter group → parameter code → parameter setting value), which can be easily viewed and modified through the PRG, ENTER, and ▲▼ keys on the operator.

4.2 Motor parameter self-tuning

In order to achieve high-performance vector control, motor parameter self-tuning [F4-00] is a crucial step. The manual provides a detailed explanation of two self-tuning methods:

Rotational self-tuning: When the motor is completely disconnected from the load, the most accurate motor parameters can be obtained, including stator/rotor resistance, mutual inductance, leakage inductance, and no-load current.

Static self-tuning: When the motor cannot be disconnected from the load, some parameters can be measured, and the control performance is slightly inferior to rotational self-tuning.

Before the self-tuning operation, it is necessary to correctly input the rated power, voltage, current, frequency, and speed according to the motor nameplate 【 F4-01~F4-06 】.

5、 Powerful 485 communication function

The Cs-H100 series is equipped with a standard RS-485 communication interface and supports Modbus RTU slave protocol. Through communication, the upper computer can easily achieve remote monitoring, parameter modification, start stop control, and frequency setting of the frequency converter.

5.1 Communication parameter settings

Through the F8 parameter set, users can flexibly configure communication protocols:

F8-00: Baud rate, supports up to 38400bps.

F8-01: Data format, supports no parity, even parity, odd parity, and different stop bits.

F8-02: Slave address, ranging from 1 to 247, with 0 being the broadcast address.

F8-04: Communication timeout, used to detect communication failures.

5.2 Communication Protocol and Register

The manual provides a detailed explanation of the message structure of Modbus RTU and offers communication examples for function codes 03h (read hold register) and 06h (write single register). Register addresses are divided into EEPROM area and RAM area:

EEPROM area: used to store parameter set values, which are saved after writing with power off, but have a write life limit and are suitable for parameters that are not frequently modified.

RAM area: used for writing process data such as running commands and frequency settings, lost after power failure, suitable for real-time control of frequent operations.

The manual also thoughtfully lists commonly used communication register addresses, such as control commands (start stop, jog, fault reset) [Address 2000h], frequency commands [Address 9000h], and various operating status monitoring (operating frequency, current, voltage, etc.) [Address 1000h series].

6、 Deep analysis of advanced application functions

The strength of Cs-H100 lies in its rich and practical built-in application functions.

6.1 PID Control

The built-in PID control function enables it to easily build closed-loop control systems for scenarios such as constant pressure water supply, constant temperature control, and constant tension control.

Given and feedback sources [FA-00, FA-03]: Both target values and feedback quantities can be flexibly selected from keyboard, analog input, communication, or pulse input.

Parameter Switching [FA-21]: Supports automatic switching of two different PID parameters (P, I, D) based on the DI terminal status or deviation size to adapt to optimal control under different operating conditions.

Sleep and wake-up [L6 group]: Especially suitable for water supply systems, when the water consumption decreases to a certain extent, the frequency converter automatically sleeps and stops to save energy; When the pressure/flow rate drops to the set value, it automatically wakes up for operation.

6.2 Simple PLC and Multi speed

Through FC group parameters, users can pre-set up to 16 segments (0-15 segments) of operating frequency and time, just like using a small PLC, to achieve automated process control. Each speed can independently select one of the four acceleration and deceleration times, and real-time switching between multiple speeds can be achieved through the DI terminal.

6.3 Master slave control

The L4 group parameters are specifically designed for master-slave control functions and are suitable for situations where multiple motors drive the same load (such as large conveyor belts, converters).

The host is responsible for sending frequency or torque commands.

The slave receives commands from the host through the 485 network and can achieve precise load distribution by setting the receiving frequency coefficient [L4-04] and torque coefficient [L4-05], ensuring synchronous operation or torque balance of multiple motors.

6.4 Other Practical Functions

Swing frequency function [Fb group]: By setting the center frequency, swing amplitude, jump, and period, periodic triangular wave changes in frequency can be achieved, which is widely used in winding control in the textile and chemical fiber industries.

Counting and Counting Function [Fb Group]: Using DI terminals to receive pulse signals, achieve length or quantity statistics of products.

Brake Control [L5 Group]: Tailored for lifting equipment, it ensures safe and smooth lifting and lowering processes through reasonable logic control (such as establishing torque before releasing the brake during startup and holding the brake before releasing the torque during shutdown).

7、 Fault diagnosis and maintenance

7.1 Fault codes and handling

When the frequency converter detects an abnormality, it will immediately cut off the output (trip) and display a fault code. Chapter 5 of the manual provides a detailed list of fault codes (Err01~Err47), listing possible causes of faults and system troubleshooting strategies for each code. For example, for the common "Err04 acceleration overcurrent", possible reasons include motor short circuit, incorrect motor parameters, short acceleration time, or improper V/F torque increase.

7.2 Fault Records

The U0 parameter set is a powerful diagnostic tool that can record the detailed inverter status during the last three faults, including fault frequency, current, bus voltage, input/output terminal status, cumulative power on time, etc. This is crucial for analyzing the root cause of intermittent faults.

7.3 Daily and Regular Maintenance

The manual recommends daily inspections (such as running sound, vibration, and cooling fans) and regular inspections (such as loose screws, clean air ducts, and corrosion). It is particularly pointed out that the lifespan components of the frequency converter - cooling fan (2-3 years) and filtering electrolytic capacitor (4-5 years) - are closely related to environmental temperature and maintenance conditions, and preventive replacement should be considered upon expiration.