HITACHI P1 VFD Installation
Here is a manual listing all parameters
VFD Control Type
There are 3 different ways a Hitachi VFD may be connected to MachMotion control: Ethercat, TCP Modbus, or Hardwired. Use the following procedure to determine which method your VFD uses. Then in each section of the manual go to that control method for information on how to program or connect it.
Scroll down about 2/3s the list to the Spindle section. The Device that is selected for Spindle Fwd and / or Spindle Rev shows how the spindle is controlled. Use the pictures below to identify which method is used.
For a hardwired VFD, it could be controlled through a Beckhoff Device OR an Apollo III.
Control Cable: The VFD Control cable is the green Ethernet cable that runs from the Yaskawa VFD to the Control PC as shown in Figure 1. Or if you have an Apollo III motion controller, connect the VFD control cable into Ethernet 1 Port on the Apollo III.
(Figure 1 Ethernet Connection to Control PC)
Spindle Motor: Connect your spindle motor to the terminals labeled U/T1,V/T2, and W/T3 as shown in Figure 2. If your spindle moves the wrong direction when you turn it on, just swap any three of the (U,V,W) leads.
(Figure 2 Spindle Motor Connections)
Brake Resistor: Connect your brake resistor by placing the two wires on the RB and P terminals as shown in Figure 3.
(Note: If needed to extend the wires use High Temp rated wire.)
Mount Resistor: Mount the resistor to the cabinet. Wire as shown in Figure 3.
(Figure 3 Resistor Connections)
Must enable braking resistor. See Hitachi P1 Parameters.
Thermistor: If your spindle has a thermistor, please make sure to connect it. Use the following knowledge base from Yaskawa to understand what a thermistor is: Motor Protection Using Positive Temperature Coefficient (PTC) Thermistors.
Wire the thermistor to the TH+ and TH- inputs on the VFD:
The level of detecting resistance abnormality can be adjusted from 0 to 10000Ω. Impedance at abnormal temperature: 3kΩ. Yaskawa Sigma SD drives have a operating resistance of around 1.6k Ohms and a fault at 4k Ohms.
Changing Parameters on the drive through the front panel
Use the F1 key to enter into menu mode.
Setup the IP Address
To modify the IP address follow these steps:
Before the Control can connect to the VFD these parameters need to be set. On default you should only need to set the ones in bold.
|oL-01||IPv4 IP Address (1)||192||
|oL-02||IPv4 IP Address (2)||168||
|oL-03||IPv4 IP Address (3)||208||
|oL-04||IPv4 IP Address (4)||95||
|oL-09||IPv4 Default Gateway (1)||192||
|oL-10||IPv4 Default Gateway (2)||168||
|oL-11||IPv4 Default Gateway (3)||208||
|oL-12||IPv4 Default Gateway (4)||1||
Open the Configurable Parameters
To program the VFD you will need to utilize the Parameters. Follow the next few steps to find the Hitachi parameters.
While in the Parameters Type "Hitachi" in the search field as shown in Figure 5. This will populate the parameters for the Hitachi P1 VFD as shown below).
(Figure 5 Default Parameters)
Enable the VFD
For a main spindle, set Control Source to Mach and Modbus Control Enabled to Yes. For any other spindle like a grind wheel, regulating wheel, or sub spindle, set Control Source to Auxiliary and Modbus Control Enabled to Yes.
Hitachi VFD EtherCAT Installation:
To set up the Hitachi VFD to be commanded by EtherCAT you will need to modify 2 parameters:
|Description||Default Value||Desired Value|
|Main Speed Source_M||1 (Term.[Ai1])||9 (Option-1)|
|AA111||Run-cmd. Source_M1||0 (Term.[FW]/[RV])||4 (Option-1)|
The RapidPath plugin controls (writes to) some parameters for operation. If you change the value of any of them, your change will be overwritten.
This can be done automatically via Mach.
Go to Configure | Plugins | RapidPath - MachMotion:
Select the Other Devices tab, Click on the Hitachi VFD in the dropdown on the left and then select the Device Parameters at the bottom of the page:
From here you can click the Load from File button. Navigate to the Plugins/Dependencies/RapidPath/DriveConfig/Hitachi_VFD directory and select the file: Hitachi_Install_EtherCAT_I_O_device.drvprm.
Once it has loaded the parameter values, those which were updated, will be highlighted in green:
Click Write Changes button to save the updates to the drive.
You will need to recycle the drive for the change to the fan to take immediate effect.
Hitachi VFD Modbus Converter Installation:
For use with a STRIDE Modbus gateway model number: SGW-MB1511-T
Initial Connection to Converter
The gateway is configured through a web console, which is accessed using any web browser. The default management interface access is:
- IP address: 192.168.0.249 (if connecting at port E1)
- Port: 80
- Username: admin
- Password: admin
Change the IP address to what is states on the Schematic: 192.168.208.90, .91, etc
Parameters that need to be changed on the Hitachi VFD:
Power cycle the drive after parameters have been set.
Hitachi VFD Hardwired Analog Installation:
Setup RapidPath Analog Spindle Control
Follow the steps in this link Analog Spindle to configure the analog output for spindle control
Setup Analog Output Signal
Follow these steps in this link Mapping Analog Outputs setup the analog output signal in Mach Config
To be able to program the Hitachi VFD you will either need to change the parameters physically on the VFD or with the Hitachi ProDrive Next software.
Download "Download ProDriveNext 18.104.22.168". Unzip the file. Then run the setup.
- Software requirements: Mini USB Cable connected to the VFD and the computer that will be doing the programming.
By default from Hitachi, the AA101 and AA111 parameters are setup correctly:
|Description||Default Value||Desired Value|
|Main Speed Source_M||1 (Term.[Ai1])||1|
|AA111||Run-cmd. Source_M1||0 (Term.[FW]/[RV])||
|bA-61||Enable Braking Resistor||0||
|bA-63||Brake Resistor Resistance (Ohms)||10||
Applicable resistor value
HITACHI P1 Parameters
If there is a delayed safety relay (knob or switches on the front of the safety relay), you will need to set up the following:
(BOM Example: )
- CA-03: 31 (Sets S3 input to fast stop)
- CA-23: 1 (Sets S3 input to Normally Closed)
- AC-126: 4 (Or to your deceleration time)
Set up the motor parameters
Find your motor nameplate and enter in the parameters based on the table below.
If you cannot locate the motor’s base frequency, the name plate should tell you how many poles there are on the motor. You can also call the motor manufacturer to figure out the number of poles. Using the motor’s maximum RPM and its number of poles, you can calculate the base frequency with the formula below:
Base Frequency = Rated RPM * Number of Poles / 120
Max Frequency = Max RPM * Number of Poles / 120
|AC120||Motor Accel. Time||4 Seconds||0.0 to 3600.0 Seconds|
|AC122||Motor Decel. Time||3 Seconds||0.0 to 3600.0 Seconds|
|Hb102||Motor Rated KWs||1.5 kW||0.00 to 650.00 kW|
|HB103||Number Of Motor Poles||4 Poles||2 to 12 Poles|
|HB104||Motor Base Frequency||60 Hz||1.0 to 590.0 Hz|
|HB105||Motor Max Output Frequency||60 Hz||1.0 to 590.0 Hz|
|HB106||Motor Max Output Voltage||220 Volts||1-510 Volts|
|HB108||Motor Rated Current||5 Amps||10% to 200% of drive rated current|
|HB130||Motor Min Output Frequency||0.5 Hz||0.1 to 590.0 Hz|
Braking Resistor Enable
|1||1 Enables the Braking Resistor While Decel Only (Running)|
You can also modify the fan settings with this parameter.
|Description||Default Value||Desired Value|
|Cooling fan control||0 (Always on)||
2 (Temperature controlled)
Overspeed a Motor
If you want to command your spindle motor or grinding wheel to go faster than the base frequency, command the spindle to go max RPM and use a tachometer to measure the speed. Then use the following formula to calculate your new Max Output Frequency (Hb105):
Desired Max RPM * Current Max Frequency / Current Max RPM = New Max Frequency
For example, if your Current Max Frequency is 60 and you measure the spindle runs 1030 RPM but you actually want it to go 1515 RPM, calculate your new Max Frequency as follows:
1515 * 60 / 1030=88 Hz.
Make sure to recalibrate your RPM feedback and your spindle speed as both shown below.
Calibrate Spindle Speed
If your P1 is setup as a Mach spindle (under MachMotion Parameters), click on Configure -> Control at top of the Mach screen. Then select the "Spindle" tab shown in Figure 7. Set your max spindle RPM for each spindle range here.
(Figure 7 Spindle Tab)
If your VFD is enabled as an Auxiliary spindle (under MachMotion Parameters), set the Auxiliary Control Max RPM to the max RPM of the motor.
Calibrate RPM Feedback
If your VFD is enabled as a Mach spindle (and there can only be one enabled at a time), follow the procedure below.
You will need to scale your emulated RPM feedback in the Mach software. Calculate your feedback ratio as follows:
- Max Spindle RPM / 3600 = Feedback Ratio
Then while the control is disabled follow the next few steps:
Step 1: Click on Configure -> Control at top of the Mach screen. Then select the "Spindle" tab shown in Figure 7.
(Figure 7 Spindle Tab)
Step 2: Enter in the value you calculated in FeedBack Ratio from the calculation you have done for Spindle Gear 1 as shown in Figure 8.
(Figure 8 Enter Feedback Ratio)
If you were to get an alarm on the VFD you will receive a message on the computer screen from the Global Message System. In the description of the alarm it will describe the necessary steps to try to resolve the alarm.
To test what is failing here, disconnect the motor from the VFD and run the VFD. If the error doesn't come back, then the VFD is good and there is a problem with the wiring / motor. This error could be caused by a short or arcing on the wiring. It could also be caused by a locked rotor.
For additional testing you could do a diode test on the drive on T1, T2, and T3.
Regen Resistor Hot
If your regen resistor is hot, check your incoming voltage. If it is high, the regen resistors will be used constantly and can overheat. Fix the overvoltage issue first. If you cannot, then increase the resistor's wattage. For example, a 400VAC P1's voltage range is 380-500VAC.
To test any modbus VFD, review the following items to confirm it is setup correctly:
Does the VFD run the spindle? The VFD RUN light should be on solid when it is up to speed. If it isn't, the VFD is not programmed correctly.
Does the RPM change when you change the spindle speed on the control?
Does the VFD go both directions?
If you disconnect the VFD control cable does the control time out with a VFD Disconnected Error?
Is the RPM feedback correct?
Does up to speed and at speed work correctly inside the control?
EMA can repair Hitachi VFDs if needed. This is Hitachi's preferred repair house.
Make sure the VFD is powered all the time. Otherwise the VFD will not connect correctly.
Wire the Estop circuit as shown below:
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