1. Introduction
This manual provides essential information for the safe and efficient operation of your ZUKED HE200/HE100 Series Frequency Converter. This device is designed to convert single-phase 220V input power to three-phase 380V output power, enabling the control of various motor types with power ratings from 1.5kW to 7.5kW. It supports both V/F and vector control methods, offering precise speed and torque control for industrial applications.
Please read this manual thoroughly before installation, operation, or maintenance to ensure proper usage and prevent potential hazards.
2. Safety Information
WARNING: Read the user manual before operation.
Risk of electrical shock. Wait 10 minutes after removing power before servicing.
- Always ensure the power supply is disconnected before performing any wiring, maintenance, or inspection.
- Only qualified personnel should install, operate, and maintain this equipment.
- Ensure proper grounding of the frequency converter and the motor.
- Do not touch electrical components immediately after power-off, as residual voltage may be present.
- Protect the unit from moisture, dust, corrosive gases, and direct sunlight.
- Ensure adequate ventilation to prevent overheating.
3. Product Overview
3.1 Key Features
- Power Range: 1.5kW to 7.5kW
- Input Voltage: Single-phase 220V (170V-240V)
- Output Voltage: Three-phase 380V (330V-440V)
- Output Current: 3.8A - 17A (depending on model)
- Frequency Range: 0.1-400Hz
- Control Modes: Space vector, V/F control (V/F curve can be set arbitrarily)
- Accuracy: 0.1Hz output frequency accuracy
- Built-in PID Controller: For precise process control.
- Communication: Standard RS485 (MODBUS) communication function.
- Protective Functions: Overload, overvoltage, undervoltage, short circuit, over current, parameter lock.
3.2 Model Identification
The ZUKED frequency converters are available in various power ratings. The model number typically indicates the series (e.g., HE200, HE100) and the power rating. For example, ZUKED-HE200-1.5KW refers to a 1.5kW model in the HE200 series.
Figure 3.2.1: ZUKED HE200/HE100 Series Frequency Converter showing various power ratings and control types.
3.3 Keyboard Description
The front panel of the frequency converter features a display and several keys for programming and operation. Refer to the diagram below for a detailed description of each key and its function.
Figure 3.3.1: Keyboard layout and function description.
- Status Indicator: Various states of inverter operation can be displayed separately.
- Display Area: Displays set values and abnormal content of parameters, running frequency, and current.
- PRG (Program) Key: Used to enter program settings for parameter configuration.
- Numeric Modifier Keys (Up/Down Arrows): Used to set function codes or increment/decrement values.
- Displacement Key: Selects modification bits of set data or status monitoring parameters.
- RUN Key: Starts the inverter operation.
- ENTER Key: Used to store settings or enter the next level menu.
- STOP/RESET Key: Stops the inverter operation and resets it.
4. Specifications
4.1 General Technical Indicators
Figure 4.1.1: Detailed technical specifications.
| Parameter | Specification |
|---|---|
| Rated Voltage | 1PH/3PH AC 220V 50/60Hz, 3PH AC380V 50/60Hz |
| Voltage Allowable Range | Input: 220V: 170V-240V; 380V: 330V-440V |
| Output Voltage | 220V: 0-220V, 380V: 0-380V |
| Output Frequency | 0.1-400Hz |
| Control Method | Space vector, V/F control |
| Display | Four-digit digital tube display, indicator light display, display set frequency, output frequency, output current, rotation direction, rotation speed, fault, etc. |
| Output Frequency Range | 0.1-400.0Hz |
| Frequency Setting Resolution | Digital setting: 0.10Hz, analog setting: 0.1% of the maximum output frequency |
| Output Frequency Accuracy | 0.1Hz |
| V/F Control | The V/F curve can be set arbitrarily to meet the needs of various loads. |
| Torque Control | Automatic boost, Torque boost is automatically determined according to load conditions; Manual boost: 0.0-20.0% torque boost can be set. |
| Multi-function Input Terminal | 4 multi-function input terminals, realize 15-stage speed control, 4-stage acceleration and deceleration switching during program operation, UP/DOWN function, emergency stop and other functions. |
| Multi-function Output Terminal | There is one multi-function output terminal, which can realize the indication and alarm output of running, zero speed, external abnormality, program running, etc. |
| Acceleration/Deceleration Time Setting | Acceleration/deceleration time can be set separately from 0 to 999.9s. |
| PID Control | Built-in PID control. |
| RS485 | Standard RS485 communication function (MODBUS). |
| Analog Input | Analog 0-10V, 4-20mA, keyboard direct setting, RS485 setting, UP/DOWN setting, etc. Note: AVI terminal can select analog voltage input (0-10V) and analog current by switching J2 input (4-20mA). |
| Multi-speed | 4 multi-function input terminals, can form 15 speed. |
| Automatic Voltage Regulation | Automatic voltage regulation function can be selected as required. |
| Counter | Built-in 2 sets of counters. |
| Overload Protection | Constant torque 150%/1 minute, variable torque 120%/1 minute. |
| Overvoltage Protection | Overvoltage protection can be configured. |
| Undervoltage Protection | Protection can be set. |
| Other Protection | Short circuit protection, over current protection, parameter lock, etc. |
| Ambient Temperature | -10°C - +40°C (no freezing). |
| Environment Humidity | Below 95% (no condensation). |
| Altitude | Below 1000m (over 1000m, need to downshift). |
| Vibration | Below 0.5G. |
| Cooling Method | Forced air cooling. |
| Protection Class | IP20. |
| Installation Method | Wall-mounted, standard 35mm rail installation. |
5. Installation & Setup
5.1 Dimensions
Ensure sufficient space for installation and ventilation. The frequency converter supports standard 35mm rail installation for models under 5.5kW. Refer to the diagram and table below for specific dimensions (W, H, D, A, B, d in mm).
Figure 5.1.1: Dimensions of HE200 series frequency converters.
| Model | W | H | D | A | B | d |
|---|---|---|---|---|---|---|
| HE200-T3-0R7G—HE200-T3-2R2G | 72 | 142 | 112.2 | 130 | 61 | 4.5 |
| HE200-T3-3R7G—HE200-T3-5R5G | 80 | 180 | 116 | 167 | 72 | 5.5 |
| HE200-T3-7R5G—HE200-T3-011G | 106 | 240 | 153 | 230 | 96 | 4.5 |
| HE200-T3-015G—HE200-T3-022G | 151 | 332 | 165.5 | 318 | 137 | 7 |
5.2 Wiring
Proper wiring is crucial for the safe and correct operation of the frequency converter. Ensure all connections are secure and follow local electrical codes.
5.2.1 Main Circuit Wiring Diagram
The diagram below illustrates the main power connections for the frequency converter, converting single-phase 220V input to three-phase 380V output for a motor. A braking resistor connection is also shown.
Figure 5.2.1: Main circuit wiring diagram (1-phase 220V input, 3-phase 380V output).
- Input (L, N): Connect single-phase 220V power supply.
- Output (U, V, W): Connect to the three-phase 380V motor.
- Ground (GND): Ensure proper grounding.
- P, B: Connections for an optional braking resistor.
5.2.2 Control Circuit Terminal Diagram
The control terminals allow for external control signals and communication. Refer to the diagram and table for terminal identification and function.
Figure 5.2.2: Control circuit terminal diagram.
| Terminal name | Function Description |
|---|---|
| AI2 | Analog input terminal |
| X1, X2, X3, X4 | Switch input terminal |
| TA-TC | Switch input terminal |
| AO1 | Analog output terminal |
| +10V, GND | Auxiliary power terminal |
| A+, A- | Rs485 communication terminal |
6. Operating Instructions
After successful installation and wiring, the frequency converter is ready for operation. Basic operation involves using the front panel keyboard for control and parameter setting.
6.1 Basic Operation
- Power On: Apply single-phase 220V power to the L and N terminals. The display area will light up.
- Parameter Setting (PRG Key):
- Press the PRG key to enter the parameter setting mode.
- Use the Up/Down Arrow keys to navigate through parameters.
- Press ENTER to select a parameter and modify its value.
- Use Up/Down Arrow keys to change the value, and the Displacement key to move between digits.
- Press ENTER again to save the new value.
- Press PRG to exit the parameter setting mode.
- Starting the Motor (RUN Key):
- Ensure all parameters are set correctly.
- Press the RUN key to start the motor. The status indicator will show the running state.
- Stopping/Resetting (STOP/RESET Key):
- Press the STOP/RESET key to stop the motor.
- If an error occurs, pressing STOP/RESET will clear the fault and reset the inverter.
6.2 Control Methods
The inverter supports both V/F (Voltage/Frequency) control and Space Vector control. The V/F curve can be adjusted to match specific load requirements, providing flexibility for various applications.
6.3 Frequency Setting
The output frequency can be set within a range of 0.1 to 400Hz. Settings can be made digitally via the keyboard, or through analog input (0-10V, 4-20mA) or RS485 communication.
6.4 PID Control
The built-in PID controller allows for precise control in closed-loop systems, maintaining desired process variables such as pressure, flow, or temperature by adjusting motor speed.
6.5 RS485 Communication
The frequency converter includes a standard RS485 (MODBUS) communication interface, enabling remote control, monitoring, and parameter adjustment when integrated into a larger control system.
7. Maintenance
Regular maintenance ensures the longevity and reliable operation of your ZUKED frequency converter.
- Cleaning: Periodically clean the exterior of the unit, especially the ventilation openings, to prevent dust accumulation which can lead to overheating. Use a soft, dry cloth. Do not use liquid cleaners.
- Inspection: Regularly inspect wiring connections for tightness and signs of wear or damage. Check for any unusual noises or vibrations during operation.
- Environmental Conditions: Ensure the operating environment remains within specified temperature and humidity ranges (-10°C to +40°C, below 95% humidity, no condensation).
- Capacitor Life: Electrolytic capacitors have a finite lifespan. Consider professional inspection or replacement after several years of continuous operation.
- Fan Replacement: Cooling fans may need replacement if they become noisy or stop functioning, as they are crucial for heat dissipation.
Always disconnect power and wait at least 10 minutes before performing any maintenance or inspection to allow residual voltage to dissipate.
8. Troubleshooting
The frequency converter is equipped with various protective functions to ensure safe operation. If a fault occurs, the display may show an error code or the unit may shut down. Refer to the general protective functions below for common issues.
- Overload Protection: If the motor draws excessive current (e.g., constant torque 150%/1 min, variable torque 120%/1 min), the inverter will trip to protect itself and the motor. Check for mechanical issues with the load or ensure the motor is not undersized.
- Overvoltage Protection: Occurs if the DC bus voltage exceeds a safe limit, often due to regenerative braking or an unstable input voltage. Check input power and braking resistor if used.
- Undervoltage Protection: Occurs if the input voltage drops below a safe threshold. Check the input power supply.
- Short Circuit Protection: Protects against short circuits in the output wiring or motor. Immediately disconnect power and inspect wiring and motor for faults.
- Over Current Protection: Similar to overload, but typically for instantaneous current spikes.
- Parameter Lock: If parameters are locked, they cannot be changed. Refer to the manual for unlocking procedures (not detailed in provided data).
For specific error codes and detailed troubleshooting steps, please consult the full product manual (if available) or contact ZUKED technical support.
9. User Tips
- Frequency Converter Sizing:
- For light loads, it is recommended to choose a frequency converter one grade larger than the motor (e.g., for a 1.5kW motor, choose a 2.2kW inverter).
- For heavy loads, consider choosing a frequency converter two grades larger (e.g., for a 2.2kW motor, choose a 5.5kW inverter).
- This oversizing is particularly important when converting voltage (e.g., 220V single-phase to 380V three-phase) to account for the increased stress on the inverter and ensure sufficient margin for stable operation.
- Motor Compatibility: This inverter is designed for 3-phase 380V motors when using a 1-phase 220V input. Ensure your motor is compatible with the output voltage and frequency range.
10. Warranty & Support
For warranty information, technical support, or service inquiries, please contact your authorized ZUKED dealer or visit the official ZUKED website. Keep your purchase receipt and product model information handy when contacting support.
