Yaskawa 600V User Manual

YASKAWA AC Drive Z1000

AC Drive for HVAC Fan and Pump

Safety Precautions

Type: CIMR-ZU Models:

To properly use the product, read these precautions and refer to the CD-ROM packaged with the product. Ensure the end user receives these precautions and the CD-ROM No. TOECC71061615.

600 V Class: 2 to 250 HP

MANUAL NO. TOEP YAIZ1U 02A

No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of Yaskawa. No patent liability is assumed with respect to the use of the information contained herein. Moreover, because Yaskawa is constantly striving to improve its high-quality products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. Yaskawa assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication.

Z1000 Safety Precautions

This document provides essential safety information for the Z1000 series AC drive (600 V models). Refer to the CD-ROM packaged with the product for complete product instructions necessary for proper installation, set-up, troubleshooting and maintenance. CD part number TOECC71061615. The 1000 Series CD-ROM contains the Z1000 User Manual (600 V models) No. TOEPYAIZ1U03, Programming Manual No. SIEPYAIZ1U03, and additional 1000-Series manuals.

i.1 GENERAL SAFETY.................................................................................................5

i.2 MECHANICAL INSTALLATION SAFETY...............................................................9

i.3 ELECTRICAL INSTALLATION SAFETY...............................................................13

i.4 STANDARD CONNECTION DIAGRAM.................................................................16

i.5 HOA KEYPAD OPERATION..................................................................................32

i.6 START UP..............................................................................................................34

i.7 PARAMETER TABLE............................................................................................38

i.8 TROUBLESHOOTING............................................................................................45

i.9 UL AND CSA STANDARDS..................................................................................53

i.10 EUROPEAN STANDARDS....................................................................................57

i.11 REVISION HISTORY..............................................................................................62

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

Applicable Models

This Safety Precautions document applies to the drive models in Table i.1.

Table i.1 Applicable Models

Drive Series Drive Model Number Software Version

Z1000 (600 V models)

Warranty Information

Restrictions

CIMR-ZU5Aoooo

PRG: 4800

The drive is not designed or manufactured for use in devices or systems that may directly affect or threaten human lives or health.

Customers who intend to use the product described in this manual for devices or systems relating to transportation, health care, space aviation, atomic power, electric power, or in underwater applications must first contact their Yaskawa representatives or the nearest Yaskawa sales office.

WARNING! Injury to Personnel. This product has been manufactured under strict quality-control guidelines. However, if this product is to be installed in any location where failure of this product could involve or result in a life-and-death situation or loss of human life or in a facility where failure may cause a serious accident or physical injury, safety devices must be installed to minimize the likelihood of any accident.

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

i.1 General Safety

Supplemental Safety Information

General Precautions

• The diagrams in this manual may be indicated without covers or safety shields to show details. Replace the covers or shields before operating the drive and run the drive according to the instructions described in this manual.

• Any illustrations, photographs, or examples used in this manual are provided as examples only and may not apply to all products to which this manual is applicable.

• The products and specifications described in this manual or the content and presentation of the manual may be changed without notice to improve the product and/or the manual.

• When ordering a new copy of the manual due to damage or loss, contact your Yaskawa representative or the nearest Yaskawa sales office and provide the manual number shown on the front cover.

• If nameplate becomes worn or damaged, order a replacement from your Yaskawa representative or the nearest Yaskawa sales office.

WARNING

Read and understand this manual before installing, operating or servicing this drive. The drive must be installed according to this manual and local codes.

The following conventions are used to indicate safety messages in this manual. Failure to heed these messages could result in serious or fatal injury or damage to the products or to related equipment and systems.

DANGER

Indicates a hazardous situation, which, if not avoided, will result in death or serious injury.

WARNING

Indicates a hazardous situation, which, if not avoided, could result in death or serious injury.

WARNING! may also be indicated by a bold key word embedded in the text followed by an italicized safety message.

CAUTION

Indicates a hazardous situation, which, if not avoided, could result in minor or moderate injury.

CAUTION! may also be indicated by a bold key word embedded in the text followed by an italicized safety message.

NOTICE

Indicates a property damage message.

NOTICE: may also be indicated by a bold key word embedded in the text followed by an italicized safety message.

Safety Messages

DANGER

Heed the safety messages in this manual.

Failure to comply will result in death or serious injury. The operating company is responsible for any injuries or equipment damage resulting from failure to heed the warnings in

this manual.

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

i.1 General Safety

DANGER

Electrical Shock Hazard

Before servicing, disconnect all power to the equipment. The internal capacitor remains charged even after the power supply is turned off. The charge indicator LED will extinguish when the DC bus voltage is below 50 Vdc. To prevent electric shock, wait for at least the time specified on the warning label, once all indicators are OFF, measure for unsafe voltages to confirm the drive is safe prior to servicing.

Failure to comply will result in death or serious injury.

WARNING

Sudden Movement Hazard

System may start unexpectedly upon application of power, resulting in death or serious injury.

Clear all personnel from the drive, motor and machine area before applying power. Secure covers, couplings, shaft keys and machine loads before applying power to the drive.

Unpredictable equipment operation may result in death or serious injury. Take special note of custom I/O programming in the drive before attempting to operate equipment.

Electrical Shock Hazard

Do not attempt to modify or alter the drive in any way not explained in this manual.

Failure to comply could result in death or serious injury. Yaskawa is not responsible for any modification of the product made by the user. This product must not be modified.

Do not allow unqualified personnel to use equipment.

Failure to comply could result in death or serious injury. Maintenance, inspection, and replacement of parts must be performed only by authorized personnel familiar with installation,

adjustment and maintenance of AC drives.

Do not remove covers or touch circuit boards while the power is on.

Failure to comply could result in death or serious injury.

Make sure the protective earthing conductor complies with technical standards and local safety regulations.

Because the leakage current exceeds 3.5 mA, IEC/EN 61800-5-1 states that either the power supply must be automatically disconnected in case of discontinuity of the protective earthing conductor or a protective earthing conductor with a crosssection of at least 10 mm2 (Cu) or 16 mm2 (Al) must be used. Failure to comply may result in death or serious injury.

Always use appropriate equipment for Ground Fault Circuit Interrupters (GFCIs).

The drive can cause a residual current with a DC component in the protective earthing conductor. Where a residual current operated protective or monitoring device is used for protection in case of direct or indirect contact, always use a type B GFCI according to IEC/EN 60755.

Fire Hazard

Do not use an improper voltage source.

Failure to comply could result in death or serious injury by fire. Verify that the rated voltage of the drive matches the voltage of the incoming power supply before applying power.

Install adequate branch circuit protection according to applicable local codes and this Installation Manual. Failure to comply could result in fire and damage to the drive or injury to personnel.

The device is suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes, 600 Vac maximum (600 V class) when protected by branch circuit protection devices specified in this document.

Branch circuit protection shall be provided by any of the following: Non-time delay Class J, T, or CC fuses sized at 300% of the drive input rating, or Time delay Class J, T, or CC fuses sized at 175% of the drive input rating, or MCCB sized at 200% maximum of the drive input rating.

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

i.1 General Safety

WARNING

Crush Hazard

Do not use this drive in lifting applications without installing external safety circuitry to prevent accidental dropping of the load.

The drive does not possess built-in load drop protection for lifting applications.

Failure to comply could result in death or serious injury from falling loads. Install electrical and/or mechanical safety circuit mechanisms independent of drive circuitry.

CAUTION

Crush Hazard

Do not carry the drive by the front cover.

Failure to comply may result in minor or moderate injury from the main body of the drive falling.

NOTICE

Observe proper electrostatic discharge procedures (ESD) when handling the drive and circuit boards.

Failure to comply may result in ESD damage to the drive circuitry.

Do not perform a withstand voltage test on any part of the drive.

Failure to comply could result in damage to the sensitive devices within the drive.

Do not operate damaged equipment.

Failure to comply could result in further damage to the equipment. Do not connect or operate any equipment with visible damage or missing parts.

If a fuse is blown or a Ground Fault Circuit Interrupter (GFCI) is tripped, check the wiring and the selection of the peripheral devices.

Contact your supplier if the cause cannot be identified after checking the above.

Do not restart the drive immediately operate the peripheral devices if a fuse is blown or a GFCI is tripped.

Check the wiring and the selection of peripheral devices to identify the cause. Contact your supplier before restarting the drive or the peripheral devices if the cause cannot be identified.

Do not expose the drive to halogen group disinfectants.

Failure to comply may cause damage to the electrical components in the drive. Do not pack the drive in wooden materials that have been fumigated or sterilized. Do not sterilize the entire package after the product is packed.

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

i.1 General Safety

Periodic Maintenance Safety

WARNING! Electrical Shock Hazard. Capacitors in the drive do not immediately discharge after shutting off the power. Wait for at least the

amount of time specified on the drive before touching any components after shutting off the power. Failure to comply may cause injury to personnel from electrical shock.

WARNING! Burn Hazard. Because the heatsink can get very hot during operation, take proper precautions to prevent burns. When replacing the cooling fan, shut off the power and wait at least 15 minutes to be sure that the heatsink has cooled down. Failure to comply may cause burn injury to personnel.

Motor Application Safety

WARNING! Electrical Shock Hazard. When a drive is running a PM motor, voltage continues to be generated at the motor terminals after

the drive is shut off while the motor coasts to stop. Take the precautions described below to prevent shock and injury:

• In applications where the machine can still rotate after the drive has fully stopped a load, install a switch to the drive output side to disconnect the motor and the drive.

• Do not allow an external force to rotate the motor beyond the maximum allowable speed or to rotate the motor when the drive has been shut off.

• Wait for at least the time specified on the warning label after opening the load switch on the output side before inspecting the drive or performing any maintenance.

• Do not open and close the load switch while the motor is running.

• If the motor is coasting, make sure the power to the drive is turned on and the drive output has completely stopped before closing the load switch.

NOTICE: Equipment Damage. A motor connected to a PWM drive may operate at a higher temperature than a utility-fed motor and the operating speed range may reduce motor cooling capacity. Ensure that the motor is suitable for drive duty and/or the motor service factor is adequate to accommodate the additional heating with the intended operating conditions.

Insulation Tolerance

NOTICE: Consider motor voltage tolerance levels and motor insulation in applications with an input voltage of over 440 V or particularly

long wiring distances.

High-Speed Operation

NOTICE: Problems may occur with the motor bearings and dynamic balance of the machine when operating a motor beyond its rated speed.

Contact the motor or machine manufacturer.

Torque Characteristics

Torque characteristics differ compared to operating the motor directly from line power. The user should have a full understanding of the load torque characteristics for the application.

Audible Noise

The audible noise of the motor varies based on the carrier frequency setting. However, drive current derating may be required. When using a high carrier frequency, audible noise from the motor is comparable to the motor noise generated when running from line power.

Receiving Safety

CAUTION

Do not carry the drive by the front cover or the terminal cover.

Failure to comply may cause the main body of the drive to fall, resulting in minor or moderate injury.

NOTICE

Observe proper electrostatic discharge procedures (ESD) when handling the drive and circuit boards.

Failure to comply may result in ESD damage to the drive circuitry.

Transporting the Drive

NOTICE: Never steam clean the drive. During transport, keep the drive from coming into contact with salts, fluorine, bromine, phthalate

ester, and other such harmful chemicals.

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

i.2 Mechanical Installation Safety

WARNING

Fire Hazard

Provide sufficient cooling when installing the drive inside an enclosed panel or cabinet.

Failure to comply could result in overheating and fire. When multiple drives are placed inside the same enclosure panel, install proper cooling to ensure air entering the enclosure

does not exceed 40 °C.

Crush Hazard

Only allow qualified personnel to operate a crane or hoist to transport the drive.

Failure to comply may result in serious injury or death from falling equipment.

Use a dedicated lifter when transporting the drive by a lifter.

Failure to comply may result in serious injury or death from falling equipment.

Only use vertical suspension to temporarily lift the drive during installation to an enclosure panel. Do not use vertical suspension to transport the drive.

Failure to comply may result in serious injury or death from falling equipment.

Use screws to securely affix the drive front cover, terminal blocks, and other drive components prior to vertical suspension.

Failure to comply may result in serious injury or death from falling equipment.

Do not subject the drive to vibration or impact greater than 1.96 m/s2 (0.2 G) while it is suspended by the cables.

Failure to comply may result in serious injury or death from falling equipment.

Do not attempt to flip the drive over or leave the drive unattended while it is suspended by the wires.

Failure to comply may result in serious injury or death from falling equipment.

NOTICE

Equipment Hazard

Prevent foreign matter such as metal shavings or wire clippings from falling into the drive during drive installation and project construction.

Failure to comply could result in damage to the drive. Place a temporary cover over the top during installation. Be sure to remove the temporary cover before start-up, as the cover will reduce ventilation and cause the unit to overheat.

Observe proper electrostatic discharge (ESD) procedures when handling the drive.

Failure to comply could result in ESD damage to the drive circuitry.

When the input voltage is 440 V or higher or the wiring distance is greater than 100 meters, pay special attention to the motor insulation voltage or use a drive-rated motor with reinforced insulation.

Failure to comply could lead to motor winding failure.

Never lift the drive up while the cover is removed.

This can damage the terminal board and other components.

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

i.2 Mechanical Installation Safety

Installation Environment

Install the drive in an environment matching the specifications in Table i.2 to help prolong the optimum performance life of the drive.

Table i.2 Installation Environment

Environment Conditions

Installation Area Indoors

IP20/NEMA Type 1 enclosure: -10 °C to +40 °C (14 °F to 104 °F) IP00/Open Type enclosure: -10 °C to +50 °C (14 °F to 122 °F)

Ambient Temperature

Humidity 95% RH or less and free of condensation

Storage Temperature -20 °C to +60 °C (-4 °F to +104 °F)

Surrounding Area

Altitude 1000 m (3281 ft.) or lower, up to 3000 m (9843 ft.) with derating

Vibration

Orientation Install the drive vertically to maintain maximum cooling effects.

Drive reliability improves in environments without wide temperature fluctuations. When using the drive in an enclosure panel, install a cooling fan or air conditioner in the area to ensure that the air temperature inside the enclosure does not exceed the specified levels. Do not allow ice to develop on the drive.

Install the drive in an area free from:

• oil mist and dust

• metal shavings, oil, water, or other foreign materials

• radioactive materials

• combustible materials (e.g., wood)

• harmful gases and liquids

• excessive vibration

• chlorides

• direct sunlight.

10 to 20 Hz at 9.8 m/s2 (32.15 ft/s2) 20 to 55 Hz at 5.9 m/s2 (19.36 ft/s2) (Models 5A0003 to 5A0099) or

2.0 m/s2 (6.56 ft/s2) (Models 5A0125 to 5A0242)

NOTICE: Avoid placing drive peripheral devices, transformers, or other electronics near the drive as the noise created can lead to erroneous operation. If such devices must be used in close proximity to the drive, take proper steps to shield the drive from noise.

NOTICE: Prevent foreign matter such as metal shavings and wire clippings from falling into the drive during installation. Failure to comply could result in damage to the drive. Place a temporary cover over the top of the drive during installation. Remove the temporary cover before drive start-up, as the cover will reduce ventilation and cause the drive to overheat.

Installation Orientation and Spacing

Install the drive upright as illustrated in Figure i.1 to maintain proper cooling.

Figure i.1 Correct Installation Orientation

NOTICE: Install the drive upright as specified in the manual. Failure to comply may damage the drive due to improper cooling.

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

B B

Side Clearance Top/Bottom Clearance

Side Clearance

Line up the tops of the drives.

Top/Bottom Clearance

i.2 Mechanical Installation Safety

Single Drive Installation

Figure i.2 shows the installation distance required to maintain sufficient space for airflow and wiring. Install the heatsink

against a closed surface to avoid diverting cooling air around the heatsink.

A – 50 mm minimum B – 30 mm minimum

C – 120 mm minimum D – Airflow direction

Figure i.2 Correct Installation Spacing

Note: IP20/NEMA Type 1 enclosure and IP00/Open Type enclosure models require the same amount of space above and below the drive for

installation.

Multiple Drive Installation (Side-by-Side Installation)

Models 5A0003 to 5A0032 can take advantage of Side-by-Side installation.

When installing multiple drives into the same enclosure panel, mount the drives according to Figure i.2 and set L8-35, Installation Method Selection, to 1 (Side-by-Side Mounting).

When mounting drives with the minimum clearance of 2 mm according to Figure i.3, set parameter L8-35 to 1 while considering derating.

A – 50 mm minimum B – 30 mm minimum

Note: Align the tops of the drives when installing drives of different heights in the same enclosure panel. Leave space between the tops and bottoms

of stacked drives for easier cooling fan replacement.

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

C – 2 mm minimum D – 120 mm minimum

Figure i.3 Space Between Drives (Side-by-Side Mounting)

i.2 Mechanical Installation Safety

Remove the top protective covers of all drives as shown in Figure i.4 when mounting IP20/NEMA Type 1 enclosure drives side-by-side.

Figure i.4 IP20/NEMA 1 Side-by-Side Mounting in Enclosure

Drive Dimensions

NOTICE

Refer to the Z1000 User Manual TOEPYAIZ1U03 (600 V models) for IP20/NEMA Type 1, IP00/Open Chassis, drive dimensions.

The 1000 Series CD-ROM No. TOECC71061615, packaged with the drive contains the Z1000 User Manual No. TOEPYAIZ1U03 and additional 1000-Series manuals.

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

i.3 Electrical Installation Safety

NOTICE

Refer to the Z1000 User Manual (600 V models) TOEPYAIZ1U03 on the CD-ROM packaged with the product for more information regarding the Electrical Installation and for complete product instructions necessary for proper installation, set- up, troubleshooting and maintenance. CD-ROM part number TOECC71061615.

DANGER

Electrical Shock Hazard

Failure to comply will result in death or serious injury.

WARNING

Make sure the protective earthing conductor complies with technical standards and local safety regulations.

Failure to comply may result in death or serious injury.

Always use appropriate equipment for Ground Fault Circuit Interrupters (GFCIs).

WARNING

Electrical Shock Hazard

Do not operate equipment with covers removed.

Failure to comply could result in death or serious injury. The diagrams in this section may show drives without covers or safety shields to show details. Be sure to reinstall covers or

shields before operating the drives and run the drives according to the instructions described in this manual.

Always ground the motor-side grounding terminal.

Improper equipment grounding could result in death or serious injury by contacting the motor case.

Do not perform work on the drive while wearing loose clothing, jewelry or without eye protection.

Failure to comply could result in death or serious injury. Remove all metal objects such as watches and rings, secure loose clothing, and wear eye protection before beginning work

on the drive.

Do not remove covers or touch circuit boards while the power is on.

Failure to comply could result in death or serious injury.

Do not allow unqualified personnel to perform work on the drive.

Failure to comply could result in death or serious injury. Installation, maintenance, inspection, and servicing must be performed only by authorized personnel familiar with

installation, adjustment, and maintenance of AC drives.

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

i.3 Electrical Installation Safety

WARNING

Do not touch any terminals before the capacitors have fully discharged.

Failure to comply could result in death or serious injury. Before wiring terminals, disconnect all power to the equipment. The internal capacitor remains charged even after the power

supply is turned off. After shutting off the power, wait for at least the amount of time specified on the drive before touching any components.

Fire Hazard

Tighten all terminal screws to the specified tightening torque.

Loose electrical connections could result in death or serious injury by fire due to overheating of electrical connections.

Do not use improper combustible materials.

Failure to comply could result in death or serious injury by fire. Do not install the drive to a combustible surface. Never place combustible materials on the drive.

Do not use an improper voltage source.

Failure to comply could result in death or serious injury by fire. Verify that the rated voltage of the drive matches the voltage of the incoming power supply before applying power.

When installing dynamic braking options, perform all wiring exactly as specified in the wiring diagrams provided.

Failure to do so can result in fire. Improper wiring may damage braking components.

Shut off the drive with a magnetic contactor (MC) when a fault occurs in any external equipment such as braking resistors. Failure to comply may cause resistor overheating, fire, and injury to personnel.

WARNING

Fire Hazard

Properly handle the HOA keypad battery.

Improper use of the battery may cause fire by explosion and personal injury. Correctly install the battery, paying attention to polarity (+/-). Do not attempt to charge the battery or improperly disassemble the HOA keypad.

CAUTION

Do not carry the drive by the front cover or the terminal cover.

Failure to comply may cause the main body of the drive to fall, resulting in minor or moderate injury.

NOTICE

Observe proper electrostatic discharge procedures (ESD) when handling the drive and circuit boards.

Failure to comply may result in ESD damage to the drive circuitry.

Never connect or disconnect the motor from the drive while the drive is outputting voltage.

Improper equipment sequencing could result in damage to the drive.

Do not use unshielded cable for control wiring.

Failure to comply may cause electrical interference resulting in poor system performance. Use shielded, twisted-pair wires and ground the shield to the ground terminal of the drive.

Do not allow unqualified personnel to use the product.

Failure to comply could result in damage to the drive or braking circuit. Carefully review instruction manual TOBPC72060000 or TOBPC72060001 when connecting a dynamic braking option to

the drive.

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

i.3 Electrical Installation Safety

NOTICE

Do not modify the drive circuitry.

Failure to comply could result in damage to the drive and will void warranty. Yaskawa is not responsible for any modification of the product made by the user. This product must not be modified.

Check all the wiring to ensure that all connections are correct after installing the drive and connecting any other devices.

Failure to comply could result in damage to the drive. Do not connect power supply lines to output terminals U/T1, V/T2, or W/T3. Failure to comply will destroy the drive.

Be sure to perform a final check of all sequence wiring and other connections before turning on the power and also check for short circuits on the control terminals, which may damage the drive.

To get the full performance life out of the electrolytic capacitors and circuit relays, refrain from switching the drive power supply off and on more than once every 30 minutes. Frequent use can damage the drive. Use the drive to stop and

start the motor.

NOTICE

Do not heat or throw the battery into fire.

The battery remains in use even when power to the drive has been shut off. Be sure to also remove the battery in the HOA keypad when the drive will be shut off for long periods of time. A dead battery left inside the HOA keypad may leak and damage the keypad and drive. Be sure to replace the battery with a new one immediately after the expected lifespan has passed or when the “bAT” error is displayed on the HOA keypad.

Be sure to observe the Perchlorate Best Management Practices (BMPs).

BMPs apply to primary lithium (manganese dioxide) coin batteries sold or distributed in California. Perchlorate Material special handling may apply, please refer to: www.dtsc.ca.gov/hazardouswaste/perchlorate.

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

i.4 Standard Connection Diagram

Connect the drive and peripheral devices as shown in Figure i.5. It is possible to set and run the drive via the HOA keypad without connecting digital I/O wiring.

WARNING! Fire Hazard. Install adequate branch circuit protection according to applicable local codes and this manual. Failure to comply could result in fire and damage to the drive or injury to personnel. The device is suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes 600 Vac maximum (600 V class), when protected by branch circuit protection devices specified in this manual. Branch circuit protection shall be provided by any of the following: Non-time delay Class J, T, or CC fuses sized at 300% of the drive input rating, or Time delay Class J, T, or CC fuses sized at 175% of the drive input rating, or MCCB sized at 200% maximum of the drive input rating.

WARNING! Sudden Movement Hazard. Do not close the wiring for the control circuit unless the multifunction input terminal parameters are properly set. Improper sequencing of run/stop circuitry could result in death or serious injury from moving equipment.

WARNING! Sudden Movement Hazard. Ensure start/stop and safety circuits are wired properly and in the correct state before energizing the drive. Failure to comply could result in death or serious injury from moving equipment. When programmed for 3-Wire control, a momentary closure on terminal S1 may cause the drive to start.

WARNING! Sudden Movement Hazard. When using a 3-Wire sequence, set the drive to 3-Wire sequence prior to wiring the control terminals and set parameter b1-17 to 0 so the drive will not accept a Run command at power up (default). If the drive is wired for a 3-Wire sequence but set up for a 2-Wire sequence (default), and parameter b1-17 is set to 1 so the drive accepts a Run command at power up, the motor will rotate in reverse direction at drive power up and may cause injury.

WARNING! Sudden Movement Hazard. Confirm the drive I/O signals and external sequence before executing the application preset function. Executing the application preset function or setting A1-06 ≠ 0 will change the drive I/O terminal functions and may cause unexpected equipment operation. Failure to comply may cause death or serious injury.

NOTICE: When using the automatic fault restart function with wiring designed to shut off the power supply upon drive fault, make sure the drive does not trigger a fault output during fault restart (L5-02 = 0, default). Failure to comply will prevent the automatic fault restart function from working properly.

NOTICE: When the input voltage is 440 V or higher or the wiring distance is greater than 100 meters, pay special attention to the motor insulation voltage or use a drive duty motor. Failure to comply could lead to motor insulation breakdown.

NOTICE: Do not connect AC control circuit ground to drive enclosure. Improper drive grounding can cause control circuit malfunction.

NOTICE: Route motor leads U/T1, V/T2, and W/T3 separate from all other leads to reduce possible interference related issues. Failure to

comply may result in abnormal operation of drive and nearby equipment.

Note: The minimum load for the relay outputs M1-M2, M3-M4, M5-M6, and MA-MB-MC is 10 mA.

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

for connection options. Never connect power supply lines to these terminals

DC link choke

(option)

U X

－

U X

0 V

S-

Z1000 Drive (600 V)

B11

2 k

0 V

E (G)

<1>

<2>

<9>

<7>

<8>

<6>

<4>

<3>

－

+24 V

Jumper

Braking resistor (option)

Forward Run / Stop

Reverse Run / Stop

External fault

Fault reset

Multi-speed step 1

Multi-speed step 2

Jog speed

Multi-function

digtial inputs

(default setting)

Sink / Source mode selection

Factory installed wire link

(default: Sink)

CN5-C

CN5-B

CN5-A

Option board

Shield ground terminal

Multi-function analog inputs

Power supply +10.5 Vdc, max. 20 mA

Analog Input 1 (Frequency Reference Bias) 0 to +10 Vdc (20 kΩ) Resolution: Unsigned 12 bit 4 to 20 mA (250 Ω) / 0 to 20 mA (250 Ω)

MEMOBUS/Modbus Communication RS-422/RS-485 Maximum 115.2 kbps BACnet Communication Apogee FLN, Siemens Metasys N2, Johnson Controls

Termination resistor

(120 , 1/2 W)

DIP Switch S2

Multi-function relay output (During Run) 250 Vac, max. 1 A 30 Vdc, max 1 A (min. 5 Vdc, 10 mA)

Multi-function analog output 1 (Output frequency)

-10 to +10 or 0 to +10 Vdc (2 mA) or 4 to 20 mA

Main Circuit

Control Circuit

shielded line

twisted-pair shielded line

main circuit terminal

control circuit terminal

R/L1 S/L2 T/L3

R S

Main

Switch

Fuse

EMC Filter

Multi-function relay output (Zero Speed) 250 Vac, max. 1 A 30 Vdc, max 1 A (min. 5 Vdc, 10 mA)

AMFM

Off

DIP Switch S2 Term. Res. On/Off

Jumper S1 A1/A2 Voltage/Current Selection

Jumper S5 AM/FM Voltage/Current Selection

Terminal board jumpers and switches

<5>

<10>

Ω

<9>

Multi-function analog output 2 (Output current)

-10 to +10 or 0 to +10 Vdc (2 mA) or 4 to 20 mA

Three-Phase Power Supply 600 V 50/60 Hz

<11>

U/T1

V/T2

W/T

Ground

Cooling fan

connectors

Ω

Analog Input 2 (Frequency Reference Bias) 0 to +10 Vdc (20 kΩ) Resolution: Unsigned 12 bit 4 to 20 mA (250 Ω) / 0 to 20 mA (250 Ω)

Fault output 250 Vac, max. 1 A 30 Vdc, max 1 A (min. 5 Vdc, 10 mA)

A1 A2

Multi-function relay output (Speed Agree 1) 250 Vac, max. 1 A 30 Vdc, max 1 A (min. 5 Vdc, 10 mA)

External power supply 24 Vdc, max. 150 ma

Terminals , 1, 2, B1, B2 are

－

+24 Vdc

External Supply

(max. 150 mA)

－

i.4 Standard Connection Diagram

<1> Remove the jumper when installing a DC link choke. Models 5A0041 to 5A0242 come with a built-in DC link choke. <2> Set L8-55 to 0 to disable the protection function of the built-in braking transistor of the drive when using an optional regenerative

converter or dynamic braking option. Leaving L8-55 enabled may cause a braking resistor fault (rF). Additionally, disable Stall Prevention (L3-04 = 0) when using an optional regenerative converter, regenerative or braking units, or dynamic braking option. Leaving If L3-04 enabled may prevent the drive from stopping within the specified deceleration time.

<3> Supplying power to the control circuit separately from the main circuit requires 24 V power supply (option).

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

Figure i.5 Drive Standard Connection Diagram

i.4 Standard Connection Diagram

<4> This figure illustrates an example of a sequence input to S1 through S7 using a non-powered relay or an NPN transistor. Install

the wire link between terminals SC-SP for Sink mode, between SC-SN for Source mode, or leave the link out for external power

supply. Never short terminals SP and SN, as it will damage the drive. <5> This voltage source supplies a maximum current of 150 mA. <6> The maximum output current capacity for the +V terminal on the control circuit is 20 mA. Never short terminals +V and AC, as

it can cause erroneous operation or damage the drive. <7> Set jumper S1 to select between a voltage or current input signal to terminal A2. The default setting is for voltage input. <8> Set DIP switch S2 to the ON position to enable the termination resistor in the last drive in a MEMOBUS/Modbus network. <9> Monitor outputs work with devices such as analog frequency meters, ammeters, voltmeters, and wattmeters. They are not

intended for use as a feedback-type signal. <10> Use jumper S5 to select between voltage or current output signals at terminals AM and FM. Set parameters H4-07 and H4-08

accordingly. <11> Self-cooling motors do not require the same wiring necessary for motors with cooling fans.

Main Circuit Wiring

WARNING! Electrical Shock Hazard. Do not connect the AC power line to the drive output terminals U/T1, V/T2, and W/T3 . Failure to

comply could result in death or serious injury by fire as a result of drive damage from line voltage application to output terminals.

NOTICE

Refer to the Z1000 User Manual (600 V models) TOEPYAIZ1U03 on the CD-ROM packaged with the product for complete product instructions necessary for proper installation, set-up, troubleshooting and maintenance. CD part number TOECC71061615.

NOTICE: Route motor leads U/T1, V/T2, and W/T3 separate from all other leads to reduce possible interference related issues. Failure to comply may result in abnormal operation of drive and nearby equipment.

NOTICE: Do not use the negative DC bus terminal “–” as a ground terminal. This terminal is at high DC voltage potential. Improper wiring connections could damage the drive.

NOTICE: Do not solder the ends of wire connections to the drive. Soldered wiring connections can loosen over time. Improper wiring practices could result in drive malfunction due to loose terminal connections.

NOTICE: Do not switch the drive input to start or stop the motor. Frequently switching the drive on and off shortens the life of the DC bus charge circuit and the DC bus capacitors, and can cause premature drive failures. For the full performance life, refrain from switching the drive on and off more than once every 30 minutes.

NOTICE: When connecting the motor to the drive output terminals U/T1, V/T2, and W/T3, the phase order for the drive and motor should match. Failure to comply with proper wiring practices may cause the motor to run in reverse if the phase order is backward.

NOTICE: Do not connect phase-advancing capacitors or LC/RC noise filters to the output circuits. Failure to comply could result in damage to the drive, phase-advancing capacitors, LC/RC noise filters or ground fault circuit interrupters.

Note: Wire gauge recommendations based on drive continuous current ratings (ND) using 75 °C 600 Vac vinyl-sheathed wire assuming ambient

temperature within 40 °C and wiring distance less than 100 m.

Yaskawa recommends using closed-loop crimp terminals on all drive models. To maintain UL/cUL approval, UL Listed closed-loop crimp terminals are specifically required when wiring the drive main circuit terminals on models 5A0041 to 5A0242. Use only the tools recommended by the terminal manufacturer for crimping.

Main Circuit Terminal Functions

Table i.3 Main Circuit Terminal Functions

Terminal Type

Drive Model 5A0003 to 5A0032 5A0041, 5A0052 5A0062 to 5A0242

R/L1

Main circuit power supply input Connects line power to the drive 17S/L2

T/L3

U/T1

Drive output Connects to the motor 17V/T2

W/T3

Function Page

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

i.4 Standard Connection Diagram

Terminal Type

Drive Model 5A0003 to 5A0032 5A0041, 5A0052 5A0062 to 5A0242

⊕2 • DC link choke

⊕1

⊖

⊕3

Note: Use terminals B1 and ⊖ when installing a CDBR-type braking unit on drives with built-in braking transistors (Models 5A0003 to 5A0052).

Protecting Main Circuit Terminals

Insulation Caps or Sleeves

connection (⊕1, ⊕2) (remove the shorting bar between ⊕1 and ⊕2)

• DC power supply input (⊕1, ⊖)

Braking resistor Not available

Not available

DC power supply input (⊕1, ⊖)

Not available

10 Ω or less Grounding terminal 24

• DC power supply input (⊕1, ⊖)

• Braking unit connection (⊕3, ⊖)

Available for connecting a braking resistor or a braking resistor unit option

For connecting:

• the drive to a DC power supply

• dynamic braking options

• a DC link choke

Function Page

–

Use insulation caps or sleeves when wiring the drive with crimp terminals. Take particular care to ensure that the wiring does not touch nearby terminals or the surrounding case.

Main Circuit Wire Gauges and Tightening Torque

Use the tables in this section to select the appropriate wires and crimp terminals.

Gauges listed in the tables are for use in the United States.

Note: 1. Wire gauge recommendations based on drive continuous current ratings (ND) using 75 °C 600 Vac vinyl-sheathed wire assuming ambient

temperature within 40 °C and wiring distance less than 100 m.

2. Terminals ⊕1, ⊕2, ⊕3, ⊖, B1 and B2 are for connecting optional power devices. Use caution to connect only approved devices to the correct terminal(s).

• Consider the amount of voltage drop when selecting wire gauges. Increase the wire gauge when the voltage drop is greater than 2% of motor rated voltage. Ensure the wire gauge is suitable for the terminal block. Use the following formula to calculate the amount of voltage drop:

Line drop voltage (V) =

3 × wire resistance (Ω/km) × wire length (m) × current (A) × 10

-3

• Refer to instruction manual TOBP C720600 00 for braking transistor option or braking resistor option wire gauges.

• Use terminals ⊕1 and ⊖ when connecting a regenerative converter or a regen unit.

NOTICE: Do not connect a braking resistor to terminals ⊕1 or ⊖. Failure to comply may cause damage to the drive circuitry.

• Use terminals B1 and ⊖ when installing a CDBR-type braking unit on drives with built-in braking transistors (models 5A0003 to 5A0052).

NOTICE: Do not connect a braking resistor to terminals ⊕1 or ⊖. Failure to comply may cause damage to the drive circuitry.

• Refer to UL Standards Compliance on page 53 for information on UL compliance.

Yaskawa recommends using closed-loop crimp terminals on all drive models. Use only the tools recommended by the terminal manufacturer for crimping. Refer to Closed-Loop Crimp Terminal Size on page 23 for closed-loop crimp terminal recommendations.

The wire gauges listed below are Yaskawa recommendations. Refer to local codes for proper wire gauge selections.

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

i.4 Standard Connection Diagram

Three-Phase 600 V Class

Table i.4 Wire Gauge and Torque Specifications (Three-Phase 600 V Class)

Drive Model Terminal

R/L1, S/L2, T/L3

U/T1, V/T2, W/T3

5A0003 5A0004 5A0006

5A0009

5A0011

5A0017

5A0022

⊖, ⊕1, ⊕2

B1, B2 –

R/L1, S/L2, T/L3

U/T1, V/T2, W/T3

⊖, ⊕1, ⊕2

B1, B2 –

R/L1, S/L2, T/L3

U/T1, V/T2, W/T3

⊖, ⊕1, ⊕2

B1, B2 –

R/L1, S/L2, T/L3

U/T1, V/T2, W/T3

⊖, ⊕1, ⊕2

B1, B2 –

R/L1, S/L2, T/L3

U/T1, V/T2, W/T3

⊖, ⊕1, ⊕2

B1, B2 –

Recomm. Gauge

mm2 (AWG, kcmil)

2.5

(14)

2.5

(14)

–

6.0

(10)

2.5

(14)

2.5

(14)

–

6.0

(10)

6.0

(10)

2.5

(14)

–

(8)

6.0

(10)

6.0

(10)

–

(8)

6.0

(10)

–

(8)

Wire Range

mm2 (AWG, kcmil)

2.5 to 6.0 (14 to 10)

4.0 to 6.0 (12 to 10)

2.5 to 16 (14 to 6)

2.5 to 6.0 (14 to 10)

4.0 to 6.0 (12 to 8)

6.0 to 16 (10 to 6)

6.0 to 10 (10 to 8)

6.0 to 10 (12 to 8)

6.0 to 16 (10 to 6)

6.0 to 10 (10 to 8)

6.0 to 10 (10 to 6)

Screw

Size

Tightening Torque

N·m (lb.in.)

1.2 to 1.5

(10.6 to 13.3)

1.2 to 1.5

(10.6 to 13.3)

2.1 to 2.3

(18.6 to 20.4)

2.0 to 2.5

(17.7 to 22.1)

3.6 to 4.0

(31.8 to 35.4)

2.7 to 3.0

(23.9 to 26.6)

5.4 to 6.0

(47.8 to 53.1)

3.6 to 4.0

(31.8 to 35.4)

2.7 to 3.0

(23.9 to 26.6)

5.4 to 6.0

(47.8 to 53.1)

YASKAWA ELECTRIC TOEP YAIZ1U 02A YASKAWA AC Drive – Z1000 Safety Precautions

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