Yaskawa 656 DC5 User Manual

YASKAWA

VARISPEED-656DC5

INSTRUCTION MANUAL



PWM TRANSISTOR CONVERTER

MODEL: CIMR-D5A

200 to 230 V, 27 to 120 HP (20 to 90 kW) 380 to 460 V, 27 to 496 HP (20 to 370 kW)

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference.

YA S K A WA

MANUAL NO. TOBP C710656 00C

All rights reserved. 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. Nevertheless, 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.

PREFACE

• Some drawings in this manual are shown with the protective cover or shields 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 of the product, modification, or changes in specifications. Such modifications are denoted by a revised manual No.

• To order a copy of this manual, if your copy has been damaged or lost, contact your YASKAWA representative.

• YASKAWA is not responsible for any modification of the product made by the user, since that will void your guarantee.

YASKAWA’s VARISPEED-656DC5 is a PWM transistor converter. This instruction man-

ual describes installation, maintenance and inspection, troubleshooting, and specifications of

the VS-656DC5. Read this instruction manual thoroughly before operation.

YASKAWA ELECTRIC CORPORATION

General Precautions

SAFETY INFORMATION

Read this instruction manual thoroughly before installation, operation, maintenance or

inspection of the VS-656DC5. In this manual, NOTES FOR SAFE OPERATION are classi-

fied as “WARNING” or “CAUTION.”

WARNING

CAUTION

Indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury to personnel.

Indicates a potentially hazardous situation which, if not avoided, may result in minor

or moderate injury to personnel and damage to equipment.

It may also be used to alert against unsafe practices.

Even items described in may result in a vital accident in some situations.

In either case, follow these important notes.

CAUTION

NOTE

These are steps to be taken to insure proper operation.

iii

NOTES FOR SAFE OPERATION

 RECEIVING

CAUTION

(Ref. Page)

• Do not install or operate any VS-656DC5 which is damaged or has missing parts.

Failure to observe this caution may result in personal injury or equipment damage.

 INSTALLATION

CAUTION

• Lift the cabinet by the base. When moving the VS-656DC5, never lift by the front

cover or the front panel.

Otherwise, the main unit may be dropped causing personal injury or damage to the VS656DC5.

• Mount the VS-656DC5 on nonflammable material (i.e. metal).

Failure to observe this caution may result in a fire.

• When mounting several Units in an enclosure, install a fan or other cooling device to

keep the intake air temperature below 45 °C.

Overheating may cause a fire or damage to the VS-656DC5.

E-3

(Ref. Page)

E-5

 WIRING

WARNING

(Ref. Page)

• Only commence wiring after verifying that the power supply is tunred OFF.

Failure to observe this warning may result in an electric shock or a fire.

• Wiring should be performed only by qualified personnel.

Failure to observe this warning may result in an electric shock or a fire.

• Make sure to ground the ground terminal before connecting the other terminals.

(200 V class: Ground to 100 Ω or less, 400 V class: Ground to 10 Ω or less).

Failure to observe this warning may result in an electric shock or a fire.

CAUTION

• Verify that the VS-656DC5 rated voltage coincides with the AC power supply volt-

age.

Failure to observe this caution may result in personal injury or a fire.

E-11

(Ref. Page)

E-11

• Do not perform a withstand voltage test of the VS-656DC5.

Failure to observe this caution may result in damage to the semi-conductor elements.

• Connect the input AC reactor, harmonics filter reactor, and the harmonics filter

capacitor as described in this instruciton manual.

Failure to observe this caution may result in a fire.

• Verify that the rated voltage of the VS-656DC5 coincides with the rated voltage of

the Inverter to be connected.

Failure to observe this caution may result in a fire.

• Tighten terminal screws.

Failure to observe this caution may result in a fire.

E-11

 OPERATION

WARNING

(Ref. Page)

• Only turn ON the input power supply after attaching the front cover or the terminal

cover. Do not remove the cover while current is flowing.

Failure to observe this warning may result in an electric shock.

• Never operate the Digital Operator or other switches when your hand is wet.

Failure to observe this warning may result in an electric shock.

• Never touch the terminals while current is flowing, even if the VS-656DC5 stops.

Failure to observe this warning may result in an electric shock.

CAUTION

• Never touch the radiation fins (heatsink) or input reactor since the temperature is

very high.

Failure to observe this caution may result in harmful burns to the body.

• The VS-656DC5 is factory set to the suitable settings. Do not change the settings

unnecessarily.

E-30

(Ref. Page)

E-30

Failure to observe this caution may result in damage to the unit.

 MAINTENANCE AND INSPECTION

WARNING

(Ref. Page)

• Never touch high-voltage terminals in the VS-656DC5.

Failure to observe this warning may result in an electric shock.

• Perform maintenance or inspection only after verifying that the CHARGE LED goes

OFF, after the main circuit power supply is turned OFF.

The capacitors are still charged and can be dangerous.

• Only authorized personnel should be permitted to perform maintenance, inspec-

tions, or parts replacement.

[Remove all metal objects (watches, bracelets, etc.) before operation.] (Use tools which are insulated against electric shock.) Failure to observe this warning may result in an electric shock.

CAUTION

• A CMOS IC is used in the control board. Handle the control board and CMOS IC

carefully. The CMOS IC can be destroyed by static electricity if touched directly.

E-39

(Ref. Page)

E-39

The CMOS IC may be destroyed by static electricity if touched directly.

• Do not change the wiring, or connect/disconnect the connectors while power is

applied to the circuit.

Failure to observe this caution may result in personal injury.

 OTHERS

WARNING

• Never modify the product.

Failure to observe this warning may result in an electric shock or personal injury.

CAUTION

• Do not subject the VS-656DC5 to halogen gases, such as fiuorine, chlovine, bro-

mine, and iodine, at any time even during transportation or installation.

E-39

(Ref. Page)

E-39

(Ref. Page)

E-39

Otherwise, the VS-656DC5 can be damaged or interior parts burnt.

vii

 Warning Label Position

A warning label is displayed on the front cover of the VS-656DC5, as shown below. Follow

these instructions when handling the VS-656DC5.

Warning Label

WARNING − Risk of electric shock.

Read manual before installing.

Wait 5 minutes for capacitor discharge after disconnecting power supply.

Use proper grounding techniques.

AVERTISSMENT -

electrique.

Risque de decharge

Lisez le manuel avant installation.

Attendez 5 minutes apres la coupure de l’ alimentation electrique afin que les condensateurs soient completement decharges.

Soyez a la masse par une bonne technique.

NPJT31393-1-0

viii

WARRANTY INFORMATION

 Warranty Period

This product is warranted for twelve months after being delivered to Yaskawa’s customer or

if applicable eighteen months from the date of shipment from Yaskawa’s factory, whichever

comes first.

 Scope of Warranty

 Inspections

Periodic inspections must be conducted by the customer. However, upon request, Yaskawa

or one of Yaskawa’s Service Centers can inspect the product for a fee. In this case, if after

conferring with the customer, a Yaskawa product is found to be defective due to Yaskawa

workmanship or materials and the defect occurs during the warranty period, then this fee

will be waived and the problem remedied free of charge.

 Repairs

If a Yaskawa product is found to be defective due to Yaskawa workmanship or materials and

the defect occurs during the warranty period, Yaskawa will provide a replacement, repair the

defective product, and provide shipping to and from the site free of charge.

However, if the Yaskawa Authorized Service Center determines that the problem with a

Yaskawa product is not due to defects in Yaskawa’s workmanship or materials, then the cus-

tomer will be responsible for the cost of any necessary repairs. Some problems that are out-

side the scope of this warranty are:

• Problems due to improper maintenance or handling, carelessness, or other reasons where

the customer is determined to be responsible.

• Problems due to additions or modifications made to a Yaskawa product without

Yaskawa’s understanding.

• Problems due to the use of a Yaskawa product under conditions that do not meet the rec-

ommended specifications.

• Problems caused by natural disaster or fire.

• Or other problems not due to defects in Yaskawa workmanship or materials.

Warranty service is only applicable within Japan.

However, after-sales service is available for customers outside of Japan for a reasonable fee.

Contact your local Yaskawa representative for more information.

 Exceptions

Any inconvenience to the customer or damage to non-Yaskawa products due to Yaskawa's

defective products whether within or outside the warranty period are NOT covered by this

warranty.

RESTRICTIONS

• The VS-656DC5 was 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 or electric power, or under-

water use must contact their Yaskawa representatives or the nearest Yaskawa sales office

beforehand.

• 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 mini-

mize the likelihood of any accident.

INSTRUCTIONS

Varispeed-656DC5

1 RECEIVING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-3

1.1 Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-3

1.2 Nameplate Information - - - - - - - - - - - - - - - - - - - - - - - - - - - E-3

2 INSTALLATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-5

2.1 Checking Installation Site - - - - - - - - - - - - - - - - - - - - - - - - - E-5

2.2 Clearances - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-6

2.3 Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-7

2.4 Removing/Attaching the Digital Operator - - - - - - - - - - - - - - E-9

2.5 Removing/Attaching the Front Cover - - - - - - - - - - - - - - - - E-10

3 WIRING - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -E-11

3.1 Connection and Specifications of Peripheral Devices - - - - E-12

3.2 External Dimensions of Peripheral Devices - - - - - - - - - - - E-14

3.3 Interconnection Diagram with Varispeed G7 - - - - - - - - - - - E-18

3.4 Interconnection Diagram with VS-616G5 - - - - - - - - - - - - - E-20

3.5 Wiring Precautions - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-22

3.6 WIRING MAIN CIRCUIT TERMINALS - - - - - - - - - - - - - - - E-24

3.7 EXTERNAL TERMINALS - - - - - - - - - - - - - - - - - - - - - - - - E-28

4 OPERATION - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-30

4.1 Checkpoints before Turning ON the Power Supply - - - - - - E-30

4.2 Setting the Power Supply Voltage Jumper (For 400 V Class VS-656DC5 with 22 kW or More) - - - - - E-31

4.3 Using the Digital Operator - - - - - - - - - - - - - - - - - - - - - - - E-32

4.4 Power ON/OFF Sequence - - - - - - - - - - - - - - - - - - - - - - - E-38

E-1

5 MAINTENANCE AND INSPECTION - - - - - - - - - - - - - - - - E-39

5.1 Maintenance Period - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-39

5.2 Daily Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-40

5.3 Periodic Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-40

5.4 PERIODIC MAINTENANCE OF PARTS - - - - - - - - - - - - - E-41

6 TROUBLESHOOTING - - - - - - - - - - - - - - - - - - - - - - - - - -E-42

6.1 Fault Detection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-42

6.2 Minor Fault Detection - - - - - - - - - - - - - - - - - - - - - - - - - - - E-45

6.3 Operation Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-46

6.4 Informing the VS-656DC5 of a Peripheral Device Fault to Stop the VS-656DC5 (External Fault Function) - - - - - - E-47

7 SPECIFICATIONS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - E-48

Appendix A CONSTANTS LIST - - - - - - - - - - - - - - - - - - - - - E-50

A.1 Monitor Constant List - - - - - - - - - - - - - - - - - - - - - - - - - - E-50

A.2 Constant List Other Than Monitor Constants - - - - - - - - - - E-54

A.3 Multi-function I/O Terminals (H Constants) - - - - - - - - - - - E-57

Appendix B PRECAUTIONS ON VS-656DC5

APPLICATION - - - - - - - - - - - - - - - - - - - - - - - - E-58

E-2

1 RECEIVING

• Do not install or operate any VS-656DC5 which is damaged or has missing parts.

Failure to observe this caution may result in personal injury or equipment damage.

This chapter describes how to verify the VS-656DC5 after delivery to the user.

1.1 Checks

he VS-656DC5 model number

Does t correspond with the purchase order?

Are any parts damaged? Visually check the exterior and verify that there was no dam-

Are any screws or other components loose? Use a screwdriver or other tools to check for tightness.

1 RECEIVING

CAUTION

Table 1 Checks

Item Method

Check the model number on the nameplate on the side of the VS-656DC5. (Refer to page E-4.)

age during transport.

If any of the above items are not satisfactory, contact your YASKAWA representative.

1.2 Nameplate Information

 Nameplate Example

The following nameplate is an example for a standard domestic (Japan) VS-656DC5:

3-phase, 400 VAC, 30 kW, IEC IP00.

Converter Unit model

Input Specification

Output Specification

LOT number

Serial No.

MODEL CIMR-D5A4030

INPUT

OUTPUT SPEC SER NO

AC3PH 380 - 460V 50Hz

DC660V 60A

40300A

YASKAWA ELECTRIC CORPORATION MADE IN JAPAN

380-460V 60Hz

Fig. 1 Nameplate

64A

MASS: 33kg

Converter Unit specifications

Mass

E-3

 VS-656DC5 Model Number and Specifications

CIMR − 5AD 4 030 0

Converter Unit

VS-656DC5 series

Symbol

Specifications

Japan standard model

2 4

Voltage Class 3-phase, 200 V 3-phase, 400 V

Symbol

015 to 300

* Protected so that parts of the human body cannot reach electrically

charged parts from the front when the VS-656DC5 is mounted in a control panel.

Fig. 2 VS-656DC5 Model Number and Specifications

Protective Structure

Open chassis (IEC IP00)*

Max. Applicable Inverter Output

15 to 300 kW

E-4

2 INSTALLATION

• Lift the cabinet by the base. When moving the VS-656DC5, never lift by the front cover or the front

panel.

Otherwise, the main unit may be dropped causing personal injury or damage to the VS-656DC5.

• Mount the VS-656DC5 on nonflammable material (i.e. metal).

Failure to observe this caution may result in a fire.

• When mounting several Units in an enclosure, install a fan or other cooling device to keep the

intake air temperature below 45 °C.

Overheating may cause a fire or damage to the VS-656DC5.

2 INSTALLATION

CAUTION

This chapter describes the configuration, location, and space when mounting the VS-656DC5.

2.1 Checking Installation Site

 Installation Site

Install the VS-656DC5 under the following conditions.

Type Ambient Operating Temperature Humidity

Open chassis

To ensure proper performance and long operating life, follow the recommendations below

when choosing a location for installing the VS-656DC5. Make sure the VS-656DC5 is pro-

tected from the following conditions:

• Extreme cold and heat

Use only within ambient temperature range: -10 °C to +45 °C

• Rain, moisture

• Oil sprays, splashes

• Salt spray

• Direct sunlight (Avoid using outdoors.)

• Corrosive gases or liquids

• Dust or metallic particles in the air

• Physical shock, vibration

• Magnetic noise (Example: welding machines, power devices, etc.)

• High humidity

• Radioactive materials

• Combustibles: thinners, solvents, etc.

-10 to + 45 °C 90 % RH or less (no condensation)

E-5

 Controlling the Ambient Temperature

To enhance the reliability of operation, the VS-656DC5 should be installed in an environ-

ment free from extreme temperature increases. If the VS-656DC5 is installed in an enclosed

environment, such as a box, use a cooling fan or air conditioner to maintain the internal air

temperature below 45 °C.

 Protecting the VS-656DC5 from Foreign Matter

Place a cover over the VS-656DC5 during installation to shield it from metal powder pro-

duced by drilling.

Always remove the cover from the VS-656DC5 after completing installation. Otherwise,

ventilation will be reduced, causing the VS-656DC5 to overheat.

2.2 Clearances

Install the VS-656DC5 vertically and allow sufficient clearances for effective cooling as

shown in Fig. 3.

NOTE

50 mm or more

120 mm or more

30mm or more 30 mm

50 mm or more

(a) Front View (b) Side View

When installing the open chassis type of 200 V/400 V 30 kW or more, extra spacing will be required

on either side for eyebolts or main circuit wiring.

or more

Fig. 3 Clearances

120 mm or more

Air

E-6

2.3 Dimensions

 Models of 200 V/400 V 15 kW or Less

The following figure shows a 200 V 15 kW model.

DRIVE FWD REV REMOTE

SEQ REF

U1 01 = 00.00 HZ

DIGITAL OPERATOR JVOP - 130

LOCAL

REMOTE

JOG

FWD REV

RUN STOP

2 INSTALLATION

ESC

DATA

ENTER

RESET

4-d

Fig. 4 Dimensions of VS-656DC5

 Models of 200 V/400 V 22 kW or More

The following figure shows a 200 V 22 kW model.

DRIVEFWD REV REMOTE

SEQ REF

U1 01 = 00.00HZ

DIGITAL OPERATOR

JVOP - 130

LOCAL

ESC

REMOTE

DATA

JOG

ENTER

FWD REV

RESET

RUN STOP

4-d

E-7

Table 2 VS-656DC5 External Dimensions and Approx. Masses

Voltage

Class

VS-656DC5

Model

CIMR-

Open Chassis (IP00)

W H D W1 H1 H2 Approx.

D5A

200 V Class

2015

2022 325 450 285 275 435 7.5 23 M6

250 380 225 236 365 7.5 11 M6

2037 425 725 350 320 700 12.5 47 M10

475 800 350 370 775 12.5 65 M10

575 925 400 445 895 15.0 135 M12

400 V Class

2055

2075

4015 250 380 225 236 365 7.5 11 M6

4022 325 450 285 275 435 7.5 26 M6

4030 325 625 285 275 610 7.5 33 M6

4045 36 M6

4075 455 820 350 350 795 12.5 60 M10

4160 575 925 400 445 895 15.0 117 M12

4300

−

* Contact your YASKAWA representative. Note: An attachment is required to mount the cooling fins (fin section) on

the outside of the control panel for 200 V/400 V class VS-656DC5 of 15 kW or less. Contact your YASKAWA representative for details. For dimensional drawings for models with externally mounted cooling fins or other special requirements, contact your YASKAWA representative.

Mass

[kg]

Unit: mm

Mount-

ing

Hole d

E-8

2.4 Removing/Attaching the Digital Operator

Remove and attach the Digital Operator as follows.

 Removing the Digital Operator

2 INSTALLATION

Front cover

Digital Operator

Fig. 5 Removing the Digital Operator

 Attaching the Digital Operator

Digital Operator

Front cover

Push the Digital Operator lever in the direction shown by arrow 1 and lift the Digital Operator in the direction shown by arrow 2 to remove the Digital Operator from the front cover.

Attach the Digital Operator on claws A in

the direction shown by arrow 1 and then on claws B in the direction shown by arrow 2, to lock the Digital Operator.

Claws A

NOTE

Claws B

Fig. 6 Attaching the Digital Operator

Never attach the Digital Operator in any other direction or by any other method, as faulty contact may

result.

E-9

2.5 Removing/Attaching the Front Cover

 Models of 15 kW or Less

To remove the front cover, first remove the Digital Operator in the direction shown by arrow

1. (Refer to 2.4 Removing/Attaching the Digital Operator.) Then squeeze the cover in the

direction shown by arrows 2 on both sides and lift in the direction shown by arrow 3.

Front cover

Fig. 7 Removing/Attaching the Front Cover (15 kW or Less)

 Models of 22 kW or More

To remove the front cover, first remove the Digital Operator in the direction shown by arrow

1. (Refer to 2.4 Removing/Attaching the Digital Operator.)

Then loosen the four screws shown by arrow 2 and slide the front cover in the direction

shown by arrow 3.

NOTE

Fig. 8 Removing/Attaching the Front Cover (22 kW or More)

Do not attach the front cover with the Digital Operator connected, as faulty contact may result. Attach

the front cover first, and then attach the Digital Operator on the cover. Refer to 2.4 Removing/Attach-

ing the Digital Operator for attaching the Digital Operator.

E-10

3 WIRING

• Only commence wiring after verifying that the power supply is tunred OFF.

Failure to observe this warning may result in an electric shock or a fire.

• Wiring should be performed only by qualified personnel.

Failure to observe this warning may result in an electric shock or a fire.

• Make sure to ground the ground terminal before connecting the other terminals.

(200 V class: Ground to 100 Ω or less, 400 V class: Ground to 10 Ω or less).

Failure to boserve this warning may result in an electric shock or a fire.

3 WIRING

WARNING

CAUTION

• Verify that the VS-656DC5 rated voltage coincides with the AC power supply voltage.

Failure to observe this caution may result in personal injury or a fire.

• Do not perform a withstand voltage test of the VS-656DC5.

Failure to observe this caution may result in damage to the semi-conductor elements.

• Connect the input AC reactor, harmonics filter reactor, and the harmonics filter capacitor as

described in this instruciton manual.

Failure to observe this caution may result in a fire.

• Verify that the rated voltage of the VS-656DC5 coincides with the rated voltage of the Inverter to be

connected.

Failure to observe this caution may result in a fire.

• Tighten terminal screws.

Failure to observe this caution may result in a fire.

E-11

MCCB

3.1 Connection and Specifications of Peripheral Devices

 Connection

PWM transistor converter VS-656DC5

Input AC

reactor

R/L1

S/L2

T/L3

PWM inverter

Reactor

Capacitor

UVW

X Y Z

Harmonics

filter

RUN-SB

STOP

External fault

Fault reset

Multi-function contact input

External base block

r1/

t1/

+24V

Sequence common

Shielded sheath

connection terminal

Digital Operator JVOP-130

Multi-function

analog

monitor

Grounding

C RUN

250 VAC 1 A or less 30 VDC 1A or less

During MC motion

C READY

Fault contact output

250 VAC 1 A or less 30 VDC 1A or less

Open-collector

output

48 VDC 50 mA or

less

Input power monitor

(-10 to +10V)

Input current monitor

(-10 to +10V) Multi-function analog output common

* 1. Be sure to attach the input AC reactor (reactor) and harmonics filter (capacitor). * 2. For models CIMR-D5A2022 to -D5A2075 of the 200 V Class and CIMR- D5A4022 to

-D5A4300 of the 400 V Class, the wiring was done prior to shipment. Connections are not needed for CIMR-D5A2015 and -D5A4015.

The terminals r/

and /2 in the above diagram are the terminal names for 200 V Class

VS-656DC5 with 37 to 75 kW. The terminal names are as follows respectively for each VS656DC5 capacity: y 200 V Class 22 kW, 400 V Class 22 to 45 kW: /2, t/3

and 1/21, t/3 and t1/31 are

connected respectively.)

y 400 V Class 75 and 160 kW: r/

, 400/2400

* 3. When a noise filter is attached on the VS-656DC5 power supply side, use a noise filter of the

reactor type (without a capacitor) such as finemet zero-phase reactor, and attach it behind the MCCB at the power supply side. Do not use a capacitor-built-in type noise filter since the harmonic components may overheat or damage the capacitor.

E-12

+ 49 hidden pages