YASKAWA CIMR-G7A21P5, Varispeed G7, CIMR-G7A22P2, CIMR-G7A23P7, CIMR-G7A25P5 Instruction Manual

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Page 1

YASKAWA

Varispeed G7

INSTRUCTION MANUAL

GENERAL PURPOSE INVERTER (ADVANCED VECTOR CONTROL)

MODEL: CIMR-G7A

200V CLASS 0.4 to 110kW (1.2 to 160kVA) 400V CLASS 0.4 to 300kW (1.4 to 460kVA)

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. TOE-S616-60.1D

Page 2

Preface

This manual is designed to ensure correct and suitable application of Varispeed G7-Series Inverters. Read this manual before attempting to install, operate, maintain, or inspect an Inverter and keep it in a safe, convenient location for future reference. Be sure you understand all precautions and safety information before attempting application.

General Precautions

• The diagrams in this manual may be indicated without covers or safety shields to show details. Be sure to restore covers or shields before operating the Units and run the Units 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 representatives or the nearest Yaskawa sales office and provide the manual number shown on the front cover.

• If nameplates become warn or damaged, order new ones from your Yaskawa representatives or the nearest Yaskawa sales office.

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Safety Information

The following conventions are used to indicate precautions in this manual. Failure to heed precautions provided in this manual can result in serious or possibly even fatal injury or damage to the products or to related equipment and systems.

WARNING

CAUTION

IMPORTANT

Indicates precautions that, if not heeded, could possibly result in loss of life or serious injury.

Indicates precautions that, if not heeded, could result in relatively serious or minor injury, damage to the product, or faulty operation.

Failure to heed a precaution classified as a caution can result in serious consequences depending on the situation.

Indicates important information that should be memorized.

Page 4

Safety Precautions

 Confirmations upon Delivery

• Never install an Inverter that is damaged or missing components.

Doing so can result in injury.

 Installation

• Always hold the case when carrying the Inverter.

If the Inverter is held by the front cover, the main body of the Inverter may fall, possibly resulting in injury.

• Attach the Inverter to a metal or other noncombustible material.

Fire can result if the Inverter is attached to a combustible material.

• Install a cooling fan or other cooling device when installing more than one Inverter in the same enclosure so that the temperature of the air entering the Inverters is below 45°C.

Overheating can result in fires or other accidents.

CAUTION

 Wiring

• Always turn OFF the input power supply before wiring terminals.

• Wiring must be performed by an authorized person qualified in electrical work.

• Be sure to ground the ground terminal. (200 V Class: Ground to 100 Ω or less, 400 V Class:

• Always check the operation of any emergency stop circuits after they are wired.

• Never touch the output terminals directly with your hands or allow the output lines to come into con-

• If the power supply is turned ON during the FWD (or REV) Run Command is given, the motor will

• When the 3-wire sequence is set, do not make the wiring for the control circuit unless the multi-

WARNING

Otherwise, an electric shock or fire can occur.

Ground to 10 Ω or less)

Otherwise, an electric shock or fire can occur.

Otherwise, there is the possibility of injury. (Wiring is the responsibility of the user.)

tact with the Inverter case. Never short the output circuits.

Otherwise, an electric shock or ground short can occur.

start automatically. Turn the power supply ON after verifying that the RUN signal is OFF.

Failure to observe this warning may result in injury.

function input terminal constant is set.

Failure to observe this warning may result in injury.

CAUTION

• Check to be sure that the voltage of the main AC power supply satisfies the rated voltage of the Inverter.

Injury or fire can occur if the voltage is not correct.

• Do not perform voltage withstand tests on the Inverter.

Otherwise, semiconductor elements and other devices can be damaged.

• Connect braking resistors, Braking Resistor Units, and Braking Units as shown in the I/O wiring examples.

Otherwise, a fire can occur.

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• Tighten all terminal screws to the specified tightening torque.

Otherwise, a fire may occur.

• Do not connect AC power to output terminals U, V, and W.

The interior parts of the Inverter will be damaged if voltage is applied to the output terminals.

• Do not connect phase-advancing capacitors or LC/RC noise filters to the output circuits.

The Inverter can be damaged or interior parts burnt if these devices are connected.

• Do not connect electromagnetic switches or magnetic contactors to the output circuits.

If a load is connected while the Inverter is operating, surge current will cause the overcurrent protection circuit inside the Inverter to operate.

 Setting User Constants

• Disconnect the load (machine, device) from the motor before performing rotational autotuning.

The motor may turn, possibly resulting in injury or damage to equipment. Also, motor constants cannot be correctly set with the motor attached to a load.

• Stay clear of the motor during rotational autotuning.

The motor may start operating suddenly when stopped, possibly resulting in injury.

 Trial Operation

CAUTION

WARNING

• Check to be sure that the front cover is attached before turning ON the power supply.

An electric shock may occur.

• Do not come close to the machine when the fault reset function is used. If the alarmed is cleared, the machine may start moving suddenly.

Also, design the machine so that human safety is ensured even when it is restarted. Injury may occur.

• Provide a separate emergency stop switch; the Digital Operator STOP Key is valid only when its function is set.

Injury may occur.

• Reset alarms only after confirming that the RUN signal is OFF.

Injury may occur.

CAUTION

• Don't touch the radiation fins (heatsink), braking resistor, or Braking Resistor Unit. These can become very hot.

Otherwise, a burn injury may occur.

• Be sure that the motor and machine is within the applicable ranges before starting operation.

Otherwise, an injury may occur.

• Provide a separate holding brake if necessary. Always construct the external sequence to confirm that the holding brake is activated in the event of an emergency, a power failure, or an abnormality in the Inverter.

Failure to observe this caution can result in injury.

• If using an Inverter with an elevator, take safety measures on the elevator to prevent the elevator from dropping.

Failure to observe this caution can result in injury.

• Don't check signals while the Inverter is running.

Otherwise, the equipment may be damaged.

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• Be careful when changing Inverter settings. The Inverter is factory set to suitable settings.

Otherwise, the equipment may be damaged.

 Maintenance and Inspection

• Do not touch the Inverter terminals. Some of the terminals carry high voltages and are extremely dangerous.

Doing so can result in electric shock.

• Always have the protective cover in place when power is being supplied to the Inverter. When attaching the cover, always turn OFF power to the Inverter through the MCCB.

Doing so can result in electric shock.

• After turning OFF the main circuit power supply, wait until the CHARGE indicator light goes out before performing maintenance or inspections.

The capacitor will remain charged and is dangerous.

• Maintenance, inspection, and replacement of parts must be performed only by authorized personnel.

Remove all metal objects, such as watches and rings, before starting work. Always use grounded tools. Failure to heed these warning can result in electric shock.

• For 400-V class Inverters of 55 kW to 300 kW with SPEC E or later, take safety measures such as the installation of an emergency-stop switch before adjusting constants.

Failure to do so may result in injury caused by the motor accidentally rotating during stationary autotuning performed by the Inverter when the constants are adjusted.

CAUTION

WARNING

 Other

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.

• Do not change the wiring, or remove connectors or the Digital Operator, during operation.

Doing so can result in personal injury.

WARNING

• Do not attempt to modify or alter the Inverter.

Doing so can result in electrical shock or injury.

CAUTION

• Do not subject the Inverter to halogen gases, such as fluorine, chlorine, bromine, and iodine, at any time even during transportation or installation.

Otherwise, the Inverter can be damaged or interior parts burnt.

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Warning Information and Position

There is warning information on the Inverter in the position shown in the following illustration. Always heed the warnings.

Warning information position

Illustration shows the CIMR-G7A20P4

Warning Information

WARNING

Risk of electric shock.

yRead manual before installing. yWait 5 minutes for capacitor discharge

after disconnecting power supply.

AVERTISSEMENT

Risque de décharge électrique.

yLire le manuel avant l' installation. yAttendre 5 minutes aprés la coupure de

l' allmentation. Pour permettre la décharge des condensateurs.

Illustration shows the CIMR-G7A2018

Page 8

Warranty Information

 Free Warranty Period and Scope

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 customer will be responsible for the cost of any necessary repairs. Some problems that are outside 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 recom-

mended 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 Varispeed G7 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 underwater 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 minimize the likelihood of any accident.

vii

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Registered Trademarks

The following registered trademarks are used in this manual.

• DeviceNet is a registered trademark of the ODVA (Open DeviceNet Vendors Association,

Inc.).

• InterBus is a registered trademark of Phoenix Contact Co.

• ControlNet is a registered trademark of ControlNet International, Ltd.

• LONWORKS is a registered trademark of the Echelon.

Before Reading This Manual

There are places in this manual where the constants and explanations depend on the software version. Explanations for both old and new versions are provided. Parts that are shaded and parts where “PRG: 102 only” appears apply to G7-series Inverters with software version PRG: 102 and later. Parts where “PRG: 103 only” appears apply only to G7-series Inverters with software version PRG: 103. Be sure to confirm the PRG number on the Inverter’s nameplate. An example is given below.

Inverter model

Input specifications

Output specifications

Lot number

Serial number

UL file number

UL FILE NO.: E131457

1020

Inverter specifications

Mass

Version of software

viii

Page 10

1 Handling Inverters .................................................................. 1-1

Varispeed G7 Introduction ............................................................................1-2



Varispeed G7 Models .....................................................................................................1-2

Confirmations upon Delivery ........................................................................1-3



Checks............................................................................................................................1-3

 Nameplate Information ...................................................................................................1-3

 Component Names......................................................................................................... 1-5

Exterior and Mounting Dimensions...............................................................1-7



Open Chassis Inverters (IP00) .......................................................................................1-7

 Enclosed Wall-mounted Inverters [NEMA1 (Type 1)] .....................................................1-8

Checking and Controlling the Installation Site ............................................1-10



Installation Site .............................................................................................................1-10

 Controlling the Ambient Temperature ...........................................................................1-10

 Protecting the Inverter from Foreign Matter..................................................................1-10

Installation Orientation and Space .............................................................. 1-11

Removing and Attaching the Terminal Cover .............................................1-12



Removing the Terminal Cover ......................................................................................1-12

 Attaching the Terminal Cover........................................................................................1-12

Removing/Attaching the Digital Operator and Front Cover ........................1-13



Inverters of 15 kW or Less............................................................................................1-13

 Inverters of 18.5 kW or More ........................................................................................1-16

Removing and Attaching the Protection Cover...........................................1-17



Removing the Protection Cover....................................................................................1-17

 Attaching the Protection Cover.....................................................................................1-18

2 Wiring....................................................................................... 2-1

Connections to Peripheral Devices ..............................................................2-2

Connection Diagram.....................................................................................2-3

Terminal Block Configuration ........................................................................2-5

Wiring Main Circuit Terminals .......................................................................2-6



Applicable Wire Sizes and Closed-loop Connectors ......................................................2-6

 Main Circuit Terminal Functions ...................................................................................2-13

 Main Circuit Configurations...........................................................................................2-14

 Standard Connection Diagrams....................................................................................2-15

 Wiring the Main Circuits................................................................................................2-16

Wiring Control Circuit Terminals .................................................................2-22

Page 11

 Wire Sizes and Closed-loop Connectors...................................................................... 2-22

 Control Circuit Terminal Functions ............................................................................... 2-24

 Control Circuit Terminal Connections........................................................................... 2-28

 Control Circuit Wiring Precautions ............................................................................... 2-29

Wiring Check.............................................................................................. 2-30



Checks ......................................................................................................................... 2-30

Installing and Wiring Option Boards........................................................... 2-31



Option Board Models and Specifications...................................................................... 2-31

 Installation ....................................................................................................................2-31

 PG Speed Control Board Terminals and Specifications ............................................... 2-32

 Wiring ........................................................................................................................... 2-34

 Wiring Terminal Blocks................................................................................................. 2-38

 Selecting the Number of PG (Encoder) Pulses............................................................ 2-39

3 Digital Operator and Modes....................................................3-1

Digital Operator ............................................................................................ 3-2



Digital Operator Display ................................................................................................. 3-2

 Digital Operator Keys ..................................................................................................... 3-2

Modes .......................................................................................................... 3-4



Inverter Modes ............................................................................................................... 3-4

 Switching Modes ............................................................................................................ 3-5

 Drive Mode ..................................................................................................................... 3-6

 Quick Programming Mode.............................................................................................. 3-7

 Advanced Programming Mode....................................................................................... 3-9

 Verify Mode .................................................................................................................. 3-12

 Autotuning Mode .......................................................................................................... 3-13

4 Trial Operation .........................................................................4-1

Trial Operation Procedure............................................................................ 4-2

Trial Operation Procedures .......................................................................... 4-3



Setting the Power Supply Voltage Jumper (400 V Class Inverters of 55 kW or Higher) 4-3

 Power ON....................................................................................................................... 4-3

 Checking the Display Status .......................................................................................... 4-4

 Basic Settings.................................................................................................................4-5

 Settings for the Control Methods.................................................................................... 4-7

 Autotuning ......................................................................................................................4-9

 Application Settings......................................................................................................4-15

 No-load Operation ........................................................................................................ 4-15

 Loaded Operation......................................................................................................... 4-15

 Check and Recording User Constants ......................................................................... 4-16

Adjustment Suggestions ............................................................................ 4-17

Page 12

5 User Constants ....................................................................... 5-1

User Constant Descriptions..........................................................................5-2



Description of User Constant Tables ..............................................................................5-2

Digital Operation Display Functions and Levels ...........................................5-3

User Constants Settable in Quick Programming Mode ..................................................5-4



User Constant Tables ...................................................................................5-8

A: Setup Settings............................................................................................................5-8



 Application Constants: b...............................................................................................5-10

 Autotuning Constants: C...............................................................................................5-21

 Reference Constants: d ................................................................................................5-27

 Motor Constant Constants: E........................................................................................5-33

 Option Constants: F......................................................................................................5-39

 Terminal Function Constants: H ...................................................................................5-46

 Protection Function Constants: L..................................................................................5-58

 N: Special Adjustments.................................................................................................5-68

 Digital Operator Constants: o........................................................................................5-72

 T: Motor Autotuning ......................................................................................................5-76

 U: Monitor Constants ....................................................................................................5-77

 Factory Settings that Change with the Control Method (A1-02) ...................................5-86

 Factory Settings that Change with the Inverter Capacity (o2-04) ................................. 5-89

6 Constant Settings by Function.............................................. 6-1

Frequency Reference ...................................................................................6-2



Selecting the Frequency Reference Source ...................................................................6-2

 Using Multi-Step Speed Operation .................................................................................6-5

Run Command .............................................................................................6-8



Selecting the Run Command Source .............................................................................6-8

Stopping Methods.......................................................................................6-10



Selecting the Stopping Method when a Stop Command is Sent...................................6-10

 Using the DC Injection Brake........................................................................................6-14

 Using an Emergency Stop ............................................................................................6-15

Acceleration and Deceleration Characteristics...........................................6-16



Setting Acceleration and Deceleration Times...............................................................6-16

 Accelerating and Decelerating Heavy Loads (Dwell Function) ..................................... 6-20

 Preventing the Motor from Stalling During Acceleration

(Stall Prevention During Acceleration Function) ...........................................................6-21

 Preventing Overvoltage During Deceleration

(Stall Prevention During Deceleration Function)...........................................................6-23

 Preventing Overvoltage by Automatically Reducing the Regenerative Torque Limit

(Overvoltage Inhibit Function, PRG: 102 only) ..........................................................6-24

Adjusting Frequency References ...............................................................6-26



Adjusting Analog Frequency References .....................................................................6-26

 Operation Avoiding Resonance (Jump Frequency Function) .......................................6-29

 Adjusting Frequency Reference Using Pulse Train Inputs ...........................................6-31

Page 13

Speed Limit (Frequency Reference Limit Function) ...................................6-32



Limiting Maximum Output Frequency........................................................................... 6-32

 Limiting Minimum Frequency ....................................................................................... 6-32

Improved Operating Efficiency ................................................................... 6-34



Reducing Motor Speed Fluctuation (Slip Compensation Function).............................. 6-34

 Compensating for Insufficient Torque at Startup and Low-speed Operation

(Torque Compensation) ................................................................................................6-36

 Hunting-prevention Function ........................................................................................ 6-38

 Stabilizing Speed (Speed Feedback Detection Function) ............................................ 6-39

Machine Protection ....................................................................................6-40



Reducing Noise and Leakage Current ......................................................................... 6-40

 Limiting Motor Torque (Torque Limit Function) ............................................................ 6-44

 Preventing Motor Stalling During Operation ................................................................. 6-47

 Changing Stall Prevention Level during Operation Using an Analog Input .................. 6-48

 Using Frequency Detection: L4-01 to L4-05................................................................. 6-48

 Detecting Motor Torque ................................................................................................ 6-51

 Changing Overtorque and Undertorque Detection Levels Using an Analog Input ....... 6-54

 Motor Overload Protection ........................................................................................... 6-55

 Setting Motor Protection Operation Time ..................................................................... 6-57

 Motor Overheating Protection Using PTC Thermistor Inputs ....................................... 6-58

 Limiting Motor Rotation Direction ................................................................................. 6-60

Continuing Operation ................................................................................. 6-61



Restarting Automatically After Power Is Restored........................................................ 6-61

 Speed Search............................................................................................................... 6-62

 Continuing Operation at Constant Speed When Frequency Reference Is Lost ........... 6-69

 Restarting Operation After Transient Fault (Auto Restart Function) ............................ 6-70

Inverter Protection...................................................................................... 6-71



Performing Overheating Protection on Mounted Braking Resistors ............................. 6-71

 Reducing Inverter Overheating Pre-Alarm Warning Levels ......................................... 6-72

Input Terminal Functions ............................................................................6-73



Temporarily Switching Operation between Digital Operator

and Control Circuit Terminals ....................................................................................... 6-73

 Blocking Inverter Outputs (Baseblock Commands)...................................................... 6-74

 Stopping Acceleration and Deceleration (Acceleration/Deceleration Ramp Hold)....... 6-75

 Raising and Lowering Frequency References Using Contact Signals (UP/DOWN) .... 6-76

 Accelerating and Decelerating Constant Frequencies in the Analog References

(+/- Speed) ................................................................................................................... 6-79

 Hold Analog Frequency Using User-set Timing ........................................................... 6-80

 Switching Operations between a Communications Option Board and Control Circuit

Terminals ...................................................................................................................... 6-80

 Jog Frequency Operation without Forward and Reverse Commands (FJOG/RJOG) . 6-81  Stopping the Inverter by Notifying Programming Device Errors to the Inverter

(External Fault Function) .............................................................................................. 6-82

xii

Output Terminal Functions ......................................................................... 6-83

Page 14

Monitor Constants.......................................................................................6-85



Using the Analog Monitor Constants ............................................................................6-85

 Using Pulse Train Monitor Contents .............................................................................6-87

Individual Functions....................................................................................6-89



Using MEMOBUS Communications .............................................................................6-89

 Using the Timer Function............................................................................................6-101

 Using PID Control .......................................................................................................6-102

 Energy-saving.............................................................................................................6-111

 Setting Motor Constants .............................................................................................6-113

 Setting the V/f Pattern.................................................................................................6-116

 Torque Control............................................................................................................6-123

 Speed Control (ASR) Structure...................................................................................6-131

 Increasing the Speed Reference Response (Feed Forward Control).........................6-137

 Droop Control Function...............................................................................................6-138

 Zero-servo Function....................................................................................................6-140

Digital Operator Functions........................................................................6-143



Setting Digital Operator Functions..............................................................................6-143

 Copying Constants .....................................................................................................6-146

 Prohibiting Writing Constants from the Digital Operator .............................................6-150

 Setting a Password.....................................................................................................6-151

 Displaying User-set Constants Only ...........................................................................6-152

Options .....................................................................................................6-153



Performing Speed Control with PG.............................................................................6-153

 Using Digital Output Boards .......................................................................................6-157

 Using an Analog Reference Board .............................................................................6-159

 Using a Digital Reference Board ................................................................................6-160

Using Inverters for Elevating Machines ....................................................6-165



Brake ON/OFF Sequence...........................................................................................6-165

 Stall Prevention during Deceleration...........................................................................6-167

 Autotuning...................................................................................................................6-167

 Braking Resistor Overheating Protection....................................................................6-167

 Momentary Power Loss Restart .................................................................................6-167

 Torque Limit ................................................................................................................6-167

 I/O Open-phase Protection and Overtorque Detection ...............................................6-168

 External Baseblock Signal..........................................................................................6-168

 Acceleration/Deceleration Time..................................................................................6-168

 Magnetic Contactor on the Inverter’s Output-side ......................................................6-168

 Control-related Adjustments .......................................................................................6-169

 Reducing Shock during Elevating Machine Start, Stop, Acceleration,

and Deceleration.........................................................................................................6-171

 Confirming Startup Current and Reducing Carrier Frequency.................................... 6-174

 Overvoltage Inhibit Function.......................................................................................6-174

xiii

Page 15

7 Troubleshooting ......................................................................7-1

Protective and Diagnostic Functions............................................................ 7-2



Fault Detection ............................................................................................................... 7-2

 Alarm Detection............................................................................................................ 7-11

 Operation Errors........................................................................................................... 7-15

 Errors During Autotuning............................................................................................. 7-17

 Errors when Using the Digital Operator Copy Function................................................ 7-18

Troubleshooting.......................................................................................... 7-19



If Constant Constants Cannot Be Set........................................................................... 7-19

 If the Motor Does Not Operate ..................................................................................... 7-20

 If the Direction of the Motor Rotation is Reversed........................................................ 7-22

 If the Motor Does Not Put Out Torque or If Acceleration is Slow.................................. 7-22

 If the Motor Operates Higher Than the Reference ....................................................... 7-22

 If the Slip Compensation Function Has Low Speed Precision ..................................... 7-23

 If There is Low Speed Control Accuracy at High-speed Rotation

in Open-loop Vector Control Method ............................................................................ 7-23

 If Motor Deceleration is Slow........................................................................................ 7-23

 If the Motor Overheats.................................................................................................. 7-24

 If There is Noise When the Inverter is Started or From an AM Radio .......................... 7-25

 If the Ground Fault Interrupter Operates When the Inverter is Run ............................. 7-25

 If There is Mechanical Oscillation................................................................................. 7-25

 If the Torque Generated for the Motor is Insufficient (Insufficient Power)..................... 7-27

 If the Torque Reference (U1-09) at Low Speeds in Open-loop Vector 2 Control

is Large Compared to That at Medium and High Speeds ............................................ 7-27

 If Shock Occurs Near the Speed Estimator Switching Frequency

in Open-loop Vector 2 Control (PRG: 102 only)........................................................ 7-27

 If Torque Ripple Occurs at Very Low Speeds in Open-loop Vector 2 Control

(PRG: 102 only) ........................................................................................................ 7-28

 If the Motor Rotates Even When Inverter Output is Stopped ....................................... 7-28

 If OV is Detected When the Fan is Started, or Fan Stalls............................................. 7-28

 If Output Frequency Does Not Rise to Frequency Reference ...................................... 7-28

xiv

8 Maintenance and Inspection ..................................................8-1

Maintenance and Inspection ........................................................................ 8-2



Outline of Warranty......................................................................................................... 8-2

 Daily Inspection .............................................................................................................. 8-2

 Periodic Inspection ......................................................................................................... 8-2

 Periodic Maintenance of Parts ....................................................................................... 8-3

 Procedure for Adjusting Constants after Replacement of Control Board ....................... 8-3

 Types and Number of Cooling Fans Used in the Drive .................................................. 8-5

 Cooling Fan Replacement Outline ................................................................................. 8-6

 Circulation Fan Replacement Outline........................................................................... 8-13

 Removing and Mounting the Control Circuit Terminal Board ....................................... 8-16

Page 16

9 Specifications ......................................................................... 9-1

Standard Inverter Specifications...................................................................9-2



Specifications by Model ..................................................................................................9-2

 Common Specifications ..................................................................................................9-4

Specifications of Options and Peripheral Devices ........................................9-6

10 Appendix ............................................................................... 10-1

Varispeed G7 Control Methods ..................................................................10-2



Control Methods and Features .....................................................................................10-2

 Control Methods and Applications ................................................................................10-4

Inverter Application Precautions.................................................................10-6



Selection ....................................................................................................................... 10-6

 Installation..................................................................................................................... 10-7

 Settings.........................................................................................................................10-7

 Handling........................................................................................................................10-8

Motor Application Precautions....................................................................10-9



Using the Inverter for an Existing Standard Motor........................................................10-9

 Using the Inverter for Special Motors..........................................................................10-10

 Power Transmission Mechanism (Speed Reducers, Belts, and Chains)....................10-10

Wiring Examples.......................................................................................10-11



Using a Braking Resistor Unit..................................................................................... 10-11

 Using a Braking Unit and Braking Resistor Unit .........................................................10-12

 Using Braking Units in Parallel ...................................................................................10-13

 Using a Braking Unit and Three Braking Resistor Units in Parallel ............................10-14

 Using a VS Operator...................................................................................................10-15

 Using Transistors for Input Signals and a 0-V Common in Sinking Mode

with an Internal Power Supply ....................................................................................10-16

 Using Transistors for Input Signals and a +24-V Common in Sourcing Mode............ 10-17

 Using Transistors for Input Signals and a 0-V Common in Sinking Mode

with an External Power Supply ...................................................................................10-18

 Using Contact and Open Collector Outputs................................................................10-19

User Constants.........................................................................................10-20

Page 17

Handling Inverters

This chapter describes the checks required upon receiving or installing an Inverter.

Varispeed G7 Introduction ........................................... 1-2

Confirmations upon Delivery........................................ 1-3

Exterior and Mounting Dimensions..............................1-7

Checking and Controlling the Installation Site ...........1-10

Installation Orientation and Space ............................. 1-11

Removing and Attaching the Terminal Cover ............1-12

Removing/Attaching the Digital Operator and Front

Cover .........................................................................1-13

Removing and Attaching the Protection Cover.......... 1-17

Page 18

Varispeed G7 Introduction

 Varispeed G7 Models

The Varispeed-G7 Series of Inverters included two Inverters in two voltage classes: 200 V and 400 V. Maximum

motor capacities vary from 0.4 to 300 kW (41 models).

Table 1.1 Varispeed G7 Models

Voltage

Class

200 V Class

400 V Class

Maximum

Motor

Capacity

0.4 1.2 CIMR-G7A20P4

0.75 2.3 CIMR-G7A20P7 20P71

1.5 3.0 CIMR-G7A21P5 21P51

2.2 4.6 CIMR-G7A22P2 22P21

3.7 6.9 CIMR-G7A23P7 23P71

5.5 10 CIMR-G7A25P5 25P51

7.5 13 CIMR-G7A27P5 27P51 11 19 CIMR-G7A2011 2011 15 25 CIMR-G7A2015 20151

18.5 30 CIMR-G7A2018 20180 20181 22 37 CIMR-G7A2022 20220 20221 30 50 CIMR-G7A2030 20300 20301 37 61 CIMR-G7A2037 20370 20371 45 70 CIMR-G7A2045 20450 20451 55 85 CIMR-G7A2055 20550 20551 75 110 CIMR-G7A2075 20750 20751 90 140 CIMR-G7A2090 20900 -

110 160 CIMR-G7A2110 21100 -

0.4 1.4 CIMR-G7A40P4

0.75 2.6 CIMR-G7A40P7 40P71

1.5 3.7 CIMR-G7A41P5 41P51

2.2 4.7 CIMR-G7A42P2 42P21

3.7 6.9 CIMR-G7A43P7 43P71

5.5 11 CIMR-G7A45P5 45P51

7.5 16 CIMR-G7A47P5 47P51 11 21 CIMR-G7A4011 40111 15 26 CIMR-G7A4015 40151

18.5 32 CIMR-G7A4018 40180 40181 22 40 CIMR-G7A4022 40220 40221 30 50 CIMR-G7A4030 40300 40301 37 61 CIMR-G7A4037 40370 40371 45 74 CIMR-G7A4045 40450 40451 55 98 CIMR-G7A4055 40550 40551 75 130 CIMR-G7A4075 40750 40751 90 150 CIMR-G7A4090 40900 40901

110 180 CIMR-G7A4110 41100 41101 132 210 CIMR-G7A4132 41320 41321 160 250 CIMR-G7A4160 41600 41601 185 280 CIMR-G7A4185 41850 - 220 340 CIMR-G7A4220 42200 - 300 460 CIMR-G7A4300 43000 -

Output

Capacity

kVA

Varispeed G7

Basic Model Number

(Always specify through the protective structure when ordering.)

Open Chassis

(IEC IP00)

CIMR-G7

Remove the top and bottom cov-

ers from the Enclosed Wall-

mounted model.

Remove the top and bottom cov-

ers from the Enclosed Wall-

mount model.

Specifications

Enclosed Wall-mounted

[IEC IP20, NEMA 1 (Type 1)]

CIMR-G7A

20P41

40P41

1-2

Page 19

Confirmations upon Delivery

 Checks

Check the following items as soon as the Inverter is delivered.

Table 1.2 Checks

Item Method

Has the correct model of Inverter been delivered?

Check the model number on the nameplate on the side of the Inverter.

Confirmations upon Delivery

Is the Inverter damaged in any way?

Are any screws or other components loose?

Inspect the entire exterior of the Inverter to see if there are any scratches or other damage resulting from shipping.

Use a screwdriver or other tools to check for tightness.

If you find any irregularities in the above items, contact the agency from which you purchased the Inverter or your Yaskawa representative immediately.

 Nameplate Information

There is a nameplate attached to the side of each Inverter. The nameplate shows the model number, specifications, lot number, serial number, and other information on the Inverter.

 Example Nameplate

The following nameplate is an example for a standard domestic (Japan) Inverter: 3-phase, 200 VAC, 0.4 kW, IEC IP20 and NEMA 1 (Type 1) standards

Inverter model

Input specifications

Output specifications

Lot number

Serial number

1020

Inverter specifications

Mass

Version of software

UL file number

UL FILE NO.: E131457

Fig 1.1 Nameplate

1-3

Page 20

Inverter Model Numbers

The model number of the Inverter on the nameplate indicates the specification, voltage class, and maximum motor capacity of the Inverter in alphanumeric codes.

CIMR - G7 A 2 0P4

Inverter

Varispeed G7

No.

Specification

Standard domestic model

Voltage Class

AC input, 3-phase, 200 V

AC input, 3-phase, 400 V

0P4 0P7

300

"P" indicates the decimal point.

Fig 1.2 Inverter Model Numbers

Max. Motor Capacity

No.

0.4 kW

0.75 kW to

300 kW

Inverter Specifications

The Inverter specifications (“SPEC”) on the nameplate indicate the voltage class, maximum motor capacity, the protective structure, and the revision of the Inverter in alphanumeric codes.

2 0P4 1

No.

Voltage Class

AC input, 3-phase, 200 V

AC input, 3-phase, 400 V

TERMS

Max. Motor Capacity

No. 0P4 0P7

to 300

"P" indicates the decimal point.

0.4 kW

0.75 kW to

300 kW

No.

Protective Structure

Open chassis (IEC IP00)

Enclosed wall-mounted [IEC IP20,

NEMA 1 (Type 1)]

Fig 1.3 Inverter Specifications

Open Chassis Type (IEC IP00)

Protected so that parts of the human body cannot reach electrically charged parts from the front when the Inverter is mounted in a control panel.

Enclosed Wall-mounted Type [IEC IP20, NEMA 1 (Type 1)]

The Inverter is structured so that the Inverter is shielded from the exterior, and can thus be mounted to the interior wall of a standard building (not necessarily enclosed in a control panel). The protective structure conforms to the standards of NEMA 1 (Type 1) in the USA. The protective covers (see Fig. 1.4) are required for an IEC IP20 or NEMA 1 (Type 1) protective structure.

1-4

Page 21

Confirmations upon Delivery

 Component Names

 Inverters of 15 kW or Less

The external appearance and component names of the Inverter are shown in Fig 1.4. The Inverter with the terminal cover removed is shown in Fig 1.5.

Top protective cover

Front cover

Digital Operator

Terminal cover

Fig 1.4 Inverter Appearance (15 kW or Less)

Mounting hole

Diecast case

Nameplate

Bottom protective cover

Control circuit terminals

Fig 1.5 Terminal Arrangement (15 kW or Less)

Main circuit terminals

Charge indicator

Ground terminal

1-5

Page 22

 Inverters of 18.5 kW or More

The external appearance and component names of the Inverter are shown in Fig 1.6. The Inverter with the terminal cover removed is shown in Fig 1.7.

Mounting holes

Inverter cover

Control circuit terminals

Main circuit terminals

Front cover

Digital Operator

Terminal cover

Cooling fan

Nameplate

Fig 1.6 Inverter Appearance (18.5 kW or More)

Charge indicator

Ground terminal

Fig 1.7 Terminal Arrangement (18.5 kW or More)

1-6

Page 23

Exterior and Mounting Dimensions

 Open Chassis Inverters (IP00)

Exterior diagrams of the Open Chassis Inverters are shown below.

Exterior and Mounting Dimensions

200 V/400 V Class Inverters of 0.4 to 15 kW

4-d

H1H2DH

6-d

(5)*

* (10) for 200 V Class Inverters of 30 to 110 kW or 400 V Class Inverters of 55 to 160 kW.

200 V Class Inverters of 18.5 to 110 kW 400 V Class Inverters of 18.5 to 160 kW

4-d

(5)*

(5)

400 V Class Inverters of 185 to 300 kW

H2 H1

Fig 1.8 Exterior Diagrams of Open Chassis Inverters

1-7

Page 24

 Enclosed Wall-mounted Inverters [NEMA1 (Type 1)]

Exterior diagrams of the Enclosed Wall-mounted Inverters [NEMA1 (Type 1)] are shown below.

200 V/400 V Class Inverters of 0.4 to 15 kW

4-d

H1H2DH0

4 H

Fig 1.9 Exterior Diagrams of Enclosed Wall-mounted Inverters

* (7.5) for 200 V Class Inverters of 30 to 75 kW or 400 V

Class Inverters of 55 to 160 kW.

200 V Class Inverters of 18.5 to 75 kW 400 V Class Inverters of 18.5 to 160 kW

4-d

(5)*(5)*

Grommet

Max.10

D(5)

1-8

Page 25

Table 1.3 200 VAC and 400 VAC (0.4 kW to 300 kW) Inverter Dimensions (mm) and Masses (kg)

Max.

Appli-

Voltage

cable

Class

Motor

Output

W H D W1H1H2D1 t1

[kW]

0.4

0.75 43 42 85

140 280

1.5 58 47 105

2.2

3.7 12264186

5.5 200 300 197 186 285 8 65.5

7.5 7 7 263 112 375

240 350 207 216 335

200 V

(3-phase)

15 380 30 473 174 647

18.5 250 400

22 275 450 220 435 24 279 615 220 450 435 165 27 679 257 936

375 600

37 328

450 725 348 325 700

55 87 95 1474 607 2081

75 500 850 358 370 820

575 885 378 445 855 140 150 ---

110 2389 1194 3583

0.4

0.75 21 44 65

140 280

1.5

2.2 41 49 90

3.7 76 64 140

5.5 200 300 197 186 285 8 65.5

7.5 198 106 304

240 350 207 216 335

15 311 135 446

18.5 275 450 258 220 435 100 26 279 535 258 220 450 435

400 V

(3-phase)

22 516 210 726

325 550 283 260 535 105 37 329

37 737 285 1022

45 715 165 40 929 340 1269

450 725 348 325 700 12.5

75 91 99 1554 596 2150

500 850 358 370 820 15

110 127 137 2299 928 3227

132

575 916 378 445 855 46 140

160 175 185 3614 1501 5115

185

300

* Same for Open Chassis and Enclosed Wall-mounted Inverters.

Open Chassis (IP00) Enclosed Wall-mounted [NEMA1 (Type 1)]

157

126 266 7

177 59 4 177 59 4

2.3

78 11 240

7.5

12.5

100

3.2

258

298

195 385

250 575

130

15 4.5

157

126 266 7

177 59 4.5 177 59 4.5

78 10 240 350 207 216 350 335

2.3

7.5

3.2

130

4.5

Exterior and Mounting Dimensions

Dimensions (mm)

Appro

W H D W1H0H1H2H3D1 t1

Mass

140 280

157

126 280 266 7

200 300 197 186 300 285 8 65.5

350

207 216 350 335

21 254 535

380 809

63 328

453 1027 348 325 725 700 302

195 400 385 135

258

298

250 600 575

7.5

100

209

12.5

130

108 504 1243 358 370 850 820 15 393 4.5 114

3.5

140 280

157

126 280 266 7

7 200 300 197 186 300 285 8 65.5

7.5

635

283 260 550 535 105

453 1027 348 325 725 700 12.5 302

109

504 1243 358 370 850 820 15 393

165

579 1324 378 445 916 855 46 408 140

100 29

130

See Table 1.4220

Appro

Mass

2.3

78 11

3.2

78 10

2.3

3.2

4.5

Heat Genera-

tion (W)

Tot a l

Inter-

nal

Heat Gen-

eration

Exter

Mount-

ing

Holes

nal

21 36 57

83 53 136

18787274

357 136 493

24 599 242 839

68 1080 434 1514

94 1291 510 1801

878 362 1240

M10

2009 823 2832

M12

1660 871 2531

3.5

10 39 49

33 46 79

132 79 211

246 116 362

354 174 528

127

175 2612 1105 3717

633 246 879

1239 488 1727

M10

1928 762 2690

M12

Cooling Method

Natu-

ral

Fan

Natu-

ral

Fan

Voltage

Class

400 V

(3-phase)

Table 1.4 400 VAC (185 to 300 kW) Inverter Dimensions (mm) and Masses (kg)

Max. Applicable Motor

W H D W1W2W3 H1 H2 D1 t1

Output

[kW]

185

710 1305 413 540 240 270 1270 15 125.5 4.5

300 916 1475 413 730 365 365 1440 15 125.5 4.5 415 6749 2941 9690

Open Chassis (IP00)

Dimensions (mm) Heat Generation (W)

Appr

ox.

Mass

260

Enclosed Wall-mounted [NEMA (Type1)]

WHDW1W2W3H1H2D1 t1

--- M12

Appr

ox.

Mass

Mount-

Exter-

ing

Holes

4436 1994 6430

Inter-

nal

Tot a l Heat

Gener-

ation

Cooling Method

Fan220 280 5329 2205 7534

1-9

Page 26

Checking and Controlling the Installation Site

Install the Inverter in the installation site described below and maintain optimum conditions.

 Installation Site

Install the Inverter under the following conditions and a pollution level of 2 or less (UL standard).

Table 1.5 Installation Site

Type Ambient Operating Temperature Humidity

Enclosed wall-mounted -10 to + 40 °C 95% RH or less (no condensation)

Open chassis -10 to + 45 °C 95% RH or less (no condensation)

Protection covers are attached to the top and bottom of the Inverter. Be sure to remove the protection covers before installing a 200 or 400 V Class Inverter with an output of 15 kW or less in a panel. Refer to Page 1-17 on how to remove the protection covers.

Observe the following precautions when mounting the Inverter.

• Install the Inverter in a clean location free from oil mist and dust. It can be installed in a totally enclosed

panel that is completely shielded from floating dust.

• When installing or operating the Inverter, always take special care so that metal powder, oil, water, or other

foreign matter does not get into the Inverter.

• Do not install the Inverter on combustible material, such as wood.

• Install the Inverter in a location free from radioactive materials and combustible materials.

• Install the Inverter in a location free from harmful gasses and liquids.

• Install the Inverter in a location without excessive oscillation.

• Install the Inverter in a location free from chlorides.

• Install the Inverter in a location not in direct sunlight.

 Controlling the Ambient Temperature

To enhance the reliability of operation, the Inverter should be installed in an environment free from extreme temperature increases. If the Inverter 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 Inverter from Foreign Matter

Place a cover over the Inverter during installation to shield it from metal powder produced by drilling.

Always remove the cover from the Inverter after completing installation. Otherwise, ventilation will be reduced, causing the Inverter to overheat.

1-10

Page 27

Installation Orientation and Space

Install the Inverter vertically so as not to reduce the cooling effect. When installing the Inverter, always provide the following installation space to allow normal heat dissipation.

Installation Orientation and Space

A mm min.

30 mm min.

B mm min.

Air

120 mm min.

Air

Vertical SpaceHorizontal Space

200 V Class Inverters of 110 kW or 400 V Class Inverters of 160 to 220 kW*: A = 120, B = 120 400 V Class Inverters of 300 kW*: A = 300, B = 300 All other Inverters*: A = 50, B = 120

*If, however, there is a fan in the top of the control panel with sufficient exhaust capacity, the following dimensions may be used: A = 50, B = 120.

Fig 1.10 Inverter Installation Orientation and Space

1. The same space is required horizontally and vertically for both Open Chassis (IP00) and Enclosed Wallmounted [IP20, NEMA 1 (Type 1)] Inverters.

IMPORTANT

2. Always remove the protection covers before installing a 200 or 400 V Class Inverter with an output of 15 kW or less in a panel. Refer to Page 1-17 on how to remove the protection covers. Always provide enough space for suspension eye bolts and the main circuit lines when installing a 200 or 400 V Class Inverter with an output of 18.5 kW or more in a panel.

1-11

Page 28

Removing and Attaching the Terminal Cover

Remove the terminal cover to wire cables to the control circuit and main circuit terminals.

 Removing the Terminal Cover

 Inverters of 15 kW or Less

Loosen the screws at the bottom of the terminal cover, press in on the sides of the terminal cover in the direc-

tions of arrows 1, and then lift up on the terminal in the direction of arrow 2.

Fig 1.11 Removing the Terminal Cover (Model CIMR-G7A23P7 Shown Above)

 Inverters of 18.5 kW or More

Loosen the screws on the left and right at the top of the terminal cover, pull out the terminal cover in the direction of arrow 1 and then lift up on the terminal in the direction of arrow 2.

1-12

Fig 1.12 Removing the Terminal Cover (Model CIMR-G7A2018 Shown Above)

 Attaching the Terminal Cover

When wiring the terminal block has been completed, attach the terminal cover by reversing the removal procedure.

For Inverters with an output of 15 kW or less, insert the tab on the top of the terminal cover into the grove on the Inverter and press in on the bottom of the terminal cover until it clicks into place.

Page 29

Removing/Attaching the Digital Operator and Front Cover

The methods of removing and attaching the Digital Operator and Front Cover are described in this section.

 Inverters of 15 kW or Less

To attach optional boards or change the terminal board connector, remove the Digital Operator and front cover in addition to the terminal cover. Always remove the Digital Operator from the front cover before removing the terminal cover.

The removal and attachment procedures are given below.

Removing the Digital Operator

Press the lever on the side of the Digital Operator in the direction of arrow 1 to unlock the Digital Operator and lift the Digital Operator in the direction of arrow 2 to remove the Digital Operator as shown in the following illustration.

Fig 1.13 Removing the Digital Operator (Model CIMR-G7A43P7 Shown Above)

1-13

Page 30

Removing the Front Cover

Press the left and right sides of the front cover in the directions of arrows 1 and lift the bottom of the cover in the direction of arrow 2 to remove the front cover as shown in the following illustration.

Fig 1.14 Removing the Front Cover (Model CIMR-G7A43P7 Shown Above)

Mounting the Front Cover

After wiring the terminals, mount the front cover to the Inverter by performing in reverse order to the steps to remove the front cover.

1. Do not mount the front cover with the Digital Operator attached to the front cover; otherwise, Digital Operator may malfunction due to imperfect contact.

2. Insert the tab of the upper part of the front cover into the groove of the Inverter and press the lower part of the front cover onto the Inverter until the front cover snaps shut.

Mounting the Digital Operator

After attaching the terminal cover, mount the Digital Operator onto the Inverting using the following procedure.

1. Hook the Digital Operator at A (two locations) on the front cover in the direction of arrow 1 as shown in the following illustration.

2. Press the Digital Operator in the direction of arrow 2 until it snaps in place at B (two locations).

1-14

Page 31

Removing/Attaching the Digital Operator and Front Cover

Fig 1.15 Mounting the Digital Operator

IMPORTANT

1. Do not remove or attach the Digital Operator or mount or remove the front cover using methods other than those described above, otherwise the Inverter may break or malfunction due to imperfect contact.

2. Never attach the front cover to the Inverter with the Digital Operator attached to the front cover. Imperfect contact can result. Always attach the front cover to the Inverter by itself first, and then attach the Digital Operator to the front cover.

1-15

Page 32

 Inverters of 18.5 kW or More

For Inverter with an output of 18.5 kW or more, remove the terminal cover and then use the following procedures to remove the Digital Operator and front cover.

Removing the Digital Operator

Use the same procedure as for Inverters with an output of 18.5 kW or less.

Removing the Front Cover

Lift up at the location label 1 at the top of the control circuit terminal board in the direction of arrow 2.

Fig 1.16 Removing the Front Cover (Model CIMR-G7A2018 Shown Above)

 Attaching the Front Cover

After completing required work, such as mounting an optional board or setting the control circuit terminal board, attach the front cover by reversing the procedure to remove it.

1. Confirm that the Digital Operator is not mounted on the front cover. Contact faults can occur if the cover is attached while the Digital Operator is mounted to it.

2. Insert the tab on the top of the front cover into the slot on the Inverter and press in on the cover until it clicks into place on the Inverter.

Attaching the Digital Operator

Use the same procedure as for Inverters with an output of 15 kW or less.

1-16

Page 33

Removing and Attaching the Protection Cover

Inverters of 18.5 kW or less have protection covers on the top and bottom as shown in Fig. 1.4.Always remove the protection covers before installing an Inverter of 18.5 kW or less in a panel. Use the following procedure to remove and attach a protection cover.

 Removing the Protection Cover

Top Protection Cover

Insert the tip of the straightedge screwdriver in the slot. Then, lift the cover up in the direction shown by the arrow to remove it.

Slot

Fig 1.17 Removing the Top Protection Cover (Model CIMR-G7A43P7 Shown Above)

Bottom Protection Cover

1. Remove the terminal cover as described on Page 1-12.

2. Loosen the two screws, and remove the protection cover.

3. Return the screws to their original position and tighten (them).

4. Reattach the terminal cover as described on Page 1-12.

Screws

Bottom Protection Cover

Terminal Cover

Fig 1.18 Removing the Bottom Protection Cover (Model CIMR-G7A43P7 Shown Above)

1-17

Page 34

 Attaching the Protection Cover

Top Protection Cover

The protection cover has four hooks: two hooks on the bottom and two on the sides. Fit the bottom hooks into the holes, bend the cover slightly, and press the cover down until the hooks on the side snap.

Holes for bottom hooks

Fig 1.19 Attaching the Top Protection Cover (Model CIMR-G7A43P7 Shown Above)

Bottom Protection Cover

To attach the bottom protection cover, reverse the procedure used to remove it.

1-18

Page 35

Wiring

This chapter describes wiring terminals, main circuit terminal connections, main circuit termi-

nal wiring specifications, control circuit terminals, and control circuit wiring specifications.

Connections to Peripheral Devices.............................. 2-2

Connection Diagram ....................................................2-3

Terminal Block Configuration .......................................2-5

Wiring Main Circuit Terminals ......................................2-6

Wiring Control Circuit Terminals ................................2-22

Wiring Check .............................................................2-30

Installing and Wiring Option Boards ..........................2-31

Page 36

Connections to Peripheral Devices

Examples of connections between the Inverter and typical peripheral devices are shown in Fig 2.1.

Power supply

Molded-case circuit breaker or ground fault interrupter

Magnetic contactor (MC)

AC reactor for power factor improvement

Zero phase reactor

Input noise filter

Inverter

Ground

Output noise filter

Braking resistor

Varispeed F7

DC reactor for power factor improvement

Zero phase reactor

2-2

Motor

Ground

Fig 2.1 Example Connections to Peripheral Devices

Page 37

Connection Diagram

)

+ 3

The connection diagram of the Inverter is shown in Fig 2.2.

When using the Digital Operator, the motor can be operated by wiring only the main circuits.

3-phase power

to 240 V

2 50/60 Hz

2MCCB

1MCCB

FU FV FW

R/L1

S/L2

T/L3

Thermal switch contact

Braking Unit

(optional)

Inverter

CIMR-G7A2018

Level detector

U/T1

V/T2

W/T3

Thermal relay trip contact

43 21

Braking Resistor Unit (optional)

Connection Diagram

Motor

Cooling fan

2MCCB THRX OFF

Thermal relay trip contact

for Braking Resistor Unit

Thermal relay trip contact for motor cooling fan

External frequency references

Multi-function contact inputs

TRX

Fault contact

Factory settings

Pulse train input

Frequency setter

Ω

Forward Run/Stop

Reverse Run/Stop

Thermal switch contact

for Braking Unit

External fault

Fault reset

Multi-step speed reference 1

(Main speed switching)

Multi-step speed reference 2

Jog frequency selection

External baseblock command

Multi-step speed reference 3

Multi-step speed reference 4

Acc/dec time 1

Emergency stop (NO)

Frequency setting adjustment

Ω

0 to 10 V

4 to 20 mA

0 to 10 V

MEMOBUS communications RS-485/422

S10

S11

S12

CN5 (NPN setting)

E (G)

-V

+24V

Shield wire connection terminal

Master speed pulse train

0 to 32 kHz (3 kΩ) High level: 3.5 to 13.2 V input

Frequency setting power

+15 V, 20 mA

Master speed reference

0 to 10 V (20 kΩ)

Master speed reference 4 to 20 mA (250 [0 to 10 V (20 k

Multi-function anlog input

0 to 10 V (20 kΩ)

Factory setting:

Auxiliary frequency command

(15V 20mA)

Terminating resistance

R+ R-

S+

S-

+24V 8mA

Ω)

Ω

) input]

TA1

3 4

TA3

TA2

(Ground to 100 max.)

Shieded twisted-pair wires

Pulse monitor output

Pulse A

30 mA max.

Wiring distance:d:

Pulse B

30 m max.

Pulse train output

0 to 32 kHz (2.2 k

Default: Output frequency

Ω)

Ammeter adjustment 20 kΩ

Multi-function analog output 2

-10 to 10 V 2 mA

Default: Output current 0 to +10 V

Ammeter adjustment 20 kΩ

Multi-function analog output 1

-10 to 10 V 2 mA

Default: Output frequency 0 to +10 V

PG-B2

(optional)

E(G)

Error contact output 250 VAC, 10 mA min. 1 A max.

30 VAC, 10 mA min. 1 A max.

Multi-function contact oputput 250 VAC, 10 mA min. 1 A max. 30 VAC, 10 mA min. 1 A max.

Default: Running signal

Open collector 1

Default: Zero speed

Open collector 2

Default: Frequency agree signal

Open collector 3

Factory setting: Inverter operation ready

Open collector 4

Factory setting: FOUT frequency detection 2

Multi-function open-collector outputs

48 VDC 50 mA max.

Fig 2.2 Connection Diagram (Model CIMR-G7A2018 Shown Above)

2-3

Page 38

IMPORTANT

1. Control circuit terminals are arranged as shown below.

2. The output current capacity of the +V terminal is 20 mA.

3. Disable the stall prevention during deceleration (set constant L3-04 to 0) when using a Braking Resistor Unit. If this user constant is not changed to disable stall prevention, the system may not stop during deceleration.

4. Main circuit terminals are indicated with double circles and control circuit terminals are indicated with single circles.

5. The wiring for a motor with a cooling fan is not required for self-cooling motors.

6. PG circuit wiring (i.e., wiring to the PG-B2 Board) is not required for control without a PG.

7. Sequence input signals S1 to S12 are labeled for sequence connections (0 V common and sinking mode) for no-voltage contacts or NPN transistors. These are the default settings. For PNP transistor sequence connections (+24V common and sourcing mode) or to provide a 24-V external power supply, refer to Table 2.13.

8. The master speed frequency reference can set to input either a voltage (terminal A1) or current (terminal A2) by changing the setting of parameter H3-13. The default setting is for a voltage reference input.

9. The multi-function analog output is a dedicated meter output for an analog frequency meter, ammeter, voltmeter, wattmeter, etc. Do not use this output for feedback control or for any other control purpose.

10.DC reactors to improve the input power factor are built into 200 V Class Inverters for 18.5 to 110 kW and 400 V Class Inverters for 18.5 to 300 kW. A DC reactor is thus an option only for Inverters for 15 kW or less.

11.Set parameter L8-01 to 1 when using a breaking resistor (ERF). When using a Braking Resistor Unit, a shutoff sequence for the power supply must be made using a thermal relay trip.

12.The permissible load of a multi-function contact output and an error contact output is between 10 mA and 1 A. Use a multi-function open-collector output for a load less than 10 mA.

2-4

Page 39

Terminal Block Configuration

The terminal arrangement for 200 V Class Inverters are shown in Fig 2.3 and Fig 2.4.

Terminal Block Configuration

Control circuit terminals

Main circuit terminals

Charge indicator

Ground terminal

Fig 2.3 　Terminal Arrangement (200 V Class Inverter for 0.4 kW Shown Above)

Control circuit terminals

Charge indicator

Main circuit terminals

Ground terminal

Fig 2.4 Terminal Arrangement (200 V Class Inverter for 18.5 kW Shown Above)

2-5

Page 40

Wiring Main Circuit Terminals

 Applicable Wire Sizes and Closed-loop Connectors

Select the appropriate wires and crimp terminals from to Table 2.3. Refer to instruction manual TOE-C726-2 for wire sizes for Braking Resistor Units and Braking Units.

Table 2.1 200 V Class Wire Sizes

Inverter

Model

CIMR-

G7A20P4

Terminal Symbol

R/L1, S/L2, T/L3, , 1, 2, B1, B2, U/T1, V/T2, W/T3

Tightening

Termi-

nal

Screws

M4 1.2 to 1.5

To rq u e

(N•m)

Possible

Wire Sizes

(AWG)

2 to 5.5

(14 to 10)

Recommended

Wire Size

(AWG)

(14)

Wire Type

G7A20P7

G7A21P5

G7A22P2

G7A23P7

G7A25P5

G7A27P5

G7A2011

G7A2015

G7A2018

G7A2022

R/L1, S/L2, T/L3, , 1, 2, B1, B2, U/T1, V/T2, W/T3

R/L1, S/L2, T/L3, , 1, 2, U/T1, V/T2, W/T3

B1, B2

R/L1, S/L2, T/L3, , 1, 2, U/T1, V/T2, W/T3

B1, B2

R/L1, S/L2, T/L3, , 1, U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L31

R/L1, S/L2, T/L3, , 1 U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L31

M4 1.2 to 1.5

M5 2.5

M6 4.0 to 5.0

M5 2.5

M6 4.0 to 5.0

M8 9.0 to 10.0

M5 2.5

M6 4.0 to 5.0

M8 9.0 to 10.0

M6 4.0 to 5.0

M8 9.0 to 10.0

M6 4.0 to 5.0

M8 9.0 to 10.0

2 to 5.5

(14 to 10)

2 to 5.5

(14 to 10)

2 to 5.5

(14 to 10)

2 to 5.5

(14 to 10)

8 to 14 (8 to 6)

(6)

22 to 30

(4 to 3)

8 to 14 (8 to 6)

(4)

22 to 38

(4 to 2)

8 to 14 (8 to 6)

(4)

30 to 60

(3 to 1)

8 to 22 (8 to 4)

22 to 38

(4 to 2)

50 to 60

(1 to 1/0)

8 to 22 (8 to 4)

22 to 38

(4 to 2)

(14)

3.5

(12)

5.5

(10)

(8)

(6)

(4)

(3)

(4)

(3)

(4)

(1)

(4)

Power cables,

e.g., 600 V

vinyl power

cables

2-6

Page 41

Inverter

Model

CIMR-

G7A2030

G7A2037

G7A2045

G7A2055

G7A2075

G7A2090

Table 2.1 200 V Class Wire Sizes (Continued)

Terminal Symbol

R/L1, S/L2, T/L3, , 1 U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L31

r/ 1, / 2

R/L1, S/L2, T/L3, , 1 U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L31

r/ 1, / 2

R/L1, S/L2, T/L3, , 1, U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L31

r/ 1, / 2

, 1

R/L1, S/L2, T/L3, U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L31

r/ 1, / 2

R/L1, S/L2, T/L3, , 1

U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L31

r/ 1, / 2

R/L1, S/L2, T/L3, , 1

U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L31

r/ 1, / 2

Te rm i -

Screws

Tightening

nal

M10 17.6 to 22.5

M8 8.8 to 10.8

M10 17.6 to 22.5

M4 1.3 to 1.4

M10 17.6 to 22.5

M8 8.8 to 10.8

M10 17.6 to 22.5

M4 1.3 to 1.4

M10 17.6 to 22.5

M8 8.8 to 10.8

M10 17.6 to 22.5

M4 1.3 to 1.4

M12 31.4 to 39.2

M10 17.6 to 22.5

M8 8.8 to 10.8

M12 17.6 to 22.5

M4 1.3 to 1.4

M12 31.4 to 39.2

M8 8.8 to 10.8

M12 31.4 to 39.2

M4 1.3 to 1.4

M12 31.4 to 39.2

M8 8.8 to 10.8

M12 31.4 to 39.2

M4 1.3 to 1.4

Torque

(N•m)

Wiring Main Circuit Terminals

Possible

Wire Sizes

(AWG)

60 to 100

(2/0 to 4/0)

5.5 to 22 (10 to 4)

30 to 60

(2 to 2/0)

0.5 to 5.5

(20 to 10)

80 to 125

(3/0 to 250)

5.5 to 22 (10 to 4)

38 to 60

(1 to 2/0)

0.5 to 5.5

(20 to 10)

50 to 100

(1/0 to 4/0)

5.5 to 60

(10 to 2/0)

30 to 60

(3 to 4/0)

0.5 to 5.5

(20 to 10)

80 to 125

(3/0 to 250)

80 to 100

(3/0 to 4/0)

5.5 to 60

(10 to 2/0)

80 to 200

(2/0 to 400)

0.5 to 5.5

(20 to 10)

150 to 200

(250 to 350)

100 to 150

(4/0 to 300)

5.5 to 60

(10 to 2/0)

60 to 150

(2/0 to 300)

0.5 to 5.5

(20 to 10)

200 to 325

(350 to 600)

150 to 325

(300 to 600)

5.5 to 60

(10 to 2/0)

150

(300)

0.5 to 5.5

(20 to 10)

Recommended

Wire Size

(AWG)

(2/0)

(2)

1.25 (16)

(3/0)

(1)

1.25 (16)

50 × 2P

(1/0 × 2P)

(1/0)

1.25 (16)

80 × 2P

(3/0 × 2P)

80 × 2P

(3/0 × 2P)

(2/0)

1.25 (16)

150 × 2P

(250 × 2P)

100 × 2P

(4/0 × 2P)

60 × 2P

(2/0 × 2P)

1.25 (16)

200 × 2P, or

50 × 4P

(350 × 2P, or 1/0 × 4P) 150 × 2P, or

50 × 4P

(300 × 2P, or 1/0 × 4P)

150 × 2P

(300 × 2P)

1.25 (16)

Wire Type

Power cables, e.g., 600 V vinyl power cables

2-7

Page 42

Table 2.1 200 V Class Wire Sizes (Continued)

Inverter

Model

Terminal Symbol

CIMR-

R/L1, S/L2, T/L3, , 1

U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/

G7A2110

L31

r/ 1, / 2

* The wire thickness is set for copper wires at 75°C

Tightening

Termi-

nal

Screws

To rq u e

(N•m)

M12 31.4 to 39.2

M8 8.8 to 10.8

M12 31.4 to 39.2

M4 1.3 to 1.4

Possible

Wire Sizes

(AWG)

200 to 325

(350 to 600)

150 to 325

(300 to 600)

5.5 to 60

(10 to 2/0)

150

(300)

0.5 to 5.5 (20 to 10)

Recommended

Wire Size

(AWG)

200 × 2P, or

50 × 4P

(350 × 2P, or 1/0 × 4P) 150 × 2P, or

50 × 4P

(300 × 2P, or 1/0 × 4P)

150 × 2P

(300 × 2P)

1.25 (16)

Wire Type

Power cables,

e.g., 600 V

vinyl power

cables

2-8

Page 43

Inverter

Model

CIMR-

G7A40P4

Table 2.2 400 V Class Wire Sizes

Terminal Symbol

R/L1, S/L2, T/L3, , 1, 2, B1, B2, U/T1, V/T2, W/T3

Te rm i -

Screws

Tightening

nal

M4 1.2 to 1.5

Torque

(N•m)

Wiring Main Circuit Terminals

Possible

Wire Sizes

(AWG)

2 to 5.5

(14 to 10)

Recommended

Wire Size

(AWG)

(14)

Wire Type

G7A40P7

G7A41P5

G7A42P2

G7A43P7

G7A45P5

G7A47P5

G7A4011

G7A4015

G7A4018

G7A4022

G7A4030

G7A4037

R/L1, S/L2, T/L3, , 1, 2, B1, B2, U/T1, V/T2, W/T3

R/L1, S/L2, T/L3, , 1, 2, U/T1, V/T2, W/T3

B1, B2

R/L1, S/L2, T/L3, , 1, 3, U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L31

R/L1, S/L2, T/L3, , 1, U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L31

M4 1.2 to 1.5

M5 2.5

(M6)

M5 4.0 to 5.0

M5 2.5

(M6)

M6 4.0 to 5.0

M8 9.0 to 10.0

M6 4.0 to 5.0

M8 9.0 to 10.0

M6 4.0 to 5.0

M8 9.0 to 10.0

M6 4.0 to 5.0

M8 9.0 to 10.0

2.5

(4.0 to 5.0)

4.0 to 5.0

2 to 5.5

(14 to 10)

2 to 5.5

(14 to 10)

2 to 5.5

(14 to 10)

2 to 5.5

(14 to 10)

3.5 to 5.5

(12 to 10)

5.5 to 14 (10 to 6)

8 to 14

(8 to 6)

5.5 to 14 (10 to 6)

8 to 14

(8 to 6)

(8)

8 to 22

(8 to 4)

14 to 22

(6 to 4)

14 to 38

(6 to 2)

(4)

22 to 38

(4 to 2)

22 to 60

(4 to 1/0)

8 to 22

(8 to 4)

22 to 38

(4 to 2)

30 to 60

(2 to 1/0)

8 to 22

(8 to 4)

22 to 38

(4 to 2)

(14)

3.5

(12)

(14)

3.5

(12)

5.5

(10)

(8)

5.5

(10)

(8)

(6)

(4)

(2)

(4)

(2)

(4)

Power cables, e.g., 600 V vinyl power cables

2-9

Page 44

Inverter

Model

CIMR-

G7A4045

G7A4055

G7A4075

G7A4090

G7A4110

G7A4132

G7A4160

Table 2.2 400 V Class Wire Sizes (Continued)

Terminal Symbol

R/L1, S/L2, T/L3, , 1, U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L31

r/ 1, 200/2200, 400/2400

R/L1, S/L2, T/L3, , 1, U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L31

r/ 1, 200/2200, 400/2400

R/L1, S/L2, T/L3, , 1, U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L33

r/ 1, 200/2200, 400/2400

R/L1, S/L2, T/L3, , 1, U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L33

r/ 1, 200/2200, 400/2400

R/L1, S/L2, T/L3, , 1, U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L31

r/ 1, 200/2200, 400/2400

R/L1, S/L2, T/L3, , 1, U/T1, V/T2, W/T3, R1/L11, S1/L21, T1/L31

r/ 1, 200/2200, 400/2400

Tightening

Termi-

nal

Screws

M8 9.0 to 10.0

M6 4.0 to 5.0

M8 9.0 to 10.0

M10 17.6 to 22.5

M8 8.8 to 10.8

M10 17.6 to 22.5

M4 1.3 to 1.4

M10 17.6 to 22.5

M8 8.8 to 10.8

M10 17.6 to 22.5

M4 1.3 to 1.4

M10 17.6 to 22.5

M8 8.8 to 10.8

M10 17.6 to 22.5

M4 1.3 to 1.4

M10 17.6 to 22.5

M8 8.8 to 10.8

M10 17.6 to 22.5

M4 1.3 to 1.4

M12 31.4 to 39.2

M8 8.8 to 10.8

M12 31.4 to 39.2

M4 1.3 to 1.4

M12 31.4 to 39.2

M8 8.8 to 10.8

M12 31.4 to 39.2

M4 1.3 to 1.4

To rq u e

(N•m)

Possible

Wire Sizes

(AWG)

50 to 60

(1 to 1/0)

8 to 22 (8 to 4)

22 to 38

(4 to 2)

50 to 100

(1/0 to 4/0)

5.5 to 22 (10 to 4) 38 to 60

(2 to 2/0)

0.5 to 5.5 (20 to 10)

80 to 100

(3/0 to 4/0)

8 to 22

(8 to 4) 50 to 100 (1 to 4/0)

0.5 to 5.5 (20 to 10)

50 to 100

(1/0 to 4/0)

8 to 60 (8 to 2/0) 60 to 150

(2/0 to 300)

0.5 to 5.5 (20 to 10)

60 to 100

(2/0 to 4/0)

8 to 60 (8 to 2/0)

100 to 150

(4/0 to 300)

0.5 to 5.5 (20 to 10)

80 to 200

(3/0 to 400)

8 to 60 (8 to 2/0) 50 to 150

(1/0 to 300)

0.5 to 5.5 (20 to 10)

100 to 200

(4/0 to 400)

80 to 60 (8 to 2/0) 50 to 150

(1/0 to 300)

0.5 to 5.5 (20 to 10)

Recommended

Wire Size

(AWG)

(1)

(4)

(1/0)

(2)

1.25 (16)

100

(4/0)

(1)

1.25 (16)

50 × 2P

(1/0 × 2P)

(2/0)

1.25 (16)

80 × 2P

(3/0 × 2P)

100

(4/0)

1.25 (16)

80 × 2P

(3/0 × 2P)

50 × 2P

(1/0 × 2P)

1.25 (16)

100 × 2P

(4/0 × 2P)

50 × 2P

(1/0 × 2P)

1.25 (16)

Wire Type

Power cables,

e.g., 600 V

vinyl power

cables

2-10

Page 45

Table 2.2 400 V Class Wire Sizes (Continued)

Inverter

Model

CIMR-

Terminal Symbol

R/L1, S/L2, T/L3

U/T1, V/T2, W/T3 R1/L11, S1/L21, T1/L33

G7A4185

, 1,

r/ 1, 200/2200, 400/2400

R/L1, S/L2, T/L3

U/T1, V/T2, W/T3 R1/L11, S1/L21, T1/L33

G7A4220

, 1,

r/ 1, 200/2200, 400/2400

R/L1, S/L2, T/L3

U/T1, V/T2, W/T3 R1/L11, S1/L21, T1/L33

G7A4300

, 1,

r/ 1, 200/2200, 400/2400

* The wire thickness is set for copper wires at 75°C.

Te rm i -

Screws

Tightening

nal

M16 78.4 to 98

M4 1.3 to 1.4

M16 78.4 to 98

M4 1.3 to 1.4

M16 78.4 to 98

M4 1.3 to 1.4

Torque

(N•m)

Wiring Main Circuit Terminals

Possible

Wire Sizes

(AWG)

100 to 325

(4/0 to 600)

100 to 325

(4/0 to 600)

100 to 325

(4/0 to 600)

100 to 325

(4/0 to 600)

100 to 325

(4/0 to 600)

0.5 to 5.5

(20 to 10)

100 to 325

(4/0 to 600)

100 to 325

(4/0 to 600)

100 to 325

(4/0 to 600)

100 to 325

(4/0 to 600)

100 to 325

(4/0 to 600)

0.5 to 5.5

(20 to 10)

100 to 325

(4/0 to 600)

100 to 325

(4/0 to 600)

100 to 325

(4/0 to 600)

100 to 325

(4/0 to 600)

100 to 325

(4/0 to 600)

0.5 to 5.5

(20 to 10)

Recommended

Wire Size

(AWG)

325

(600)

250

(500)

200 × 2P

(400 × 2P)

150

(300)

1.25 (16)

200 × 2P

(400 × 2P)

150 × 2P

(350 × 2P)

325 × 4P

(600 × 4P)

200

(400)

1.25 (16)

325 × 4P

(600 × 4P)

250 × 4P

(500 × 4P)

125 × 4P

(250 × 4P)

325 × 2P

(600 × 2P)

1.25 (16)

Wire Type

Power cables,

e.g., 600 V

vinyl power

cables

2-11

Page 46

Table 2.3 Closed-loop Connector Sizes (JIS C2805) (200 V Class and 400 V Class)

Wire Thickness (mm

)

Terminal Screws Size

M3.5 1.25 to 3.5

0.5 M4 1.25 to 4

M3.5 1.25 to 3.5

0.75 M4 1.25 to 4

1.25

M3.5 1.25 to 3.5

M4 1.25 to 4

M3.5 2 to 3.5

M4 2 to 4

M5 2 to 5

M6 2 to 6

M8 2 to 8

M4 5.5 to 4

M5 5.5 to 5

3.5/5.5 M6 5.5 to 6

M8 5.5 to 8

M5 8 to 5

M6 8 to 6

M8 8 to 8

M6 14 to 6

M8 14 to 8

M6 22 to 6

M8 22 to 8

30/38 M8 38 to 8

M8 60 to 8

50/60

M10 60 to 10

80 to 10

M10

100 100 to 10

2-12

IMPORTANT

100

150 150 to 12

M12

100 to 12

200 200 to 12

M12 x 2 325 to 12

325

M16 325 to 16

Determine the wire size for the main circuit so that line voltage drop is within 2% of the rated voltage. Line

voltage drop is calculated as follows:

Line voltage drop (V) =

x wire resistance (W/km) x wire length (m) x current (A) x 10

-3

Page 47

Wiring Main Circuit Terminals

 Main Circuit Terminal Functions

Main circuit terminal functions are summarized according to terminal symbols in Table 2.4. Wire the terminals correctly for the desired purposes.

Table 2.4 Main Circuit Terminal Functions (200 V Class and 400 V Class)

Purpose Terminal Symbol

R/L1, S/L2, T/L3 20P4 to 2110 40P4 to 4300

Main circuit power input

R1/L11, S1/L21, T1/L31 2018 to 2110 4018 to 4300

Inverter outputs U/T1, V/T2, W/T3 20P4 to 2110 40P4 to 4300

200 V Class 400 V Class

Model: CIMR-G7A

DC power input

Braking Resistor Unit connection

DC reactor connection

Braking Unit connection

Ground 20P4 to 2110 40P4 to 4300

B1, B2 20P4 to 27P5 40P4 to 4015

1, 2

20P4 to 2110 40P4 to 4300

20P4 to 2015 40P4 to 4015

2018 to 2110 4018 to 4300

2-13

Page 48

 Main Circuit Configurations

The main circuit configurations of the Inverter are shown in Fig 2.5.

Table 2.5 Inverter Main Circuit Configurations

200 V Class 400 V Class

CIMR-G7A20P4 to 2015

R/L1 S/L2

T/L3

−

CIMR-G7A2018, 2022

R/L1 S/L2 T/L3

R1/L11 S1/L21 T1/L31

−

Power supply

CIMRG7A40P4 to 4015

Power supply

B1 B2

Control circuits

U/T1

V/T2

W/T3

B1 B2

Control circuits

U/T1

V/T2 W/T3

R/L1 S/L2 T/L3

−

CIMR-G7A4018 to 4045

R/L1

S/L2 T/L3

R1/L11 S1/L21 T1/L31

−

Control circuits

U/T1

V/T2

W/T3

Power supply

Control circuits

U/T1

V/T2

W/T3

2-14

CIMR-G7A2030 to 2110

a b

Power supply

Control circuits

200/

400/

CIMR-G7A4055 to 4300

R/L1 S/L2 T/L3

R1/L11

S1/L21

T1/L31

−

200

400

a b

Power

Control

supply

a b

circuits

Note Consult your Yaskawa representative before using 12-phase rectification. * These terminals are wired before shipment. When using DC power for the main circuit power supply, remove the wires between R-r/l

200 V Class Inverters, input 200 VAC to r/l

- s/l2, or, for 400 V Class Inverters, input either 200 VAC to r/l1- s200/l2200 or 400 VAC to r/l1- s400/l2400.

U/T1

V/T2

W/T3

and S-s/l2, then, for

Page 49

Wiring Main Circuit Terminals

 Standard Connection Diagrams

Standard Inverter connection diagrams are shown in Fig 2.5. These are the same for both 200 V Class and 400 V Class Inverters. The connections depend on the Inverter capacity.

CIMR-G7A20P4 to 2015 and 40P4 to

CIMR-G7A2018, 2022, and 4018 to 4045

4015

2B1 B2

Braking Resistor Unit (optional)

U/T1 V/T2

W/T3

3-phase 200 VAC (400 VAC)

R/L1 S/L2

T/L3 R1/L11

S1/L21 T1/L31

The DC reactor is built in.

DC reactor (optional)

−

1 R/L1 S/L2

3-phase 200 VAC (400 VAC)

T/L3

Be sure to remove the short-circuit bar before connecting the DC reactor.

CIMR-G7A2030 to 2110 CIMR-G7A4055 to 4300

Braking Resistor Unit (optional)

Braking Unit (optional)

−

U/T1 V/T2

W/T3

R/L1

3-phase 400 VAC

S/L2 T/L3

R1/L11 S1/L21

T1/L31

r/l1

3-phase 200 VAC

1 R/L1 S/L2

T/L3 R1/L11

S1/L21 T1/L31

r/l1

200/l

2200

400/l2400

Braking Resistor Unit (optional)

Braking Unit (optional)

−

U/T1 V/T2

W/T3

Braking Resistor Unit (optional)

Braking Unit (optional)

−

U/T1 V/T2

W/T3

Control power is supplied internally from the main circuit DC power supply for all Inverter models.

Fig 2.5 Main Circuit Terminal Connections

2-15

Page 50

 Wiring the Main Circuits

This section describes wiring connections for the main circuit inputs and outputs.

Wiring Main Circuit Inputs

Observe the following precautions for wiring the main circuit power supply inputs.

Installing a Molded-case Circuit Breaker

Always connect the power input terminals (R, S, and T) and power supply via a molded-case circuit breaker (MCCB) suitable for the Inverter.

• Choose an MCCB with a capacity of 1.5 to 2 times the Inverter's rated current.

• For the MCCB's time characteristics, be sure to consider the Inverter's overload protection (one minute at

150% of the rated output current).

• If the same MCCB is to be used for more than one Inverter, or other devices, set up a sequence so that the

power supply will be turned OFF by a fault output, as shown in Fig 2.6.

Power

supply

20P4 to 2030: 3-phase, 200 to 240 VAC, 50/60 Hz

2037 to 2110: 3-phase, 200 to 230 VAC, 50/60 Hz

40P4 to 4300: 3-phase, 380 to 460 VAC, 50/60 Hz

* For 400 V Class Inverters, connect a 400/200 V transformer.

Fig 2.6 MCCB Installation

Inverter

R/L1

S/L2

T/L3

Fault output (NC)

Installing a Ground Fault Interrupter

Inverter outputs use high-speed switching, so high-frequency leakage current is generated. Therefore, at the Inverter primary side, use a ground fault interrupter to detect only the leakage current in the frequency range that is hazardous to humans and exclude high-frequency leakage current.

• For the special-purpose ground fault interrupter for Inverters, choose a ground fault interrupter with a sen-

sitivity amperage of at least 30 mA per Inverter.

• When using a general ground fault interrupter, choose a ground fault interrupter with a sensitivity amper-

age of 200 mA or more per Inverter and with an operating time of 0.1 s or more.

2-16

Page 51

Wiring Main Circuit Terminals

Installing a Magnetic Contactor

If the power supply for the main circuit is to be shut off during a sequence, a magnetic contactor can be used.

When a magnetic contactor is installed on the primary side of the main circuit to forcibly stop the Inverter, however, the regenerative braking does not work and the Inverter will coast to a stop.

• The Inverter can be started and stopped by opening and closing the magnetic contactor on the primary side.

Frequently opening and closing the magnetic contactor, however, may cause the Inverter to break down. Start and stop the Inverter at most once every 30 minutes.

• When the Inverter is operated with the Digital Operator, automatic operation cannot be performed after

recovery from a power interruption.

• If the Braking Resistor Unit is used, program the sequence so that the magnetic contactor is turned OFF by

the contact of the Unit's thermal overload relay.

Connecting Input Power Supply to the Terminal Block

Input power supply can be connected to any terminal R, S or T on the terminal block; the phase sequence of input power supply is irrelevant to the phase sequence.

Installing an AC Reactor or DC Reactor

If the Inverter is connected to a large-capacity power transformer (600 kW or more) or the phase advancing capacitor is switched, an excessive peak current may flow through the input power circuit, causing the converter unit to break down.

To prevent this, install an optional AC Reactor on the input side of the Inverter or a DC reactor to the DC reactor connection terminals.

This also improves the power factor on the power supply side.

Installing a Surge Absorber

Always use a surge absorber or diode for inductive loads near the Inverter. These inductive loads include magnetic contactors, electromagnetic relays, solenoid valves, solenoids, and magnetic brakes.

Installing a Noise Filter on Power Supply Side

Install a noise filter to eliminate noise transmitted between the power line and the Inverter.

• Correct Noise Filter Installation

Power supply

MCCB

Noise filter

Inverter

MCCB

Fig 2.7 Correct Power supply Noise Filter Installation

Other controllers

Use a special-purpose noise filter for Inverters.

2-17

Page 52

• Incorrect Noise Filter Installation

Power supply

MCCB

Power supply

MCCB

Generalpurpose noise filter

Inverter

Other controllers

Inverter

Other controllers

Do not use general-purpose noise filters. No generalpurpose noise filter can effectively suppress noise generated from the Inverter.

Fig 2.8 Incorrect Power supply Noise Filter Installation

Wiring the Output Side of Main Circuit

Observe the following precautions when wiring the main output circuits.

Connecting the Inverter and Motor

Connect output terminals U, V, and W to motor lead wires U, V, and W, respectively.

Check that the motor rotates forward with the Forward Run Command. Switch over any two of the output terminals to each other and reconnect if the motor rotates in reverse with the Forward Run Command.

Never Connect a Power Supply to Output Terminals

Never connect a power supply to output terminals U, V, and W. If voltage is applied to the output terminals, the internal circuits of the Inverter will be damaged.

Never Short or Ground Output Terminals

If the output terminals are touched with bare hands or the output wires come into contact with the Inverter casing, an electric shock or grounding will occur. This is extremely hazardous. Do not short the output wires.

Do Not Use a Phase Advancing Capacitor or Noise Filter

Never connect a phase advancing capacitor or LC/RC noise filter to an output circuit. The high-frequency components of the Inverter output may result in overheating or damage to these part or may result in damage to the Inverter or cause other parts to burn.

Do Not Use an Electromagnetic Switch

Never connect an electromagnetic switch (MC) between the Inverter and motor and turn it ON or OFF during operation. If the MC is turned ON while the Inverter is operating, a large inrush current will be created and the overcurrent protection in the Inverter will operate.

2-18

Page 53

Wiring Main Circuit Terminals

When using an MC to switch to a commercial power supply, stop the Inverter and motor before operating the MC. Use the speed search function if the MC is operated during operation. If measures for momentary power interrupts are required, use a delayed release MC.

Installing a Thermal Overload Relay

This Inverter has an electronic thermal protection function to protect the motor from overheating. If, however, more than one motor is operated with one Inverter or a multi-polar motor is used, always install a thermal relay (THR) between the Inverter and the motor and set L1-01 to 0 (no motor protection). The sequence should be designed so that the contacts of the thermal overload relay turn OFF the magnetic contactor on the main circuit inputs.

Installing a Noise Filter on Output Side

Connect a noise filter to the output side of the Inverter to reduce radio noise and inductive noise.

Power supply

Inductive Noise: Electromagnetic induction generates noise on the signal line, causing the controller to malfunction.

Radio Noise: Electromagnetic waves from the Inverter and cables cause the broadcasting radio receiver to make

noise.

MCCB

Inverter

Noise filter

Signal line

Inductive noise

Controller

Radio noise

AM radio

Fig 2.9 Installing a Noise Filter on the Output Side

Countermeasures Against Inductive Noise

As described previously, a noise filter can be used to prevent inductive noise from being generated on the output side. Alternatively, cables can be routed through a grounded metal pipe to prevent inductive noise. Keeping the metal pipe at least 30 cm away from the signal line considerably reduces inductive noise.

Power supply

MCCB

Inverter

Metal pipe

30 cm min.

Signal line

Controller

Fig 2.10 Countermeasures Against Inductive Noise

2-19

Page 54

Countermeasures Against Radio Interference

Radio noise is generated from the Inverter as well as from the input and output lines. To reduce radio noise, install noise filters on both input and output sides, and also install the Inverter in a totally enclosed steel box.

The cable between the Inverter and the motor should be as short as possible.

Noise filter

Steel box

Inverter

Noise filter

Metal pipe

Power supply

MCCB

Fig 2.11 Countermeasures Against Radio Interference

Cable Length between Inverter and Motor

If the cable between the Inverter and the motor is long, the high-frequency leakage current will increase, causing the Inverter output current to increase as well. This may affect peripheral devices. To prevent this, adjust the carrier frequency (set in C6-01, C6-02) as shown in Table 2.6. (For details, refer to Chapter 5 User Con- stants.)

Table 2.6 Cable Length between Inverter and Motor

Cable length 50 m max. 100 m max. More than 100 m

Carrier frequency 15 kHz max. 10 kHz max. 5 kHz max.

Ground Wiring

Observe the following precautions when wiring the ground line.

• Always use the ground terminal of the 200 V Inverter with a ground resistance of less than 100 Ω and that

of the 400 V Inverter with a ground resistance of less than 10 Ω.

• Do not share the ground wire with other devices, such as welding machines or power tools.

• Always use a ground wire that complies with technical standards on electrical equipment and minimize the

length of the ground wire. Leakage current flows through the Inverter. Therefore, if the distance between the ground electrode and the ground terminal is too long, potential on the ground terminal of the Inverter will become unstable.

• When using more than one Inverter, be careful not to loop the ground wire.

2-20

Fig 2.12 Ground Wiring

Page 55

Wiring Main Circuit Terminals

Connecting the Braking Resistor (ERF)

A Braking Resistor that mounts to the Inverter can be used with 200 V and 400 V Class Inverters with outputs from 0.4 to 3.7 kW.

Connect the braking resistor as shown in Fig 2.13.

Table 2.7

L8-01 (Protect selection for internal DB resistor) 1 (Enables overheat protection)

L3-04 (Stall prevention selection during deceleration) (Select either one of them.)

Inverter

Fig 2.13 Connecting the Braking Resistor

The braking resistor connection terminals are B1 and B2. Do not connect to any other terminals. Connecting to any terminals other than B1 or B2 can cause the resistor to overheat, resulting in damage to the equipment.

IMPORTANT

0 (Disables stall prevention function)

3 (Enables stall prevention function with braking resistor)

Braking resistor

Connecting the Braking Resistor Unit (LKEB) and Braking Unit (CDBR)

Use the following settings when using a Braking Resistor Unit. Refer to Wiring Examples on page 10-11 for connection methods for a Braking Resistor Unit.

A Braking Resistor that mounts to the Inverter can also be used with Inverters with outputs from 0.4 to

3.7 kW.

Table 2.8

L8-01 (Protect selection for internal DB resistor) 0 (Disables overheat protection)

L3-04 (Stall prevention selection during deceleration) (Select either one of them.)

0 (Disables stall prevention function)

3 (Enables stall prevention function with braking resistor)

L8-01 is used when a braking resistor without thermal overload relay trip contacts (ERF type mounted to Inverter) is connected.

The Braking Resistor Unit cannot be used and the deceleration time cannot be shortened by the Inverter if L304 is set to 1 (i.e., if stall prevention is enabled for deceleration).

2-21

Page 56

Wiring Control Circuit Terminals

 Wire Sizes and Closed-loop Connectors

For remote operation using analog signals, keep the control line length between the Digital Operator or operation signals and the Inverter to 50 m or less, and separate the lines from high-power lines (main circuits or relay sequence circuits) to reduce induction from peripheral devices.

When setting frequencies from an external frequency setter (and not from a Digital Operator), use shielded twisted-pair wires and ground the shield to terminal E (G), as shown in the following diagram.

Shield terminal

E(G)

Speed setting power supply, +15 V 20 mA

＋

2 kΩ

2ｋΩ

2 kΩ

2ｋΩ

Master speed reference, 0 to 10 V (-10 to 10 V)

Master speed reference, 4 to 20 mA

(0 to 10 V, -10 to 10 V)

2 kΩ

2ｋΩ

2 kΩ

2ｋΩ

Auxiliary reference, 0 to 10 V (-10 to 10 V)

Pulse input, 32 kHz max.

Analog common

Fig 2.14

Terminal numbers and wire sizes are shown in Table 2.9.

Table 2.9 Terminal Numbers and Wire Sizes (Same for all Models)

Recommended

Wire Size

(AWG)

0.75 (18)

1.25 (12)

Wire Type

• Shielded, twisted-pair wire

• Shielded, polyethylene-covered, vinyl sheath cable (KPEV-S by Hitachi Electrical Wire or equivalent)

Possible Wire

Sizes

(AWG)

Terminals

Termi-

nal

Screws

Tightening

Torque

(N•m)

FM, AC, AM, P1, P2,

PC, SC, A1, A2, A3, +V,

-V, S1, S2, S3, S4, S5, S6, S7, S8, MA, MB, MC,

M3.5 0.8 to 1.0

0.5 to 2 (20 to 14)

M1, M2

P3, C3, P4, C4, MP, RP,

R+, R-, S9, S10, S11,

S12, S+, S-, IG

Phoenix

type

0.5 to 0.6

Single wire

0.14 to 2.5 Stranded wire:

0.14 to 1.5 (26 to 14)

E (G) M3.5 0.8 to 1.0

* 1. Use shielded twisted-pair cables to input an external frequency reference. * 2. Refer to Table 2.3 Closed-loop Connector Sizes (JIS C2805) (200 V Class and 400 V Class) for suitable closed-loop crimp terminal sizes for the wires. * 3. We recommend using straight solderless terminal on signal lines to simplify wiring and improve reliability.

0.5 to 2 (20 to 14)

2-22

Page 57

 Straight Solderless Terminals for Signal Lines

Models and sizes of straight solderless terminal are shown in the following table.

Table 2.10 Straight Solderless Terminal Sizes

Wire Size mm

(AWG)

0.25 (24) AI 0.25 - 8YE 0.8 2 12.5

0.5 (20) AI 0.5 - 8WH 1.1 2.5 14

0.75 (18) AI 0.75 - 8GY 1.3 2.8 14

1.25 (16) AI 1.5 - 8BK 1.8 3.4 14

2 (14) AI 2.5 - 8BU 2.3 4.2 14

Model d1 d2 L Manufacturer

Wiring Control Circuit Terminals

Phoenix Contact

Fig 2.15 Straight Solderless Terminal Sizes

Wiring Method

Use the following procedure to connect wires to the terminal block.

1. Loosen the terminal screws with a thin-slot screwdriver.

2. Insert the wires from underneath the terminal block.

3. Tighten the terminal screws firmly.

Thin-slot screwdriver

Control circuit terminal block

Blade of screwdriver

Strip the end for 7 mm if no solderless terminal is used.

Wires

Solderless terminal or wire without soldering

Blade thickness: 0.6 mm max.

Fig 2.16 Connecting Wires to Terminal Block

3.5 mm max.

2-23

Page 58

 Control Circuit Terminal Functions

The functions of the control circuit terminals are shown in Table 2.11. Use the appropriate terminals for the correct purposes.

Table 2.11 Control Circuit Terminals

Type

No. Signal Name Function Signal Level

S1 Forward Run/Stop Command Forward run when ON; stopped when OFF.

S2 Reverse Run/Stop Command Reverse run when ON; stopped when OFF.

Multi-function input 1

Multi-function input 2

Factory setting: External fault when ON.

Factory setting: Fault reset when ON.

Se-

quence

input

signals

Analog

input

signals

Multi-function input 3

Multi-function input 4

Multi-function input 5

Multi-function input 6

Multi-function input 7

S10

Multi-function input 8

S11

Multi-function input 9

S12

Multi-function input 10

Factory setting: Multi-speed reference 1 effective when ON.

Factory setting: Multi-speed reference 2 effective when ON.

Factory setting: Jog frequency selected when ON.

Factory setting: External baseblock when ON.

Factory setting: Multi-speed reference 3 effective when ON.

Factory setting: Multi-speed reference 4 effective when ON.

Factory setting: Acceleration/deceleration time selected when ON.

Factory setting: Emergency stop (NO con-

tact) when ON.

24 VDC, 8 mA Photocoupler isolation

SC Sequence input common -

+V +15 V power output +15 V power supply for analog references

-V -15 V power output -15 V power supply for analog references

Master speed frequency ref-

erence

-10 to +10 V/-100 to 100% 0 to +10 V/100%

4 to 20 mA/100%, -10 to +10 V/-100 to

A2 Multi-function analog input

+100%, 0 to +10 V/100% Factory setting: Added to terminal A1

+15 V (Max. current: 20 mA)

-15 V (Max. current: 20 mA)

-10 to +10 V, 0 to +10 V (Input impedance: 20 kΩ)

4 to 20 mA (Input impedance: 250 Ω)

(H3-09 = 0)

A3 Multi-function analog input

-10 to +10 V/-100 to +100%, 0 to +10 V/ 100% Factory setting: Analog speed 2 (H3-05 = 2)

-10 to +10 V, 0 to +10 V (Input impedance: 20 kΩ)

AC Analog reference common 0 V -

2-24

Shield wire, optional ground

E(G)

line connection point

Page 59

Type

Photoc

oupler

outputs

Wiring Control Circuit Terminals

Table 2.11 Control Circuit Terminals (Continued)

No. Signal Name Function Signal Level

P1 Multi-function PHC output 1

Factory setting: Zero-speed Zero-speed level (b2-01) or below when ON.

Factory setting: Frequency agreement detec-

P2 Multi-function PHC output 2

tion Frequency within 2 Hz of set frequency when ON.

Photocoupler output common

for P1 and P2

50 mA max. at 48 VDC

Relay

outputs

Analog

moni-

tor out-

puts

Pulse

I/O

Multi-function PHC output 3

Multi-function PHC output 4

Fault output signal (NO con-

tact)

Fault output signal (NC con-

tact)

Relay contact output com-

mon

Multi-function contact output (NO contact)

Multi-function analog moni-

tor 1

Multi-function analog monitor 2

Factory setting: Ready for operation when ON.

Factory setting: FOUT frequency detected when ON.

Fault when CLOSED across MA and MC Fault when OPEN across MB and MC

Factory setting: Operating Operating when ON across M1 and M2.

Factory setting: Output frequency 0 to 10 V/100% frequency

Factory setting: Current monitor 5 V/Inverter's rated current

AC Analog common -

Factory setting: Frequency reference input

Multi-function pulse input

MP Multi-function pulse monitor

(H6-01 = 0)

Factory setting: Output frequency (H6-06 = 2)

Dry contacts Contact capacity: 10 mA min. 1 A max. at 250 VAC

10 mA min. 1 A max. at 30 VDC Minimum permissible

load: 5 VDC, 10 mA

-10 to +10 VDC ±5% 2 mA max.AM

0 to 32 kHz (3 kΩ)

0 to 32 kHz (2.2 kΩ)

R+

RS-

485/

422

MEMOBUS communications input

R-

S+

MEMOBUS communications output

S-

For 2-wire RS-485, short R+ and S+ as well as R- and S-.

Differential input, photocoupler isolation

Differential output, photocoupler isolation

IG Communications shield wire - -

* 1. For a 3-wire sequence, the default settings are a 3-wire sequence for S5, multi-step speed setting 1 for S6 and multi-step speed setting 2 for S7. * 2. When driving a reactive load, such as a relay coil, always insert a flywheel diode as shown in Fig 2.17. * 3. Pulse input specifications are given in the following table. * 4. Use the photocoupler outputs when the minimum permissible load is 5 VDC or less and 10 mA or less.

Low level voltage 0.0 to 0.8 V

High level voltage 3.5 to 13.2 V

H duty 30% to 70%

Pulse frequency 0 to 32 kHz

2-25

Page 60

Flywheel diode

External power: 48 V max.

Coil

50 mA max.

Fig 2.17 Flywheel Diode Connection

Shunt Connector CN5 and DIP Switch S1

The shunt connector CN 5 and DIP switch S1 are described in this section.

CN5

The rating of the flywheel diode must be at least as high as the circuit voltage.

OFF ON

Note: Refer to Table 2.12 for S1

Terminating resistance

Analog input switch

: Factory settings

functions and to Table

2.13 for CN5 functions.

Fig 2.18 Shunt Connector CN5 and DIP Switch S1

The functions of DIP switch S1 are shown in the following table.

Table 2.12 DIP Switch S1

Name Function Setting

S1-1

RS-485 and RS-422 terminating resistance

S1-2 Input method for analog input A2

OFF: No terminating resistance ON: Terminating resistance of 110 Ω

OFF: 0 to 10 V, -10 to 10 V (internal resistance: 20 kΩ) ON: 4 to 20 mA (internal resistance: 250 Ω)

 Sinking/Sourcing Mode

The input terminal logic can be switched between sinking mode (0-V common) and sourcing mode (+24-V common) if shunt connector CN5 is used. An external 24-V power supply is also supported, providing more freedom in signal input methods.

2-26

Page 61

Wiring Control Circuit Terminals

Table 2.13 Sinking/Sourcing Mode and Input Signals

Internal Power Supply External Power Supply

Sink-

ing

Mode

Sourc-

ing

Mode

CN5

Shunt position

CN5

CN5 (NPN set) Factory setting

CN5 (PNP set)

IP24V (24 V)

CN5

External +24 V

CN5

External + 24 V

CN5 (EXT set)

IP24V (24 V)

CN5 (EXT set)

IP24V (24 V)

2-27

Page 62

 Control Circuit Terminal Connections

Connections to Inverter control circuit terminals are shown in Fig 2.19.

Inverter

CIMR-G7A2018

External frequency references

Multi-function contact input

Defaults

Pulse train input

Frequency setter

2 kΩ

Forward Run/Stop

Reverse Run/Stop

Thermal switch contact

for Braking Unit

External fault

Fault reset

Multi-step command 1 (Main speed switching)

Multi-step speed setting 2

Jog frequency selection

External baseblock command

Multi-step speed setting 3

Multi-step speed setting 4

Acc/dec time 1

Emergency stop (NO)

2 kΩ

0 to 10 V

4 to 20 mA

0 to 10 V

MEMOBUS communications RS-485/422

Frequency setting adjustment

S10

S11

S12

CN5 (NPN setting)

E(G)

-V

R+

R-

S+

S-

+24V 8mA

+24V

Shield wire connection terminal

Master speed pulse train

0 to 32 kHz (3 kΩ)

High level: 3.5 to 13.2 V input

Frequency setting power

+15 V 20 mA

Master speed reference

0 to 10 V (20 kΩ)

Master speed reference

4 to 20 mA (250 Ω) [0 to 10 V (20 kΩ) input]

Multi-function anlog input

0 to 10 V

(20 kΩ)

Factory setting:

Auxiliary frequency command

(−15V 20mA)

Terminating resistance

E(G)

Pulse train output

0 to 32 kHz (2.2 kΩ)

Default: Output frequency

Ammeter adjustment

20 kΩ

Multi-function analog output 2

-10 to 10 V 2 mA

−

Default: Output current

0 to +10 V

Ammeter adjustment

20 kΩ

Multi-function analog output 1

+−

-10 to 10 V 2 mA

Default: Output current 0 to +10 V

Error contact output

250 VAC, 10 mA min. 1 A max. 30 VDC, 10 mA min. 1 A max.

Multi-function contact output 250 VAC, 10 mA min. 1 A max.

30 DC, 10 mA min. 1 A max.

Default: Running signal

Open collector 1

Default: Zero speed

Open collector 2

Default: Frequency agree signal

Open collector 3

Factory setting: Inverter operation ready

Open collector 4

Factory setting: Minor fault

Multi-function open-collector outputs 48 VDC, 50 mA

2-28

Fig 2.19 Control Circuit Terminal Connections

Page 63

 Control Circuit Wiring Precautions

Observe the following precautions when wiring control circuits.

• Separate control circuit wiring from main circuit wiring (terminals R/L1, S/L2, T/L3, B1, B2, U/T1, V/T2,

W/T3, , 1, 2, and 3) and other high-power lines.

• Separate wiring for control circuit terminals MA, MB, MC, M1, and M2 (contact outputs) from wiring to

other control circuit terminals.

• Use shielded twisted-pair cables for control circuits to prevent operating faults. Process cable ends as

shown in Fig 2.20.

• Connect the shield wire to terminal E (G).

• Insulate the shield with tape to prevent contact with other signal lines and equipment.

• Use a class 2 power supply (UL standard) when connecting to the control terminals.

Wiring Control Circuit Terminals

Shield sheath

Connect to shield sheath terminal at Inverter (terminal E (G))

Fig 2.20 Processing the Ends of Shielded Twisted-pair Cables

Insulate with tape

Armor

Do not connect here.

2-29

Page 64

Wiring Check

 Checks

Check all wiring after wiring has been completed. Do not perform a buzzer check on control circuits. Perform the following checks on the wiring.

• Is all wiring correct?

• Have any wire clippings, screws, or other foreign material been left?

• Are all screws tight?

• Are any wire ends contacting other terminals?

2-30

Page 65

Installing and Wiring Option Boards

 Option Board Models and Specifications

Up to three option boards can be mounted in the Inverter. You can mount up one Board into each of the three places on the control board (A, C, and D) shown in Fig 2.21.

Table 2.14 lists the type of option boards and their specifications.

Table 2.14 Option Board Specifications

Board Model Specifications

PG Speed Control Boards

Speed Reference Boards

PG-A2 Serial open-collector/complimentary inputs A

PG-B2 Phase A/B complimentary inputs A

PG-D2 Single line-driver inputs A

PG-X2 Phase A/B line-driver inputs A

Input signal levels

AI-14U

AI-14B

DI-08 8-bit digital speed reference setting C

0 to 10 V DC (20 kΩ), 1 channel 4 to 20 mA (250 Ω), 1 channel Input resolution: 14-bit

Input signal levels 0 to 10 V DC (20 kΩ) 4 to 20 mA (250 Ω), 3 channels Input resolution: 13-bit with sign bit

Mounting Loca-

tion

DI-16H2 16-bit digital speed reference setting C

DeviceNet Communications Board

Profibus-DP Communications Board

CC-Link Communications Board

ONWORKS

L Communications Board

Analog Monitor Board

Digital Output Board

SI-N1 DeviceNet communications support C

SI-P1 Profibus-DP communications support C

SI-C CC-Link communications support C

SI-J

SI-W1

AO-08 8-bit analog outputs, 2 channels D

AO-12 12-bit analog outputs, 2 channels D

DO-08 Six photocoupler outputs and 2 relay outputs D

DO-02C 2 relay outputs D

ONWORKS communications support C

 Installation

Before mounting an option board, remove the terminal cover and be sure that the charge indicator inside the Inverter is not lit. After confirming that the charge indicator is not lit, remove the Digital Operator and front cover and then mount the option board.

Refer to documentation provided with the option board for actual mounting instructions for option slots A, C, and D.

2-31

Page 66

 Preventing C and D Option Board Connectors from Rising

After installing an option board into slot C or D, insert an option clip to prevent the side with the connector from rising. The option clip can be easily removed by holding onto the protruding portion of the clip and pulling it out.

Remove the option clip before installing an option board into slot C or D. The option board can not be installed completely and may not function properly if it is installed with the option clip attached.

A option board mounting spacer hole

4CN A option board connector

2CN C option board connector

A option board mounting spacer (Provided with A Option Board.)

C option board mounting spacer

Option Clip (To prevent raising of C and D option boards)

3CN D option board connector

A option board

A option board mounting spacer

C option board

D option board

D option board mounting spacer

Fig 2.21 Mounting Option Boards

 PG Speed Control Board Terminals and Specifications

The terminal specifications for the PG Speed Control Boards are given in the following tables.

PG-A2

The terminal specifications for the PG-A2 are given in the following table.

Table 2.15 PG-A2 Terminal Specifications

Terminal No. Contents Specifications

Power supply for pulse generator

2 0 VDC (GND for power supply)

12 VDC (±5%), 200 mA max.

2-32

Terminal for switching between12 V voltage input and open collector input. For open collector input, short across 3 and 4.

H: +4 to 12 V; L: +1 V max. (Maximum response frequency: 30 kHz)

TA1

+12 V/open collector switching terminal

Pulse input terminal

6 Pulse input common

12 VDC (±10%), 20 mA max.

Pulse motor output terminal

8 Pulse monitor output common

TA2 (E) Shield connection terminal -

Page 67

Installing and Wiring Option Boards

PG-B2

The terminal specifications for the PG-B2 are given in the following table.

Table 2.16 PG-B2 Terminal Specifications

Terminal No. Contents Specifications

Power supply for pulse generator

2 0 VDC (GND for power supply)

A-phase pulse input terminal

TA1

4 Pulse input common

B-phase pulse input terminal

6 Pulse input common

A-phase monitor output terminal

2 A-phase monitor output common

TA2

B-phase monitor output terminal

4 B-phase monitor output common

12 VDC (±5%), 200 mA max.

H: +8 to 12 V L: +1 V max. (Maximum response frequency: 30 kHz)

Open collector output, 24 VDC, 30 mA max.

TA3 (E) Shield connection terminal -

PG-D2

The terminal specifications for the PG-D2 are given in the following table.

Table 2.17 PG-D2 Terminal Specifications

Terminal No. Contents Specifications

Power supply for pulse generator

2 0 VDC (GND for power supply)

3 5 VDC (±5%), 200 mA max.*

TA1

TA2 (E) Shield connection terminal -

* 5 VDC and 12 VDC cannot be used at the same time.

4 Pulse input + terminal

5 Pulse input - terminal

6 Common terminal -

7 Pulse monitor output + terminal

8 Pulse monitor output - terminal

12 VDC (±5%), 200 mA max.*

Line driver input (RS-422 level input) Maximum response frequency: 300 kHz

Line driver output (RS-422 level output)

2-33

Page 68

PG-X2

The terminal specifications for the PG-X2 are given in the following table.

Table 2.18 PG-X2 Terminal Specifications

Terminal No. Contents Specifications

TA1

TA2

Power supply for pulse generator

2 0 VDC (GND for power supply)

3 5 VDC (±5%), 200 mA max.*

4 A-phase + input terminal

5 A-phase - input terminal

6 B-phase + input terminal

7 B-phase - input terminal

8 Z-phase + input terminal

9 Z-phase - input terminal

10 Common terminal 0 VDC (GND for power supply)

1 A-phase + output terminal

2 A-phase - output terminal

3 B-phase + output terminal

4 B-phase - output terminal

12 VDC (±5%), 200 mA max.*

Line driver input (RS-422 level input) Maximum response frequency: 300 kHz

Line driver output (RS-422 level output)

5 Z-phase + output terminal

6 Z-phase - output terminal

7 Control circuit common Control circuit GND

TA3 (E) Shield connection terminal -

* 5 VDC and 12 VDC cannot be used at the same time.

 Wiring

Wiring examples are provided in the following illustrations for the option boards.

 Wiring the PG-A2

Wiring examples are provided in the following illustrations for the PG-A2.

Three-phase, 200 VAC (4 00 VA C)

Inverter

R/L1

V/T2

W/T3

U/T1

V/T2

W/T3

4CN

PC-A2

4CN

TA1

TA2 (E )

+12 V power supply

0 V power supply

12 V voltage input (A/B phase)

Pulse 0 V

6 7 8

Pulse monitor output

2-34

Fig 2.22 Wiring a 12 V Voltage Input

Page 69

Installing and Wiring Option Boards

Three-phase, 200 VAC (400 VAC) Inverter

R/L1

U/T1

V/T2

W/T3

4CN

PC-A2

TA2 (E )

TA1

+12 V power supply

0 V power supply

Open collector output (A/B phase)

Pulse 0 V

Pulse monitor output

• Shielded twisted-pair wires must be used for signal lines.

• Do not use the pulse generator's power supply for anything other than the pulse generator (encoder).

Using it for another purpose can cause malfunctions due to noise.

• The length of the pulse generator's wiring must not be more than 100 meters.

PG power supply +12 V

Short for open-collector input

Pulse input

Fig 2.23 Wiring an Open-collector Input

Pulse input

Fig 2.24 I/O Circuit Configuration of the PG-A2

Pulse monitor output

2-35

Page 70

 Wiring the PG-B2

Wiring examples are provided in the following illustrations for the PG-B2.

Three-phase 200 VAC (4 00 VA C)

Inverter

Power supply +12 V

Power supply 0 V

A-phase pulse output (+)

A-phase pulse output (-)

B-phase pulse output (+)

B-phase pulse output (-)

A-phase pulse monitor output

B-phase pulse monitor output

• Shielded twisted-pair wires must be used for signal lines.

• Do not use the pulse generator's power supply for anything other than the pulse generator (encoder).

Using it for another purpose can cause malfunctions due to noise.

• The length of the pulse generator's wiring must not be more than 100 meters.

• The direction of rotation of the PG can be set in user constant F1-05. The factory preset if for forward

rotation, A-phase advancement.

PG power supply +12 V

A-phase pulse input

B-phase pulse input

Fig 2.25 PG-B2 Wiring

A-phase pulse

monitor output A-phase pulses

B-phase pulse

monitor output B-phase

Division rate circuit

pulses

When connecting to a voltage-output-type PG (encoder), select a PG that has an output impedance with

•

a current of at least 12 mA to the input circuit photocoupler (diode).

• The pulse monitor dividing ratio can be changed using constant F1-06 (PG division rate).

A-phase pulses

B-phase pulses

• The pulse monitor emitter is connected to common inside the PG-B2. The emitter common must be used

for external circuits.

2-36

Fig 2.26 I/O Circuit Configuration of the PG-B2

Page 71

Wiring the PG-D2

Wiring examples are provided in the following illustrations for the PG-D2.

Installing and Wiring Option Boards

Three-phase 200 VAC (400 VAC)

Inverter

Power supply +12 V Power supply 0 V

Power supply +5 V

Pulse input + (A/B phase)

Pulse input - (A/B phase)

• Shielded twisted-pair wires must be used for signal lines.

• Do not use the pulse generator's power supply for anything other than the pulse generator (encoder).

Using it for another purpose can cause malfunctions due to noise.

• The length of the pulse generator's wiring must not be more than 100 meters.

Fig 2.27 PG-D2 Wiring

Wiring the PG-X2

Wiring examples are provided in the following illustrations for the PG-X2.

Pulse monitor output

Three-phase 200 VAC (400 VAC )

Inverter

R/L1

U/T1

S/L2

V/T2

W/T3T/L3

Power supply +12 V Power supply 0 V

Power supply +5 V

A-phase pulse input (+)

A-phase pulse input (-) B-phase pulse input (+)

B-phase pulse input (-)

A-phase pulse monitor output

B-phase pulse monitor output

Z-phase pulse monitor output

• Shielded twisted-pair wires must be used for signal lines.

• Do not use the pulse generator's power supply for anything other than the pulse generator (encoder).

Using it for another purpose can cause malfunctions due to noise.

• The length of the pulse generator's wiring must not be more than 100 meters.

• The direction of rotation of the PG can be set in user constant F1-05 (PG Rotation). The factory preset if

for motor forward rotation, A-phase advancement.

Fig 2.28 PG-X2 Wiring

2-37

Page 72

 Wiring Terminal Blocks

Use no more than 100 meters of wiring for PG (encoder) signal lines, and keep them separate from power lines.

Use shielded, twisted-pair wires for pulse inputs and pulse output monitor wires, and connect the shield to the shield connection terminal.

Wire Sizes (Same for All Models)

Terminal wire sizes are shown in Table 2.19.

Table 2.19 Wire Sizes

Te rm i na l

Pulse generator power supply Pulse input terminal Pulse monitor output terminal

Shield connection terminal M3.5 0.5 to 2

Terminal

Screws

Wire Thickness (mm

Stranded wire: 0.5 to 1.25 Single wire: 0.5 to 1.25

Straight Solderless Terminals for Control Circuit Terminals

We recommend using straight solderless terminal on signal lines to simplify wiring and improve reliability.

)

• Shielded, twisted-pair wire

• Shielded, polyethylene-covered, vinyl sheath cable (KPEV-S by Hitachi Electric Wire or equivalent)

Wire Type

Refer to Straight Solderless Terminal Sizes for specifications.

Closed-loop Connector Sizes and Tightening Torque

The closed-loop connectors and tightening torques for various wire sizes are shown in Table 2.20.

Table 2.20 Closed-loop Connectors and Tightening Torques

Wire Thickness [mm

0.5

0.75 1.25 - 3.5

1.25 1.25 - 3.5

2 2 - 3.5

]

Terminal

Screws

M3.5

Crimp Terminal Size Tightening Torque (N • m)

1.25 - 3.5

0.8

Wiring Method and Precautions

The wiring method is the same as the one used for straight solderless terminals. Refer to page 2-23. Observe the following precautions when wiring.

• Separate the control signal lines for the PG Speed Control Board from main circuit lines and power lines.

• Connect the shield when connecting to a PG. The shield must be connected to prevent operational errors

caused by noise. Also, do not use any lines that are more than 100 m long. Refer to Fig 2.20 for details on connecting the shield.

• Connect the shield to the shield terminal (E).

• Do not solder the ends of wires. Doing so may cause contact faults.

• When not using straight solderless terminals, strip the wires to a length of approximately 5.5 mm.

2-38

Page 73

Installing and Wiring Option Boards

 Selecting the Number of PG (Encoder) Pulses

The setting for the number of PG pulses depends on the model of PG Speed Control Board being used. Set the correct number for your model.

PG-A2/PG-B2

The maximum response frequency is 32,767 Hz.

Use a PG that outputs a maximum frequency of approximately 20 kHz for the rotational speed of the motor.

Motor speed at maximum frequency output (min

−

)

× PG rating (p/rev) = 20,000 Hz

Some examples of PG output frequency (number of pulses) for the maximum frequency output are shown in Table 2.21.

Table 2.21 PG Pulse Selection Examples

Motor's Maximum Speed (min

−1

)

PG Rating

(p/rev)

1800 600 18,000

1500 600 15,000

1200 900 18,000

900 1200 18,000

Note 1. The motor speed at maximum frequency output is expressed as the sync rotation speed.

2. The PG power supply is 12 V.

3. A separate power supply is required if the PG power supply capacity is greater than 200 mA. (If momentary power loss must be handled, use a backup capacitor or other method.)

PG power supply

PG Output Frequency for Maximum Fre-

quency Output (Hz)

Capacitor for momentary power loss

Signals

Fig 2.29 PG-B2 Connection Example

2-39

Page 74

PG-D2/PG-X2

There are 5 V and 12 V PG power supplies. Check the PG power supply specifications before connecting.

The maximum response frequency is 300 kHz.

Use the following equation to computer the output frequency of the PG (f

(Hz) =

Motor speed at maximum frequency output (min

−

)

× PG rating (p/rev)f

A separate power supply is required if the PG power supply capacity is greater than 200 mA. (If momentary power loss must be handled, use a backup capacitor or other method.)

PG-X2

TA 1

IP12

IP5

A (+)

A (-)

B (+)

B (-)

Z (+)

Z (-)

TA 3

Capacitor for momentary power loss

PG power supply

0V +12V

0 V

+12 V

Fig 2.30 PG-X2 Connection Example (for 12 V PG power supply)

2-40

Page 75

Digital Operator and Modes

This chapter describes Digital Operator displays and functions, and provides an overview of

operating modes and switching between modes.

Digital Operator............................................................3-2

Modes ..........................................................................3-4

Page 76

Digital Operator

This section describes the displays and functions of the Digital Operator.

 Digital Operator Display

The key names and functions of the Digital Operator are described below.

Drive Mode Indicators

FWD: Lit when there is a Forward Run Command input. REV: Lit when there is a Reverse Run Command input.

Frequency Ref

SEQ: Lit when the Run Command from the control circuit terminal is enabled. REF: Lit when the frequency reference from control circuit terminals A1 and A2 is enabled. ALARM: Lit when an error or alarm has occurred.

Data Display Displays monitor data, constant numbers, and settings.

Mode Display (Displayed at upper left of data display.) DRIVE: Lit in Drive Mode. QUICK: Lit in Quick Programming Mode. ADV: Lit in Advanced Programming Mode. VERIFY: Lit in Verify Mode. A. TUNE: Lit in Autotuning Mode.

Keys

Execute operations such as setting user constants, monitoring, jogging, and autotuning.

Fig 3.1 Digital Operator Component Names and Functions

 Digital Operator Keys

The names and functions of the Digital Operator Keys are described in Table 3.1.

Table 3.1 Key Functions

Key Name Function

Switches between operation via the Digital Operator (LOCAL) and

LOCAL/REMOTE Key

MENU Key Selects menu items (modes).

control circuit terminal operation (REMOTE). This Key can be enabled or disabled by setting user constant o2-01.

3-2

ESC Key Returns to the status before the DATA/ENTER Key was pressed.

JOG Key

Enables jog operation when the Inverter is being operated from the Digital Operator.

Page 77

Table 3.1 Key Functions (Continued)

Key Name Function

Digital Operator

FWD/REV Key

Shift/RESET Key

Selects the rotation direction of the motor when the Inverter is being operated from the Digital Operator.

Sets the number of digits for user constant settings. Also acts as the Reset Key when a fault has occurred.

Selects menu items, sets user constant numbers, and increments set

Increment Key

values. Used to move to the next item or data.

Selects menu items, sets user constant numbers, and decrements set

Decrement Key

values. Used to move to the previous item or data.

DATA/ENTER Key

RUN Key

Pressed to enter menu items, user constants, and set values. Also used to switch from one display to another.

Starts the Inverter operation when the Inverter is being controlled by the Digital Operator.

Stops Inverter operation.

STOP Key

This Key can be enabled or disabled when operating from the control circuit terminal by setting user constant o2-02.

Note Except in diagrams, Keys are referred to using the Key names listed in the above table.

There are indicators on the upper left of the RUN and STOP Keys on the Digital Operator. These indicators will light and flash to indicate operating status.

The RUN Key indicator will flash and the STOP Key indicator will light during initial excitation of the dynamic brake. The relationship between the indicators on the RUN and STOP Keys and the Inverter status is shown in the Fig 3.2.

Inverter output frequency

STOP

Frequency setting

RUN

STOP

Lit Blinking Not lit

RUN

STOP

Fig 3.2 RUN and STOP Indicators

3-3

Page 78

Modes

This section describes the Inverter's modes and switching between modes.

 Inverter Modes

The Inverter's user constants and monitoring functions are organized in groups called modes that make it easier to read and set user constants.The Inverter is equipped with 5 modes.

The 5 modes and their primary functions are shown in the Table 3.2.

Table 3.2 Modes

Mode Primary function(s)

The Inverter can be run in this mode.

Drive mode

Quick programming mode

Advanced programming mode Use this mode to reference and set all user constants.

Verify mode

Use this mode when monitoring values such as frequency references or output current, displaying fault information, or displaying the fault history.

Use this mode to reference and set the minimum user constants to operate the Inverter (e.g., the operating environment of the Inverter and Digital Operator).

Use this mode to read/set user constants that have been changed from their factoryset values.

Use this mode when running a motor with unknown motor constants in the vector

Autotuning mode*

* Always perform autotuning with the motor before operating using vector control. Autotuning mode will not be displayed during operation or when an error

has occurred. The default setting of the Inverter is for open-loop vector 1 control (A1-02 = 2).

control method. The motor constants are calculated and set automatically. This mode can also be used to measure only the motor line-to-line resistance.

3-4

Page 79

 Switching Modes

The mode selection display will appear when the MENU Key is pressed from a monitor or setting display. Press the MENU Key from the mode selection display to switch between the modes.

Press the DATA/ENTER Key from the mode selection key to monitor data and from a monitor display to access the setting display.

Display at Startup

-DRIVE-

Frequency Ref

U1- 01=60.00Hz

U1-02=60.00Hz U1-03=10.05A

Rdy

Modes

Mode Selection Display

-DRIVE-

** Main Menu **

Operation

-QUICK-

** Main Menu **

Quick Setting

-ADV-

** Main Menu **

Programming

-VERIFY-

** Main Menu **

Modified Consts

-A.TUNE-

** Main Menu **

Auto-Tuning

DATA

ENTER

ESC

DATA

ENTER

ESC

DATA

ENTER

ESC

DATA

ENTER

ESC

DATA

ENTER

ESC

Monitor Display Setting Display

-DRIVE-

Monitor

U1 - 01=60.00Hz

U1-02=60.00Hz U1-03=10.05A

-QUICK-

Control Method

A1-02=2

Open Loop Vector

-ADV-

Initialization

Rdy

A1 - 00=1

Select Language

-VERIFY-

None Modified

-A.TUNE-

Tuning Mode Sel

T1- 01=0 1

Standard Tuning

"0"

*2*

*0*

RESET

ESC

RESET

ESC

DATA ENTER

ESC

DATA

ENTER

ESC

-DRIVE-

Frequency Ref

U1- 01=060.00Hz

(0.00←→60.00)

-QUICK-

Control Method

Open Loop Vector

-ADV-

Select Language

DATA

ENTER

ESC

English

Rdy

*1*

-DRIVE-

Reference Source

U1- 01=60.00Hz

U1-02=60.00Hz U1-03=10.05A

-ADV-

Select Language

A1-00 =0

The constant number will be displayed if a constant has been changed. Press the DATA/ENTER Key to enable the change.

DATA

ENTER

ESC

-A.TUNE-

Tuning Mode Sel

DATA

ENTER

"0.00Hz"

A1-02= 2

DATA ENTER

A1- 00= 0

English

T1- 01= 0

Standard Tuning

"0"

Rdy

*2*

*1*

*0*

IMPORTANT

Fig 3.3 Mode Transitions

When running the Inverter after using Digital Operator, press the MENU Key to select the drive mode (displayed on the LCD screen) and then press the DATA/ENTER Key from the drive mode display to bring up the monitor display. Run Commands can't be received from any other display. (Monitor display in the drive mode will appear when the power is turned ON.)

3-5

Page 80

 Drive Mode

Drive mode is the mode in which the Inverter can be operated. The following monitor displays are possible in drive mode: The frequency reference, output frequency, output current, and output voltage, as well as fault information and the fault history. When b1-01 (Reference selection) is set to 0, the frequency can be changed from the frequency setting display. Use the Increment, Decrement, and Shift/RESET Keys to change the frequency. The user constant will be written and the monitor display will be returned to when the DATA/ENTER Key is pressed after changing the setting.

Example Operations

Key operations in drive mode are shown in the following figure.

Display at Startup

-DRIVE-

Frequency Ref

U1- 01=60.00Hz

U1-02=60.00Hz

U1-03=10.05A

Rdy

Display

-DRIVE-

** Main Menu **

Operation

-QUICK-

** Main Menu **

Quick Setting

-ADV-

** Main Menu **

Programming

-VERIFY-

** Main Menu **

Modified Consts

-A.TUNE-

** Main Menu **

Auto-Tuning

DATA

ENTER

ESC

Monitor Display Frequency Setting DisplayMode Selection

A B

Monitor

Rdy

RESET

ESC

RESET

ESC

RESET

ESC

RESET

ESC

RESET

ESC

RESET

ESC

RESET

ESC

-DRIVE-

U1- 01=60.00Hz

-DRIVE-

U1- 02=60.00Hz

-DRIVE-

FAN Elapsed Time

U1- 40 = 10H

-DRIVE-

U2 - 01 = OC

-DRIVE-

U2 - 02 = OV

-DRIVE-

U3 - 01 = OC

-DRIVE-

U3 - 02 = OV

-DRIVE-

U1 - 01=60.00Hz

U1-02=60.00Hz U1-03=10.05A

-DRIVE-

U1 - 02=60.00Hz

U1-03=10.05A

U1-04= 2

-DRIVE-

U1 -40 = 10H

U1-01=60.00Hz U1-02=60.00Hz

-DRIVE-

Fault Trace

U2 - 01=OC

U2-02= OV

U2-03=60.00Hz

-DRIVE-

Fault Trace

U2 - 02 = OV

U3-03=60.00Hz U3-04=60.00Hz

-DRIVE-

Fault History

U3 - 01= OC

U3-02= OV U3-03= OH

-DRIVE-

Fault Message 2

U3 - 02 = OV

U3-03= OH U3-04= UV

A B

Fig 3.4 Operations in Drive Mode

1 2

Frequency Ref

U1-02=60.00Hz U1-03=10.05A

Output Freq

U1-03=10.05A

U1-04= 2

U1-01=60.00Hz U1-02=60.00Hz

1 2

3 4

Current Fault

U2-02=OV

U2-03=60.00Hz

Last Fault

U3-03=60.00Hz U3-04=60.00Hz

3 4

5 6

Last Fault

U3-02=OV U3-03=OH

Fault Message 2

U3-03= OH U3-04= UV

5 6

DATA

ENTER

DATA

ENTER

Rdy Rdy

Rdy

-DRIVE-

Frequency Ref

U1 -01= 060.00Hz

(0.00←→60.00)

ESC

0.00Hz

The Frequency Setting Display will not be displayed when using an analog reference.

Rdy

The fault name will be displayed if the DATA/ENTER Key is pressed while a constant is being displayed for which a fault code is being displayed.

DATA

ENTER

Rdy

U2 -01= OC

Over Current

ESC

DATA

Rdy

ENTER

U2 -02= OV

Rdy

DC Bus Overvolt

ESC

DATA ENTER

DATA

Rdy

ENTER

U3 -01= OC

Rdy

Over Current

ESC

Rdy

DATA

ENTER

U3 -02= OV

Rdy

DC Bus Overvolt

ESC

3-6

Page 81

Note When changing the display with the Increment and Decrement Keys, the next display after the one for the last parameter number will be the one for the

first parameter number and vise versa. For example, the next display after the one for U1-01 will be U1-40. This is indicated in the figures by the letters A and B and the numbers 1 to 6.

The display for the first monitor constant (frequency reference) will be displayed when power is turned ON. The monitor item displayed at startup can be set in o1-02 (Monitor Selection after Power Up).

IMPORTANT

Operation cannot be started from the mode selection display.

 Quick Programming Mode

In quick programming mode, the constants required for Inverter trial operation can be monitored and set.

Constants can be changed from the setting displays. Use the Increment, Decrement, and Shift/RESET Keys to change the frequency. The user constant will be written and the monitor display will be returned to when the DATA/ENTER Key is pressed after changing the setting.

Modes

Refer to Chapter 5 User Constants for details on the constants displayed in quick programming mode.

Example Operations

Key operations in quick programming mode are shown in the following figure.

3-7

Page 82

Mode Selection Display

-DRIVE-

** Main Menu **

Operation

-QUICK-

** Main Menu **

Quick Setting

-ADV-

** Main Menu **

Programming

-VERIFY-

** Main Menu **

Modified Consts

-A.TUNE-

** Main Menu **

Auto-Tuning

DATA

ENTER

ESC

Monitor Display

A B

-QUICK-

Control Method

A1-02=2

Open Loop Vector

-QUICK-

Reference Source

b1-01=1

-QUICK-

Run Source

b1-02=1

-QUICK-

Terminal AM Gain

H4-05=0.50

(0.00←→2.50)

-QUICK-

MOL Fault Select

L1-01=1

Std Fan Cooled

-QUICK-

StallP Decel Sel

L3-04=1

Terminals

0.50

Enabled

*2*

*1*

Frequency Setting Display

DATA

ENTER

ESC

DATA

ENTER

-QUICK-

Control Method

A1-02= 2

Open Loop Vector

-QUICK-

Reference Source

b1-01= 1

ESC

DATA

ENTER

-QUICK-

b1-02= 1

ESC

DATA

ENTER

-QUICK-

Terminal AM Gain

H4-05= 0 .50

ESC

DATA

ENTER

ESC

DATA

ENTER

-QUICK-

MOL Fault Select

L1-01= 1

Std Fan Cooled

-QUICK-

StallP Decel Sel

L3-04= 1

ESC

Terminals

Run Source

Terminals

(0.00 2.50)

0.50

Enabled

*2*

*1*

A B

Fig 3.5 Operations in Quick Programming Mode

3-8

Page 83

 Advanced Programming Mode

In advanced programming mode, all Inverter constants can be monitored and set.

Refer to Chapter 5 User Constants for details on the constants.

Example Operations

Key operations in advanced programming mode are shown in the following figure.

Monitor Display Setting DisplayMode Selection Display

Modes

-ADV-

** Main Menu **

Programming

-VERIFY-

** Main Menu **

Modified Consts

-A.TUNE-

** Main Menu **

Auto-Tuning

-DRIVE-

** Main Menu **

Operation

-QUICK-

** Main Menu **

Quick Setting

DATA ENTER

ESC

A B

-ADV-

Initialization

A1-00=1

Select Language

-ADV-

Initialization

A1-02 =2

Control Method

-ADV-

PID Control

b5-01=0

PID Mode

-ADV-

PID Control

b5 - 14= 1.0Sec

Fb los Det Time

-ADV-

Torque Limit

L7-01=200%

Fwd Torque Limit

-ADV-

Torque Limit

L7- 04= 200%

Fwd Torque Limit

RESET

ESC

RESET

ESC

RESET

ESC

RESET

ESC

RESET

ESC

1 2

-ADV-

Select Language

A1- 00 =0

English

-ADV-

Control Method

A1- 02 =2

Open Loop Vector

1 2

3 4

-ADV-

PID Mode

b5- 01 =0

Disabled

-ADV-

Fb los Det Time

b5- 14= 1.0Sec

(0.00 25.5)

1.0Sec

3 4

5 6

-ADV-

Fwd Torque Limit

L7- 01= 200%

(0 300)

200%

-ADV-

Fwd Torque Limit

L7- 04= 200%

(0 300)

200%

DATA

ENTER

-ADV-

*1*

ESC

DATA

ENTER

*2*

ESC

DATA

ENTER

*0* *0*

ESC

DATA

ENTER

ESC

DATA

ENTER

ESC

DATA

ENTER

ESC

Select Language

A1- 00= 0

English

-ADV-

Control Method

A1- 02= 2

Open Loop Vector

-ADV-

PID Mode

b5-01= 0

Disabled

-ADV-

Fb los Det Time

b5-14=01.0Sec

(0.00 25.5)

1.0Sec

-ADV-

Fwd Torque Limit

L7-01= 2 00%

(0 300)

200%

-ADV-

Torq Lmt Rev Rgn

L7-04= 2 00%

(0 300)

200%

*1*

*2*

A B

5 6

Fig 3.6 Operations in Advanced Programming Mode

3-9

Page 84

Setting User Constants

Here, the procedure is shown to change C1-01 (Acceleration Time 1) from 10 s to 20 s.

Table 3.3 Setting User Constants in Advanced Programming Mode

Step

No.

1 Power supply turned ON.

2 MENU Key pressed to enter drive mode.

3 MENU Key pressed to enter quick programming mode.

4 MENU Key pressed to enter advanced programming mode.

5 DATA/ENTER pressed to access monitor display.

Digital Operator Display Description

-DRIVE-

Frequency Ref

Rdy

U1- 01=60.00Hz

U1-02=60.00Hz

U1-03=10.05A

-DRIVE-

** Main Menu **

Operation

-QUICK-

** Main Menu **

Quick Setting

-ADV-

** Main Menu **

Programming

-ADV-

Initialization

A1-00=1

Select Language

-ADV-

Accel Time 1

6 Increment or Decrement Key pressed to display C1-01 (Acceleration Time 1).

8 Shift/RESET Key pressed to move the flashing digit to the right.

9 Increment Key pressed to change set value to 20.00 s.

10 DATA/ENTER Key pressed to enter the set data.

C1-00= 10.0Sec

(0.0←→6000.0)

10.0Sec

-ADV-

Accel Time 1

C1-01= 0 010.0Sec

(0.0←→6000.0)

10.0Sec

-ADV-

Accel Time 1

C1-01= 0 010.0Sec

(0.0←→6000.0)

10.0Sec

-ADV-

Accel Time 1

C1-01= 00 10.0Sec

(0.0←→6000.0)

10.0Sec

-ADV-

Accel Time 1

C1-01= 00 20.0Sec

(0.0←→6000.0)

10.0Sec

-ADV-

Entry Accepted

DATA/ENTER Key pressed to access setting display. The setting of C1-01 (10.00) is displayed.

“Entry Accepted” is displayed for 1.0 s after the data setting has been confirmed with the DATA/ENTER Key.

3-10

-ADV-

12 The monitor display for C1-01 returns.

Accel Time 1

C1- 01= 20.0Sec

(0.0←→6000.0)

10.0Sec

Page 85

External Fault Setting Procedure

Examples of the Digital Operator displays that appear when setting an eternal error for a multi-function contact input in Advanced Programming Mode are shown in the following diagram.

Monitor Display Setting DisplayMode Selection Display

Modes

-ADV-

** Main Menu **

Programming

-VERIFY-

** Main Menu **

Modified Consts

-A.TUNE-

** Main Menu **

Auto-Tuning

-DRIVE-

** Main Menu **

Operation

-QUICK-

** Main Menu **

Quick Setting

DATA

ENTER

DATA

ENTER

ESC

A B

-ADV-

Digital Inputs

H1-01=24

Terminal S3 Sel

-ADV-

Digital Inputs

H1-02 =14

Terminal S4 Sel

-ADV-

Digital Inputs

H1-08 =08

Terminal S8 Sel

-ADV-

Digital Inputs

H2-01= 0

Term M1-M2 Sel

-ADV-

Pulse I/O Setup

H6-01= 0

Pulse Input Sel

A B

RESET

ESC

RESET

ESC

RESET

ESC

1 2

-ADV-

Terminal S3 Sel

H1- 01 =24

External Fault

"24"

-ADV-

Terminal S4 Sel

H1- 02 =14

Fault Reset

"14"

-ADV-

Terminal S8 Sel

H1- 08 =08

Ext BaseBlk N.O.

"08"

1 2

*24*

*14*

*08*

DATA

ENTER

ESC

3 4

-ADV-

Terminal S3 Sel

H1- 01= 24

NO/Always Det

Coast to Stop

-ADV-

Terminal S3 Sel

H1- 01= 25

NC/Always Det

Coast to Stop

-ADV-

Terminal S3 Sel

H1- 01= 26

NO/During RUN

Coast to Stop

-ADV-

Terminal S3 Sel

H1- 01= 27

NC/During RUN

Coast to Stop

-ADV-

Terminal S3 Sel

H1- 01= 2F

NC/During RUN

Alarm Only

*24*

Fig 3.7 External Fault Function Setting Example

3 4

3-11

Page 86

 Verify Mode

Verify mode is used to display any constants that have been changed from their default settings in a programming mode or by autotuning. “None” will be displayed if no settings have been changed.

Of the environment mode settings, only A1-02 will be displayed if it has been changed. Other environment modes settings will not be displayed even if they have been changed from their default settings.

Even in verify mode, the same procedures can be used to change settings as are used in the programming modes. Use the Increment, Decrement, and Shift/RESET Keys to change the frequency. The user constant will be written and the monitor display will be returned to when the DATA/ENTER Key is pressed after changing the setting.

Example Operations

An example of key operations is given below for when the following settings have been changed from their default settings: b1-01 (Reference Selection), C1-01 (Acceleration Time 1), E1-01 (Input Voltage Setting), and E2-01 (Motor Rated Current).

Monitor Display Setting DisplayMode Selection Display

DATA

ENTER

-ADV-

** Main Menu **

Programming

A B

-VERIFY-

Reference Source

b1-01=0

-VERIFY-

Accel Time 1

C1-01=200.0Sec

(0.0 6000.0)

-VERIFY-

Input Voltage

E1-01=200VAC

(155 255)

-VERIFY-

Motor Rated FLA

E2-01=2.00A

(0.32 6.40)

Terminals

"1"

10.0Sec

200VAC

1.90A

*0*

A B

DATA

ENTER

ESC

DATA

ENTER

ESC

DATA

ENTER

ESC

DATA

ENTER

ESC

-VERIFY-

Reference Source

b1-01= 0

Terminals

"1"

-VERIFY-

Accel Time 1

C1-01=0200.0Sec

(0.0 6000.0)

10.0Sec

-VERIFY-

Input Voltage

E1-01= 200VAC

(155 255)

200V

-VERIFY-

Motor Rated FLA

E2-01= 2.00A

(0.32 6.40)

1.90A

-VERIFY-

** Main Menu **

Modified Consts

-A.TUNE-

** Main Menu **

Auto-Tuning

-DRIVE-

** Main Menu **

Operation

-QUICK-

** Main Menu **

Quick Setting

DATA

ENTER

ESC

*0*

3-12

Fig 3.8 Operations in Verify Mode

Page 87

 Autotuning Mode

Autotuning automatically tunes and sets the required motor constants when operating in the vector control methods. Always perform autotuning before starting operation.

When V/f control has been selected, stationary autotuning for only line-to-line resistance can be selected.

When the motor cannot be disconnected from the load, perform stationary autotuning. Contact your Yaskawa representatives to set motor constants by calculation.

The Inverter's autotuning function automatically determines the motor constants, while a servo system's autotuning function determines the size of a load, so these autotuning functions are fundamentally different. The default setting of the Inverter is for open-loop vector 1 control.

Example of Operation

Set the motor output power (in kW), rated voltage, rated current, rated frequency, rated speed, and number of poles specified on the nameplate on the motor and then press the RUN Key. The motor is automatically run and the motor constants measured based on these settings and autotuning will be set.

Modes

Always set the above items. Autotuning cannot be started otherwise, e.g., it cannot be started from the motor rated voltage display.

The following example shows autotuning for open-loop vector control while operating the motor without switching to motor 2.

3-13

Page 88

Monitor Display Setting DisplayMode Selection Display

DATA

ENTER

-VERIFY-

** Main Menu **

Modified Consts

DATA

-A.TUNE-

** Main Menu **

ENTER

Auto-Tuning

ESC

-DRIVE-

** Main Menu **

Operation

-QUICK-

** Main Menu **

Quick Setting

-ADV-

** Main Menu **

Programming

* TUn10 will be displayed during rotational autotuning and TUn11 will be displayed during stationary autotuning. The DRIVE indicator will light when

autotuning starts.

-A.TUNE-

Tuning Mode Sel T1- 01 =0 *0*

Standard Tuning

"0"

-A.TUNE-

Rated Frequency

T1- 05 = 60.0Hz

(0.0 400.0)

0.0Hz

-A.TUNE-

Number of Poles

T1- 06 = 4

(2 48)

-A.TUNE-

Auto-Tuning

0.0Hz/0.0A

Tuning Ready ?

Press RUN key

DATA

ENTER

ESC

DATA

ENTER

ESC

DATA

ENTER

ESC

Rdy

RUN

The display will automatically change depending on the status of autotuning.

-A.TUNE-

Tuning Mode Sel

T1- 01 = 0 *0*

Standard Tuning

"0"

-A.TUNE-

Rated Frequency

T1- 05 = 0 60.0Hz

(0.0 400.0)

0.0Hz

-A.TUNE-

Number of Poles

T1- 06 = 04

(2 48)

-A.TUNE-

Tune Proceeding

48.0Hz/10.5A

START GOAL

STOP

-A.TUNE-

Tune Aborted

STOP key

-A.TUNE-

Tune Proceeding

48.0Hz/10.5A

30%

START GOAL

-A.TUNE-

Tune Proceeding

30%

Tune Successful

-A.TUNE-

Tune Successful

30%

IMPORTANT

Fig 3.9 Operation in Autotuning Mode

The setting displays in for autotuning depend on the control method (V/f, V/f with PG, or open-loop vector). If a fault occurs during autotuning, refer to Chapter 7 Troubleshooting.

3-14

Page 89

Trial Operation

This chapter describes the procedures for trial operation of the Inverter and provides an example

of trial operation.

Trial Operation Procedure............................................4-2

Trial Operation Procedures.......................................... 4-3

Adjustment Suggestions ............................................4-17

Page 90

Trial Operation Procedure

Perform trial operation according to the following flowchart.

START

Installation

Wiring

Select operating method.

(Default: A1-02 = 0)

Settings according to control mode

Set power supply voltage.

Turn ON power.

Confirm status.

Basic settings

(Quick programming mode)

V/f control?

YES

V/f

PG?

Set E1-03. V/f default: 200 V/60 Hz(400 V/60 Hz)

Motor cable over

50 m or heavy load possibly

causing motor to stall or

overload?

Vector (A1-02 = 2, 3, or 4)*5

V/f with PG (A1-02 = 1)

YES

Set E1-03, E2-04, and F1-01. V/f default: 200 V/60 Hz (400 V/60 Hz)

motor during autotuning?

OK to operate

Application settings

(Advanced programming mode)

No-load operation

Loaded operation

Optimum adjustments and

constant settings

Check/record constants.

END

Fig 4.1 Trial Operation Flowchart

YES

Stationary autotuning for line-to-line resistance only

*1 Set for 400 V Class Inverter for 55 kW or more.

*2 If there is a reduction gear between the motor and PG, set the reduction ratio in F1-12 and F1-13 in advanced programming mode.

*3 Use rotational autotuning to increase autotuning accuracy whenever it is okay for the motor to be operated.

*4 If the motor cable changes to 50 m or longer for the actual installation, perform stationary autotuning for the line-to-line resistance only on-site. *5 The default control mode is open-loop vector control 2 (A1-02 = 2).

Rotational autotuning

Stationary autotuning

4-2

Page 91

Trial Operation Procedures

The procedure for the trial operate is described in order in this section.

 Setting the Power Supply Voltage Jumper (400 V Class Inverters of 55 kW

or Higher)

Set the power supply voltage jumper after setting E1-01 (Input Voltage Setting) for 400 V Class Inverters

of 55 kW or higher. Insert the jumper into the power tap nearest to the actual power supply

voltage.

The jumper is factory-set to 440 V when shipped. If the power supply voltage is not 440 V, use the

following procedure to change the setting.

1. Turn OFF the power supply and wait for at least 5 minutes.

2. Confirm that the CHARGE indicator has gone out.

3. Remove the terminal cover.

4. Insert the jumper at the position for the voltage supplied to the Inverter (see Fig 4.2).

5. Return the terminal cover to its original position.

200 V Class power supply

400 V class power supply

Power supply input terminals

Fig 4.2 Power Supply Voltage Jumper

 Power ON

Confirm all of the following items and then turn ON the power supply.

• Check that the power supply is of the correct voltage.

200 V Class: 3-phase 200 to 240 VDC, 50/60 Hz 400 V Class: 3-phase 380 to 480 VDC, 50/60 Hz

• Make sure that the motor output terminals (U, V, W) and the motor are connected correctly.

• Make sure that the Inverter control circuit terminal and the control device are wired correctly.

• Set all Inverter control circuit terminals to OFF.

• When using a PG Speed Control Board, make sure that it is wired correctly.

• Make sure that the motor is not connected to the mechanical system (no-load status)

Power tap

Jumper (factory-set position)

CHARGE indicator

4-3

Page 92

 Checking the Display Status

If the Digital Operator's display at the time the power is connected is normal, it will read as follows:

Display for normal operation

-DRIVE-

Frequency Ref

U1- 01= 60.0 0Hz

U1-01= 0 0 0.0 0Hz

U1-02=60.00Hz

U1-03=10.05A

Rdy

The frequency reference monitor is displayed in the data display section.

When an fault has occurred, the details of the fault will be displayed instead of the above display. In that case, refer to Chapter 7 Troubleshooting. The following display is an example of a display for faulty operation.

Display for fault operation

-DRIVE-

Frequency Ref

DC Bus Undervolt

The display will differ depending on the type of fault. A low voltage alarm is shown at left.

4-4

Page 93

Trial Operation Procedures

 Basic Settings

Switch to the quick programming mode (“QUICK” will be displayed on the LCD screen) and then set the following user constants. Refer to Chapter 3 Digital Operator and Modes for Digital Operator operating procedures and to Chapter 5 User Constants and Chapter 6 Constant Settings by Function for details on the user constants.

Constants that must be set are listed in Table 4.1 and those that are set according to the application are listed in

Table 4.2.

Table 4.1 Constants that Must Be Set

Constant

Number

A1-02

b1-01

Name Description

Set the control method for the Inverter.

0: V/f control Control method selection

Reference selection

1: V/f control with PG

2: Open-loop vector 1 control

3: Flux vector

4: Open-loop vector 2 control

Set the frequency reference input method.

0: Digital Operator

1: Control circuit terminal (analog input)

2: MEMOBUS communications

3: Option board

4: Pulse train input

Setting

Range

0 to 4 2 5-8

0 to 4 1

Factory Setting

Page

5-10

6-2 6-73 6-91

b1-02

C1-01

C1-02

E1-01

E2-01

L1-01

Set the Run Command input method.

Operation method selection

Acceleration time 1Set the acceleration time in seconds for the output

Deceleration time 1Set the deceleration time in seconds for the output

Input voltage setting

Motor rated current

Motor protection selection

0: Digital Operator 1: Control circuit terminal (sequence input) 2: MEMOBUS communications 3: Option board

frequency to climb from 0% to 100%.

frequency to fall from 100% to 0%.

Set the Inverter's nominal input voltage in volts. This setting is used as a reference value in protection functions.

Set the motor rated current.

Set to enable or disable the motor overload protection function using the electronic thermal relay. 0: Disabled 1: General motor protection 2: Inverter motor protection 3: Vector motor protection

0 to 3 1

0.0 to 6000.0 10.0 s

200 V

155 to 255 V

(200 V Class)

310 to 510 V

(400 V Class)

10% to 200%

of Inverter's rated current

0 to 3 1

(200 V

Class)

400 V

(400 V

Class)

Setting for

generalpurpose

motor of

same

capacity

as Inverter

5-10

6-8 6-73 6-91

5-21 6-16

5-33

6-116

5-34 6-55

6-113

5-58 6-55

4-5

Page 94

Table 4.2 Constants that Are Set as Required

Constant

Number

b1-03

C6-02

C6-11

d1-01 to

d1-04 and

d1-17

H4-02

and H4-

L3-04

Name Description

Select stopping method when Stop Command is

sent. Stopping method selection

Carrier frequency selection

Carrier frequency selection for open-loop vector 2 control

Frequency references 1 to 4 and jog frequency reference

FM and AM terminal output gain

Stall prevention selection during deceleration

0: Deceleration to stop 1: Coast to stop 2: DC braking stop 3: Coast to stop with timer

The carrier frequency is set low if the motor cable

is 50 m or longer or to reduce radio noise or leak-

age current.

Set the required speed references for multi-step

speed operation or jogging.

Set the voltage level gain for the multi-function

analog output 1 (H4-02) and 2 (H4-05).

Set the number of multiples of 10 V to be output as

the 100 % output for the monitor item.

0: Disabled (Deceleration as set. If deceleration

time is too short, a main circuit overvoltage may result.)

1: Enabled (Deceleration is stopped when the

main circuit voltage exceeds the overvoltage level. Deceleration restarts when voltage is returned.)

2: Intelligent deceleration mode (Deceleration

rate is automatically adjusted so that the Inverter can decelerate in the shortest possible time. Set deceleration time is disregarded.)

3: Enabled (with Braking Resistor Unit) When a braking option (Braking Resistor, Braking Resistor Unit, Braking Unit) is used, always set to 0 or 3.

Setting

Range

0 to 3 0

1 to F

1 to 4

0 to 400.00 Hz

0.00 to 2.50

0 to 3 1

Factory

Setting

Depends

on capac-

ity, voltage, and

control

method.

Depends

on kVA

setting.

d1-01 to

d1-04:

0.00 Hz d1-17:

6.00 Hz

H4-02:

1.00

H4-05:

0.50

Page

5-10 6-10

5-26

5-27

5-54

5-61 6-23

4-6

Page 95

Trial Operation Procedures

 Settings for the Control Methods

Autotuning methods depend on the control method set for the Inverter. Make the settings required by the control method.

Overview of Settings

Make the required settings in quick programming mode and autotuning mode according to the following flowchart.

START

V/f control?

Vector (A1-02 = 2, 3, or 4)*3

YES V/f

(Default: A1-02 = 0)

Set E1-03. V/f default: 200 V/60 Hz(400 V/60 Hz)

Motor cable over

50 m or heavy load possibly

causing motor to stall

(A1-02 = 0 or 1)

PG?

or overload?

YES

(A1-02 = 1)

Set E1-03, E2-04, and F1-01. V/f default: 200 V/60 Hz(400 V/60 Hz)

YES

Stationary autotuning for line-to-line resistance only

motor during autotuning?*1

Rotational autotuning

Control mode selection

OK to operate

YES

Stationary autotuning

END

Note If the motor cable changes to 50 m or longer for the actual installation, perform stationary autotuning for the line-to-line resistance only on-site. * 1. Use rotational autotuning to increase autotuning accuracy whenever it is okay for the motor to be operated. Always perform rotational autotuning when

using open-loop vector 2 control. * 2. If there is a reduction gear between the motor and PG, set the reduction ratio in F1-12 and F1-13. * 3. The default setting of the Inverter is for open-loop vector 1 control (A1-02 = 2). * 4. If the maximum output frequency is different from the base frequency, set the maximum output frequency (E1-04) to the value of the base frequency

after autotuning.

Fig 4.3 Settings According to the Control Method

4-7

Page 96

Setting the Control Method

Any of the following five control methods can be set.

Control Method

V/f control A1-02 = 0 Voltage/frequency ratio fixed control

Constant Set-

ting

Basic Control Main Applications

Variable speed control, particularly control of multiple motors with one Inverter and replacing existing Inverters

V/f control with PG A1-02 = 1

Open-loop vector 1

control

Flux vector control A1-02 = 3 Flux vector control

Open-loop vector 2

control

Note With vector control, the motor and Inverter must be connected 1:1. The motor capacity for which stable control is possible is 50% to 100% of the capac-

ity of the Inverter.

A1-02 = 2 (factory setting)

A1-02 = 4

Voltage/frequency ratio fixed control with speed compensation using a PG

Current vector control without a PG

Current vector control without a PG with an ASR (speed controller) (Always perform rotational autotuning.)

Applications requiring high-precision speed control using a PG on the machine side

Variable speed control, applications requiring speed and torque accuracy using vector control without a PG

Very high-performance control with a PG (simple servo drives, high-precision speed control, torque control, and torque limiting)

Very high-performance control without a PG (torque control without a PG, torque limiting, applications requiring a 1:200 speed control range without a PG)

V/f Control (A1-02 = 0)

• Set either one of the fixed patterns (0 to E) in E1-03 (V/f Pattern Selection) or set F in E1-03 to specify a

user-set pattern as required for the motor and load characteristics in E1-04 to E1-13 in advanced programming mode.

Simple operation of a general-purpose motor at 50 Hz:

E1-03 = 0

Simple operation of a general-purpose motor at 60 Hz:

E1-03 = F (default) or 1 If E1-03 = F, the default setting in the user setting from E1-04 to E1-13 are for 60 Hz

4-8

• Perform stationary autotuning for the line-to-line resistance only if the motor cable is 50 m or longer for

the actual installation or the load is heavy enough to produce stalling. Refer to the following section on Autotuning for details on stationary autotuning.

V/f Control with PG (A1-02=1)

• Set either one of the fixed patterns (0 to E) in E1-03 (V/f Pattern Selection) or set F in E1-03 to specify a

user-set pattern as required for the motor and load characteristics in E1-04 to E1-13 in advanced programming mode.

Simple operation of a general-purpose motor at 50 Hz:

E1-03 = 0

Simple operation of a general-purpose motor at 60 Hz:

E1-03 = F (default) or 1 If E1-03 = F, the default setting in the user setting from

E1-04 to E1-13 are for 60 Hz

• Set the number of motor poles in E2-04 (Number of Motor Poles)

• Set the number of rotations per pulse in F1-01 (PG Constant). If there is a reduction gear between the

motor and PG, set the reduction ratio in F1-12 and F1-13 in advanced programming mode.

Page 97

Trial Operation Procedures

• Perform stationary autotuning for the line-to-line resistance only if the motor cable is 50 m or longer for

the actual installation or the load is heavy enough to produce stalling. Refer to the following section on Autotuning for details on stationary autotuning.

Open-loop Vector 1 Control (A1-02 = 2)

Perform autotuning. If the motor can be operated, perform rotational autotuning. If the motor cannot be operated, perform stationary autotuning. Refer to the following section on Autotuning for details on autotuning.

Flux Vector Control (A1-02 = 3)

Open-loop Vector 2 Control (A1-02 = 4)

Perform autotuning. Be sure to perform rotational autotuning. Refer to the following section on Autotuning for details on autotuning.

 Autotuning

Use the following procedure to perform autotuning to automatically set motor constants when using the vector control method, when the cable length is long, etc.

If the control method was changed after autotuning, be sure to perform autotuning again.

One of the following three autotuning modes can be set.

• Rotational autotuning

• Stationary autotuning

• Stationary autotuning for line-to-line resistance only

 Precautions Before Using Autotuning

Read the following precautions before using autotuning.

• Autotuning the Inverter is fundamentally different from autotuning the servo system. Inverter autotuning

automatically adjusts parameters according to detected motor constants, whereas servo system autotuning adjusts parameters according to the detected size of the load.

• When speed or torque precision is required at high speeds (i.e., 90% of the rated speed or higher), use a

motor with a rated voltage that is 20 V less than the input power supply voltage of the Inverter for 200Vclass Inverters and 40 V less for 400V-class Inverters. If the rated voltage of the motor is the same as the input power supply voltage, the voltage output from the Inverter will be unstable at high speeds and sufficient performance will not be possible.

• Use stationary autotuning whenever performing autotuning for a motor that is connected to a load.

• Use rotational autotuning whenever performing autotuning for a motor that has fixed output characteris-

tics, when high precision is required, or for a motor that is not connected to a load.

• If rotational autotuning is performed for a motor connected to a load, the motor constants will not be found

accurately and the motor may exhibit abnormal operation. Never perform rotational autotuning for a motor connected to a load.

• If the wiring between the Inverter and motor changes by 50 m or more between autotuning and motor

installation, perform stationary autotuning for line-to-line resistance only.

• If the motor cable is long (50 m or longer), perform stationary autotuning for line-to-line resistance only

even when using V/f control.

4-9

Page 98

• The status of the multi-function inputs and multi-function outputs will be as shown in the following table

during autotuning. When performing autotuning with the motor connected to a load, be sure that the holding brake is not applied during autotuning, especially for conveyor systems or similar equipment.

Tuning Mode Multi-function Inputs Multi-function Outputs

Rotational autotuning Do not function.

Same as during normal

operation

Stationary autotuning Do not function.

Stationary autotuning for line-

to-line resistance only

• To cancel autotuning, always use the STOP Key on the Digital Operator.

1. Power will be supplied to the motor when stationary autotuning is performed even though the motor will not turn. Do not touch the motor until autotuning has been completed.

IMPORTANT

2. When performing stationary autotuning connected to a conveyor or other machine, ensure that the holding brake is not activated during autotuning.

Do not function.

Maintain same status as

when autotuning is started.

Maintain same status as

when autotuning is started.

Setting the Autotuning Mode

Rotational Autotuning (T1-01 = 0)

Rotational autotuning is used only for open-vector control. Set T1-01 to 0, input the data from the nameplate, and then press the RUN Key on the Digital Operator. The Inverter will stop the motor for approximately 1 minute and then set the required motor constants automatically while operating the motor for approximately 1 minute.

Stationary Autotuning (T1-01 = 1)

Stationary autotuning is used for open-vector control or flux vector control. Set T1-01 to 1, input the data from the nameplate, and then press the RUN Key on the Digital Operator. The Inverter will supply power to the stationary motor for approximately 1 minute and some of the motor constants will be set automatically. The remaining motor constants E2-02 (Motor rated slip) and E2-03 (Motor no-load current) will be set automatically the first time operation is started in drive mode.

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To perform an operation immediately after stationary autotuning, use the following procedure under the recommended conditions.

1. Check the values of E2-02 and E2-03 in verify mode or advanced programming mode.

2. Run the motor once in drive mode under the following conditions.

• The Inverter and the motor are connected.

• The motor shaft is not locked with a mechanical brake or other stopping mechanism (or function).

• A motor-load ratio of 30% or less is maintained.

• A speed of 30% or more of the base frequency set at E1-06 (default = highest frequency) is maintained

at a constant speed for one second or more.

3. After stopping the motor, check the values of E2-02 and E2-03 again in verify mode or advanced programming mode. If the values of E2-02 and E2-03 differ from the ones before the first operation was carried out, the settings have been successfully completed. Next, check if the values are suitable or not.

If the values of E2-02 and E2-03 differed greatly from the reference data of the motor in the test report or the instruction manual, hunting, motor vibrations, insufficient motor torque, or an overcurrent may occur because the motor is operated although the aforementioned conditions have not been fulfilled after stationary autotuning. For elevators, failure to observe this caution may result in the cage falling or injury. If so, perform

Page 99

Trial Operation Procedures

stationary autotuning again and run the motor using the aforementioned procedure under the recommended conditions or perform rotational autotuning.

Usually the standard setting for E2-02 is 1 Hz to 3 Hz, and that for E2-03 is 30% to 65% of the rated current for a general-purpose motor. Generally, the larger the motor capacity is, the smaller the rated slip and the ratio of the no-load current to the rated current become. Use the data given in Factory Settings that Change with the Inverter Capacity (o2-04) of Chapter 5 User Constants as a reference.

Stationary Autotuning for Line-to-Line Resistance Only (T1-01 = 2)

Stationary autotuning for line-to-line resistance only can be used in any control method. This is the only autotuning possible for V/f control and V/f control with PG modes.

Autotuning can be used to prevent control errors when the motor cable is long (50 m or longer) or the cable length has changed since installation or when the motor and Inverter have different capacities.

Set T1-01 to 2 for open-loop vector control, and then press the RUN Key on the Digital Operator. The Inverter will supply power to the stationary motor for approximately 20 seconds and the Motor Line-to-Line Resistance (E2-05) and cable resistance will be automatically measured.

Precautions for Rotational and Stationary Autotuning

Lower the base voltage based on Fig 4.4 to prevent saturation of the Inverter’s output voltage when the rated voltage of the motor is higher than the voltage of the power supply to the Inverter. Use the following procedure to perform autotuning.

1. Input the voltage of the input power supply to T1-03 (Motor rated voltage).

2. Input the results of the following formula to T1-05 (Motor base frequency):

(Base frequency from the motor’s nameplate × setting of T1-03)/(Rated voltage from motor’s nameplate)

3. Perform autotuning.

After having completed autotuning, set E1-05 (Motor maximum frequency) to the base frequency shown on the motor nameplate.

Output voltage

Rated voltage from motor nameplate

T1-03

Base frequency from motor nameplate

Rated voltage from motor nameplate

×T1-03

Base frequency from motor nameplate

Output frequency

IMPORTANT

Fig 4.4 Motor Base Frequency and Inverter Input Voltage Setting

1. When speed precision is required at high speeds (i.e., 90% of the rated speed or higher), set T1-03 (Motor rated voltage) to the input power supply voltage × 0.9.

2. When operating at high speeds (i.e., 90% of the rated speed or higher), the output current will increase as the input power supply voltage is reduced. Be sure to provide sufficient margin in the Inverter current.

4-11

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Precautions After Using Rotational and Stationary Autotuning

• After completing autotuning, set E1-04 (Max. output frequency) to the base frequency from the motor’s

nameplate.

• In stationary autotuning, when the motor is first operated in the drive mode after tuning, the remaining

motor constants E2-02 (Motor rated slip) and E2-03 (Motor no-load current) are set automatically. To perform an operation immediately after stationary autotuning, use the following procedure under the recommended conditions.

1. Check the values of E2-02 and E2-03 in verify mode or advanced programming mode.

2. Run the motor once in drive mode under the following conditions.

• The Inverter and the motor are connected.

• The motor shaft is not locked with a mechanical brake or other stopping mechanism (or function).

• A motor-load ratio of 30% or less is maintained.

• A speed of 30% or more of the base frequency set at E1-06 (default = highest frequency) is maintained

at a constant speed for one second or more.

4-12

YASKAWA CIMR-G7A21P5, Varispeed G7, CIMR-G7A22P2, CIMR-G7A23P7, CIMR-G7A25P5 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Safety Information

Safety Precautions

Warning Information and Position

Warranty Information

Registered Trademarks

Before Reading This Manual

Contents

Handling Inverters

Varispeed G7 Introduction

 Varispeed G7 Models

Confirmations upon Delivery

 Checks

 Nameplate Information

 Component Names

Exterior and Mounting Dimensions

 Open Chassis Inverters (IP00)

 Enclosed Wall-mounted Inverters [NEMA1 (Type 1)]

Checking and Controlling the Installation Site

 Installation Site

 Controlling the Ambient Temperature

 Protecting the Inverter from Foreign Matter

Installation Orientation and Space

Removing and Attaching the Terminal Cover

 Removing the Terminal Cover

 Attaching the Terminal Cover

Removing/Attaching the Digital Operator and Front Cover

 Inverters of 15 kW or Less

 Inverters of 18.5 kW or More

Removing and Attaching the Protection Cover

 Removing the Protection Cover

 Attaching the Protection Cover

Wiring

Connections to Peripheral Devices

Connection Diagram

Terminal Block Configuration

Wiring Main Circuit Terminals

 Applicable Wire Sizes and Closed-loop Connectors

 Main Circuit Terminal Functions

 Main Circuit Configurations

 Standard Connection Diagrams

 Wiring the Main Circuits

Wiring Control Circuit Terminals

 Wire Sizes and Closed-loop Connectors

 Control Circuit Terminal Functions

 Control Circuit Terminal Connections

 Control Circuit Wiring Precautions

Wiring Check

 Checks

Installing and Wiring Option Boards

 Option Board Models and Specifications

 Installation

 PG Speed Control Board Terminals and Specifications

 Wiring

 Wiring Terminal Blocks

 Selecting the Number of PG (Encoder) Pulses

Digital Operator and Modes

Digital Operator

 Digital Operator Display

 Digital Operator Keys

Modes

 Inverter Modes

 Switching Modes

 Drive Mode

 Quick Programming Mode

 Advanced Programming Mode

 Verify Mode

 Autotuning Mode

Trial Operation

Trial Operation Procedure

Trial Operation Procedures

 Power ON

 Checking the Display Status

 Basic Settings

 Settings for the Control Methods

 Autotuning