Yaskawa CIMR-PU User Manual

YASKAWA AC Drive P1000

Industrial Fan and Pump Drive

Safety Precautions

Type: CIMR-PU Models:

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

200 V Class: 3/4 to 175 HP ND 400 V Class: 3/4 to 1000 HP ND 600 V Class: 1 to 250 HP ND

MANUAL NO. TOEP YAIP1U 03B

This Page Intentionally Blank

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

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

P1000 Safety Precautions

This document provides essential safety information for the P1000 series AC drive. Refer to the P1000 Quick Start Procedure TM.P1000.01 packaged with the drive to configure the drive for basic operation. Refer to the CD-ROM packaged with the product for complete product instructions necessary for proper installation, set-up, troubleshooting and maintenance. CD part number TOECC71061615. The 1000 Series CD-ROM contains the P1000 Technical Manual No. SIEPYAIP1U01 and additional 1000 Series manuals.

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

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

i.3 ELECTRICAL INSTALLATION SAFETY................................................................15

i.4 KEYPAD OPERATION...........................................................................................44

i.5 START UP..............................................................................................................47

i.6 PARAMETER TABLE.............................................................................................51

i.7 TROUBLESHOOTING............................................................................................54

i.8 UL AND CSA STANDARDS...................................................................................61

i.9 EUROPEAN STANDARDS.....................................................................................66

i.10 REVISION HISTORY..............................................................................................72

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

Applicable Models

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

Table i.1 Applicable Models

Drive Series Drive Model Number Software Version

CIMR-PU2Aoooo

P1000

Warranty Information

Restrictions

CIMR-PU2Aoooo

CIMR-PU5Aoooo

All

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

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

WARNING!

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.

Injury to Personnel. This product has been manufactured under strict quality-control guidelines. However, if this product is to

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

i.1 General Safety

Supplemental Safety Information

General Precautions

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

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

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

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

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

WARNING

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

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

DANGER

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

WARNING

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

WARNING!

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

CAUTION

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

CAUTION!

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

NOTICE

Indicates a property damage message.

NOTICE:

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

Safety Messages

DANGER

Heed the safety messages in this manual.

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

this manual.

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

i.1 General Safety

DANGER

Electrical Shock Hazard

Do not connect or disconnect wiring while the power is on.

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

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

WARNING

Sudden Movement Hazard

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

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

Electrical Shock Hazard

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

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

Do not allow unqualified personnel to use equipment.

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

adjustment and maintenance of AC drives.

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

Failure to comply could result in death or serious injury.

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

Because the leakage current exceeds 3.5 mA in models 4A0414 and larger, IEC/EN 61800-5-1 states that either the power supply must be automatically disconnected in case of discontinuity of the protective earthing conductor or a protective earthing conductor with a cross-section of at least 10 mm2 (Cu) or 16 mm2 (Al) must be used. Failure to comply may result in death or serious injury.

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

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

Fire Hazard

Do not use an improper voltage source.

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

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

The device is suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes, 240 Vac maximum (200 V class) and 480 Vac maximum (400 V class), and 600 Vac maximum (600 V class) when protected by branch circuit protection devices specified in this document.

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

i.1 General Safety

WARNING

Crush Hazard

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

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

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

CAUTION

Crush Hazard

Do not carry the drive by the front cover.

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

NOTICE

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

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

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

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

Do not operate damaged equipment.

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

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

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

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

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

Do not expose the drive to halogen group disinfectants.

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

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

i.1 General Safety

Periodic Maintenance Safety

WARNING!

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

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

WARNING!

the cooling fan, shut off the power and wait at least 15 minutes to be sure that the heatsink has cooled down. Failure to comply may cause burn injury to personnel.

NOTICE:

operating speed range may reduce motor cooling capacity. Ensure that the motor is suitable for drive duty and/or the motor service factor is adequate to accommodate the additional heating with the intended operating conditions.

Insulation Tolerance

NOTICE:

long wiring distances.

High-Speed Operation

NOTICE:

Contact the motor or machine manufacturer.

Torque Characteristics

Burn Hazard. Because the heatsink can get very hot during operation, take proper precautions to prevent burns. When replacing

Motor Application Safety

Equipment Damage. A motor connected to a PWM drive may operate at a higher temperature than a utility-fed motor and the

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

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

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

Audible Noise

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

Receiving Safety

CAUTION

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

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

NOTICE

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

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

Transporting the Drive

NOTICE:

ester, and other such harmful chemicals.

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

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

i.2 Mechanical Installation Safety

WARNING

Fire Hazard

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

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

does not exceed 40 °C.

Crush Hazard

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

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

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

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

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

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

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

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

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

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

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

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

NOTICE

Equipment Hazard

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

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

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

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

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

Failure to comply could lead to motor winding failure.

Never lift the drive up while the cover is removed.

This can damage the terminal board and other components.

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

i.2 Mechanical Installation Safety

Installation Environment

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

Table i.2 Installation Environment

Environment Conditions

Installation Area Indoors

-10 °C to +40 °C (IP20/NEMA Type 1 enclosure)

-10 °C to +50 °C (IP00/Open Type enclosure)

Ambient Temperature

Humidity 95% RH or less and free of condensation

Storage Temperature -20 to +60 °C

Surrounding Area

Altitude 1000 m or lower, up to 3000 m with derating

Vibration

Orientation Install the drive vertically to maintain maximum cooling effects.

<1>

Models 4A0930 and 4A1200 are rated at 5.9 m/s2 (19.36 ft/s2)

NOTICE:

Avoid placing drive peripheral devices, transformers, or other electronics near the drive as the noise created can lead to erroneous

operation. If such devices must be used in close proximity to the drive, take proper steps to shield the drive from noise.

NOTICE:

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

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

Install the drive in an area free from:

• oil mist and dust

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

• radioactive materials

• combustible materials (e.g., wood)

• harmful gases and liquids

• excessive vibration

• chlorides

• direct sunlight.

10 to 20 Hz at 9.8 m/s2 (32.15 ft/s2) 20 to 55 Hz at 5.9 m/s2 (19.36 ft/s2) (Models 2A0004 to 2A0211, 4A0002 to 4A0165, and 5A0003 to 5A0099) or

2.0 m/s2 (6.56 ft/s2) (Models 2A0250 to 2A0415, 4A0208 to 4A1200, and 5A0125 to 5A0242)

<1>

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

i.2 Mechanical Installation Safety

Instructions on Installation Using the Eye Bolts

Eye bolts are used to install the drive or to temporarily lift the drive when replacing it. Using the eye bolts, the drive can be installed in an enclosure panel or on a wall. Do not leave the drive suspended by the wires in a horizontal or vertical position for long periods of time. Do not transport the drive over long distances. Read the following precautions and instructions before installing the drive.

WARNING!

falling equipment. Only use vertical suspension to temporarily lift the drive during installation to an enclosure panel. Do not use vertical suspension to transport the drive. Use screws to securely affix the drive front cover, terminal blocks, and other drive components prior to vertical suspension. Do not subject the drive to vibration or impact greater than 1.96 m/s2 (0.2 G) while it is suspended by the wires. Do not leave the drive unattended while it is suspended by the wires. Do not attempt to flip the drive over while it is suspended by the wires.

Horizontal Suspension of Drive Models 2A0360, 2A0415, and 4A0250 to 4A0675

Crush Hazard. Observe the following instructions and precautions. Failure to comply could result in serious injury or death from

To make a wire hanger or frame for use when lifting the drive with a crane, lay the drive in a horizontal position and pass a wire through the holes of the four eye bolts.

NOTICE:

damage the drive when lifted.

Damage to Equipment. When lifting the drive, confirm that the spring washer is fully closed. Failure to comply may deform or

A – No space between drive and washer B – Spring washer fully closed

Figure i.1 Spring Washer

Vertical Suspension of Drive Models 2A0360, 2A0415, and 4A0250 to 4A1200

Models 2A0360, 2A0415, and 4A0250 to 4A0675

C – Space between drive and washer D – Spring washer open

When vertical suspension of the drive is required in an enclosure panel, change the orientation of the eye bolts for these models by turning the eye bolts counterclockwise 90 degrees.

Figure i.2 Adjusting Angle of Eye Bolts

Models 4A0930 and 4A1200

When suspending models 4A0930 or 4A1200 with wires, follow the procedure described below.

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

Eye bolt

i.2 Mechanical Installation Safety

WARNING!

maximum allowable load of the eye bolts cannot be guaranteed when the drive is suspended with the wires at angles less than 50°. Failure to comply may result in serious injury or death from falling equipment.

Crush Hazard. Use an adequate length of wire to ensure a 50° or wider suspension angle as illustrated in Figure i.4. The

Remove the four eye bolts from the drive side panels and fix them securely on the top panel.

Figure i.3 Eye Bolt Repositioning

Pass wire through the holes of all four eye bolts.

A – Eye bolt B – Wires

Figure i.4 Suspension Wire Angle Example

Gradually take up the slack in the wires and hoist the drive after the wires are stretched tight.

Lower the drive when ready to install in the enclosure panel. Stop lowering the drive when it is near the floor then

C – Suspending angle: 50° or greater

begin lowering the drive again very slowly until the drive is placed correctly.

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

B B

Side Clearance Top/Bottom Clearance

Installation Orientation and Spacing

Install the drive upright as illustrated in Figure i.5 to maintain proper cooling.

Figure i.5 Correct Installation Orientation

i.2 Mechanical Installation Safety

NOTICE:

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

Single Drive Installation

Figure i.6 shows the installation distance required to maintain sufficient space for airflow and wiring. Install the heatsink

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

A – 50 mm minimum B – 30 mm minimum

Figure i.6 Correct Installation Spacing

C – 120 mm minimum D – Airflow direction

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

Multiple Drive Installation (Side-by-Side Installation)

installation.

Models 2A0004 to 2A0081, 4A0002 to 4A0044, and 5A0003 to 5A0032 can take advantage of Side-by-Side installation.

When installing multiple drives into the same enclosure panel, mount the drives according to Figure i.6 and set L8-35, Installation Method Selection, to 1 (Side-by-Side Mounting).

When mounting drives with the minimum clearance of 2 mm according to Figure i.7, set parameter L8-35 to 1 while considering derating.

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

Side Clearance

Line up the tops of the drives.

Top/Bottom Clearance

i.2 Mechanical Installation Safety

A – 50 mm minimum B – 30 mm minimum

C – 2 mm minimum D – 120 mm minimum

Figure i.7 Space Between Drives (Side-by-Side Mounting)

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

of stacked drives for easier cooling fan replacement.

Remove the top protective covers of all drives as shown in Figure i.8 when mounting IP20/NEMA Type 1 enclosure drives side-by-side.

Figure i.8 IP20/NEMA 1 Side-by-Side Mounting in Enclosure

Drive Dimensions

NOTICE

Refer to the P1000 Technical Manual SIEPYAIP1U01 for IP20/NEMA Type 1, IP00/Open Chassis and Flange Type Enclosure (NEMA 12 Backside) drive dimensions.

The 1000 Series CD-ROM No. TOECC71061615, packaged with the drive contains the P1000 Technical Manual No. SIEPYAIP1U01 and additional 1000 Series manuals.

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

i.3 Electrical Installation Safety

NOTICE

Refer to the P1000 Technical Manual SIEPYAIP1U01 on the CD-ROM packaged with the product for more information regarding the Electrical Installation and for complete product instructions necessary for proper installation, set-up, troubleshooting and maintenance. CD-ROM part number TOECC71061615.

DANGER

Electrical Shock Hazard

Do not connect or disconnect wiring while the power is on.

Failure to comply will result in death or serious injury.

WARNING

Electrical Shock Hazard

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

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

WARNING

Electrical Shock Hazard

Do not operate equipment with covers removed.

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

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

Always ground the motor-side grounding terminal.

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

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

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

on the drive.

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

Failure to comply could result in death or serious injury.

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

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

installation, adjustment, and maintenance of AC drives.

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

i.3 Electrical Installation Safety

WARNING

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

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

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

Fire Hazard

Tighten all terminal screws to the specified tightening torque.

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

Do not use improper combustible materials.

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

Do not use an improper voltage source.

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

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

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

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

CAUTION

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

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

NOTICE

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

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

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

Improper equipment sequencing could result in damage to the drive.

Do not use unshielded cable for control wiring.

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

Do not allow unqualified personnel to use the product.

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

the drive.

Do not modify the drive circuitry.

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

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

i.3 Electrical Installation Safety

NOTICE

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

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

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

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

start the motor.

NOTICE

Install a fuse and a GFCI in models 4A0930 and 4A1200. Failure to comply may result in serious damage to the facilities if the drive is defective. Refer to Wiring Fuses for Models 4A0930 and 4A1200 on page 22 for details.

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

i.3 Electrical Installation Safety

Standard Connection Diagram

WARNING!

properly set. Improper sequencing of run/stop circuitry could result in death or serious injury from moving equipment.

WARNING!

the drive. Failure to comply could result in death or serious injury from moving equipment. When programmed for 3-Wire control, a momentary closure on terminal S1 may cause the drive to start.

WARNING!

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

WARNING!

Executing the application preset function or setting A1-06 ≠ 0 will change the drive I/O terminal functions and may cause unexpected equipment operation. Failure to comply may cause death or serious injury.

NOTICE:

drive does not trigger a fault output during fault restart (L5-02 = 0, default). Failure to comply will prevent the automatic fault restart function from working properly.

NOTICE:

The drive is suitable for circuits capable of delivering not more than 100,000 RMS symmetrical amperes, 240 Vac maximum (200 V class), 480 Vac maximum (400 V class), 600 Vac maximum (600 V class).

NOTICE:

insulation voltage or use a drive duty motor. Failure to comply could lead to motor insulation breakdown.

NOTICE:

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

NOTICE:

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

Sudden Movement Hazard. Do not close the wiring for the control circuit unless the multifunction input terminal parameters are

Sudden Movement Hazard. Ensure start/stop and safety circuits are wired properly and in the correct state before energizing

Sudden Movement Hazard. When using a 3-Wire sequence, set the drive to 3-Wire sequence prior to wiring the control terminals

Sudden Movement Hazard. Confirm the drive I/O signals and external sequence before executing the application preset function.

When using the automatic fault restart function with wiring designed to shut off the power supply upon drive fault, make sure the

Inadequate wiring could result in damage to the drive. Install adequate branch circuit short circuit protection per applicable codes.

When the input voltage is 440 V or higher or the wiring distance is greater than 100 meters, pay special attention to the motor

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

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

Correctly set Sink/Source jumper S3 for internal power supply. Failure to comply may result in damage to the drive.

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

Terminals -, +1, +2, B1, B2 are for connection options. Never connect power supply lines to these terminals

DC link choke

(option)

U X

－

U X

0 V

S-

P1000 Drive

B112

2 k

0 V

E (G)

<1>

<2>

<10>

<7>

<9>

<6>

<4>

<3>

－

+24 V

Jumper

Braking resistor (option)

Forward Run / Stop

Reverse Run / Stop

External fault

Fault reset

Multi-speed step 1

Multi-speed step 2

External Baseblock

Jog speed

Multi-function

digtial inputs

(default setting)

Sink / Source mode selection wire link (default: Sink)

CN5-C

CN5-B

CN5-A

Option board

Pulse Train Input (max 32 kHz)

Shield ground terminal

Multi-function analog/pulse

train inputs

Power supply +10.5 Vdc, max. 20 mA

Analog Input 1 (Frequency Reference Bias) 0 to +/-10Vdc (20 kΩ) 4 to 20 mA (250 Ω) / 0 to 20 mA (250 Ω)

MEMOBUS/Modbus comm.

RS-422/RS-485

max. 115.2 kBps

Termination resistor

(120 , 1/2 W)

DIP Switch S2

Multi-function relay output (Speed Agree H2-03) 250 Vac, max. 1 A 30 Vdc, max 1 A (min. 5 Vdc, 10 mA)

Multi-function relay output (During Run H2-01) 250 Vac, max. 1 A 30 Vdc, max 1 A (min. 5 Vdc, 10 mA)

Multi-function analog output 1 (Output frequency)

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

Main Circuit

Control Circuit

shielded line

twisted-pair shielded line

main circuit terminal

control circuit terminal

R/L1

S/L2

T/L3

R S

Main

Switch

Fuse

EMC Filter

Multi-function relay output (Zero Speed H2-02) 250 Vac, max. 1 A 30 Vdc, max 1 A (min. 5 Vdc, 10 mA)

<8>

AMFM

Off

DIP Switch S2 Term. Res. On/Off

Jumper S1 A1/A2/A3 Volt./Curr. Selection

Jumper S5 AM/FM Volt./Curr. Selection

Terminal board jumpers and switches

－

<5>

<11>

Ω

<10>

Multi-function analog output 2 (Output current)

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

Three-Phase Power Supply 200 to 600 V 50/60 Hz

<12>

U/T1

V/T2

W/T

Ground

Cooling fan

connectors

(Depending on model capacity)

Ω

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

Analog Input 3 (Aux. Frequency Reference) 0 to +/-10Vdc (20 kΩ) 4 to 20 mA (250 Ω) / 0 to 20 mA (250 Ω)

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

Note: When A1 & A3 using current input Resolution = 10 bit plus sign

A1 A2 A3

24V

+24 Vdc

Transducer

Supply

(max. 150 mA)

－

Models 4A0930 and 4A1200 are compatible with 12-Phase Rectification.

i.3 Electrical Installation Safety

Figure i.9 Drive Standard Connection Diagram (example: model 2A0040)

<1> Remove the jumper when installing a DC link choke. Models 2A0110 to 2A0415 and 4A0058 to 4A1200 come with a built-in

DC link choke.

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

i.3 Electrical Installation Safety

<2> Set L8-55 to 0 to disable the protection function of the built-in braking transistor of the drive when using an optional regenerative

converter or dynamic braking option. Leaving L8-55 enabled may cause a braking resistor fault (rF). Additionally, disable Stall Prevention (L3-04 = 0) when using an optional regenerative converter, regenerative or braking units, or dynamic braking option.

Leaving If L3-04 enabled may prevent the drive from stopping within the specified deceleration time. <3> Supplying power to the control circuit separately from the main circuit requires 24 V power supply (option). <4> This figure illustrates an example of a sequence input to S1 through S8 using a non-powered relay or an NPN transistor. Install

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

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

it can cause erroneous operation or damage the drive. <7> Set jumper S1 to select between a voltage or current input signal to terminal A2. The default setting is for current input. <8> Set jumper S1 to select between a voltage or current input signal to terminal A1 and A3. The default setting is for voltage input. <9> Set DIP switch S2 to the ON position to enable the termination resistor in the last drive in a MEMOBUS/Modbus network. <10> Monitor outputs work with devices such as analog frequency meters, ammeters, voltmeters, and wattmeters. They are not

intended for use as a feedback-type signal. <11> Use jumper S5 to select between voltage or current output signals at terminals AM and FM. Set parameters H4-07 and H4-08

accordingly. <12> Self-cooling motors do not require the same wiring necessary for motors with cooling fans.

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

i.3 Electrical Installation Safety

Main Circuit Wiring

WARNING!

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

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

NOTICE

Refer to the P1000 Technical Manual SIEPYAIP1U01 on the CD-ROM packaged with the product for complete product instructions necessary for proper installation, set-up, troubleshooting and maintenance. CD part number TOECC71061615.

NOTICE:

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

NOTICE:

connections could damage the drive.

NOTICE:

could result in drive malfunction due to loose terminal connections.

NOTICE:

charge circuit and the DC bus capacitors, and can cause premature drive failures. For the full performance life, refrain from switching the drive on and off more than once every 30 minutes.

NOTICE:

match. Failure to comply with proper wiring practices may cause the motor to run in reverse if the phase order is backward.

NOTICE:

to the drive, phase-advancing capacitors, LC/RC noise filters or ground fault circuit interrupters.

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

Do not use the negative DC bus terminal “–” as a ground terminal. This terminal is at high DC voltage potential. Improper wiring

Do not solder the ends of wire connections to the drive. Soldered wiring connections can loosen over time. Improper wiring practices

Do not switch the drive input to start or stop the motor. Frequently switching the drive on and off shortens the life of the DC bus

When connecting the motor to the drive output terminals U/T1, V/T2, and W/T3, the phase order for the drive and motor should

Do not connect phase-advancing capacitors or LC/RC noise filters to the output circuits. Failure to comply could result in damage

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

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

Yaskawa recommends using closed-loop crimp terminals on all drive models. To maintain UL/cUL approval, UL Listed closed-loop crimp terminals are specifically required when wiring the drive main circuit terminals on models 2A0110 to 2A0415, 4A0058 to 4A1200, and 5A0041 to 5A0242. Use only the tools recommended by the terminal manufacturer for crimping.

Main Circuit Terminal Functions

Table i.3 Main Circuit Terminal Functions

Terminal Type

200 V Class

400 V Class

600 V Class

Drive Model

R/L1

S/L2

T/L3

R1-L11

S1-L21

T1-L31

U/T1

W/T3

2A0004 to

2A0081

4A0002 to

4A0044

5A0003 to

5A0032

Braking resistor Not available

2A0110, 2A0138

4A0058, 4A0072

5A0041, 5A0052

Main circuit power supply input Connects line power to the drive

Not available

Drive output Connects to the motor 19V/T2

2A0169 to

2A0415

4A0088 to

4A0675

5A0062 to

5A0242

–

4A0930, 4A1200

–

Main circuit power supply input

Function Page

Connects line power to the drive Remove the shorting bars connecting R/L1-R1/L11, S/L2S1/L21, T/L3-T1/L31 when using 12-phase rectification.

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

–

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

i.3 Electrical Installation Safety

Terminal Type

200 V

Class

400 V

Class

600 V

Class

Drive Model

⊕2 • DC link choke

⊕1

⊖

⊕3

2A0004 to

2A0081

4A0002 to

4A0044

5A0003 to

5A0032

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

• DC power supply input (⊕1, ⊖)

2A0110, 2A0138

4A0058, 4A0072

5A0041, 5A0052

DC power supply input (⊕1, ⊖)

Not available

2A0169 to

2A0415

4A0088 to

4A0675

5A0062 to

5A0242

Not available

• DC power supply input (⊕1, ⊖)

• Braking unit connection (⊕3, ⊖)

For 200 V class: 100 Ω or less

For 400 V class: 10 Ω or less For 600 V class: 10 Ω or less

–

4A0930, 4A1200

–

Function Page

For connecting:

• the drive to a DC power supply

• dynamic braking options

• a DC link choke

Grounding terminal 35

–

Note: Use terminals B1 and ⊖ when installing a CDBR-type braking unit on drives with built-in braking transistors (Models 2A0004 to 2A0138,

4A0002 to 4A0072, and 5A0003 to 5A0052).

Wiring Fuses for Models 4A0930 and 4A1200

NOTICE:

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

to identify the cause. Contact Yaskawa before restarting the drive or the peripheral devices if the cause cannot be identified.

Install a fuse on the input side to protect drive wiring and prevent other secondary damage. Wire the fuse so that leakage current in the upper controller power supply will trigger the fuse and shut off the power supply.

Select the appropriate fuse from Table i.4.

Table i.4 Input Fuses for Models 4A0930 and 4A1200

Voltage

Class

Three-

Phase 400 V

Class

Protecting Main Circuit Terminals

Insulation Caps or Sleeves

Model

4A0930 480 V 1500 A

4A1200 480 V 1500 A

Input Voltage Current

Selection Input Fuse (Example)

Pre-arc I2t (A2s)

140000 to

3100000

320000 to

3100000

Model Manufacturer Rating

CS5F-1200 Fuji Electric AC500 V, 1200 A 276000

FWH-1200A Bussman AC500 V, 1200 A –

CS5F-1500 Fuji Electric AC500 V, 1500 A 351000

FWH-1600A Bussman AC500 V, 1600 A –

Pre-arc

I2t (A2s)

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

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

i.3 Electrical Installation Safety

Insulation Barrier

Insulation barriers are packaged with drive models 4A0414 through 4A1200 to provide added protection between terminals. Yaskawa recommends using the provided insulation barriers to ensure proper wiring. Refer to Figure i.10 for instructions on placement of the insulation barriers.

Insulation Barrier

Figure i.10 Installing Insulation Barriers

Main Circuit Wire Gauges and Tightening Torque

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

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

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

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

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

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

Line drop voltage (V) = 3 × wire resistance (Ω/km) × wire length (m) × current (A) × 10

-3

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

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

NOTICE:

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

• Use terminals B1 and ⊖ when installing a CDBR-type braking unit on drives with built-in braking transistors (models 2A0004 to 2A0138, 4A0002 to 4A0072, and 5A0003 to 5A0052).

NOTICE:

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

• Refer to UL Standards Compliance on page 61 for information on UL compliance.

Yaskawa recommends using closed-loop crimp terminals on all drive models. UL/cUL approval requires the use of closedloop crimp terminals when wiring the drive main circuit terminals on models 2A0110 to 2A0415 and 4A0058 to 4A1200. Use only the tools recommended by the terminal manufacturer for crimping. Refer to Closed-Loop Crimp Terminal Size on page

31 for closed-loop crimp terminal recommendations.

The wire gauges listed in the following tables are Yaskawa recommendations. Refer to local codes for proper wire gauge selections.

YASKAWA ELECTRIC TOEP YAIP1U 03B YASKAWA AC Drive – P1000 Safety Precautions

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