YASKAWA CIMR-R5U20151A, CIMR-R5U25P51A, CIMR-R5U20181A, CIMR-R5U20221A, CIMR-R5U20301A Instruction Manual

...

YASKAWA - RC5

Power Regenerative Unit

Instruction Manual

Type: Models:

To properly use the product, read this manual thoroughly and retain for easy reference, inspection, and maintenance. Ensure the end user receives this manual.

CIMR-R5U

200 V Class, Three-Phase Input: 3.7 to 37 kW 400 V Class, Three-Phase Input: 3.7 to 75 kW

MANUAL NO. TOEP C710656 01C

This Page Intentionally Blank

All rights reserved. No part of this publication may be reproduced, stored in a retrieva l 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 im prove its high-quality products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the prepa ration 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

2 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

I. PREFACE.......................................................................................................................................... 3

i.1 Conditions of Acceptability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

NEC, CEC and UL Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CSA Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

i.2 Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Supplemental Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

i.3 Notes for Safe Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Maintenance and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Warning Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1. RECEIVING ..................................................................................................................................... 11

1.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1.2 Inspection Checkpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Receiving Checkpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Checking the Nameplate Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2. INSTALLATION............................................................................................................................... 15

2.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.2 Checking Installation Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Controlling the Ambient Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Protecting the Power Regenerative Unit from Foreign Matter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.3 Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Models of 200 V/400 V 30 kW and Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Models of 200 V/400 V 37 kW and Higher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.5 Removing and Replacing the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.6 Removing and Replacing the LCD Monitor/Digital Operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Removing the LCD Monitor/Digital Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Replacing the LCD Monitor/Digital Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3. WIRING............................................................................................................................................ 23

3.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.2 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Connection Diagram with Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.3 Selecting Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Selecting Heavy Duty or Standard Duty RC5 Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Main Circuit Input Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Power Coordination and Current Suppression Reactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Wiring Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.4 Wiring Main Circuit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Required Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Closed-Loop Connectors Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

3.5 External Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Main Circuit Terminal Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Control Circuit Terminal Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 3

4. OPERATION.................................................................................................................................... 33

4.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.2 Checks Prior to Main Power Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.3 Setting the Power Supply Voltage Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.4 Using the Digital Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

4.5 Digital Operator Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Navigating Digital Operator Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Operation Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.6 Power On/Off Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.7 Run Command Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Auto Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Manual Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5. MAINTENANCE AND INSPECTION............................................................................................... 45

5.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5.2 Periodic Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Periodic Maintenance of Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6. TROUBLESHOOTING .................................................................................................................... 49

6.1 Fault Detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.2 Minor Fault Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6.3 Operation Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

7. SPECIFICATIONS........................................................................................................................... 55

A. PARAMETER LIST ......................................................................................................................... 59

Revision History

4 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

Preface

YASKAWA’s RC5 is a power regenerative unit which has both braking and regenerative functions. This instruction manual describes installation, maintenance and inspection, troubleshooting, and specifications of the RC5. Read this instruction manual thoroughly before operation.

I.1 CONDITIONS OF ACCEPTABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

I.2 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

I.3 NOTES FOR SAFE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 3

i.1 Conditions of Acceptability

◆ NEC, CEC and UL Compliance

In order to comply with the NEC, CEC and UL, the following conditions of use must be strictly adhered to:

■ Surge Protector Installation

• An MOV must be installed on the input of the RC5 Unit.

■ Current Suppression Reactor Installation

• The Current Suppression Reactor must be installed as shown in Figure 3.1.

■ Terminal Blocks

• The Power Terminal Blocks of the RC5 unit are for factory wiring use only.

■ Installation Environment

• Install the RC5 Unit in a protective enclosure suitable to its environment.

◆ CSA Standards Compliance

The RC5 is CSA certified as following.

■ Products

CLASS 3211 06

INDUSTRIAL CONTROL EQUIPMENT

Motor Controllers Miscellaneous

CLASS 2411 02

ELEVATOR EQUIPMENT

Enclosed Elevator and Escalator Electrical Equipment

■ Applicable Requirements

CAN/CSA C22.2 No.0.4-04

Bonding of Electrical Equipment

CAN/CSA C22.2 No.14-05

Industrial Control Equipment

CSA B44.1-04/ASME A17.5-2004

Elevator and Escalator Electrical Equipment

Figure i.1

CSA B44.1 / ASME A17.5

Figure i.1 CSA B44.1-04/ASME A17.5-2004 Mark

4 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

i.2 Safety Information

W ARNING

DANGER

W ARNING

CAUTION

NOTICE

i.2 Safety Information

Read this instruction manual thoroughly before installation, operation, maintenance or inspection of the RC5. In this manual, NOTES FOR SAFE OPERATION are classified as “WARNING” or “CAUTION.”

◆ Supplemental Safety Information

General Precautions

• Some drawings in this manual are shown with the protective cover or shields removed, in order to describe detail with more clarity. Make sure all covers and shields are replaced before operating this product.

• This manual may be modified when necessary because of improvement of the product, modification, or changes in specifications.

• Such modifications are denoted by a revised manual No.

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

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

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 possibly even fatal injury or damage to the products or to related equipment and systems.

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

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

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

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

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

Indicates a property damage message.

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

Even items described in a Caution may result in a vital accident in some situations. In either case, follow these important notes.

Note: These are steps to be taken to insure proper operation.

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 5

i.3 Notes for Safe Operation

CAUTION

W ARNING

CAUTION

i.3 Notes for Safe Operation

◆ Receiving

Do not install or operate any power regenerative unit which is damaged or has missing parts.

Failure to observe this caution may result in personal injury or equipment damage (Refer to page 12)

◆ Installation

Lift the cabinet by the base. When moving the unit, never lift by the front cover or the front panel.

Otherwise, the main unit may be dropped causing damage to the unit. (Refer to page 16)

Mount the power regenerative unit on nonflammable material (i.e. metal).

Failure to observe this caution can result in a fire. (Refer to page 16)

When mounting units in an enclosure, install a fan or other cooling device to keep the intake air temperature below 45°C.

Overheating may cause a fire or damage to the unit. (Refer to page 16)

In order to comply to UL regulations, the MOV and current suppression reactor must be installed on the input of the R5 unit.

Refer to the installation diagram. (Refer to page 16)

◆ Wiring

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

Failure to observe this warning can result in an electric shock or a fire. (Refer to page 24)

Wiring should be performed only by qualified personnel.

Failure to observe this warning can result in an electric shock or a fire. (Refer to page 24)

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

Failure to observe this warning can result in an electric shock or a fire. (Refer to page 24)

Install adequate branch short circuit protection according to applicable codes.

Failure to comply could result in damage to the drive.

The device is suitable for circuits capable of delivering up to 100 kA RMS Symmetrical Amperes, 240 Vac maximum (200 V Class), 480 Vac maximum (400 V Class) or equivalent to the SCCR rating of the VFD to which it is connected - whichever value is less.

R5 Series of Power Regenerative devices shall be connected to a VFD which incorporates Solid State Short Circuit Protection Circuitry and was found to comply with the High Fault Current Short Circuit Test.

Verify that the power regenerative unit rated voltage coincides with the AC power supply voltage.

Failure to observe this caution can result in personal injury or a fire. (Refer to page 24)

Do not perform a withstand voltage test of the power regenerative unit.

It may cause semi–conductor elements to be damaged. (Refer to page 24)

Connect the power coordinating reactor and the power suppressing reactor as described in this instruction manual.

Improper connection may cause a fire. (Refer to page 24)

Verify that the rated voltage of the power regenerative unit coincides with the rated voltage of the power regenerative unit to be connected.

Failure to observe this caution can result in a fire. (Refer to page 24)

Tighten terminal screws.

Failure to observe this caution can result in a fire. (Refer to page 24)

6 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

i.3 Notes for Safe Operation

W ARNING

CAUTION

W ARNING

CAUTION

◆ Operation

Only turn ON the input power supply after replacing the front cover or the terminal cover. Do not remove the cover while power is on.

Failure to observe this warning can result in an electric shock. (Refer to page 34)

Never operate the digital operator or other switches when your hand is wet.

Failure to observe this warning can result in an electric shock. (Refer to page 34)

Never touch the terminals while power is on, even if the power regenerative unit stops.

Failure to observe this warning can result in an electric shock. (Refer to page 34)

Never touch the heatsink or input reactors since their temperature may be very high.

Failure to observe this caution can result in harmful burns to the body. (Refer to page 34)

All the parameters of the power regenerative unit have been preset at the factory. Do not change the settings unnecessarily.

The power regenerative unit may be damaged. (Refer to page 34)

◆ Maintenance and Inspection

Never touch high-voltage terminals in the power regenerative unit.

Failure to observe this warning can result in an electric shock. (Refer to page 46)

Perform maintenance or inspection only after verifying that the CHARGE LED goes OFF, after the main circuit power supply is turned OFF.

The capacitors are still charged and can be dangerous. (Refer to page 46)

Only authorized personnel should be permitted to perform maintenance, inspections or parts replacement.

[Remove all metal objects (watches, bracelets, etc.) before operation.] (Use tools which are insulated against electric shock.)

Failure to observe this warning can result in an electric shock. (Refer to page 46)

Never modify the product.

Failure to observe this warning can result in an electric shock or personal injury and will invalidate the guarantee. (Refer to page 46)

The power regenerative unit employs semi-conductor elements. Do not touch the CMOS elements.

They are easily damaged by static electricity. (Refer to page 46)

Do not connect or disconnect wires or connectors while power is applied to the circuit.

Failure to observe this caution can result in personal injury. (Refer to page 46)

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 7

i.3 Notes for Safe Operation

Model CIMR-R5U23P7

656RC5

WARNING

-Riskofelectricshock.

Read manual before installing. Wait 5 minutes for capacitor discharge after disconnecting power supply. To conform to requirements, make sure to ground the supply neutral.

AVERTISSEMENT

- Risque de décharge électrique

Lisez le manuel avant installation. Attendez 5 minutes après la coupure de l’ alimentation électrique afin que les condensateurs soient complètement décharges. Assurez vous de connecter a la masse le fil du neutre afin d’ être en accord avec la règlementation .

◆ Warning Label

A warning label is displayed on the front cover of the power regenerative unit, as shown below. Follow these instructions when handling the power regenerative unit.

■ Warning Label

8 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

Receiving

This chapter describes how to verify the RC5 after delivery to the user.

1.1 SECTION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

1.2 INSPECTION CHECKPOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 11

1.1 Section Safety

CAUTION

1.1 Section Safety

Do not install or operate any power regenerative unit which is damaged or has missing parts.

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

12 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

1.2 Inspection Checkpoints

◆ Receiving Checkpoints

Table 1.1 Checkpoints

Checkpoints Description

Does the power regenerative unit model number correspond with the purchase order?

Are any parts damaged? Visually check the exterior and verify that there was no damage during transport.

Is hardware properly seated and securely tightened?

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

◆ Checking the Nameplate Data

■ Nameplate Data

Example of standard domestic model CIMR-R5U2011.

Figure1.1

Check the model number on the nameplate on the side of the RC5. (Refer to Figure 1.2.)

Remove the front cover of the power regenerative unit. Check all visible hardware with appropriate tools.

Figure 1.1 Nameplate Data

■ Model Designation

Figure1.2

CIMR - R5 U 2 011 1 A

Power Regenerative Unit

VS - 656RC5 Series

Symbol

U A

Symbol

2 3-phase 200 V class 4 3-phase 400 V class

■ Protective Structure

Specifications

Standard domestic model Japan standard model

Volta ge

Symbol Max. applicable motor output

3P7 3.7kW

5P5

“P” indicates the decimal point.

Figure 1.2 Model Designation

• Open Chassis Type (IEC IP00) Protected so that parts of the human body cannot reach electrically charged parts from the front when the Power regenerative unit is mounted in a control panel.

• Enclosed Wall-mounted Type (IEC IP20, NEMA 1) The power regenerative unit is structured so that the power regenerative unit 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 in the USA.

Version (Enter the specifications form number when special specifications are required.)

No.

0 Open chassis (IEC IP00)

5.5kW

37kW

Protective Structure

Enclosed wall-mounted

(IEC IP20, NEMA1)

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 13

1.2 Inspection Checkpoints

This page intentionally blank.

14 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

Installation

This chapter describes the configuration, location and space when mounting the RC5.

2.1 SECTION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

2.2 CHECKING INSTALLATION SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.3 CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.4 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.5 REMOVING AND REPLACING THE FRONT COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.6 REMOVING AND REPLACING THE LCD MONITOR/DIGITAL OPERATOR. . . . . . . . . . . . . . . . . . . . . . 22

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 15

2.1 Section Safety

CAUTION

2.1 Section Safety

Lift the cabinet by the base. When moving the unit, never lift by the front cover or the front panel.

Otherwise, the main unit may be dropped causing damage to the unit.

Mount the power regenerative unit on nonflammable material (i.e. metal).

Failure to observe this caution can result in a fire.

When mounting units in an enclosure, install a fan or other cooling device to keep the intake air temperature below 45°C.

Overheating may cause a fire or damage to the unit.

16 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

2.2 Checking Installation Site

◆ Installation Site

Install the power regenerative unit under the following conditions.

NOTICE: Do not install the power regenerative unit to an area greater than pollution degree 2 (UL standard).

Typ e Ambient Operating Temperature Humidity

Enclosed wall-mounted –10 to +40°C 90% RH or less (no condensation)

Open chassis –10 to +45°C 90% RH or less (no condensation)

Protection covers are attached to the top and bottom of the power regenerative unit. Be sure to remove the protection covers before installing a 200 or 400 V Class power regenerative unit with an output of 30 kW or less in a panel.

To ensure proper performance and long operating life, follow the recommendations below when choosing a location for installing the RC5. Make sure the power regenerative unit is protected from the following conditions:

• Extreme cold and heat. Use only within ambient temperature range: -10°C to +40°C

• Rain, moisture. (For enclosed wall-mounted type)

• Oil sprays, splashes

• Salt spray.

• Direct sunlight. (Avoid using outdoors.)

• Corrosive gases or liquids.

• Dust or metallic particles in the air. (For enclosed wall-mounted type)

• Physical shock, vibration.

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

• High humidity.

• Radioactive materials.

• Combustibles: thinners, solvents, etc.

◆ Controlling the Ambient Temperature

To enhance the reliability of operation, the power regenerative unit should be installed in an environment free from extreme temperature increases. If the power regenerative unit 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 Power Regenerative Unit from Foreign Matter

Place a cover over the power regenerative unit during installation to shield it from metal power produced by drilling.

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

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 17

2.3 Clearances

50 mm or more (1.97 in)

30 mm or more (1.18 in)

50 mm or more (1.97 in)

120mmormore (4.72 in)

Air

(b) Side View

(a) Front View

2.3 Clearances

Install the RC5 vertically and allow sufficient clearances for effective cooling as shown in Figure 2.1.

Figure 2.1

Note: 1. The clearances required at top/bottom and both sides are common in open chassis type (IP00) and enclosed wall–mounted type (NEMA 1).

Figure 2.1 Clearances

2. Remove the top and bottom covers to use the open chassis type of 200 V/400 V 30 kW or less.

3. When installing the models of 200 V/400 V 37 kW or more equipped with eyebolts, extra spacing will be required on either side. For detailed dimensions, contact your

YASKAWA representative.

4. Ensure sufficient space for the sections at the upper and lower parts marked with * in order to permit the flow of intake/exhaust air to / from the unit.

18 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

2.4 Dimensions

◆ Models of 200 V/400 V 30 kW and Lower

Figure 2.2 shows a 200 V 3.7 kW model. Use open chassis type 200 V/400 V 30 kW and lower with the top and bottom covers removed.

Figure2.2

◆ Models of 200 V/400 V 37 kW and Higher

Figure 2.3 shows a 200 V 37 kW model.

Figure2.3

Figure 2.2 Dimensions of RC5

STATUS

RUN

READY

:LIGHT :BLINK

:LIGHTOFF

RUN

ALARM

OLOH

OVUV

OC CPF

4-d

Figure 2.3

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 19

2.4 Dimensions

Vol tag e RC5 CIMR–R5U

23P7

25P5

27P5

2011

200V Class

400V Class

2015 6

2018

2022

2030

2037

43P7

45P5

47P5

4011

4015

4018

4030

4037

4045

4055

4075

Table 2.1 RC5 Dimensions mm (in) and Approx. Mass (kg)

Dimensions

mm (in)

Mounting Dimension mm (in)

W H D W1 H1 H2

140

(5.51

200

(7.87)

250

(9.84)

325

(12.80)

140

(5.51

200

(7.87)

250

(9.84)

325

(12.80)

280

(11.02)

300

(11.81)

380

(14.96)

400

(15.75

450

(17.72)

280

(11.02)

300

(11.81)

380

(14.96)

450

(17.72)

635

25.0)

180

(7.09)

205

(8.07)

225

(8.86)

285

(11.22)

180

(7.09)

205

(8.07)

225

(8.86)

285

(11.22)

285

(11.22)

285

(11.22)

285

(11.22)

126

(4.96)

186

(7.32)

236

(9.29)

275

(10.83)

126

(4.96)

186

(7.32)

236

(9.29)

275

(10.83)

275

(10.83)

275

(10.83)

275

(10.83)

266

(10.47)

285

(11.22)

365

(14.37)

435

(17.13)

266

(10.47)

285

(11.22)

365

(14.37)

435

(17.13)

610

(24.02)

7.0

(0.28)

8.0

(0.32)

7.5

(0.30)

27.5

(1.08)

7.5

(0.30)

7.0

(0.28)

8.0

(0.32)

7.5

(0.30)

7.5

(0.30)

Approx. Mass

(kg)

Mounting Hole

4.5 M5

5.5

23 IP00

3.5

10.54022

M6 IP00

Enclosure Type

IP20

Note: RC5 is offered in the following enclosure types:

• IP20: 23P7 to 2030

• IP20: 43P7 to 4030

• IP00: 2037

• IP00: 4037 to 4075

20 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

2.5 Removing and Replacing the Front Cover

To remove the front cover, first move the LCD monitor/digital operator in the direction shown by arrow 1. Then squeeze the cover in the direction shown by arrows 2 on both sides and lift in the direction shown by arrow 3.

Figure2.4

Front Cover

Figure 2.4 Removing and Replacing the Front Cover

Note: Do not replace the front cover with the LCD monitor/digital operator connected. The LCD monitor/digital operator will not be connected to the power regenerative unit.

Replace the front cover first and then install the LCD monitor/digital operator on the cover. Refer to Removing and Replacing the LCD Monitor/Digital Operator on

page 22 for replacing the LCD monitor/digital operator.

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 21

2.6 Removing and Replacing the LCD Monitor/Digital Operator

LCD Monitor/ Digital Operator

Front Cover

LCD Monitor/ Digital Operator

Front Cover

Claws A

Claws B

2.6 Removing and Replacing the LCD Monitor/Digital Operator

Remove and replace the LCD monitor/digital operator as follows.

◆ Removing the LCD Monitor/Digital Operator

Push the LCD monitor/digital operator lever in the direction shown by arrow 1 and lift the LCD monitor/digital operator in the direction shown by arrow 2 to remove the LCD monitor/digital operator from the front cover.

Figure 2.5

◆ Replacing the LCD Monitor/Digital Operator

Engage the LCD monitor/digital operator on claws A in the direction shown by arrow 1 and then on claws B in the direction shown by arrow 2 to lock the LCD monitor/digital operator.

Figure 2.6

Note: Never fit the LCD monitor/digital operator in any other direction or by any other method. The LCD monitor/digital operator will not be connected to the inverter.

Figure 2.5 Removing the LCD Monitor/Digital Operator

Figure 2.6 Replacing the LCD Monitor/Digital Operator

22 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

Wiring

3.1 SECTION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

3.2 CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.3 SELECTING PERIPHERAL DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.4 WIRING MAIN CIRCUIT TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

3.5 EXTERNAL TERMINALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 23

3.1 Section Safety

W ARNING

CAUTION

3.1 Section Safety

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

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

Wiring should be performed only by qualified personnel.

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

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

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

Install adequate branch short circuit protection according to applicable codes.

Failure to comply could result in damage to the drive.

Verify that the power regenerative unit rated voltage coincides with the AC power supply voltage.

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

Do not perform a withstand voltage test of the power regenerative unit.

It may cause semi-conductor elements to be damaged.

Connect the power coordinating reactor and the power suppressing reactor as described in this instruction manual.

Improper connection may cause a fire.

Verify that the rated voltage of the power regenerative unit coincides with the rated voltage of the power regenerative unit to be connected.

Failure to observe this caution can result in a fire.

Tighten terminal screws.

Failure to observe this caution can result in a fire.

24 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

3.2 Connection Diagram

◆ Connection Diagram with Drive

Figure 3.1 shows a diagram of a typical connection of the RC5 with the Yaskawa AC Drive.

Note: The RC5 is compatible with other Yaskawa drive (inverter) products. Refer to the application technical manual for the equivalent connection diagram.

Figure3.1

MCCB MC

<4>

Power Coordination Reactor

<4>

Current

Suppression

<4>

Reactor

MOV

MANUAL RUN

AUTO RUN

EXFLT

RESET

<6>

VS-656RC5

R/L1

<2>

S/L2

T/L3

r1/

<3>

t1/

CONV READY

Running

<5>

+24V

Sequence

Common

Shield Sheath

Connection Terminal

Analog Output

-10 to +10V

M2 M3

MA MB MC

<9>

<8>

Yaskawa AC Drive

R/L1

S/L2

T/L3

<2>

<3>

<1>

U/T1

V/T2

W/T3

Figure 3.1 Connection Diagram (When connecting a RC5 and a Yaskawa AC Drive)

<1> Connect to the terminal (+)1 for 200 V class 0.4 to 22 kW, and 400 V class 0.4 to 45 kW Yaskawa AC drive. Use terminal (+)3 for 200 V class 30 to 37 kW, and 400 V class 55 to 75 kW VS-616G5 drivers or another Yaskawa drive (inverter) product.

<2> Connect the Yaskawa AC Drive power supply terminals R/L1, S/L2, and T/L3 to the secondary side of the power coordinating reactor. Connect the RC5 AC power supply terminals R/L1, S/L2, and T/L3 to the secondary side of the power suppressing reactor.

<3> Connect terminals r/l 1, s/l 2 of VS-616G5, and terminals r1/l 11, s 1/l 21, and t1/l 31 of the RC5 to the primary side of the power coordinating reactor.

<4> Make sure to use the specified reactor, fuse and fuse holder.

<5> The sequence input terminal of RC5 is the same as terminal S1.

<6> The wiring distance between the power coordinating reactor, and RC5 and a Yaskawa AC Drive should be 10 m or less.

<7> DC bus wiring [(+) 1 - (+), ] between the Drive and the power regenerative unit should be 5 m or less.

<8> Remove the wiring of terminals r/l 1 and s/l 2 since they were connected at the factory.

<9> If installing a circuit breaker or a magnetic contactor on the RC5 output (DC) side to shut down the power supply in an emergency, observe the following precautions.

• Be sure to confirm that the charge lamps on the RC5 and the Inverter are not lit, and then turn on the circuit breaker or contactor. If the circuit breaker or contactor is turned on while power is supplied to the RC5 and the Inverter, an overcurrent may occur and damage the circuit breaker or contactor.

• Be sure to confirm that the circuit breaker or contactor is turned on before the power is turned on for the RC5.

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 25

3.3 Selecting Peripheral Devices

Selecting Heavy Duty or Standard Duty RC5 Application

The RC5 overload rating has the capability of 150% braking torque for 30 seconds and 200% peak braking torque. The overload capability is based on the standard duty rating. The RC5 overload rating can be applied to heavy duty applications. The following is a description of the heavy duty and standard duty ratings.

■ Heavy Duty

Heavy duty applications require continuous energy dissipation (100% braking torque).

The overload rating is 125% for 60 seconds with a duty cycle of 25%. Braking torque of 187.5% is available for 30 seconds. Please note the peak torque should be less than 250%.

The RC5 requires selecting Power Coordination and Current Suppression reactors according to specifications in Table 3.3.

■ Standard Duty

Standard duty applications require intermittent full energy dissipation. The continuous rating is 80% or less braking torque and 100% braking torque for 60 seconds with a duty cycle of 25% (60 seconds maximum on-time of every 240 seconds). The overload rating is 150% braking torque for 30 seconds. Please note the peak torque should be less than 200%.

The RC5 requires selecting Power Coordination and Current Suppression reactors according to specifications in Table 3.3

◆ Main Circuit Input Fuse

■ Fuse Kits

The Fuse Kit is sized for both Heavy Duty and Standard Duty applications.

Connect a fuse at the primary side of the power suppression reactor. Recommended fuses are shown in Table 3.1 and Ta bl e 3. 2.

Table 3.1 200 V Class Input Fuse

RC5 Input fuse Fuse holder

Rated

Model

CIMR-R5U

23P71A 2.2 10 UFU000151 A30QS20-1 3 UFU000157 70318 1

25P51A 3.7 15 UFU000152 A30QS30-1 3 UFU000157 70318 1

27P51A 5.5 20 UFU000152 A30QS30-1 3 UFU000157 70318 1

20111A 7.5 30 UFU000153 A30QS50-4 3 FU-002082 P243G 3

20151A 11 40 UFU000154 A30QS80-4 3 FU-002083 P243 3

20181A 15 50 UFU000154 A30QS80-4 3 FU-002083 P243 3

20221A 18 60 UFU000155 A30QS100-4 3 FU-002083 P243 3

20301A 22 80 UFU000156 A30QS150-4 3 FU-002083 P243 3

20370A 30 100 UFU000156 A30QS150-4 3 FU-002083 P243 3

Note: These fuses and fuse holders are made by FERRAZ.

regenerative

capacity (kW)

25%ED

Rated input

current

(Aac)

25%ED

Yaskawa

Part Number

Ferraz

Part Number

Amount per unit

Yaskawa

Part Number

Ferraz

Part Number

Amount per unit

26 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

3.3 Selecting Peripheral Devices

Table 3.2 400 V Class Input Fuse

RC5 Input fuse Fuse holder

Model

CIMR-R5U

43P71A 2.2 5 FU-002029 A60Q10-2 3 FU-002055 30323 1

45P51A 3.7 7.5 FU-002030 A60Q15-2 3 FU-002055 30323 1

47P51A 5.5 10 FU-002030 A60Q15-2 3 FU-002055 30323 1

40111A 7.5 15 FU-002032 A60Q30-2 3 FU-002055 30323 1

40151A 11 20 FU-002032 A60Q30-2 3 FU-002055 30323 1

40181A 15 25 FU-000783 A50P50-4 3 FU-002082 P243G 3

40221A 18 30 FU-000783 A50P50-4 3 FU-002082 P243G 3

40301A 22 40 FU-000806 A50P80-4 3 FU-002084 P243E 3

40370A 30 50 FU-000806 A50P80-4 3 FU-002084 P243E 3

40450A 37 60 FU-000807 A50P100-4 3 FU-002084 P243E 3

40550A 45 75 FU-000809 A50P150-4 3 FU-002084 P243E 3

40750A 55 100 FU-000809 A50P150-4 3 FU-002084 P243E 3

Note: These fuses and fuse holders are made by FERRAZ.

Rated

regenerative

capacity (kW)

25%ED

Rated input

current

(Aac)

25%ED

Yaskawa

Part Number

Ferraz

Part Number

Amount per unit

Yaskawa

Part Number

Ferraz

Part Number

Amount

per unit

◆ Power Coordination and Current Suppression Reactors

Both Power Coordination and Current Suppression Reactors are 3-phase input reactors that correspond to each RC5 model and are necessary when operating the RC5. Use a single Power Coordination and a single Current Suppression reactor for each RC5 application.

■ Recommended RC5 Power Cooridination and Suppression Reactor Specifications

Table 3.3 shows Yaskawa recommended specifications for Power Coordination and Current Suppression reactors for each RC5 model.

Table 3.3 Recommended RC5 Power Cooridination and Suppression Reactor Specifications

RC5 Power Coordination Reactor Current Suppression

Model CIMR-R5U Rated Current (Arms) Inductance (mH) Rated Current (Arms) Inductance (mH)

23P71A 20 0.53 15 0.31

25P51A 30 0.35 15 0.31

27P51A 40 0.265 20 0.15

20111A 60 0.18 40 0.1

200 V Class

400 V Class

20151A 80 0.13 40 0.1

20181A 90 0.12 50 0.06

20221A 120 0.09 60 0.05

20301A 160 0.07 80 0.04

20370A 200 0.05 100 0.03

43P71A 10 2.2 7.5 1.2

45P51A 15 1.42 7.5 1.2

47P51A 20 1.06 10 0.6

40111A 30 0.7 15 0.4

40151A 40 0.53 25 0.3

40181A 50 0.42 25 0.3

40221A 60 0.36 30 0.2

40301A 80 0.26 40 0.15

40370A 90 0.24 50 0.12

40450A 120 0.18 60 0.1

40550A 150 0.15 75 0.08

40750A 200 0.11 100 0.06

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 27

3.3 Selecting Peripheral Devices

0.6 mm max

3.5 mm max

Screwdriver Blade Width

7mm

NO!

◆ Wiring Precautions

The external interconnection wiring must be performed with following procedures. After completing RC5 interconnections, be sure to check that the connections are correct. Never use control circuit buzzer check.

■ Precautions on Control Circuit Wiring

• Separate control circuit wires from main circuit wires and other power cables to prevent erroneous operation caused by noise interference.

• Separate the wiring of control circuit terminals from other control terminals or main circuit wirings.

• Wiring distance should be less than 50 m.

• Insert the wire into the lower part of the terminal block and connect it tightly with a screwdriver. Wire sheath strip length must be 7 mm.

Figure 3.2

Figure 3.2 Control Circuit Terminal Wiring

• Use twisted shielded or twisted-pair shielded wire for the control circuit line and connect the shielded sheath to inverter terminal E. (See

Figure 3.3)

Figure 3.3

Shielded Sheath

Armor

Never connect.

To power regenerative unit shielded sheath terminal E

Figure 3.3 Shielded Wire Termination

Insulate these parts with insulating tape.

■ Ground Wiring

• Do not share the ground wire with other devices, such as welding machines or power tools. Separate the grounding cables from the wirings for 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 power regenerative unit. Therefore, if the distance between the ground electrode and the ground terminal is too

long, potential on the ground terminal of the power regenerative unit will become unstable.

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

Figure 3.4

Figure 3.4 Ground Wiring

28 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

3.4 Wiring Main Circuit Terminals

◆ Required Wire Size

Select wires to be used for wiring from Table 3.4 and Table 3.5.

Table 3.4 200 V Class Wire Size

3.4 Wiring Main Circuit Terminals

Circuit

Main

Control Common to all models

<1> Wire size is determined by 75°C temperature-rated copper wire.

Note: Cable size is selected assuming external wiring of single 3-core cables at an ambient temperature of 30°C. Note: For model number 2015, use closed-loop connectors that are recommended by JST (JST 14-5).

RC5

CIMR-R5U

23P7

25P5

27P5

2011

2015

2018

2022

2030

2037

Terminal Symbol

R/L1, S/L2, T/L3, (+), (+), ,

r1/ 11, 1/ 21, t1/ 31

R/L1, S/L2, T/L3, (+), (+), ,

r1/ 11, 1/ 21, t1/ 31 2 to 5.5 14 to 10

R/L1, S/L2, T/L3, (+), (+), ,

r1/ 11, 1/ 21, t1/ 31 2 to 5.5 14 to 10

R/L1, S/L2, T/L3, (+), (+), ,

r1/ 11, 1/ 21, t1/ 31 2 to 5.5 14 to 10

R/L1, S/L2, T/L3, (+), (+), ,

r1/ 11, 1/ 21, t1/ 31 2 to 5.5 14 to 10

R/L1, S/L2, T/L3, (+), (+), , M8 22 4

r1/ 11, 1/ 21, t1/ 31 M4 2 to 5.5 14 to 10

R/L1, S/L2, T/L3, (+), (+), , M8 22 4

r1/ 11, 1/ 21, t1/ 31 M4 2 to 5.5 14 to 10

R/L1, S/L2, T/L3, (+), (+), , M8 30 to 38 3 to 2

r1/ 11, 1/ 21, t1/ 31 M4 2 to 5.5 14 to 10

R/L1, S/L2, T/L3, (+), (+), , M8 50 to 60 1 to 1/0

r1/ 11, 1/ 21, t1/ 31 M4 2 to 5.5 14 to 10

S1, S2, S3, S4, SS, SP, SC, M1, M2, M3, M4, MA, MB, MC, AM, AC

E (G) M3.5 0.5 to 2 20 to 14

Ter min al

Screw

M4 2 to 5.5 14 to 10

M6 8 8

M6 14 6

—

Wire Size <1>

3.5 to 5.5 12 to 10

5.5 10

3.5 to 5.5 12 to 10

5.5 to 8 10 to 8

twisted wire

0.5 to 1.25 single

0.5 to 1.25

AWG

twisted wire

20 to 16

single

20 to 16

Wire Type

Power cable: 600 V vinyl sheathed wire or equivalent

Shielded twisted-pair wires

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 29

3.4 Wiring Main Circuit Terminals

Circuit

RC5

CIMR-R5U

43P7

45P5

47P5

R/L1, S/L2, T/L3, (+), (+), (+), ,

r1/ 11, 1/ 21, t1/ 31

R/L1, S/L2, T/L3, (+), (+), (+), ,

R/L1, S/L2, T/L3, (+), (+), ,

Table 3.5 400 V Class Wire Size

Terminal Symbol

Ter min al

Screw

Wire Size <1>

M4 2 to 5.5 14 to 10

M4 2 to 5.5 14 to 10r1/ 11, 1/ 21, t1/ 31

AWG

Wire Type

R/L1, S/L2, T/L3, (+), (+), ,

4011

r1/ 11, 1/ 21, t1/ 31

R/L1, S/L2, T/L3, (+), (+), ,

4015

r1/ 11, 1/ 21, t1/ 31 2 to 5.5 14 to 10

R/L1, S/L2, T/L3, (+), (+), , M6 8 to 14 8 to 6

4018

Main

4022

r1/ 11, 1/ 21, t1/ 31 M4 2 to 5.5 14 to 10

R/L1, S/L2, T/L3, (+), (+), , M6 8 to 14 8 to 6

r1/ 11, 1/ 21, t1/ 31 M4 2 to 5.5 14 to 10

R/L1, S/L2, T/L3, (+), (+), , M6 14 6

4030

r1/ 11, 1/ 21, t1/ 31 M4 2 to 5.5 14 to 10

R/L1, S/L2, T/L3, (+), (+), , M6 14 to 22 6 to 4

4037

r1/ 11, 1/ 21, t1/ 31 M4 2 to 5.5 14 to 10

R/L1, S/L2, T/L3, (+), (+), , M8 22 to 38 4 to 2

4045

r1/ 11, 1/ 21, t1/ 31 M4 2 to 5.5 14 to 10

R/L1, S/L2, T/L3, (+), (+), , M8 38 to 60 2 to 1/0

4055

r1/ 11, 1/ 21, t1/ 31 M4 2 to 5.5 14 to 10

R/L1, S/L2, T/L3, (+), (+), , M8 50 to 60 1 to 1/0

Control

4075

Common to all

models

r1/ 11, 1/ 21, t1/ 31 M4 2 to 5.5 14 to 10

S1, S2, S3, S4, SS, SP, SC, M1, M2, M3, M4, MA, MB, MC, AM, AC

E (G) M3.5 0.5 to 2 20 to 14

<1> Wire size is determined by 75°C temperature-rated copper wire.

Note: Cable size is selected assuming external wiring of single 3-core cables at an ambient temperature of 30°C Note: For model number 4011 and 4015, use closed-loop connectors that are recommended by JST (JST 3.5 - R5).

3.5 to 5.5 12 to 10

2 to 5.5 14 to 10

5.5 10

M6 8 8

M6 14 6

twisted wire

—

0.5 to 1.25 single

0.5 to 1.25

twisted wire

20 to 16

single

20 to 16

Power cable: 600 V vinyl sheathed wire or equivalent

Shielded twisted-pair wires

30 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

3.4 Wiring Main Circuit Terminals

◆ Closed-Loop Connectors Size

Yaskawa recommends using closed-loop crimp terminals.

UL/cUL approval requires the use of closed-loop crimp terminals when wiring the main circuit terminals.

Use only the tools recommended by the terminal manufacturer for crimping.

Table 3.6 Closed Loop Connectors Sizes (JIS C 2805) (For 200 V/400 V classes)

Wire Size

0.5 20

0.75 18

1.25 16

214

3.5 12

5.5 10

14 6 M6 3.6 to 5.1 R14-6

22 4 M8 8.2 to 10.2 R22-8

30/38 3/2 M8 8.2 to 10.2 R38-8

30/38 3/2

50/60 1/1/0 R60-10

80 3/0 R80-10

100 4/0 R100-10

100 4/0

150 300 R150-12

200 400 R200-13

AWG

Terminal Screw Tightening Torque (N•m) Closed Loop Connectors

M3.5

M4 1.2 to 1.4 R2-4

M5 2.1 to 2.5 R2-5

M4 1.2 to 1.4 3.5-4

M5 2.1 to 2.5 3.5-R5

M4 1.2 to 1.4 R5.5-4

M5 2.1 to 2.5 R5.5-5

M5 2.1 to 2.5 R8-5

M6 3.6 to 5.1 R8-6

M10 18 to 23

M12 31.5 to 39.5

0.8 to 1.0

1.2 to 1.4

R1.25-3.5

R1.25-4

R38-10

R100-12

Note: 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:

(If there is a possibility of excessive voltage drop, use a larger wire suitable to the required length.) Line voltage drop (V) = 3 x wire resistance (Ω/km) x wire length (m) x current (A) x 10

-3

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 31

3.5 External Terminals

◆ Main Circuit Terminal Functions

Terminal Symbol Description

R/L1 S/L2 T/L3

(+),

r1/ 11 1/ 21

t1/ 31

◆ Control Circuit Terminal Functions

Typ e No. <1>

Sequence Input

Photocoupler Output

Relay Output

Analog Output

<1> Indicates the terminal number of the control card.

Power Regenerative Unit

Main Circuit Input

Power Supply Voltage

Detection

Power Input for FAN and MC Supplies power for the cooling fan and inrush prevention MC of the power regenerative unit.

S1 MANUAL RUN Run when CLOSED, stops when OPEN

S2 AUTO RUN Auto run (regenerative operation) when CLOSED

S3 EXTERNAL FAULT INPUT

S4 FAULT RESET INPUT

SC Sequence Common

SS Photocoupler internal common

SP Sequence +24 V Power Supply

M1 - M2 CONV READY

M3 - M4 RUN CLOSE during run

MA - MC MB - MC

AM Input Current

AC Analog Ground

Table 3.7 Main Circuit Terminal Functions

Main circuit AC power supply terminal for the power regenerative unit.

Connect to the Drive’s DC power supply voltage input terminals.

• Two terminals are provided for both (+) and .

Detects the phase sequence and the voltage level.

• Connect to the power side of the power coordinating reactor.

Table 3.8 Control Circuit Terminal Functions

Signal Input Function Function Signal Level

External fault when

FAULT Output

CLOSED

Fault reset when CLOSED

Closed when power regenerative unit is READY

Outputs when a fault is detected. Terminal MA-MC: Closed during fault detection Ter m inal M B-M C : Open during fault detection

5 V: 100% of rated input current

Multi-function Contact Inputs (H1-01 to H1-02)

H2-01 to H2-02 48 VDC 80 mA or less

Outputs when a fault is detected. Terminal MA-MC: Closed during fault detection Ter m inal M B-M C : Open during fault detection

Multi-function Analog Output (H1-04)

24 VDC 8 mA Photocoupler isolation

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

- 10 V to + 10 VDC 2 mA or less

32 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

Operation

4.1 SECTION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

4.2 CHECKS PRIOR TO MAIN POWER APPLICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

4.3 SETTING THE POWER SUPPLY VOLTAGE JUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.4 USING THE DIGITAL OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

4.5 DIGITAL OPERATOR MODES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4.6 POWER ON/OFF SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

4.7 RUN COMMAND SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 33

4.1 Section Safety

W ARNING

CAUTION

4.1 Section Safety

Only turn ON the input power supply after replacing the front cover or the terminal cover. Do not remove the cover while power is on.

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

Never operate the digital operator or other switches when your hand is wet.

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

Never touch the terminals while current is flowing, even if the power regenerative unit stops.

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

Never touch the heatsink or input reactors since their temperature may be very high.

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

All the constants of the power regenerative unit have been preset at the factory. Do not change the settings unnecessarily.

The power regenerative unit may be damaged.

34 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

4.2 Checks Prior to Main Power Application

Check the following before turning ON the power supply.

• Check that the power supply is of the correct voltage. 200 V class: 200 to 230 VAC, 50/60 Hz 400 V class: 380 to 460 VAC, 50/60 Hz

• Make sure that the power regenerative unit and the Drive are connected correctly.

• Make sure that the phase sequence of the main circuit terminals (R/L1, S/L2, T/L3) and the power supply voltage detection terminals (r1/ 11, 1/

21, t1/ 31) are correct.

• Make sure that the power regenerative unit and the control device are wired correctly.

• Set the run command of the power regenerative unit and the drive to OFF.

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 35

4.3 Setting the Power Supply Voltage Jumper

400/415V

21CN

380V 440V 460V

23CN 24CN 25CN 26CN 22CN FU2

20CN

TB2

Jumper

4.3 Setting the Power Supply Voltage Jumper

Note: 400 V CLASS REGENERATIVE UNITS OF 37 kW OR HIGHER

Set the power supply voltage jumper for 400 V class power regenerative unit of 37 kW or higher. Insert the jumper into the voltage connector nearest to the actual power supply voltage.

Incorrect connector setting may negatively impact the performance of the power regenerative unit.

The jumper is factory-set to 460 V when shipped. If the power supply voltage is not 460 V, use the following procedure to change the setting.

1. Turn OFF the power supply switch and wait for at least five minutes before removing the front panel and setting the jumper.

2. Remove the front cover.

3. Insert the jumper at the position for the voltage supplied to the power regenerative unit (see Figure 4.1).

4. Replace the front cover.

Figure 4.1

Figure 4.1 Setting the Power Supply Voltage (For 400 V Class Power Regenerative Unit between 37 kW and 75 kW)

36 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

4.4 Using the Digital Operator

LOCAL

REMOTE

DIGITAL OPERATOR JVOP-130

ESC

DATA

ENTER

JOG

FWD

REV

RESET

RUN STOP

DRIVE FWD REV REMOTE

SEQ REF

Dc Bus Voltage

U1-02 = 300 VDC

Keys

Execute operations such as setting user parameters and monitoring.

Data Display

Two-line LCD that displays data for monitoring, parameters, and set values with 16 characters per line.

Operation Mode Indicators

DRIVE: Lit when in operation mode. FWD: Not used REV: Not used SEQ: Lit when the run command from the

control circuit terminal is enabled.

REF: Not used

4.4 Using the Digital Operator

This section describes the component names and functions of the Digital Operator. The component names and functions are shown in Figure 4.2 and Key function are described in Table 4.1.

Figure4.2

Figure 4.2 Digital Operator Component Names and Functions

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 37

4.4 Using the Digital Operator

LOCAL

REMOTE

ESC

JOG

FWD REV

RESET

DATA

ENTER

RUN

STOP

Key Name Function

LOCAL/REMOTE Key

MENU Key Displays menus.

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

JOG Key Not used.

FWD/REV Key Not used.

Table 4.1 Key Function

Switches between operation (LOCAL) via the Digital Operator and control circuit terminal (REMOTE) operation. This key can be enabled or disabled by setting o2-01.

RESET Key

Set the number of digits for parameter settings. Also acts as the reset Key when a fault has occurred.

Increment Key Selects menu items, groups, functions, and parameter names, and increments set values.

Decrement Key Selects menu items, groups, functions, and parameter names, and decrements set values.

DATA/ENTER Key Enters menu items, functions, parameters, and set values after they are set.

RUN Key Starts the RC5 operation when the RC5 in operation with the Digital Operator.

STOP Key

Stops RC5 operation. This Key can be enabled or disabled by setting o2-02 when operating from the control circuit terminal.

Note: Except diagrams, keys are referred to using the key names listed in the above table.

38 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

4.5 Digital Operator Modes

This section describes the RC5’s monitor modes, switching between modes, and accessing/setting user parameters.

◆ Modes

The RC5’s user parameters and monitoring functions have been organized in groups called modes that make it easier to read and set user parameters.

The RC5 is equipped with 4 modes, as shown in Ta bl e 4 .2 .

Table 4.2 Modes

Mode Primary function(s)

Operation mode

Initialize mode

Programming mode

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

The power regenerative unit can be run in this 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 when selecting the language displayed on the Digital Operator, selecting the access level for reading/ setting user parameters, selecting the control mode, or initializing the user parameters. Factory setting: English (A1-00=0)

Use this mode when reading/setting the user constants required for operation. The program mode functions are subdivided into the following groups:

• Application: Operation mode selection

• Tuning: No Auto-Tuning

• Option: No Option Card support

• Terminal: Settings for sequential I/O and analog I/O

• Protection: Settings for the motor and power regenerative unit protection function

• Operator: Selects the Digital Operator’s display and Key function

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 39

4.5 Digital Operator Modes

All modes / parameter status

** Main Menu **

Operation

** Main Menu **

Initialize

** Main Menu **

Programming

** Main Menu **

Modified Parameters

Power ON

Dc Bus Voltage

U1-02=300VDC

Select Language

English

Group b

Application

None Modified

ESC

DATA

ENTER

ESC

DATA

ENTER

ESC

DATA

ENTER

ESC

DATA

ENTER

A1-00 = 0***

English

Function b1

Sequence

ESC

DATA

ENTER

ESC

DATA

ENTER

Operation mode

Initialize mode

Programming mode

Modified parameter mode

(Mode Display)

Monitor (DC bus voltage)

Operator display language selection

Operation mode selection

Displays parameterss changed from factory settings

Function

(Parameter Reading)

Parameter Display

(Parameter Setting)

◆ Navigating Digital Operator Modes

Once the power regenerative unit has been put into operation mode by pressing the Menu Key, the Increment and Decrement Keys can be pressed to switch to other modes. Press the DATA/ENTER Key to read/set the user parameters in each mode.

Press the ESC Key to return to the mode display from the user parameter display.

Press the DATA/ENTER Key twice to write a parameter and then press the ESC Key to return to the mode display. This is the most Basic operation, so you should remember it.

Figure 4.3

Note: When running the power regenerative unit after using the digital operator, press the MENU Key to enter the operation mode and then press the DATA/ENTER Key from

the operation mode display to bring up the monitor display. Run commands can’t be received from any other display. (Monitor display in the operation mode appears when the power is turned ON.)

Figure 4.3 Mode Transitions

40 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

■ Parameter Setting Example

The group level will be displayed when the DATA/ENTER Key is pressed at the programming mode display.

Step Key Sequence Digital Operator Display Remarks

** Main Menu **

Operation

4.5 Digital Operator Modes

** Main Menu **

Programming

Press twice.

DATA

ENTER

DATA

ENTER

DATA

ENTER

DATA

ENTER

Group b

Application

Function b1

Sequence

Run Source

Terminals

b1-02 = 1***

Terminals

b1-02 = 0

Operator

Changed to parameter reading (function) level.

Press twice.

DATA

ENTER

Entry Accepted

Run Source

Operator

ESC

Function b1

Sequence

Writes-in the new setting.

After a few seconds, the operator display is as shown on the left.

The parameter setting has been completed (operation mode has changed from the external terminals to the operator).

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 41

4.5 Digital Operator Modes

All modes /parameters status

** Main Menu **

Operation

Output Current U1-05 = 0.0 A

Ac Frequency

U1-08 = 60.00 Hz

Function U2

Fault Trace

Power ON

(When o1-02=2 )

DC Bus Voltage

U1-02 = 300 VDC

Current Fault

None

ESC

DATA

ENTER

ESC

DATA

ENTER

Operation Mode

Output current on power side

Power supply frequency (can be changed at parameter o1-01)

Function selection U2 (fault trace)

DC Bus Voltage display

Contents of fault trace

Function U3

Fault History

Function U1

Monitor

Last Fault

None

DC Bus Voltage

U1-02= 300VDC

ESC

DATA

ENTER

ESC

DATA

ENTER

Function selection U3 (fault history)

Function selection U1 (Monitor)

Contents of fault history

Various monitors

Power ON

(When o1-02=3)

Power ON

(When o1-02=4)

◆ Operation Mode

Operation mode is the mode in which the power regenerative unit can be operated. Many user parameters can’t be changed when the power regenerative unit is operating.

Viewing monitor displays, fault information and fault history are possible in operation mode.

Note: When running the power regenerative unit after using digital operator, press the MENU Key to enter the operation mode and then press the DATA/ENTER Key from the

operation mode display to bring up the monitor display. Run commands can’t be received from any other display. (Monitor display in the operation mode appears when the power is turned ON.)

■ Operations in Operation Mode

Key operations in operation mode are shown in Figure 4.4.

Figure 4.4

Figure 4.4 Operations in Operation Mode

42 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

4.6 Power On/Off Sequence

Refer to Figure 4.5 when building a power ON/OFF sequence for the RC5.

Figure4.5

4.6 Power On/Off Sequence

FFONO

AC Power Supply

Power Regenerative Unit

READY

Drive

READY

Drive

Run Command

Drive

Output during Run

Power Regenerative Unit

Run Command

Power Regenerative Unit

Output during Run

Drive

Output Frequency

OFF

STOP

Figure 4.5 Power Supply ON/OFF Sequence

RUN

1sec

DC Injection Braking

Check the following when using the power regenerative unit.

• Run commands of the drive and the power regenerative unit should be turned ON after confirming that the drive and the power regenerative unit are READY.

• Run commands of the drive and the power regenerative unit should be turned ON at the same time.

• Never turn the run command of the power regenerative unit OFF while the drive output during run is ON.

• Run output of the power regenerative unit turns OFF one second after the run command is turned OFF.

• Turn the power OFF after the run output of the power regenerative unit is OFF.

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 43

4.7 Run Command Selection

AUTO RUN

Drive Status

Auto Run

Regeneration

DC Bus Voltage

Regenerative Unit

Run Status

Current at Power Side

RUN

AC Power Supply Voltage x 1.35

Operation Start Level

Operation Stop Level

STOP

C8-20: default setting 1 sec

MANUAL RUN

Drive Status

Regenerative Unit

Run Status

Current at Power Side

DC Bus Voltage

RUN

Regeneration

Auto Run

AC Power Supply Voltage x 1.35

C8-20: default setting 1 sec

4.7 Run Command Selection

This section explains the two run command modes of the power regenerative unit. Select the mode according to the application.

◆ Auto Run

Auto run is the mode in which the power regenerative unit detects any increase/decrease of the bus voltage and performs an auto run/stop if the terminal S2-SC is “closed.”

When the DC voltage is less than the voltage set at the auto run/stop level, the RC5 will stop after the preset time value in parameter C8-20 is passed (default: 1 sec).

Figure 4.6

Figure 4.6 Time chart of the Auto Run Mode

◆ Manual Run

Manual run is the mode in which the RC5 starts running when the terminal S1-SC is “closed,” and stops one second after S1-SC is “open.”

Figure 4.7

Figure 4.7 Time chart of the Manual Run mode

Build a sequence so that the run commands of the power regenerative unit and the inverter are turned ON at the same time.

44 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

Maintenance and

Inspection

5.1 SECTION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

5.2 PERIODIC INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 45

5.1 Section Safety

W ARNING

CAUTION

5.1 Section Safety

Never touch high-voltage terminals in the power regenerative unit.

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

Perform maintenance or inspection only after verifying that the CHARGE LED goes OFF, after the main circuit power supply is turned OFF.

The capacitors are still charged and can be dangerous.

Only authorized personnel should be permitted to perform maintenance, inspections or parts replacement.

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

Never modify the product.

Failure to observe this warning can result in an electric shock or personal injury and will invalidate the guarantee.

The power regenerative unit employs semi-conductor elements. Do not touch the CMOS elements.

They are easily damaged by static electricity.

Do not connect or disconnect wires or connectors while power is applied to the circuit.

Failure to observe this caution can result in personal injury.

46 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

5.2 Periodic Inspection and Maintenance

The maintenance period of the power regenerative unit is as follows.

Maintenance period: Within 18 months of shipping from the factory or within 12 months of being delivered to the final user, whichever comes first.

◆ Daily Inspection

Check the following items with the system in operation.

• There should be no abnormal heat generation.

• The ambient temperature should not be too high.

• The cooling fan on the power regenerative unit should be operating normally.

◆ Periodic Inspection

Check the following items during periodic maintenance.

Always turn OFF the power supply before beginning inspection. Confirm that the LED indicators on the front cover have all turned OFF, and then wait at least five minutes have elapsed before beginning the inspection. Be sure not to touch terminals right after the power has been turned OFF. Doing so can result in an electric shock.

Table 5.1 Periodic Inspections

Item Inspection Corrective Procedure

External terminals, mounting bolts, connectors, etc.

Heatsink Are the fins dirty?

PCBs Is there any conductive dirt or oil mist on the PCBs?

Cooling fan

Power elements Is there any conductive dirt or oil mist on the elements?

Smoothing capacitor Are there any irregularities, such as discoloration or odor? Replace the capacitor or power regenerative unit.

Are all screws and bolts tight? Tighten loose screws and bolts firmly.

Are connectors tight? Reconnect the loose connectors.

Is there any abnormal noise or vibration or has the total operating time exceeded 20,000 hours? <1>

Clean off any dirt and dust with an air gun using dry air at a pressure of 39.2x10

Clean off any dirt and dust with an air gun using dry air at a pressure of 39.2x104 to 58.8x104 Pa (4 to 6 kg•cm2). Replace the boards if they cannot be made clean.

Replace the cooling fan.

Clean off any dirt and dust with an air gun using dry air at a pressure of 39.2x10

to 58.8x104 Pa (4 to 6 kg•cm2).

<1> Unit power must be ON to perform this check.

◆ Periodic Maintenance of Parts

The power regenerative unit is configured of many parts, and these parts must be operating properly in order to make full use of its functionality.

Among the electronic components, there are some that require maintenance depending on their usage conditions. In order to keep the power regenerative unit operating normally over a long period of time, it is necessary to perform period inspections and replace parts according to their service life.

When replacing parts, be careful not to drop any, such as screws, inside the RC5. Failure to observe this caution may result in a short-circuit and a fire.

Periodic inspection standards vary depending the installation environment and usage conditions of the power regenerative unit. The power regenerative unit’s maintenance periods are noted below. Keep them as reference.

Table 5.2 Part Replacement Guidelines

Part Standard Replacement Period Replacement Method

Smoothing capacitor 5 years Replace with new part. (Determine need by inspection.)

Breaker relays — Determine need by inspection.

Fuses 10 years Replace with new part.

Aluminum capacitors on PCBs 5 years Replace with new board. (Determine need by inspection.)

Note: Usage conditions are as follows: • Ambient temperature: Yearly average of 30°C • Load factor: 80% max. • Operating rate: 12 hours max. per day.

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 47

5.2 Periodic Inspection and Maintenance

This page intentionally blank.

48 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

Troubleshooting

6.1 FAULT DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

6.2 MINOR FAULT DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6.3 OPERATION ERRORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 49

6.1 Fault Detection

When the power regenerative unit detects a fault, the fault code is displayed on the Digital Operator and the fault contact output operates.

When a fault has occurred, refer to the following table to identify and correct the cause of the fault.

Use one of the following methods to reset the fault after restarting the power regenerative unit.

• Turn ON the fault reset signal.

• Press the RESET Key on the Digital Operator.

• Turn the main circuit power supply OFF and then ON again.

Table 6.1 Fault Displays and Processing

Fault Display Meaning Probable Causes Corrective Actions

PUF IGBT, Fuse Failure

UV1 Dc Bus Undervolt

UV2 CTR PS Undervolt

UV3 MC Answerback

AUv Ac Undervoltage

FdVe Power F Fault

SrC Power Supply Flt.

OC Over Current

SC Short Circuit

OV Dc Bus Overvolt

OH Heatsink Overtmp

OH1 Heatsink Max temp

Fuse Blown The fuse in the main circuit is blown. The main transistor has damaged.

Main Circuit Undervoltage The main circuit DC voltage is below the undervoltage detection level (L2-05). 200 V class: Approx. 190 VDC 400 V class: Approx. 380 VDC

Control Power Fault The control power supply voltage dropped.

Inrush Prevention Circuit Fault A fault occurred in the inrush prevention circuit.

AC Power Undervoltage AC power undervoltage occurred during running. 200 V class: Approx. 150 VAC or less 400 V class: Approx. 300 VAC or less

Power Supply Frequency Fault AC power supply frequency has exceeded the setting value (F1-10).

Power Supply Fault The phase of the input power supply has changed after turning ON the control power supply.

Overcurrent The output current of the power regenerative unit exceeded the overcurrent detection level. (200% of rated current)

IGBT Short-circuit The IGBT gate signal was shortcircuited.

Main Circuit Overvoltage The main circuit DC voltage exceeded the overvoltage detection level. 200 V class: Approx. 400 VDC 400 V class: Approx. 800 VDC

Heatsink Overheating The temperature of the power regenerative unit’s cooling fins exceeded the setting in L8-02. (Stopping method can be changed by L8-03.)

Heatsink Overheating The temperature of the power regenerative unit’s cooling fins exceeded 105°C. (Stopping method: Coast to stop)

The output transistor has failed because of a short-circuit or overcurrent.

• An open-phase occurred with the input power supply.

• A momentary power loss occurred.

• The wiring terminals for the input power supply are loose.

—

• An open-phase occurred with the input power supply.

• A momentary power loss occurred.

• The wiring terminals for the input power supply are loose.

• The power supply fluctuations occurred during running.

• Power loss occurred during running.

• An open-phase occurred with the input power supply.

• A momentary power loss occurred.

• The wiring terminals for the input power supply are loose.

• A short-circuit occurred at the power regenerative output.

• Power supply drop

• Faulty wiring

A short-circuit of the PWM signal occurred.

The deceleration time is too short and the regenerative energy from the motor is too large.

The power supply voltage is too high.

The ambient temperature is too high. Install a cooling unit.

There is a heat source nearby. Remove the heat source.

The cooling fan of the power regenerative unit has stopped.

The ambient temperature is too high. Install a cooling unit.

There is a heat source nearby. Remove the heat source.

The cooling fan of the power regenerative unit has stopped.

Replace the power regenerative unit after correcting the cause.

Reset the fault after correcting its cause.

• Try turning the power supply off and on.

• Replace the power regenerative unit if the fault continues to occur.

• Try turning the power supply off and on.

• Replace the power regenerative unit if the fault continues to occur.

Reset the fault after correcting its cause.

Replace the control card.

• Increase the deceleration time.

• Check the capacity of the power regenerative unit.

• (Increase the capacity.)

Decrease the voltage so it is within specifications.

Replace the cooling fan. (Contact our sales representative.)

50 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

Fault Display Meaning Probable Causes Corrective Actions

OL Input Over Loaded

EF3 External Fault 3

EF4 External Fault 4

OPR Oper Disconnect

ERR EEPROM R/W Err

CPF00 COM-ERR (OP&CONV)

CPF01 COM-ERR (OP&CONV)

CPF02 BB Circuit Err

CPF03 EEPROM Err

CPF04 Internal A/D Err

Power Regenerative Unit Input Overload Power regenerative unit input exceeded the overload capacity.

External fault (terminal S3-SC)

External fault (terminal S4-SC)

Operator Connection Fault The Operator was disconnected during operation started by a run command from the Operator.

EEPROM Write Error —

Control Circuit Error 1 (Operator Communications Error)

Control Circuit Error 2 (Operator Communications Error)

Baseblock Circuit Error

EEPROM Error

CPU Internal A/D Converter Error

The load is too heavy. Check the size of the load.

An external fault was input from a multi-function input.

• Communications with the digital operator were not established within 5 seconds after the power was turned on.

• MPU peripheral element check fault.

• After communications were established, there was a transmission error with the digital operator for more than 2 seconds.

• MPU peripheral element check fault

The control circuit is damaged. Replace the control card.

6.1 Fault Detection

• Reset external fault inputs to the multi-function inputs.

• Remove the cause of the external fault.

— Check the Operator connection.

A verification error occurred when writing EEPROM. Try turning the power supply off and on again. Try setting the constants again.

• Disconnect the digital operator and then connect it again.

• Check the wiring of the control circuit power supply.

• Replace the control card.

• Disconnect the digital operator and then connect it again.

• Check the wiring of the control circuit power supply.

• Replace the control card.

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 51

6.2 Minor Fault Detection

Minor faults are a type of the protection function that do not operate the fault contact output and are automatically returned to their original status once the cause of the minor fault has been removed.

The Digital Operator display blinks.

Take appropriate countermeasures according to the table below.

Table 6.2 Minor Fault Displays and Processing

Minor Fault Display Meaning Probable Causes Corrective Actions

Main Circuit Undervoltage

UV Dc Bus Undervolt

OV Dc Bus Overvolt

OH Heatsink Overtmp

OL Input Over Loaded

EF3 External Fault 3

EF4 External Fault 4

The main circuit DC voltage was below the undervoltage detection level (L2-05). 200 V class: Approx. 190 VDC or less 400 V class: Approx. 380 VDC or less

Main Circuit Overvoltage The main circuit DC voltage exceeded the overvoltage detection level. 200 V class: Approx. 400 VDC 400 V class: Approx. 800 VDC

Heatsink Overheating The temperature of the power regenerative unit’s cooling fins exceeded the setting in L8-02. (Stopping method can be changed by L8-03.)

Power Regenerative Unit Input Overload Power regenerative unit input exceeded the overload capacity.

External fault (terminal S3-SC)

External fault (terminal S4-SC)

See causes for AUv, FdVe, SrC, and UV3 faults.

The regenerative energy from the motor is too large.

The power supply voltage is too high.

The ambient temperature is too high. Install a cooling unit.

There is a heat source nearby. Remove the heat source.

The cooling fan of the power regenerative unit has stopped.

The load is too heavy. Check the size of the load.

An external fault was input from a multi-function input.

Check the capacity of the power regenerative unit. (Increase the capacity.)

Decrease the voltage so it is within specifications.

Replace the cooling fan. (Contact your YASKAWA representative.)

• Reset external fault inputs to the multi-function inputs.

• Remove the cause of the external fault.

—

52 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

6.3 Operation Errors

After the parameters have been set, an operation error will occur if there is an invalid setting or a contradiction between two parameter settings.

It won’t be possible to start the power regenerative unit until the parameters have been set correctly. (The minor fault output and fault contact output will not operate, either.)

When an operation error has occurred, refer to the following table to identify and correct the cause of the errors.

Table 6.3 Operation Error Displays and Incorrect Settings

Display Meaning Incorrect settings

OPE01 kVA Selection

OPE02 Limit

OPE03 Ter mi nal

Incorrect Power Regenerative Unit Capacity Setting

Parameter Setting Range Error The parameter setting is outside of the valid setting range.

Multi-function Input Selection Error

The power regenerative unit capacity setting does not match the Unit. (Contact your YASKAWA representative.)

The same setting has been selected for two or more multi-function inputs (H1-01, H1-02)

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 53

6.3 Operation Errors

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54 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

Specifications

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 55

Note: 1. Consult the factory if connecting more than one inverter to one power regenerative unit.

2. Heavy duty applications require continuous energy dissipation (100% braking torque). The overload rating is 125% for 60 seconds with a duty cycle of 25%. Braking torque

of 187.5% is available for 30 seconds. Please note the peak torque should be less than 250%.

3. Standard duty applications require intermittent full energy dissipation. The continuous rating is 80% or less braking torque and 100% braking torque for 60 seconds with a duty cycle of 25% (60 seconds maximum on-time of every 240 seconds). The overload rating is 150% braking torque for 30 seconds. Please note the peak torque should be less than 200%.

4. Do not use this unit with single-phase power. Use three-phase power.

5. Imbalance rate between phases can be calculated using the following formula (Conforming to IEC1800-3). Imbalance rate between phases [%] = Three-phase average voltage

divided by (Max. voltage - Min. voltage) x 67. Use a power regenerative unit with larger output capacity if the imbalance rate between phases exceeds 2%

Table 7.1 200 V Class Specifications

Model CIMR-R5U 23P7 25P5 27P5 2011 2015 2018 2022 2030 2037

HP (kW)

Heavy Duty

(See Note 2)

Rated

Current on

Input Side

Rating

Rated Capacity

Standard Duty

(See Note 3)

(100% Cont.)

HP (kW)

Rated Current on Input Side (100%, 60s)

Rated DC Current A 13 19 26 37 51 64 77 102 126

Regenerative Torque

Input Power Supply

Voltage Frequency 200 to 220 VAC 50 Hz, 200 to 230 VAC 60 Hz Allowable Voltage Fluctuation + 10 to - 15% (Imbalance rate between phases: within 2%) (See Note 5) Allowable Frequency Fluctuation ± 3 Hz (3 phase rotation) Control Method 120° current conduction

Control Characteristics

Input Power Factor 0.9 or more (Rated current)

Overload Capacity

Programmable Input / Output Two Digital Inputs, Two Digital Outputs, One Analog Output.

Operation Input External terminals

Fault 1C contact output

Status Output

PHC Output Photocoupler output: 1 point can be selected (ready) Analog Output Analog output: 1 point can be selected (current monitor)

Instantaneous Overcurrent

Blown Fuse Motor stops by blown fuse.

Overload

Protective Function

Undervoltage (DC Voltage) Stops at approx. 190 VDC or less. Undervoltage (Power Side Voltage) Stops at approx. 150 VAC or less. Overload Stops at approx. 400 VDC or more. Fin Overheat Protected by thermistor Power Supply Open Phase (See Note 4) Stops at power supply open phase detection. Power Frequency Error Stops by fluctuation more than ± 3 Hz of rated input frequency. Power Charge Indication Indicated until main output voltage is approx. 50 V or less. Location Indoor (Protected from corrosive gases and dust)

Environmental Conditions

Ambient Temperature

Humidity 90% RH or less (non-condensing) Vibr ation 9.8 m/s2 (1G) less than 20 Hz, up to 1.96 m/s2 (0.2G) at 20 to 50 Hz

(2.2)

(3.7)

7.5

(5.5)

(7.5)

(11)

8 1216243240486480

(3.7)

7.5

(5.5)

(7.5)

(11)

(15)

10 15 20 30 40 50 60 80 100

Heavy Duty: 100% cont., 125% for 60 s (25% ED), 187.5% for 30 s, max. torque < 250%

Standard Duty: 80% cont., 100% for 60s (25% ED), 150% for 30s, max. torque < 200%

Standard Duty: 150% for 30 seconds

Heavy Duty: 187.5% for 30 seconds

Standard Duty: Stops at approx. 200% of the current on power side

Heavy Duty: Stops at approx. 250% of the current on power side

Standard Duty: Stops after 30 seconds at 150% of rated current.

Heavy Duty: Stops after 30 seconds at 187.5% of rated current.

- 10°C to + 40°C (Enclosed wall-mounted type)

- 10°C to + 45°C (Open chassis type)

(15)

(18.5)

(22)

(30)

(37)

56 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

Table 7.2 400 V Class Specifications

Model CIMR-R5U 43P7 45P5 47P5 4011 4015 4018 4022 4030 4037 4045 4055 4075

Rating

Rated Capacity

Heavy Duty (See Note 2)

Stand ard Duty (See Note 2)

HP (kW)

Rated Current on Input Side (100% Cont.)

HP (kW)

Rated Current on Input Side

(2.2)5 (3.7)

4 6 8 12 16 20 24 32 40 48 60 80

(3.7)

7.5

(5.5)

5 7.5 10 15 20 25 30 40 50 60 75 100

7.5

(5.5)

(7.5)

(11)

(15)

(18.5)

(22)

(100%, 60s)

Rated DC Current A 6 9 13 19 26 32 37 51 64 77 96 128

Heavy Duty: 100% cont., 125% for 60 s (25% ED), 187.5% for 30 s, max. torque < 250%

Standard Duty: 80% cont., 100% for 60s (25% ED), 150% for 30s, max. torque < 200%

Input Power Supply

Regenerative Torque

Voltage Frequency 380 to 460 VAC 50/60 Hz,

Allowable Voltage Fluctuation + 10 to - 15% (Imbalance rate between phases: within 2%) <1>

Allowable Frequency Fluctuation ± 3 Hz (3 phase rotation)

Control Method 120° current conduction

Control Characteristics

Input Power Factor 0.9 or more (Rated current)

Overload Capacity

Standard Duty: 150% for 30 seconds

Heavy Duty: 187.5% for 30 seconds

Operation Input External terminals

Fault 1C contact output

Status Output

Running, READY Signal Photocoupler output

Analog Output Analog output: 1 point can be selected (current monitor)

Instantaneous Overcurrent

Standard Duty: Stops at approx. 200% of the current on power side

Heavy Duty: Stops at approx. 250% of the current on power side

Blown Fuse Motor stops by blown fuse.

Standard Duty: Stops after 30 seconds at 150% of rated current. Heavy Duty: Stops after 30 seconds at 187.5% of rated current.

Protective Function

Overload

Undervoltage (DC Voltage) Stops at approx. 380 VDC or less.

Undervoltage (Power Side Voltage) Stops at approx. 300 VAC or less.

Overload Stops at approx. 800 VDC or less.

Fin Overheat Protected by thermistor

Power Supply Open Phase Stops at power supply open phase detection.

Power Frequency Error Stops by fluctuation more than ± 3 Hz of rated input frequency.

Power Charge Indication Indicated until main output voltage is approx. 50 V or less.

Location Indoor (Protected from corrosive gases and dust)

Environmental Conditions

Ambient Temperature

Humidity 90% RH or less (non–condensing)

- 10°C to + 40°C (Closed wall–mounted)

- 10°C to + 45°C (Open chassis type)

Vibr ation 9.8 m/s2 (1G) less than 20 Hz, up to 1.96 m/s2 (0.2G) at 20 to 50 Hz

(22)

(30)50(37)60(45)75(55)

100 (75)

Note: Use a power regenerative unit with larger output capacity if the imbalance rate between phases exceeds 2%. Note: <1> Imbalance rate between phases can be calculated using the following formula (Conforming to IEC1800-3). Imbalance rate between phases [%] = Three-phase

average voltage divided by (Max. voltage - Min. voltage) x 67.

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 57

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58 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

Parameter List

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 59

U1-12 = 00000000

1:Running

0:Notused.(always0)

1 : Reset input ON

0:Notused.(always0)

1 : Powerregenerative unitready

0 : Minor fault detected

1 : Major fault detected

Ta bl e A. 1 shows the items that can be monitored in operation mode. The output signal levels for multi-function analog outputs shown in the table are

for a gain of 100.0 and a bias of 0.00.

Table A.1 Parameters Monitored in Operation Mode

Function

Status

Monitor

Parameter

No.

U1-02

U1-04

U1-05

U1-07

U1-08

U1-10

U1-11

Parameter Name /

Display

DC bus voltage

DC Bus Voltage

Monitors the DC voltage of the power regenerative unit’s internal main circuit

Function

AC power supply voltage

AC Voltage

Current at power side

AC Current

Power at power side

AC Power

AC power supply frequency

AC Frequency

Monitors the AC power supply voltage.

Monitors the AC power supply current.

Monitors the AC power supply power.

Monitors the AC power supply frequency.

Input terminal status Shows input ON/OFF status.

Shows input ON/OFF status.

U1-10 =

Input Term Sts

00000000

1:MANUALRUN(terminalS1)ON

1 : AUTO RUN (terminal S2) ON

1:EXFLT(terminalS3)ON<1>

1 : RESET (terminal S4) ON <1>

1:Notused.(always0)

<1 > : Can be selected by H1-01 or H1-02.

Output terminal status Shows output ON/OFF status.

U1-11 = 00000000

0:Notused. (always0)

1 : Multi-function output 1

Output Term Sts

<2 > : Can be selected by H2-02 or H2-03.

(terminals M1-M2) ON <2> 1 : Multi-function output 2

(terminals M3-M4) ON <2>

0:Notused.(always0)

1 : Fault output

(terminal MA/MB-MC) ON

Operation status Power regenerative unit operating status.

Output Signal Level for

Multi-function Analog

Outputs

200 V class: 400 V/10 V 400 V class: 800 V/10 V (0 to +10 V Output)

200 V class: 200 V/5 V 400 V class: 400 V/5 V (0 to +10 V Output)

Rated current /10 V (0 to +10 V Output)

Rated power /10 V (0 to +10 V Output)

60 Hz /10 V (0 to +10 V Output)

(Cannot be output)

Min. Unit

1 V

1 A

1 kW

0.01 Hz

—

60 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

U1-12

U1-13

U1-14

U1-21

U1-28

Int Ct1 Sts 1

Cumulative operation time

Elapsed Time

Software No.

FLASH ID

Voltage deviation

V Deviation

Software No. (CPU)

CPU ID

—

Monitors the power regenerative unit’s elapsed operating time. Can be set with uparameter o2-07 or o2-08.

—

(Manufacturer’s ID number) —

Monitors the deviation between the AC power supply voltage and the main circuit DC voltage.

200 V class: 400 V/10 V 400 V class: 800 V/10 V

1 V

(Manufacturer’s ID number) (Cannot be output) —

Function

Fault

Trace

Fault

History

Parameter

No.

U2-01

U2-02

U2-04

U2-06

U2-07

U2-08

U2-10

U2-11

U2-12

U2-13

U2-14

U2-20

U3-01

U3-02

U3-03

U3-04

U3-05

U3-06

U3-07

U3-08

Parameter Name /

Display

Current fault

Current Fault

Last fault

Last Fault

DC bus voltage at fault

DC Bus Voltage

Power supply voltage at fault

AC Voltage

Power side current at fault

AC Current

Power at fault

AC Power

Power side frequency at fault

AC Frequency

Input terminal status at fault

Input Term Sts

Output terminal status at fault

Output Term Sts

Operation status at fault

Regen Unit Sts

Cumulative operation time at fault

Elapsed Time

Voltage deviation input at fault

V Deviation

Most recent fault

Last Fault

Second most recent fault

Fault Message 2

Third most recent fault

Fault Message 3

Fourth/oldest fault

Fault Message 4

Cumulative operation time at fault

Elapsed Time 1

Accumulated time of second fault

Elapsed Time 2

Accumulated time of third fault

Elapsed Time 3

Accumulated time of fourth/ oldest fault

Elapsed Time 4

Function

Information on the current fault

Output Signal Level for

Multi-function Analog

Outputs

Min. Unit

—

Information on the last fault —

Main circuit DC voltage value when the “last fault” occurred. 1 V

AC power supply voltage value when the “last fault” occurred. 1 V

Current value at AC power side when the “last fault” occurred. 1 A

Power at AC power side when the “last fault” occurred. 1 kW

Frequency at AC power side when the “last fault” occurred. 0.01 Hz

Input terminal status when the “last fault” occurred. (Same format as U1-10.)

Output terminal status when the “last fault” occurred. (Same format as U1-11.)

Operating status when the “last fault” occurred. (Same format as U1-12.)

Elapsed operating or power-on time when the “last fault” occurred. 1 H

(Cannot be output)

—

Voltage deviation when the “last fault” occurred. 1 V

Information on the last fault. —

Information on the 2nd to last fault. —

Information on the 3rd to last fault. —

Information on the 4th to last fault. —

Elapsed running or power-on time when the last fault occurred. 1 H

Elapsed running or power-on time when the 2nd to last fault occurred.

Elapsed running or power-on time when the 3rd to last fault occurred.

Elapsed running or power-on time when the 4th to last fault occurred.

1 H

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 61

Parameter

No.

A1-00

A1-01

A1-03

A1-04

b1-02

b1-06

C8-17

C8-18

C8-19

C8-20

F1-10

F1-11

H1-01

H1-02

H2-02

H2-03

Parameter Name

Display

Language selection for operator display

[Select Language]

Parameter access level

[Access Level]

Initialize

[Init Parameters]

Password 1 (Input)

[Enter Password]

Operation method selection

[Run Source]

Read sequence input twice

[Cntl Input Scans]

Automatic operation stop current

[Autorun Iout]

Bias voltage at operation start

[V Bias of Run]

Hysteresis voltage width at operation start/stop

[V Width of Stop]

Min. operating time

[Minimum Run Time]

Excessive frequency deviation detection level

[FDEV DetectLevel]

Excessive frequency deviation detection delay time

[FDEV Detect Time]

Multi-function input (terminal S3)

[Terminal S3 Sel]

Multi-function input (terminal S4)

[Terminal S4 Sel]

Multi-function output (terminal M1M2)

[Terminal M1 Sel]

Multi-function output (terminal M3M4)

[Terminal M3 Sel]

Table A.2 Parameter List

Setting Range

0, 1 0 O A

0 to 9999 4 O A

0000 to 9999 0000 x A

0000 to 9999 0 x A

0, 1 1 x A

10 to 100% 50 x A —

0.0 to 50.0 V 2.0 x A

0.5 to 50.0 V 3.0 x A

0.0 to 600.0 sec 1.0 x A —

1.0 to 10.0 Hz 3.0 x A

0.0 to 255.0 sec 70.0 x A

0 to 2F 24 O A

0 to 2F 14 O A

0 to 20 6 O A

0 to 20 0 O A

Factory Setting

Change

during

Operation

Access

Level

Description

Language selection for the Digital Operator. This parameter is not reset to the factory setting by A1-03. 0: English 1: Japanese

Selects which parameters are accessible via the Digital Operator. 0: Operation only 4: Advanced Level

Used to return all parameters to their factory or user default settings. (Initializes and then returns A1-03 to zero.) 2220: 2-Wire Initialization

When the value set into A1-04 does NOT match the value set into A1-05, parameters A1-01 thru A1-03 cannot be changed. All other parameters as determined by A1-01 can be changed. Parameter A105 can be accessed by pressing the MENU key while holding the RESET key.

Selects the run command input source. 0: Operator- RUN and STOP keys on Digital Operator. 1: Terminals - Contact closure on terminals S1 or S2.

Sets the scan rate of terminals S1 to S4 0: 500 ms - 2 scans (for quick response) 1: 5 ms - 2 scans (for noisy environments)

For 400 V class power regenerative units, double the initial setting and setting range.

Configures the frequency deviation fault (DEV) detection. DEV fault will occur if the frequency deviation is greater than the F1-10 setting for a time longer than F1-11. F1-10 is set as a percentage of the maximum output frequency (E1-04). Frequency deviation is the difference between actual input supply frequency and the frequency reference command.

Selects the function of terminal S3. 24: External fault, Normally Open, Always Detected, Coast To Stop. Refer to Tab l e A .3 .

Selects the function of terminal S4. 14: Fault reset Closed = Resets the Drive after the fault and the run command have been removed. Refer to Tab l e A .3 .

Selects the function of terminals M1 to M2. 6: Drive ready Closed - When the Drive is powered up, not in a fault state and in the DRIVE mode. Refer to Tab l e A .4 .

Selects the function of terminals M2 - M4. 0: During Run 1 Closed - When a run command is input or the Drive is outputting voltage. Refer to Tab l e A .4 .

62 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

Parameter

No.

H4-01

H4-02

H4-03

H4-07

L2-01

L2-02

L2-05

L5-01

L5-02

L8-02

L8-03

L8-07

o1-01

Parameter Name

Display

Multi-function AO (terminal AMAC)

[Terminal AM Sel]

Gain (terminal AM-AC)

[Terminal AM Gain]

Bias (terminal AM-AC)

[Terminal AM Bias]

Analog output signal polarity selection

[AM Level Select]

Momentary power loss detection

[PwrL Selection]

Momentary power loss ridethru time

[PwrL Ridethru t]

Undervoltage detection level

[PUV Det Level]

Number of auto restart attempts

[Num of Restarts]

Auto restart operation selection

[Restart Sel]

Overheat pre-alarm level

[OH Pre-Alarm Lvl]

Operation selection after overheat pre-alarm

[OH Pre-Alarm Sel]

Power supply open-phase protection selection

[Ph Loss In Sel]

Monitor selection

[User Monitor Sel]

Setting Range

Factory

Setting

Change

during

Operation

0 to 21 5 O A

0.00 to 2.50 0.50 O A

-110.0 to +110.0%

0.0 O A

0, 1 1 O A

0 to 2 0 x A

0.0 to 2.0 2.0 x A

150 to 210 V 190 x A

0 to 10 0 x A

0, 1 0 x A

50 to 110 deg 95 x A

1, 3 3 x A

0, 1 0 x A

4 to 8 8 O A

Access

Level

Description

Selects which monitor will be output on terminals AM and AC. 0: Not used 2: DC bus voltage (U1-02) 4: AC power supply voltage (U1-04) 5: Current at power side (U1-05) 7: Power at power side (U1-07) 8: AC power supply frequency (U1-08) 21: Voltage deviation (U1-21) Refer to Ta bl e A. 5 .

Sets terminal AM output level when selected monitor is at 100%.

Sets terminal AM output level when selected monitor is at 0%.

Selects the signal level of terminal AM. 0: 0 to 10 Vdc 1: -10 to +10 Vdc

Enables and disables the momentary power loss function. 0: Disabled - Unit trips on (UV1) fault when power is lost. 1: Power Loss Ride Thru Time - Unit will restart if power returns within the time set in L2-02.* 2: CPU Power Active - Unit will restart if power returns prior to control power supply shut down.* * In order for a restart to occur, the run command must be maintained throughout the ride thru period.

Sets the power loss ride-thru time. This value is dependent on the capacity of the Unit. Only effective when L2-01 = 1.

Sets the Unit’s DC Bus undervoltage trip level. If this is set lower than the factory setting, additional AC input reactance or DC bus reactance may be necessary. Consult the factory before changing this parameter setting.

Sets the counter for the number of times the Unit will perform an automatic restart. Auto restart will check to see if the fault has cleared every 5 ms. When no fault is present, the Unit will attempt an auto restart. If the Unit faults after an auto restart attempt, the counter is incremented. When the Unit operates without fault for 10 minutes, the counter will reset to the value set in L5-01.

Determines if the fault contact activates during an automatic restart attempt. 0: No Fault Relay - fault contact will not activate during an automatic restart attempt. 1: Fault Relay Active - fault contact will activate during an automatic restart attempt.

When the cooling fin temperature exceeds the value set in this parameter, an overheat alarm (OH) will occur.

Selects the Unit operation upon an OH pre-alarm detection. 1: Coast to Stop 3: Alarm Only

Selects the detection of output current open-phase. When applied motor capacity is too small for Unit capacity, output phase loss may be detected inadvertently. In this case, set to 0. 0: Disabled 1: Enabled

Selects which monitor will be displayed in the operation menu upon power-up when o1-02 = 4. 4: Power supply voltage (U1-04) 7: Power at power side (U1-07) 8: Power supply frequency (U1-08)

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 63

Parameter

No.

o1-02

o2-01

o2-02

o2-04

o2-06

o2-07

o2-08

Parameter Name

Display

Monitor selection after power up

[Power-On Monitor]

LOCAL/REMOTE key enable/ disable

[Local/Remote Key]

STOP key during remote operation

[Oper STOP Key]

kVA selection

[Regen Unit Model]

Operation selection when digital operator is disconnected

[Oper Detection]

Cumulative operation time setting

[Elapsed Time Set]

Cumulative operation time selection

[Elapsed Time Run]

Setting Range

2 to 4 2 O A

0, 1 1 x A

0, 1 0 x A

00 to FF * x A

0, 1 0 x A

0 to 65535H — x A

0, 1 0 x A

Factory Setting

Change

during

Operation

Access

Level

Description

Selects which monitor will be displayed upon powerup. 2: DC Bus Voltage (U1-02) 3: Output Current at the power side (U1-05) 4: Monitor set in o1-01

Determines if the Digital Operator Local / Remote key is functional. 0: Disabled 1: Enabled

Determines if the STOP key on the Digital Operator will stop the Unit when the Unit is operating from external terminals. 0: Enabled during run command from the digital operator 1: Enabled

Sets the kVA of the Unit. Enter the number based on the Unit model number. Use the last four digits of the model number. This parameter only needs to be set when installing a new control board. Do not change for any other reason.

Determines if the Unit will stop when the Digital Operator is removed when in LOCAL mode or b1-02 = 0. 0: Disabled - the Unit will not stop when the Digital Operator is removed. 1: Enables - The Unit will fault (OPR) and coast to stop when the Digital Operator is removed.

Sets the initial value of the elapsed operation timer U1-13.

Sets how time is accumulated for the elapsed operation timer U1-13. 0: Power-On Time - Time accumulates when the Unit is powered. 1: Running Time - time accumulates only when the Unit is running.

64 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

Setting Value

24-2F

Setting value

Table A.3 Multi-function Input Functions

Function

(H1-01, 02)

External baseblock (NO contact)

[Ext BaseBlk N.O.]

External baseblock (NC contact)

[Ext BaseBlk N.C.]

Not used

[Term Not Used]

Fault reset

[Fault Reset]

External fault

[External Fault]

Table A.4 Multi-function Output Functions

Function

(H2-02, 03)

During run

[During RUN 1]

Regenerative unit ready

[Regen Unit Ready]

During DC bus undervoltage (UV) detection

[DC Bus Undervolt]

During baseblock

[BaseBlk 1]

During MCON

[Mc On]

Fault

[Fault]

Not used

[Not Used]

Alarm

[Minor Fault]

Fault reset command active

[Reset Cmd Active]

Restart enabled

[Restart Enabled]

Overload (OL1) pre-alarm

[Overload (OL1)]

Overheat pre-alarm

[OH Prealarm]

Remarks

24: External Fault, Normally Open, Always Detected, Coast To Stop 25: External Fault, Normally Closed, Always Detected, Coast To Stop 26: External Fault, Normally Open, During Run, Coast To Stop 27: External Fault, Normally Closed, During Run, Coast To Stop 28: External Fault, Normally Open, Always Detected, Fast Stop 29: External Fault, Normally Closed, Always Detected, Fast Stop 2A: External Fault, Normally Open, During Run, Fast Stop 2B: External Fault, Normally Closed, During Run, Fast Stop 2C: External Fault, Normally Open, Always Detected, Alarm Only 2D: External Fault, Normally Closed, Always Detected, Alarm Only 2E: External Fault, Normally Open, During Run, Alarm Only 2F: External Fault, Normally Closed, During Run, Alarm Only

Remarks

Closed = When a run command is input or the Unit is outputting voltage.

Closed = When the Unit is powered up, not in a fault state, and in the DRIVE

mode.

Closed = When the DC bus voltage falls below the UV trip level set in L2-05.

Closed = When the Unit is not outputting voltage.

Closed = When the pre-charge contactor contact is energized.

Closed = When the Unit experiences a major fault.

Closed = When the Unit experiences an alarm.

Closed = When the Unit receives a reset command from a digital input terminal or

Closed = When the Unit is performing an automatic restart attempt. Automatic

restart is configured by parameter L5-01.

serial communication.

Closed = When OL1 is 80% of its trip point or greater.

Closed = When the Unit’s heatsink temperature exceeds the setting of parameter

L8-02.

YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual 65

Table A.5 Multi-function Analog Output Functions

Setting value Function (H4-01) Output signal level Remarks

Not used

[Not Used]

DC bus voltage

[DC Bus Voltage]

Power supply voltage

[AC Voltage]

Current at power side

[AC Current]

Power at power side

[AC Power]

Power supply frequency

[AC Frequency]

Voltage deviation input

[V Deviation]

200 V class: 400 V/10 V 400 V class: 800 V/10 V

200 V class: 200 V/5 V 400 V class: 400 V/5 V

(0 to +10 V output)

Rated current /10 V 100% = Unit current at the power side.

Rated power /10 V 100% = Unit power at the power side.

60 Hz/10 V 100% = Unit power supply frequency.

200 V class: 400 V/10 V 400 V class: 800 V/10 V

100% = 400 / 800 Vdc depending on the

Unit voltage rating.

66 YASKAWA ELECTRIC TOEP C710656 01C YASKAWA - RC5 Instruction Manual

Revision History

MANUAL NO.ޓTOEP C710656 01A

Published in Japan February 2010 08-4

Date of publication

Date of original publication

Revision number

Document revision dates and revision numbers are provided on the bottom of the back cover.

Date of Publication Rev. No. Section Revised Content

August 2011 Front cover,

back cover

Preface Addition: CSA Standards Compliance in Conditions of Acceptability

Chapter 2 Addition: Note on UL standard in Checking Installation Site

Chapter 3 Addition: Note on UL standard in Closed-Loop Connectors Size

September 2010 Preface Addition: Note on Short Circuit Current Rating (SCCR) in Notes for Safe Operation

Chapter 3 Addition: Note on Short Circuit Current Rating (SCCR) in Section Safety

Back cover Revision: Address

February 2010 Back cover Revision: Address

April 2008 – – First edition

Revision: Format

Revision: Note on Short Circuit Current Rating (SCCR) in Notes for Safe Operation

Revision: • Note on Short Circuit Current Rating (SCCR) in Section Safety

• Closed Loop Connectors Sizes Table

YASKAWA - RC5

Power Regenerative Unit

Instruction Manual

YASKAWA AMERICA, INC.

2121 Norman Drive South, Waukegan, IL 60085, U.S.A. Phone: (800) YASKAWA (927-5292) or 1-847-887-7000 Fax: 1-847-887-7310 http://www.yaskawa.com

DRIVE CENTER (INVERTER PLANT)

2-13-1, Nishimiyaichi, Yukuhashi, Fukuoka, 824-8511, Japan Phone: 81-930-25-3844 Fax: 81-930-25-4369 http://www.yaskawa.co.jp

YASKAWA ELECTRIC CORPORATION

New Pier Takeshiba South Tower, 1-16-1, Kaigan, Minatoku, Tokyo, 105-6891, Japan Phone: 81-3-5402-4502 Fax: 81-3-5402-4580 http://www.yaskawa.co.jp

YASKAWA ELÉTRICO DO BRASIL LTDA.

Avenda Fagundes Filho, 620 Bairro Saude, São Paulo, SP04304-000, Brasil Phone: 55-11-3585-1100 http://www.yaskawa.com.br

YASKAWA EUROPE GmbH

Hauptstrasse 185, 65760 Eschborn, Germany Phone: 49-6196-569-300 Fax: 49-6196-569-398 http://www.yaskawa.eu.com

YASKAWA ELECTRIC UK LTD.

1 Hunt Hill Orchardton Woods, Cumbernauld, G68 9LF, United Kingdom Phone: 44-1236-735000 http://www.yaskawa.co.uk

YASKAWA ELECTRIC KOREA CORPORATION

7F, Doore Bldg. 24, Yeoido-dong, Yeoungdungpo-gu, Seoul, 150-877, Korea Phone: 82-2-784-7844 http://www.yaskawa.co.kr

YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.

151 Lorong Chuan, #04-01, New Tech Park, 556741, Singapore Phone: 65-6282-3003 http://www.yaskawa.com.sg

YASKAWA ELECTRIC (SHANGHAI) CO., LTD.

No. 18 Xizang Zhong Road, 17F, Harbour Ring Plaza, Shanghai, 200001, China Phone: 86-21-5385-2200 http://www.yaskawa.com.cn

YASKAWA ELECTRIC (SHANGHAI) CO., LTD. BEIJING OFFICE

Room 1011, Tower W3 Oriental Plaza, No. 1 East Chang An Ave., Dong Cheng District, Beijing, 100738, China Phone: 86-10-8518-4086

YASKAWA ELECTRIC TAIWAN CORPORATION

9F, 16, Nanking E. Rd., Sec. 3, Taipei, 104, Taiwan Phone: 886-2-2502-5003

Fax: 55-11-5581-8795

Fax: 44-1236-458182

Fax: 82-2-784-8495

Fax: 65-6289-3003

Fax: 86-21-5385-3299

Fax: 86-10-8518-4082

Fax: 886-2-2505-1280

YASKAWA ELECTRIC CORPORATION

In the event that the end user of this product is to be the military and said product is to be employed in any weapons systems or the manufacture thereof, the export will fall under the relevant regulations as stipulated in the Foreign Exchange and Foreign Trade Regulations. Therefore, be sure to follow all procedures and submit all relevant documentation according to any and all rules, regulations and laws that may apply.

Specifications are subject to change without notice for ongoing product modifications and improvements.

MANUAL NO. TOEP C710656 01C

Published in Japan August 2011 08-4 10-10-7_YAI

YASKAWA CIMR-R5U20151A, CIMR-R5U25P51A, CIMR-R5U20181A, CIMR-R5U20221A, CIMR-R5U20301A Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Preface

i.1 Conditions of Acceptability

◆ NEC, CEC and UL Compliance

◆ CSA Standards Compliance

i.2 Safety Information

◆ Supplemental Safety Information

i.3 Notes for Safe Operation

◆ Receiving

◆ Installation

◆ Wiring

◆ Operation

◆ Maintenance and Inspection

◆ Warning Label

Receiving

1.1 Section Safety

1.2 Inspection Checkpoints

◆ Receiving Checkpoints

◆ Checking the Nameplate Data

Installation

2.1 Section Safety

2.2 Checking Installation Site

◆ Installation Site

◆ Controlling the Ambient Temperature

◆ Protecting the Power Regenerative Unit from Foreign Matter

2.3 Clearances

2.4 Dimensions

◆ Models of 200 V/400 V 30 kW and Lower

◆ Models of 200 V/400 V 37 kW and Higher

2.5 Removing and Replacing the Front Cover

2.6 Removing and Replacing the LCD Monitor/Digital Operator

◆ Removing the LCD Monitor/Digital Operator

◆ Replacing the LCD Monitor/Digital Operator

Wiring

3.1 Section Safety

3.2 Connection Diagram

◆ Connection Diagram with Drive

3.3 Selecting Peripheral Devices

Selecting Heavy Duty or Standard Duty RC5 Application

◆ Main Circuit Input Fuse

◆ Power Coordination and Current Suppression Reactors

◆ Wiring Precautions

◆ Required Wire Size

3.4 Wiring Main Circuit Terminals

◆ Closed-Loop Connectors Size

3.5 External Terminals

◆ Main Circuit Terminal Functions

◆ Control Circuit Terminal Functions

Operation

4.1 Section Safety

4.2 Checks Prior to Main Power Application

4.3 Setting the Power Supply Voltage Jumper

4.4 Using the Digital Operator

4.5 Digital Operator Modes

◆ Modes

◆ Navigating Digital Operator Modes

Operation Mode

4.6 Power On/Off Sequence

4.7 Run Command Selection

AUTO RUN

MANUAL RUN

5.1 Section Safety

5.2 Periodic Inspection and Maintenance

◆ Daily Inspection

◆ Periodic Inspection

◆ Periodic Maintenance of Parts

Troubleshooting

6.1 Fault Detection

6.2 Minor Fault Detection

6.3 Operation Errors

Specifications

Parameter List