Yaskawa D1000 User Manual
YASKAWA D1000 Series
Power Regenerative Converter
Instruction Manual
Type: CIMR-DU
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.
200 V Class, Three-Phase Input: 5 to 130 kW
400 V Class, Three-Phase Input: 5 to 630 kW
MANUAL NO. TOEP C710656 07C
Receiving
Mechanical Installation
Electrical Installation
Start-Up Programming &
Operation
Troubleshooting
Periodic Inspection &
Maintenance
Standard Configuration Devices,
Peripheral Devices, and Options
Specifications
Parameter List
MEMOBUS/Modbus
Communications
Standards Compliance
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1
2
2
3
3
4
4
5
5
6
6
7
7
A
A
B
B
C
C
E
D
D
Copyright © 2013 YASKAWA ELECTRIC CORPORATION. All rights reserved.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by
any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission
of Yaskawa. No patent liability is assumed with respect to the use of the information contained herein.
Moreover, because Yaskawa is constantly striving to improve its high-quality products, the information
contained in this manual is subject to change without notice. Every precaution has been taken in the
preparation of this manual. 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 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual
Table of Contents
i. PREFACE & GENERAL SAFETY .............................................................................. 9
i.1 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Applicable Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Terms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
i.2 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Supplemental Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General Application Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Precautions on Using Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Warning Label Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1. RECEIVING............................................................................................................... 21
1.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2 Model Numbers and Nameplates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.3 Converter Models and Enclosure Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2. MECHANICAL INSTALLATION ............................................................................... 27
2.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2 Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation Orientation and Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Precautions and Instructions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Digital Operator Remote Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Exterior and Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3 Harmonic Filter Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation Orientation and Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Harmonic Filter Module Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3. ELECTRICAL INSTALLATION ................................................................................ 45
3.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2 Standard Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual 3
3.3 Main Circuit Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
CIMR-D2A0005 to 2A0020, 4A0005 to 4A0020 . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
CIMR-D2A0030, 2A0050, 4A0030, 4A0040, 4A0060 . . . . . . . . . . . . . . . . . . . . . . . . 52
CIMR-D2A0065, 2A0090, 2A0130, 4A0100, 4A0130, 4A0185 . . . . . . . . . . . . . . . . . 53
CIMR-D4A0270, 4A0370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
CIMR-D4A0630 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
3.4 Terminal Block Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
3.5 Terminal Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Models 2A0005 to 2A0020, 4A0005 to 4A0020 (IP20/Open Type Enclosure) . . . . . . . 57
Models 2A0030 to 2A0130, 4A0030 to 4A0370 (IP00/Open Type enclosure) . . . . . . . 58
3.6 Digital Operator and Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Removing/Reattaching the Digital Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Removing/Reattaching the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.7 Main Circuit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Main Circuit Terminal Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Protecting Main Circuit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Wire Gauges and Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Ground Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.8 Harmonic Filter Module Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Terminal Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Terminal Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Protecting Circuit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Wire Gauges and Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.9 Control Circuit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Control Circuit Terminal Block Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Terminal Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Wiring the Control Circuit Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.10 Control I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Terminal A2 Input Signal Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Using the Contact Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Connect to a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
3.11 Wiring Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4. START-UP PROGRAMMING & OPERATION ......................................................... 85
4.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
4.2 Using the Digital Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
ALARM (ALM) LED Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
LO/RE LED and RUN LED Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Menu Structure for Digital Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.3 The Drive and Programming Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Navigating the Drive and Programming Modes (Default Setting) . . . . . . . . . . . . . . . . . 90
Changing Parameter Settings or Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Verifying Parameter Changes: Verify Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Switching Between LOCAL and REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
4.4 Powering Up the Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Powering Up the Converter and Operation Status Display . . . . . . . . . . . . . . . . . . . . .94
4 YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual
4.5 Operation with the Drive Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
A1000 Connection Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Varispeed G7 Connection Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Timing Chart for Turning the Power Supply On and Off . . . . . . . . . . . . . . . . . . . . . . . 97
Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
4.6 Verifying Parameter Settings and Backing Up Changes . . . . . . . . . . . . . . . . . . . . 99
Backing Up Parameter Values: o2-03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Parameter Access Level: A1-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Password Settings: A1-04, A1-05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Copy Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.7 Test Run Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5. TROUBLESHOOTING ............................................................................................ 103
5.1 Section Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5.2 Alarms, Faults, and Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Types of Alarms, Faults, and Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Alarm and Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
5.3 Fault Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Fault Displays, Causes, and Possible Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.4 Alarm Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Alarm Codes, Causes, and Possible Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.5 Operator Programming Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Operator Programming Error Codes, Causes, and Possible Solutions . . . . . . . . . . . 128
5.6 Copy Function Related Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Tasks, Errors, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
5.7 Diagnosing and Resetting Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Fault Reset Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6. PERIODIC INSPECTION & MAINTENANCE ......................................................... 133
6.1 Section Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
6.2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Recommended Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Recommended Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.3 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.4 Cooling Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Number of Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Cooling Fan Component Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Cooling Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.5 Converter Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Serviceable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Replacing the Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7. STANDARD CONFIGURATION DEVICES, PERIPHERAL DEVICES,
AND OPTIONS........................................................................................................ 163
7.1 Section Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.2 Converter Options and Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
7.3 Connecting Standard Configuration Devices and Peripheral Devices . . . . . . . . 167
YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual 5
7.4 Standard Configuration Devices Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Wire Gauges and Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
7.5 Installing Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Installing a Molded Case Circuit Breaker (MCCB) or Ground Fault Circuit Interrupter
(GFCI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Installing a Magnetic Contactor at the Power Supply Side . . . . . . . . . . . . . . . . . . . . . 172
Connecting a Surge Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
Attachment for External Heatsink Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
A. SPECIFICATIONS .................................................................................................. 173
A.1 Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
A.2 Converter Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
A.3 Heat Loss Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
A.4 Derating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
Temperature Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Altitude Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
B. PARAMETER LIST ................................................................................................. 179
B.1 Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
B.2 Parameter Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
A: Initialization Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
b: Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
C: Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
d: References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
F: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
H: Multi-Function Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
L: Protection Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
o: Operator-Related Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
U: Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
B.3 Defaults by Converter Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
C. MEMOBUS/MODBUS COMMUNICATIONS .......................................................... 203
C.1 MEMOBUS/Modbus Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
C.2 Communication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
C.3 Connecting to a Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
Network Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
Wiring Diagram for Multiple Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Network Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
C.4 MEMOBUS/Modbus Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
MEMOBUS/Modbus Serial Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
C.5 Converter Operations by MEMOBUS/Modbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Observing the Converter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Controlling the Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213
C.6 Communications Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Command Messages from Master to Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Response Messages from Converter to Master . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
6 YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual
C.7 Message Format. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Message Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Slave Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Function Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Error Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
C.8 Message Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Reading Converter MEMOBUS/Modbus Register Contents . . . . . . . . . . . . . . . . . . . 217
Loopback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Writing to Multiple Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
C.9 MEMOBUS/Modbus Data Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Command Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Monitor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Fault Trace Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Alarm Register Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
C.10 Enter Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Enter Command Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
C.11 Communication Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
MEMOBUS/Modbus Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Slave Not Responding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
C.12 Self-Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
D. STANDARDS COMPLIANCE ................................................................................. 233
D.1 Section Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
D.2 European Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
CE Low Voltage Directive Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
EMC Guidelines Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
D.3 UL Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
UL Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
UL Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
Installing Standard Configuration Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
Precautionary Notes on External Heatsink (IP00/Open Type enclosure) . . . . . . . . . 254
D.4 CSA Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Conditions of Acceptability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Installing Standard Configuration Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Main Circuit Terminal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
CSA for Industrial Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
CSA for Elevator Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Revision History............................................................................................................. 258
YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual 7
8 YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual
Preface & General Safety
This section provides safety messages pertinent to this product that, if not heeded, may result in
fatality, personal injury, or equipment damage. Yaskawa is not responsible for the consequences
of ignoring these instructions.
i.1 PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
i.2 GENERAL SAFETY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
i
YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual 9
i.1 Preface
CIMR-AA2A0021FAA
200V 3Phase 5.5kW/3.7kW
S/N:
危 険
据え付け、運転の前には必ず取扱説明書を読むこと。
通電中および電源遮断後5分以内はフロントカバー
を外さない事。
400V級インバータの場合は、電源の中性点が接地
されていることを確認すること。(対応）
保守・点検、配線を行う場合は、出力側開閉器を
遮断後5分待って実施してください。
けが．感電のおそれがあります。
高温注意
インバータ上部、両側面は高温になります。
触らないでください。
●
●
●
●
AVERTISSMENT
NPJT31470-1
Lire le manuel avant l'installation.
Attendre 5 minutes après la coupure
de l'alimentation, pour permettre
la décharge des condensateurs.
Pour répondre aux exigences , s
assurer que le neutre soit relié
à la terre, pour la série 400V.
Après avoir déconnécte la protection
entre le driver et le moteur, veuillez
patienter 5 minutes avain d’effectuer
une opération de montage ou de
câblage du variateur.
Risque de décharge électrique.
Surfaces Chaudes
Dessus et cotés du boitier Peuvent
devenir chaud. Ne Pas toucher.
WARNING
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 for 400V class.
After opening the manual switch
between the drive and motor,
please wait 5 minutes before
inspecting, performing
maintenance or wiring the drive.
Risk of electric shock.
Hot surfaces
Top and Side surfaces may
become hot. Do not touch.
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
LO
RE
F2F1
ESC
RUN STOP
ENTERRESET
ALM
DIGITAL OPERATOR JVOP-180
i.1 Preface
Yaskawa manufactures products used as components in a wide variety of industrial systems and equipment. The selection
and application of Yaskawa products remain the responsibility of the equipment manufacturer or end user. Yaskawa
accepts no responsibility for the way its products are incorporated into the final system design. Under no circumstances
should any Yaskawa product be incorporated into any product or design as the exclusive or sole safety control. Without
exception, all controls should be designed to detect faults dynamically and fail safely under all circumstances. All systems
or equipment designed to incorporate a product manufactured by Yaskawa must be supplied to the end user with
appropriate warnings and instructions as to the safe use and operation of that part. Any warnings provided by Yaskawa
must be promptly provided to the end user. Yaskawa offers an express warranty only as to the quality of its products in
conforming to standards and specifications published in the Yaskawa manual. NO OTHER WARRANTY, EXPRESS OR
IMPLIED, IS OFFERED. Yaskawa assumes no liability for any personal injury, property damage, losses, or claims
arising from misapplication of its products.
This manual is designed to ensure correct and suitable application of D1000-Series power regenerative converters. Read
this manual before attempting to install, operate, maintain, or inspect a converter and keep it in a safe, convenient location
for future reference. Be sure you understand all precautions and safety information before attempting application.
◆ Applicable Documentation
The following manuals are available for D1000 series:
YASKAWA D1000 Series
Power Regenerative Converter
Instruction Manual (TOEP C710656 07)
This guide is packaged together with the product and contains basic information required to install and wire the converter.
It also gives an fault diagnostics, maintenance, and parameter settings. The purpose of this guide is to prepare the converter
for a trial run with an application and for basic operation.
◆ Symbols
Note: Indicates a supplement or precaution that does not cause converter damage.
◆ Terms and Abbreviations
• Conveter: YASKAWA D1000 Series Power Regenerative Converter
• Drive: Yaskawa 1000-Series Drive
• BCD: Binary Coded Decimal
• H: Hexadecimal Number Format
• IGBT: Insulated Gate Bipolar Transistor
◆ Trademarks
• MECHATROLINK-I/MECHATROLINK-II are trademarks of MECHATROLINK Members Association (MMA).
• Other companies and product names mentioned in this manual are trademarks of those companies.
10 YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual
i.2 General Safety
W ARNING
DANGER
W ARNING
CAUTION
NOTICE
i.2 General Safety
◆ Supplemental Safety Information
General Precautions
• The diagrams in this manual may be indicated without covers or safety shields to show details. Replace the covers or
shields before operating the converter and run the converter according to the instructions described in this manual.
• Any illustrations, photographs, or examples used in this manual are provided as examples only and may not apply to
all products to which this manual is applicable.
• The products and specifications described in this manual or the content and presentation of the manual may be
changed without notice to improve the product and/or the manual.
• When ordering a new copy of the manual due to damage or loss, contact your Yaskawa representative or the nearest
Yaskawa sales office and provide the manual number shown on the front cover.
• If nameplate becomes worn or damaged, order a replacement from your Yaskawa representative or the nearest
Yaskawa sales office.
Read and understand this manual before installing, operating or servicing the converter. The converter must be
installed according to this manual and local codes.
The following conventions are used to indicate safety messages in this manual. Failure to heed these messages could
result in serious or fatal injury or damage to the products or to related equipment and systems.
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! may 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! may also be indicated by a bold key word embedded in the text followed by an italicized safety message.
Indicates a property damage message.
NOTICE: may also be indicated by a bold key word embedded in the text followed by an italicized safety message.
YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual 11
i.2 General Safety
DANGER
W ARNING
◆ Safety Messages
Heed the safety messages in this manual.
Failure to comply will result in death or serious injury.
The operating company is responsible for any injuries or equipment damage resulting from failure to heed the warnings
in this manual.
Electrical Shock Hazard
Do not install, wire, maintain, or inspect the product or replace parts while the power supply is turned on.
Failure to comply will result in death or serious injury.
Disconnect all power to the equipment. The internal capacitor remains charged even after the power supply is turned
off. After shutting off the power, wait for at least the amount of time specified on the converter before touching any
components.
Sudden Movement Hazard
System may start unexpectedly upon application of power, resulting in death or serious injury.
Clear all personnel from the converter, drive, motor and machine area before applying power to the converter. Secure
covers, couplings, shaft keys and machine loads.
Electrical Shock Hazard
Do not attempt to modify or alter the converter in any way not explained in this manual.
Failure to comply could result in death or serious injury.
Yaskawa is not responsible for any modification of the product made by the user. This product must not be modified.
Do not allow unqualified personnel to perform work on the converter.
Failure to comply could result in death or serious injury.
Installation, maintenance, inspection, and servicing must be performed only by authorized personnel familiar with
installation, adjustment, and maintenance of converters.
Do not remove covers or touch circuit boards while the power is on.
Failure to comply could result in death or serious injury.
Always use a ground wire that complies with technical standards on electrical equipment and minimize the
length of the ground wire.
Improper equipment grounding may cause dangerous electrical potentials on equipment chassis, which could result in
death or serious injury.
Make sure the protective earthing conductor complies with technical standards and local safety regulations.
Because the leakage current exceeds 3.5 mA in model 4A0630, IEC/EN 61800-5-1 states that either the power supply
must be automatically disconnected in case of discontinuity of the protective earthing conductor or a protective
2
earthing conductor with a cross-section of at least 10 mm
result in death or serious injury.
(Cu) or 16 mm2 (Al) must be used. Failure to comply may
Always use a type B ground fault circuit interrupter GFCI according to IEC/EN 60755 when a protective
residual current monitor/detection device is installed for indirect or direct shock hazard protection.
The converter can cause a residual current with a DC component in the protective earthing conductor.
12 YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual
i.2 General Safety
CAUTION
NOTICE
W ARNING
Do not operate equipment with covers removed.
Failure to comply could result in death or serious injury.
Fire Hazard
Do not use an improper voltage source.
Failure to comply could result in death or serious injury by fire.
Verify that the rated voltage of the converter matches the voltage of the incoming power supply before applying power.
Tighten all terminal screws to the specified tightening torque.
Loose electrical connections could result in death or serious injury by fire due to overheating of electrical connections.
Do not use improper combustible materials.
Failure to comply could result in death or serious injury by fire.
Do not install the converter to a combustible surface. Never place combustible materials on the converter.
Crush Hazard
Only allow qualified personnel to operate a crane or hoist to transport the converter.
Failure to comply may result in serious injury or death from falling equipment.
Do not carry the converter by the front cover or the terminal cover.
Failure to comply may result in minor or moderate injury from the main body of the converter falling.
Do not disconnect the wiring to the converter and harmonic filter module while the converter is outputting a
voltage.
Improper equipment sequencing could result in damage to the converter.
Connect a power supply with a capacity (kVA) that is larger than the rated input capacity (kW) of the converter.
Connecting a power supply with a capacity smaller than the rated input capacity may trigger an operating fault. If it is
necessary to connect a power supply with a capacity smaller than the rated input capacity, consult your Yaskawa
representative or the nearest Yaskawa sales office. Failure to comply may result in damage to the converter.
Observe proper electrostatic discharge procedures (ESD) when handling the converter, circuit boards, and
CMOSIC.
Failure to comply may result in ESD damage to the converter circuitry.
Do not perform a withstand voltage test on any part of the converter.
Failure to comply could result in damage to the sensitive devices within the converter.
Do not operate damaged equipment.
Failure to comply could result in further damage to the equipment.
Do not connect or operate any equipment with visible damage or missing parts.
YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual 13
i.2 General Safety
NOTICE
Install adequate branch circuit short circuit protection per applicable codes.
Failure to comply could result in damage to the converter.
The converter is suitable for circuits capable of delivering not more than 100,000 RMS symmetrical Amperes, 240 Vac
maximum (200 V Class) and 480 Vac maximum (400 V Class).
Prevent foreign matter such as metal shavings or wire clippings from falling into the converter during converter
installation and project construction.
Failure to comply could result in damage to the converter. Place a temporary cover over the top during installation. Be
sure to remove the temporary cover before start-up, as the cover will reduce ventilation and cause the converter to
overheat.
Never lift the converter up while the cover is removed.
This can damage the terminal board and other components.
Do not perform signal checks during operation.
Failure to comply could result in damage to the converter.
Do not modify the circuitry of the converter and the harmonic filter module.
Failure to comply could result in damage to the converter and will void warranty.
Yaskawa is not responsible for any modification of the product made by the user. This product must not be modified.
Connect the converters to power supply transformers on a 1:1 basis and use independent grounds.
If devices, such as office equipment, that are sensitive to noise are installed in the same location, connect them while
observing the grounding standards for each device, separate the ground wires, and use independent grounds or noise
filters to prevent noise from entering the devices though the ground wires.
Do not expose the converter to halogen group disinfectants.
Failure to comply may cause damage to the electrical components in the converter.
Do not pack the converter in wooden materials that have been fumigated or sterilized.
Do not sterilize the entire package after the product is packed.
◆ General Application Precautions
■ Total Load Capacity
Select a converter with a capacity (P
Selecting the Capacity
Use the following flowchart to select the converter capacity.
) greater than the value of P1, P2, or P3 shown in Figure i.1.
out
14 YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual
Figurei.1
Only one drive connected?
START
Select a capacity of P
4
or higher.
Are all of the motors in the
operating cycle ever in a driven or
regenerative state <1>
simultaneously?
Is P
3
the larger of P3 and P4?
Select a capacity of P1 or higher.
END
Yes (only one)
Yes (All of the motors are in either a driven or
in a regenerative state <1> at any one time.)
Yes (P
3
is larger.)
No (more than one, “N” )
No (The driven and
regenerative states <1>
can occur simultaneously.)
No (P
4
is larger.)
END
Select a capacity of P2 or higher.
END
Select a capacity of P3 or higher.
END
D1000
D1000
i.2 General Safety
=
P
1
Motor 1 efficiency<2>
=
P
2
Motor 1 efficiency<2>
Motor 1 output (kW)
Motor 1 output (kW)
– (Motor 1 efficiency <2> × Drive 1 efficiency <2> × Motor 1 output (kW) + ... + Motor N efficiency <2> × Drive N efficiency <2> × Motor N output (kW))
P
=
2
P
3
= 1/3 of total drive capacity (kW)
P
4
<1> The drive capacity is the power capacity during a normal operating condition when energy is applied to the motor. The regenerative
capacity is the capacity that is generated when the flow of power is reversed, such as when the drive is decelerated.
×
Drive 1 efficiency<2>
×
Drive 1 efficiency<2>
Figure i.1 Selecting the Converter Capacity
+
Motor 2 efficiency<2>
Total drive capacity<1>(or regenerative capacity <1>) (kW)
Total regenerative capacity <1> (kW)
Motor 2 output (kW)
×
Drive 2 efficiency<2>
+
+
･･･
Motor N efficiency<2>
Motor N output (kW)
×
Drive N efficiency<2>
YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual 15
i.2 General Safety
Example:
Draw-out direction: Regeneration Winding direction: Drive
D1000
Interphase imbalance ratio（%） =
×
67
Maximum voltage − Minimum voltage
Three-phase average voltage
D1000
Power supply capacity ≥ 3 × Input power supply rated voltage × Rated AC input current ÷ 1000
D1000
<2> Use the efficiencies of the motors and drives when known. When they are not known, use a motor efficiency of 0.9 (0.85 for 7.5 kW or
less) and a drive efficiency of 0.95 (0.9 for 7.5 kW or less).
Note: When the interphase voltage imbalance ratio of the power source exceeds 2%, use a converter with a frame one size larger than is
otherwise necessary.
Calculate the interphase voltage imbalance ratio of the power source using the following formula: (Conforms to IEC/EN 61800-3
(5.2.3).)
Selecting the Power Supply Capacity
Connect a power supply with a capacity (kVA) that is larger than the rated input capacity (kW) of the converter.
Connecting a power supply with a capacity smaller than the rated input capacity may trigger an operating fault. If it is
necessary to connect a power supply with a capacity smaller than the rated input capacity, consult your Yaskawa
representative or the nearest Yaskawa sales office.
Installing an Input-side AC Reactor and Harmonic Filter Module
Each converter requires a corresponding input-side AC reactor and harmonic filter module that consider the saturation
current and thermal factors. Always install the specified devices.
Regenerative Converter Power Losses and Harmonic Filter Installation
Sequence the power supply for the converter so the circuit opens after the operation is stopped.
Install the specified harmonic filter (harmonic filter module) to reduce the impact of voltage surges on other devices when
the circuit opens for any unexpected reason during operation. Refer to Harmonic Filter Module Wiring on page 67 for
detailed information on the harmonic filter (harmonic filter module).
Installing a Breaker or Contactor on the Converter Output (DC) Side
Take the following precautions when installing a breaker or contactor on the converter side for an emergency shutoff.
NOTICE: Damage to Equipment. Confirm that the breaker or contactor on the converter output (DC) side is closed and the CHARGE
indicators on the drive and converter are OFF before applying power to the converter. An overcurrent condition will occur and the
device may be damaged if the power supply is turned on while there is voltage present in the drive or converter.
16 YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual
i.2 General Safety
■ Installation
Enclosure Panels
Keep the converter in a clean environment by installing the converter in an enclosure panel or selecting an installation
area free of airborne dust, lint, and oil mist. Be sure to leave the required space between converters to provide for cooling,
and take proper measures so the ambient temperature remains within allowable limits and keep flammable materials away
from the converter. Yaskawa offers protective designs for converters that must be used in areas subjected to oil mist and
excessive vibration. Contact Yaskawa or your Yaskawa agent for details.
Installation Direction
NOTICE: Install the converter upright as specified in the manual. Refer to Mechanical Installation on page 27 for more information on
installation. Failure to comply may damage the converter due to improper cooling
Interlock
An interlock is required between the converter and drive to stop the drive if the converter fails or if a fault occurs in the
converter. It is also necessary to provide a suitable time to restart the drive if it will be restarted for momentary power
losses.
Restarting can be timed with the “During MC ON” signal output from the converter control circuit terminals. Create a
sequence to turn off the output from the drive with an external baseblock input to the drive or by a similar means when the
“During MC ON” signal opens. For details, refer to the Standard Connection Diagram on page 48.
Example 1: Not Restarting for Momentary Power Losses (Coasting to a Stop for Momentary Power Losses)
Connect the “During MC ON” output from the converter to the external fault input on the drive.
Use an N.C. input for the external fault input on the drive and set the drive to detect external faults only during
operation to prevent an external fault from being detected when the power supply is turned on.
Example 2: Restarting the System for Momentary Power Losses
Change the setting for the external baseblock input terminal S8 on the drive from the default setting of an N.O.
contact to an N.C. contact.
Connect the “During MC ON” output from the converter to the external baseblock input on the drive and set
restarting for momentary power losses in the drive.
Note: An external baseblock is not set by default in V1000 or J1000. Set an external baseblock (N.C.) for one of the multi-function input
terminals.
Example 3: Inputting a Run Command to the drive
Always input Run commands to the drive while the converter is operating. Check converter operating status with a
During Run 1 signal on a multi-function output. Refer to Figure 3.1 Standard Connection Diagram for an example of
a drive sequence.
■
General Handling
Wiring Check
NOTICE: Do not connect power supply lines to output terminals. Failure to comply will destroy the converter or the harmonic filter
module. Be sure to perform a final check of all sequence wiring and other connections before turning on the power and also check for
short circuits on the control terminals, which may damage the converter.
Inspection and Maintenance
WARNING! Electrical Shock Hazard. Capacitors in the converter do not immediately discharge after shutting off the power. Wait for at
least the amount of time specified on the converter before touching any components after shutting off the power. Failure to comply may
cause injury to personnel from electrical shock.
WARNING! Burn Hazard. Because the heatsink can get very hot during operation, take proper precautions to prevent burns. When
replacing the cooling fan, shut off the power and wait at least 15 minutes to be sure that the heatsink has cooled down. Failure to
comply may cause burn injury to personnel.
YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual 17
i.2 General Safety
To connect or perform maintenance for the harmonic filter module, turn off the power supply to the converter, wait for the
time that is given on the converter, and then confirm that the temperature of the reactor has sufficiently decreased before
you proceed.
Wiring
Yaskawa recommends using ring terminals on all models. Converters require the use of ring terminals for UL/cUL
compliance. Use only the tools recommended by the terminal manufacturer for crimping.
Transporting the Converter
NOTICE: Never steam clean the converter. During transport, keep the converter from coming into contact with salts, fluorine, bromine,
phthalate ester, and other such harmful chemicals.
CAUTION! Crush Hazard. Carry all standard configuration and peripheral devices in a method suitable for the weight of the device.
Incorrectly handling devices could cause them to fall and result in injury or damage to the device.
CAUTION! Crush Hazard. When standing up and lifting model 4A0630, move the eye bolts to the top panel and lift the converter from
the four eye bolts on the top panel. Failure to comply may cause the converter to fall and cause injury. Refer to Precautions and
Instructions for Installation on page 32 for details.
◆ Precautions on Using Peripheral Devices
Install a reactor-type noise filter without a capacitor such as a zero phase reactor after the MCCB on the power supply
side when installing a noise filter on the power supply.
NOTICE: Do not install a filter with a built-in capacitor. The harmonic components may cause the capacitor to overheat or may damage
the capacitor. Always install the specified harmonic noise filter.
Selecting a Circuit Breaker or Circuit Interrupter
• Yaskawa recommends installing a Ground Fault Circuit Interrupter (GFCI) to the power supply side. The GFCI should
be designed for use with AC drives (e.g., Type B according to IEC/EN 60755).
• Select a Molded Case Circuit Breaker (MCCB) according to the power factor of the converter power supply. The power
factor changes with the power supply voltage, output frequency, and load.
When using a GFCI that is not recommended, be sure to choose a GFCI with harmonic countermeasures and one with a
rated operating current of 30 mA minimum for each connected converter. High-frequency leakage current can cause
malfunctions. When a GFCI without countermeasures malfunctions, replace the GFCI with a rated operating current of
200 mA minimum for each connected converter.
Select a GFCI or MCCB with a rated trip capacity equal to or higher than the power supply short circuit current.
Magnetic Contactor Installation
Yaskawa recommends installing a magnetic contactor (MC) between the power supply and the converter to ensure that
the power to the converter can be shut off. Create a sequence in which the MC is turned off by the fault output from the
converter.
Wire Gauges and Wiring Distances
Use a motor cable gauge large enough to avoid unstable converter phase control from voltage drop caused by a long
motor cable.
When using the digital operator remotely, always use the cable specified (option). When controlling the converter
remotely using analog signals, limit the length of the control lines between the control signals and converter to 50 m or
shorter and separate the control lines from power lines (main circuit and sequence circuits) to prevent induction from
peripheral devices.
When using a multi-function analog input, connect the shield wire to the sheath ground terminal E (G) with shielded
twisted-pair wires. Refer to Standard Connection Diagram on page 48 for details.
Generator Power Supplies
Select a generator with two times the capacity of the converter input power supply. Select the deceleration time, load, and
other factors so that the regenerative power from the motor is 10% or less of the capacity of the generator. For details,
consult with your Yaskawa representative or the nearest Yaskawa sales office.
18 YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual
i.2 General Safety
YAI
Connecting an Advanced-phase Capacitor or Thyristor-controlled Device to the Power Supply
An advanced-phase capacitor is not required for the converter. Installing an advanced-phase capacitor will reduce the
power factor.
If an advanced-phase capacitor currently exists is in the same power supply system as the converter, install a series reactor
on the advanced-phase capacitor to prevent resonance with the converter.
If a device that generates voltage surge or voltage distortion, such as a thyristor-controlled DC drive or electromagnetic
mixer is installed in the same power supply system as the converter, consult with your Yaskawa representative or the
nearest Yaskawa sales office.
Countermeasures for EMC and High-frequency (Harmonic) Leakage Current
Although countermeasures are not required for harmonic currents, the same countermeasures for electrical interference
(EMC) and high-frequency (harmonic) leakage current are required as for a normal drive. If there are nearby devices that
are easily affected by electrical interference, use a reactor-type noise filter (e.g., zero phase reactor).
When installing an MCCB or GFCI at the power supply, use an MCCB or GFCI that is designed for a drive (i.e., one that
has countermeasures for high-frequency leakage current).
Compliance with Harmonic Suppression Guidelines
• Guidelines for harmonic suppression measures are applicable to consumers that receive power from a 6.6 kV or higher
system. For details, refer to the Harmonics Suppression Technical Guideline JEAG 9702-1995.
• With respect to the harmonic suppression guidelines, the converter is equivalent to a three-phase bridge that does not
generate harmonics (K
Impact of Power Supply Distortion
= 0), but the harmonic component is not completely zero.
5
Distorting the power supply voltage and connecting several devices in parallel to the same power supply will cause power
supply system harmonics to flow into the converter and increase the harmonic content.
◆ Warning Label Example
Always heed the warning information in the position shown in Figure i.2.
Figurei.2
DIGITAL OPERATOR JVOP-180
WARNING
Risk of electric shock.
●
Read manual before installing.
●
Wait 5 minutes for capacitor
discharge after disconnecting
power supply.
●
To conform to CE requirements,
make sure to ground the supply
neutral for 400V class.
●
After disconnecting from power
supply, please wait 5 minutes
before inspecting, performing
maintenance or wiring the
converter.
Hot Surfaces
●
Top and side surfaces may
become hot. Do not touch.
Figure i.2 Warning Information Position
CIMR-AA2A0021FAA
200V 3Phase 5.5kW/3.7kW
S/N:
WARNING
Risk of electric shock.
●
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 for 400V class.
●
After opening the manual switch
between the drive and motor,
please wait 5 minutes before
inspecting, performing
maintenance or wiring the drive.
Hot surfaces
●
Top and Side surfaces may
become hot. Do not touch.
●
●
●
●
ESC
RUN STOP
AVERTISSMENT
Risque de décharge électrique.
●
Lire le manuel avant l'installation.
●
Attendre 5 minutes après la coupure
de l'alimentation, pour permettre
la décharge des condensateurs.
●
Pour répondre aux exigences , s
assurer que le neutre soit relié
à la terre, pour la série 400V.
●
Après avoir déconnécte la protection
entre le driver et le moteur, veuillez
patienter 5 minutes avain d’effectuer
une opération de montage ou de
câblage du variateur.
Surfaces Chaudes
●
Dessus et cotés du boitier Peuvent
devenir chaud. Ne Pas toucher.
危 険
けが．感電のおそれがあります。
●
据え付け、運転の前には必ず取扱説明書を読むこと。
●
通電中および電源遮断後5分以内はフロントカバー
を外さない事。
●
400V級インバータの場合は、電源の中性点が接地
されていることを確認すること。(対応）
●
保守・点検、配線を行う場合は、出力側開閉器を
遮断後5分待って実施してください。
高温注意
●
インバータ上部、両側面は高温になります。
触らないでください。
F2F1
ENTERRESET
ALM
LO
RE
NPJT31470-1
Warning Label
YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual 19
i.2 General Safety
◆ Warranty Information
■ Restrictions
The converter is not designed or manufactured for use in devices or systems that may directly affect or threaten human
lives or health.
Customers who intend to use the product described in this manual for devices or systems relating to transportation, health
care, space aviation, atomic power, electric power, or in underwater applications must first contact their Yaskawa
representatives or the nearest Yaskawa sales office.
WARNING! Injury to Personnel. This product has been manufactured under strict quality-control guidelines. However, if this product is
to be installed in any location where failure of this product could involve or result in a life-and-death situation or loss of human life or in
a facility where failure may cause a serious accident or physical injury, safety devices must be installed to minimize the likelihood of any
accident.
20 YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual
1
Receiving
This chapter explains how to inspect the converter upon receipt, and gives an overview of the
different enclosure types and components.
1.1 SECTION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2 MODEL NUMBERS AND NAMEPLATES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 CONVERTER MODELS AND ENCLOSURE TYPES . . . . . . . . . . . . . . . . . . . . . . .25
YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual 21
1.1 Section Safety
CAUTION
NOTICE
1.1 Section Safety
Do not carry the converter by the front cover or the terminal cover.
Failure to comply may cause the main body of the converter to fall, resulting in minor or moderate injury.
Observe proper electrostatic discharge procedures (ESD) when handling the converter and circuit boards.
Failure to comply may result in ESD damage to circuitry.
22 YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual
1.2 Model Numbers and Nameplates
Receiving
1
D1000
PRG : 2000
YASKAWA ELECTRIC CORPORATION
2-1 Kurosaki-shiroishi, Yahatanishi-Ku, Kitakyusyu 806-0004 Japan
MADE IN JAPAN
:
CIMR-DU4A0040AAA
REV : A
: CIMR-DU4A0040AAA
: AC3PH 380-480V 50/60Hz 58A
: DC660V 61A
: 21 kg
: 6W3050-2-100
: J0073D207410100 IP00
PASS
MODEL
C/C
RATED OUTPUT CAPACITY : 40kW
INPUT
OUTPUT
MASS
O / N
S / N
VAJ123456
FILE NO: E131457
Model
Rated output capacity
Input specifications
Output specifications
MASS
Lot number
Serial number
Software version
<1>
YAI
D1000
Model
Input specifications
Output specifications
MASS
Lot number
Serial number
VAJ123456
IP00
EUJ710800
:
: AC3PH 200-240V 50/60Hz 15A
: AC3PH 200-240V 50/60Hz 15A
: 6.5 kg
: 6W3050-2-100
: J0073D207410100
MODEL
INPUT
OUTPUT
MASS
O / N
S / N
YASKAWA ELECTRIC CORPORATION
MADE IN JAPAN
2-1 Kurosaki-shiroishi, Yahatanishi-Ku, Kitakyushu 806-0004 Japan
PASS
FILE NO: E131457
1.2 Model Numbers and Nameplates
Perform the following tasks after receiving the converter and the harmonic filter module:
• Inspect the converter and the harmonic filter module for damage. If the converter or the harmonic filter module appear
damaged upon receipt, contact the shipper immediately.
• Verify receipt of the correct model by checking the information on the nameplate.
• If you have received the wrong model or the converter or the harmonic filter module does not function properly, contact
your supplier.
◆ Nameplate
Figure1.1
<1> The address of the head office of Yaskawa Electric Corporation (responsible for product liability) is shown on the nameplate.
Figure 1.1 Converter Nameplate Information Example
Figure 1.2 Harmonic Filter Module Nameplate Information Example
YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual 23
1.2 Model Numbers and Nameplates
<1>
CIMR- D A 2 A 0030 A A A
YASKAWA
Power
Regenerative
Converter
No.
Region Code
A
B
C
D
T
U
Japan
China
Europe
India
Asia
USA
No. Voltage Class
4
3-phase, 380-480 Vac
2
3-phase, 200-240 Vac
No.
Customized
Specifications
A
Standard model
No. Enclosure Type
A
No.
Environmental Specification
A
K
M
N
S
Standard
Gas-resistant
Humidity- and dust-resistant
Oil-resistant
Vibration-resistant
D1000
Series
Design
Revision
Order
IP00/Open Type
B
IP20/Open Type
D1000
◆ Model Numbers
Three-Phase 200 V Class Three-Phase 400 V Class
Model
0005 6.7 0005 6.7
0010 13.4 0010 13.4
0020 26.8 0020 26.8
0030 40 0030 40
0050 67 0040 54.0
0065 87 0060 80.0
0090 120 0100 134.0
0130 174 0130 174.0
Rated Output Capacity
(HP)
Model
Rated Output Capacity
(HP)
0185 250
0270 360
0370 500
0630 850
<1> Converters with these specifications do not guarantee complete protection for the environmental conditions indicated.
24 YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual
1.3 Converter Models and Enclosure Types
Receiving
1
1.3 Converter Models and Enclosure Types
Two types of enclosures are offered for D1000 converters:
IP00 and IP20/Open Type enclosure models are designed for installation in an enclosure panel that serves to protect
personnel from injury caused by accidentally touching live parts.
Table 1.1 describes converter enclosures and models.
Table 1.1 Models and Enclosure Types
Voltage Class
Three-Phase
200 V Class
Three-Phase
400 V Class
Enclosure Type
IP20/Open Type IP00/Open Type
2A0005 2A0030
2A0010 2A0050
2A0020 2A0065
– 2A0090
– 2A0130
4A0005 4A0030
4A0010 4A0040
4A0020 4A0060
– 4A0100
– 4A0130
– 4A0185
– 4A0270
– 4A0370
– 4A0630
YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual 25
1.3 Converter Models and Enclosure Types
26 YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual
2
Mechanical Installation
This chapter explains how to properly mount and install the converter and the harmonic filter
module.
2.1 SECTION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.2 MECHANICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
2.3 HARMONIC FILTER MODULE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 39
YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual 27
2.1 Section Safety
W ARNING
CAUTION
2.1 Section Safety
Fire Hazard
Ensure proper cooling when installing an IP00/IP20 converter in a closed panel or cabinet.
Ensure the air temperature entering the converter is 50
Failure to comply could result in overheating and fire.
Only allow qualified personnel to operate a crane or hoist to transport the converter.
Failure to comply may result in serious injury or death from falling equipment.
Use a dedicated lifter when transporting the converter by a lifter.
Failure to comply may result in serious injury or death from falling equipment.
Only use vertical suspension to temporarily lift the converter during installation to an enclosure panel.
Do not use vertical suspension to transport the converter.
Failure to comply may result in serious injury or death from falling equipment.
°C (122°F) or cooler by use of a cooling fan or air conditioner.
Crush Hazard
Use screws to securely affix the converter front cover, terminal blocks, and other converter components prior to
vertical suspension.
Failure to comply may result in serious injury or death from falling equipment.
2
Do not subject the converter to vibration or impact greater than 1.96 m/s
cables.
Failure to comply may result in serious injury or death from falling equipment.
Do not attempt to flip the converter over or leave the converter unattended while it is suspended by the wires.
Failure to comply may result in serious injury or death from falling equipment.
(0.2 G) while it is suspended by the
Crush Hazard
Do not carry the converter by the front cover or the terminal cover.
Failure to comply may result in minor or moderate injury from the main body of the converter falling.
28 YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual
2.2 Mechanical Installation
Mechanical Installation
2
2.2 Mechanical Installation
This section outlines specifications, procedures, and the environment for proper mechanical installation of the converter
and the harmonic filter module.
◆ Installation Environment
Install the converter in an environment matching the specifications in Table 2.1 to help prolong the optimum performance
life of the converter.
Table 2.1 Installation Environment
Environment Conditions
Installation Area Indoors
IP00/Open Type enclosure: -10°C to +50°C (14°F to 122°F)
IP20/Open Type enclosure: -10°C to +40°C (14°F to 104°F)
Ambient
Temperature
Humidity 95% RH or less and free of condensation
Storage
Temperature
Surrounding Area
Altitude 1000 m (3281 ft) or lower, up to 3000 m (9843 ft) with derating. Refer to Derating Data on page 178 for details.
Vibration
Orientation Install the converter vertically to maintain maximum cooling effects.
Converter reliability improves in environments without wide temperature fluctuations.
When using the converter in an enclosure panel, install a cooling fan or air conditioner in the area to ensure that the air
temperature inside the enclosure does not exceed the specified levels.
Do not allow ice to develop on the converter or the harmonic filter module.
-20°C to +60°C (-4°F to +140°F)
Install the converter and the harmonic filter module in an area free from:
• oil mist and dust
• metal shavings, oil, water, or other foreign materials
• radioactive materials
• combustible materials (e.g., wood)
• harmful gases and liquids
• excessive vibration
• chlorides
• direct sunlight.
10 to 20 Hz at 9.8 m/s
10 to 20 Hz at 9.8 m/s
10 to 20 Hz at 5.9 m/s
2
, 20 to 55 Hz at 5.9 m/s2 (2A0005 to 2A0050, 4A0005 to 4A0100)
2
, 20 to 55 Hz at 2.0 m/s2 (2A0065 to 2A0130, 4A0130 to 4A0370)
2
, 20 to 55 Hz at 2.0 m/s2 (4A0630)
NOTICE: Avoid placing converter peripheral devices, transformers, or other electronics near the converter as the noise created can
lead to erroneous operation. If such devices must be used in close proximity to the converter, take proper steps to shield the converter
from noise.
NOTICE: Prevent foreign matter such as metal shavings and wire clippings from falling into the converter during installation. Failure to
comply could result in damage to the converter. Place a temporary cover over the top of the converter during installation. Remove the
temporary cover before converter start-up, as the cover will reduce ventilation and cause the converter to overheat.
NOTICE: When installing an IP00/IP20 converter in a closed panel or cabinet, sufficiently cool the panel or cabinet with a cooling fan or
air conditioner so that the air temperature entering the converter is 50 °C (122 °F) or cooler. Failure to comply could result in
overheating and fire.
YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual 29
2.2 Mechanical Installation
◆ Installation Orientation and Spacing
Install the converter upright as illustrated in Figure 2.1 to maintain proper cooling.
Figure 2.1
Figure 2.1 Correct Installation Orientation
■ Single Converter Installation
Figure 2.2 shows the installation distance required to maintain sufficient space for airflow and wiring. Install the heatsink
against a closed surface to avoid diverting cooling air around the heatsink.
Figure 2.2
Side Clearance Top/Bottom Clearance
A
BB
A
A – 50 mm minimum C – 120 mm minimum
B – 30 mm minimum D – Airflow direction
Figure 2.2 Correct Installation Spacing (Single)
C
C
D
D
30 YASKAWA ELECTRIC TOEP C710656 07C YASKAWA Power Regenerative Converter - D1000 Instruction Manual
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