To properly use the product, read this manual thoroughly and retain
for easy reference, inspection, and maintenance. Ensure the end
user receives this manual.
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.
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.
◆ Applicable Documentation
The following manuals are available for the option and drive:
Read this manual first.
The installation manual is packaged with the
DI-101 120 Vac Interface Option and contains
installation procedures and precautions.
Yaskawa Drive
Yaskawa AC Drive
A1000-Series
Quick Start Guide
Yaskawa AC Drive
A1000-Series
Technical Manual
The drive manuals cover basic installation,
wiring, operation procedures, functions,
troubleshooting, and maintenance information.
The manuals also include important
information about parameter settings and drive
tuning. Access these sites to obtain Yaskawa
instruction manuals:
U.S.: http://www.yaskawa.com
Europe: http://www.yaskawa.eu.com
Japan: http://www.e-mechatronics.com
For questions, contact your local Yaskawa sales
office or the nearest Yaskawa representative.
Page 5
1 Preface and Safety
DANGER
W ARNING
CAUTION
NOTICE
◆ Terms
Note:Indicates supplemental information that is not related to safety messages.
Drive: Yaskawa AC Drive A1000-Series
Option: Yaskawa AC Drive A1000-Series Option Digital Input DI-101
◆ Registered Trademarks
Trademarks are the property of their respective owners.
◆ Supplemental Safety Information
Read and understand this manual before installing, operating, or servicing this option. Install
the option according to this manual and local codes.
The following conventions indicate safety messages in this manual. Failure to heed these
messages could cause fatal injury or damage products and 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.
Indicates a hazardous situation, which, if not avoided, could result in minor or
moderate injury.
• The diagrams in this book may include options and drives without covers or safety shields to
illustrate details. Be sure to reinstall covers or shields before operating any devices. Use the option
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 new copies of the manual, contact a Yaskawa representative or the nearest Yaskawa
sales office and provide the manual number shown on the front cover.
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.
Do not modify the drive or option circuitry.
Failure to comply could result in damage to the drive or option and will void warranty.
Yaskawa is not responsible for any modification of the product made by the user. This
product must not be modified.
Do not expose the drive or option to halogen group disinfectants.
Failure to comply may cause damage to the electrical components in the drive or option.
Do not pack the drive in wooden materials that have been fumigated or sterilized.
Do not sterilize the entire package after the product is packed.
The DI-101 option has eight optically isolated input terminals that can be used to connect
external 120 Vac control circuitry to the A1000 drive. The DI-101 option mounts directly to
the A1000 control board terminals (S1 to S8 and SN). This option makes it possible to
control the A1000 digital inputs with 120 Vac.
This manual explains the handling, installation and specifications of this product.
◆ Applicable Models
The option can be used with the drive models in Table 1.
Do not connect or disconnect wiring while the power is on.
Failure to comply will result in death or serious injury.
Disconnect all power to the drive and wait at least the amount of time specified on the
drive front cover safety label. After all indicators are off, measure the DC bus voltage to
confirm safe level, and check for unsafe voltages. The internal capacitor remains charged
after the power supply is turned off.
Electrical Shock Hazard
Do not remove the front covers of the drive while the power is on.
Failure to comply could result in death or serious injury.
The diagrams in this section may include options and drives without covers or safety
shields to show details. Be sure to reinstall covers or shields before operating any devices.
Use the option according to the instructions described in this manual.
Do not allow unqualified personnel to use equipment.
Failure to comply could result in death or serious injury.
Maintenance, inspection, and replacement of parts must be performed only by authorized
personnel familiar with installation, adjustment, and maintenance of this product.
Do not touch circuit boards while the power to the drive is on.
Failure to comply could result in death or serious injury.
Prior to installing the option, wire the drive, make the necessary connections to the drive
terminals, and verify that the drive functions normally. Refer to the Quick Start Guide
packaged with the drive for information on wiring and connecting the drive.
Figure 2 is an exploded view of the drive with the option and related components for
reference.
Figure 2
E
D
C
A – A1000 DriveD – Terminal Cover
B – DI-101 OptionE – A1000 TB1 - Digital Input Terminal Block,
Refer to the following instructions to install the option.
1. Shut off power to the drive, wait the appropriate amount of time for voltage to
dissipate. Remove the terminal cover screw (C) then remove the terminal cover (D).
Refer to the Quick Start Guide packaged with the drive for directions on removing
the cover. Cover removal varies depending on drive size.
DANGER! Electrical Shock Hazard. Disconnect all power to the drive and wait at least the amount of time
specified on the drive front cover safety label. After all indicators are off, measure the DC bus voltage to
confirm safe level, and check for unsafe voltages before servicing to prevent electric shock. The internal
capacitor remains charged even after the power supply is turned off.
NOTICE: Damage to Equipment. Observe proper electrostatic discharge procedures (ESD) when handling
the option, drive, and circuit boards. Failure to comply may result in ESD damage to circuitry.
2. Loosen terminals S1 to S8 and SN on the A1000 drive digital Input terminal block
Figure 4
TB1.
Figure 4 Loosen Drive Control Terminals TB1 S1 to S8 and SN
3. Remove the DI-101 option from the ESD bag.
NOTICE: When handling printed circuit boards (PCB) always use electrostatic discharge (ESD) protection.
Keep the boards in the ESD bag as long as you can. Do not lay the board on any surfaces without the ESD
protection. When handling, always hold the board from the edges and do not touch the components. Before
installing this option, a technically qualified individual, familiar with this type of equipment and the hazards
involved, should read this entire installation guide.
4. Insert the DI-101 option (B) into the A1000 drive control terminals TB1, S1 to S8
and SN at the insertion point (E).
Refer to Figure 6 for the proper placement of the option terminals into the drive TB1
terminals. Secure the DI-101 option by tightening the TB1 terminals S1 to S8 and
SN. Refer to Wire Gauges, Tightening Torques, and Crimp Terminals on
Figure 5
page 20 to confirm that the proper tightening torque is applied to each terminal.
5. Ensure the factory installed wire jumper is present between TB1 terminals SC to SP.
If no wire jumper is present, prepare and install a jumper according to Figure 7.
Route the customer-supplied option wiring through one of the cable glands on the
A1000 drive bottom conduit bracket.
about 5.5 mm (7/32”)
When not using
crimped insulated
sleeves
Strip wire insulation about 5.5 mm
and lightly twist the end with fingers,
keeping the ends from fraying.
Customer-supplied
120 Vac control circuit wires
(do not solder ends)
Loosen the screws and
insert the wire into the
opening on each terminal.
Blade depth of
0.4 mm or less
Blade width of
2.5 mm or less
6. Prepare the external 120 Vac control circuit wires (customer supplied) for terminals
Figure 7
S1 to S8 and X2 on the DI-101 option as shown in Figure 7.
Figure 7 Preparing Cable Wiring
7. Connect the customer wiring to the DI-101 option terminal block. Refer to Figure 8
for a wiring diagram example showing customer interface circuitry.
Refer to Wire Gauges, Tightening Torques, and Crimp Terminals on page 20 to
confirm that the proper tightening torque is applied to each terminal. Take particular
precaution to ensure each wire is properly connected and wire insulation is not
accidentally pinched into electrical terminals.
WARNING! Fire Hazard. Tighten terminal screws to the specified tightening torque. Loose electrical
connections could result in death or serious injury by fire due to overheating. Tightening screws beyond the
specified tightening torque may cause erroneous operation, damage the terminal block, or cause a fire.
◆ Wire Gauges, Tightening Torques, and Crimp Terminals
■Wire Gauges and Tightening Torques
Wire gauge and torque specifications are listed in Table 3.
Table 3 Wire Gauges and Tightening Torques
Terminal
signal
S1 to S8
and X2
Screw
Size
M2
Tightening
Torque
N.m (in.lb)
0.22 to 0.25
(1.95 to 2.21)
(24 to 17 AWG)
(24 to 16 AWG)
■Crimp Terminals
Yaskawa recommends using CRIMPFOX 6 by Phoenix Contact or equivalent crimp
terminals with the specifications listed in Table 4 for simplier and more reliable wiring.
Troubleshooting tips are provided below. Verify these points if the drive performance is not
as expected after installing the option:
• Verify all wire connections are tight.
• Verify all DI-101 PCB Fingers are fully inserted into the A1000 TB1 drive terminals and
the terminals are fully tightened.
• Verify the factory installed wire jumper is installed between A1000
TB1 terminals SC to SP.
• Verify the signal is present at the DI-101 option input terminals by using an AC voltmeter
to measure for a 120 Vac input signal is present on any activated terminals S1 thru S8 with
respect to the X2 terminal.
• Verify the digital input is recognized by the drive by viewing Input Terminal Status
monitor parameter U1-10.
• Verify the drive Multi-Function Digital Input parameters (H1-01 through H1-08) of the
drive are set correctly for the expected S1 to S8 input terminal behavior.
◆ Preventing Noise Interference
Take the following steps to prevent erroneous operation caused by conducted electrical noise
interference:
• Use shielded wire for the signal lines less than 24 V.
• Limit the length of I/O signal wiring to less than 50 m (164 ft.).
• Use seperate conduits or cable tray separation for 120 Vac control wiring, DC signal and
other I/O wiring, main circuit power lines.
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
YASKAWA INDIA PRIVATE LIMITED
#17/A, Electronics City, Hosur Road, Bangalore, 560 100 (Karnataka), India
Phone: 91-80-4244-1900
http://www.yaskawaindia.in
Fax: 55-11-3585-1187
Fax: 82-2-784-8495
Fax: 65-6289-3003
Fax: 86-10-8518-4082
Fax: 886-2-2505-1280
Fax: 91-80-4244-1901
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.