Yaskawa G5HHP User Manual
G5 - HHP Drive
Technical Manual
Compact High-Capacity Inverter Panels
400-V Class: 200-800 kW (320 to 1200 kVA)
575-V Class: 300-1200 kW (400 to 1500 kVA)
Models: CIMR-G5A Document Number: TM.G5HHP.01
Preface
Preface
Thank you for purchasing the compact High-capacity VARISPEED-616G5 Inverter Panels with neu-
rovector control.
This manual is designed to ensure correct and suitable application of the High-capacity VA-
RISPEED-616G5 Inverter Panels. Read this manual before attempting to install, operate, maintain,
or inspect an Inverter and keep this manual in a safe, convenient location for future reference. Be sure
you understand all precautions and safety information before attempting application.
i
Safety Information
The following conventions are used to indicate precautions in this manual. Failure to heed precautions provided in
this manual can result in seriousor possibly even fatalinjury or damage to the products or to related equipmentand
systems.
WARNING Indicates precautions that, if not heeded, could possibly result in loss of life or
!
CAUTION Indicates precautions that, if not heeded, could result in relatively serious or minor
!
The warning symbols for ISO and JIS standards are different, as shown below.
The ISO symbol is used in this manual.
Both of these symbols appearon warning labels on Yaskawa products. Please abide by thesewarning labelsregard-
less of which symbol is used.
serious injury.
injury, damage to the product, or faulty operation.
ISO JIS
Yaskawa, 1998
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. Nevertheless, 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.
ii
Visual Aids
Visual Aids
The following aids are used to indicate certain types of information for easier reference.
AEXAMPLE"
INFO
IMPORTANT
Indicates application examples.
Indicates supplemental information.
Indicates important information that should be memorized.
iii
General Precautions
D The diagrams in this manual may be indicated without covers or safety shields to show de-
tails. Be sure to restore covers or shieldsbefore operating the Units and run the Units according to the instructions described in this manual.
D 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.
D 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.
D When ordering a new copy of the manual due to damage or loss, contact your Yaskawarepre-
sentatives or the nearest Yaskawa sales office and provide the manual number shown on the
front cover.
D If nameplates become warn or damaged, order new ones from your Yaskawa representatives
or the nearest Yaskawa sales office.
iv
Safety Precautions
J Confirmations upon Delivery
D Never install an Inverter Panel that is damaged or missing components.
Doing so can result in injury.
J Transportation
D Crane operation must be performed only by an authorized person qualified to operate
cranes.
Otherwise, injury or damage caused by dropping lifted objects.
J Wiring
Safety Precautions
CAUTION
Page
2-2
CAUTION
Page
2-4
WARNING
D Always turn OFF the input power supply before wiring terminals.
Otherwise, an electric shock or fire can occur.
D Wiring must be performed by an authorized person qualified in electrical work.
Otherwise, an electric shock or fire can occur.
D Be sure to ground the ground terminal.
(400-V and 575-V Class Inverters: Ground to 10 Ω or less)
Otherwise, an electric shock or fire can occur.
D Always check the operation of any emergency stop circuits after they are wired.
Otherwise, there is the possibility of injury. (Wiring is the responsibility of the user.)
D Never touch the output terminals directly with your hands or allow the output lines to
come into contact with the Inverter Panel casing. Never short the output circuits.
Otherwise, electrical shock or grounding can occur.
CAUTION
D Check to be sure that the voltage of the main AC power supply satisfies the rated volt-
age of the Inverter Panel.
Injury or fire can occur if the voltage is not correct.
D Do not perform voltage withstand tests on the Inverter Panel.
Voltage withstand test can damage semiconductor elements and other components.
D Connect Braking Resistor Units and Braking Units as shown in the I/O wiring exam-
ples.
Otherwise, a fire can occur.
D Tighten all terminal screws to the specified tightening torque.
Otherwise, a fire may occur.
D Do not connect AC power to output terminals U, V, and W.
The internal Inverter Module will be damaged if voltage is applied to the output terminals.
Page
3-2
3-2
3-2
3-2
3-2
Page
3-2
3-2
3-2
3-2
3-2
v
CAUTION
D Do not connect phase-advancing capacitors or LC/RC noise filters to the output cir-
cuits.
The Inverter panel can be damaged or internal parts burnt if these devices are connected.
D Do not connect electromagnetic switches or contactors to the output circuits.
If a load is connected while the InverterPanel is operating, surgecurrentwill cause the overcurrent protection circuit to operate.
J Setting User Constants
CAUTION
D Disconnect the load (machine, device) from the motor before autotuning.
The motor may turn, possibly resulting in injury or damage to equipment. Also, motor constants
cannot be correctly set with the motor attached to a load.
J Trial Operation
WARNING
D Check to be sure that the front door is closed before turning ON the power supply. Do
not open the front door during operation.
An electric shock may occur if the front door is open when power is ON.
D Do not come close to the machine when the fault reset function is used. If the alarm is
cleared,the machine may startmoving suddenly.Also, design the machine so that human safety is ensured even when it is restarted.
Injury may occur.
D Provide a separate emergency stop switch; the Digital Operator STOP Key is valid
only when its function is set.
Injury may occur.
D Reset alarms only after confirming that the RUN signal is OFF. If an alarm is reset with
the RUN signal turned ON, the machine may suddenly start.
Injury may occur.
3-2
3-2
Page
4-33
Page
5-2
5-2
5-2
5-2
CAUTION
D Don’t touch the radiation fins (heat sink), braking resistor, or Braking Resistor Unit.
These can become very hot.
Otherwise, a burn injury may occur.
D Be sure that the motor and machine is within the applicable ranges before starting op-
eration.
Otherwise, an injury may occur.
D Provide a separate holding brake if necessary.
Otherwise, an injury may occur.
D Don’t check signals while the Inverter is running.
Otherwise, the equipment may be damaged.
D Be careful when changing Inverter Panel settings. The Inverter Panel is factory set to
suitable settings.
The equipment may be damaged is unsuitable settings are used.
vi
Page
5-2
5-2
5-2
5-2
5-2
J Maintenance and Inspection
WARNING
D Do not touch the Inverter Panel terminals. Some of the terminals carry high voltages
and are extremely dangerous.
Touching the terminals can result in electric shock.
D Always have the protectivecover in place when power is being supplied to the Invert-
er. When attaching the cover, always turn OFF power to the Inverter through the
MCCB.
Doing so can result in electric shock.
D After turning OFF the main circuit power supply, wait until the CHARGE indicator light
goes out before performance maintenance or inspections.
The capacitor will remain charged and is dangerous.
D Maintenance, inspection, and replacement of parts must be performed only by autho-
rized personnel.
Remove all metal objects, such as watches and rings, before starting work. Always
use grounded tools.
Failure to heed these warning can result in electric shock.
D Before mounting or dismounting a Module, make sure that the main circuit and control
power supply have been turned OFF.
Not doing so can result in electric shock.
D Do not dismount a Module until the CHARGE lamp on the Module turns OFF after turn-
ing OFF the power supply.
An electric shock may occur is the Module is dismounted while still charged.
D Use special lifts for mounting or dismounting a Module.
Not doing so can result in injury.
D The Modules are heavy, and mounting or dismounting the Modules must be per-
formed by three workers: One to operate the lift and two others for mounting and dismounting the Modules.
Not doing so can result in injury
D Before disposing of a Module, open a hole in the heat sink attached to the Module to
purge gas.
Exposingthe heatsink to a high temperaturewithout opening a hole in the heat sinkcan resultin
explosion and injury.
Safety Precautions
Page
10 - 2
10 - 2
10 - 2
10 - 2
10 - 6
10 - 6
10 - 6
10 - 6
10 - 14
CAUTION
D A CMOS IC is used in the control board. Handle the control board and CMOS IC care-
fully. The CMOS IC can be destroyed by static electricity if touched directly.
The CMOS IC can be destroyed by static electricity if touched directly.
D Do not change the wiring, or remove connectors or the Digital Operator, during opera-
tion.
Performing this word during operation can result in personal injury.
J Others
WARNING
D Do not attempt to modify or alter the Inverter.
Alterations or modifications can result in electrical shock or injury.
vii
Page
10 - 2
10 - 2
Warning Label Contents and Position
There is a warning label on the Inverter in the position shown in the following illustration. Always heed the warnings
given on this label.
Warning label
position
Warning Label Contents
The illustration shows a 400-V class (200-kW)
and a 575-V class (300-kW) Inverter.
May cause injury or electric
shock.
D Please follow the instructions in
the manual before installation or
operation.
D Disconnect all power before opening
the door of panel. Wait 5 minutes
until DC Bus capacitors discharge.
D Use proper grounding techniques.
Definition of Terms
The following definitions are used in this manual unless otherwise specified.
Inverter: Inverter Panel
Module: Inverter Module or Converter Module
WARNING
viii
How to Change the Digital Operator Display from Japanese to English
How to Change the Digital Operator Display from Japanese to English
If the Digital Operator displays messages in Japanese, change to the English mode using the following
steps.
(This manual provides descriptions for the English mode.)
Power ON
MENU
* Main Menu *
Operation
DATA
ENTER
MENU
DATA
ENTER
A1--00=0
English
DATA
ENTER
Entry Accepted
Select language
English
ix
CONTENTS
11 Introduction
12 Handling Inverters
13 Wiring
14 Setting User Constants
15 Trial Operation
16 Basic Operation
1
2
3
4
5
6
17 Advanced Operation
18 User Constants
19 Troubleshooting
10 Maintenance and Inspection
11 Specifications
12 Appendix
7
8
9
10
11
12
Table of Contents
Table of Contents
Preface i.........................................................
Safety Information ii................................................
Visual Aids iii......................................................
General Precautions iv...............................................
Safety Precautions v................................................
Warning Label Contents and Position viii.................................
Definition of Terms viii...............................................
How to Change the Digital Operator Display from Japanese to English ix......
1 Introduction 1 - 1.........................................
1.1 Outline and Functions 1 - 2..........................................
1.1.1 Outline of Control Methods 1 - 2...............................................
1.1.2 Functions 1 - 2.............................................................
1.2 Nomenclature 1 - 7................................................
1.2.1 VS-616G5 Components 1 - 7..................................................
1.2.2 Digital Operator Components 1 - 8..............................................
2 Handling Inverters 2 - 1...................................
2.1 Confirmations upon Delivery 2 - 2....................................
2.1.1 Nameplate Information 2 - 2..................................................
2.2 Temporary Storage 2 - 3............................................
2.2.1 Storage Location 2 - 3.......................................................
2.2.2 Storage Method 2 - 3........................................................
2.3 Transportation 2 - 4................................................
2.3.1 Precautions During Transportation 2 - 4.........................................
2.3.2 Lifting with Wires 2 - 4......................................................
2.3.3 Transporting on Rollers 2 - 5..................................................
2.4 External Dimensions and Mounting Dimensions 2 - 6.....................
2.5 Checking and Controlling the Installation Site 2 - 10.......................
2.5.1 Installation Site 2 - 10........................................................
2.5.2 Controlling the Ambient Temperature 2 - 10.......................................
2.5.3 Protecting the Inverter Panel from Foreign Matter 2 - 10..............................
2.5.4 Floor Level 2 - 10...........................................................
2.5.5 Inverter Panel Connections (Side-by-side Connection) 2 - 10..........................
2.5.6 Tightening Anchor Bolts 2 - 11.................................................
2.6 Installation Orientation and Space 2 - 13................................
2.7 Removing/Attaching the Digital Operator 2 - 14..........................
3 Wiring 3 - 1..............................................
3.1 Connection Diagram 3 - 3...........................................
3.2 Terminal Positions 3 - 5............................................
3.3 Cable Sizes 3 - 7..................................................
3.4 Wiring Main Circuit Terminals 3 - 9...................................
3.4.1 Main Circuit Terminal Functions 3 - 9...........................................
xiii
3.4.2 Main Circuit Configurations 3 - 10..............................................
3.4.3 Precautions for Wiring Main Circuit Power Input 3 - 10..............................
3.5 Wiring Control Circuit Terminals 3 - 12.................................
3.5.1 Control Circuit Terminal Functions 3 - 12.........................................
3.6 Wiring Check 3 - 13..................................................
3.7 Installing and Wiring PG Speed Control Cards 3 - 14......................
3.7.1 Installing a PG Speed Control Card 3 - 14.........................................
3.7.2 PG Speed Control Card Terminal Blocks 3 - 15....................................
3.7.3 Wiring a PG Speed Control Card 3 - 17...........................................
3.7.4 Wiring PG Speed Control Card Terminal Blocks 3 - 22...............................
3.7.5 Selecting the Number of PG (Encoder) Pulses 3 - 25.................................
3.8 Grounding 3 - 27...................................................
3.8.1 Connection of Ground Bus Bar 3 - 27............................................
3.8.2 Connection of Ground Cable for Control Signals 3 - 27..............................
4 Setting User Constants 4 - 1................................
4.1 Using the Digital Operator 4 - 2......................................
4.2 Modes 4 - 4......................................................
4.2.1 Inverter Modes 4 - 4........................................................
4.2.2 Switching Modes 4 - 5.......................................................
4.2.3 User Constant Access Levels 4 - 6..............................................
4.2.4 Operation Mode 4 - 12.......................................................
4.2.5 Initialize Mode 4 - 21........................................................
4.2.6 Programming Mode 4 - 29....................................................
4.2.7 Autotuning Mode 4 - 33......................................................
4.2.8 Modified Constants Mode 4 - 35................................................
5 Trial Operation 5 - 1......................................
5.1 Procedure 5 - 3...................................................
5.2 Trial Operation Procedures 5 - 4......................................
5.2.1 Power ON 5 - 4............................................................
5.2.2 Checking the Display Status 5 - 4..............................................
5.2.3 Initializing Constants 5 - 4....................................................
5.2.4 Setting Input Voltage 5 - 5....................................................
5.2.5 Autotuning 5 - 10...........................................................
5.2.6 No-load Operation 5 - 12......................................................
5.2.7 Loaded Operation 5 - 12......................................................
6 Basic Operation 6 - 1......................................
6.1 Common Settings 6 - 2.............................................
6.1.1 Setting the Access Level and Control Method: A1-01, A1-02 6 - 2.....................
6.1.2 Frequency Reference Settings: b1-01, H3-01, H3-08, H3-09 6 - 4.....................
6.1.3 Frequency Reference from Digital Operator: b1-01, o1-03, d1-01 to d1-09 6 - 7..........
6.1.4 Run Source and Sequence Input Responsiveness: b1-02, b1-06, b1-07 6 - 9..............
6.1.5 Acceleration/Deceleration Times: C1-01 through C1-08, C1-09, C1-10, C1-11 6 - 10.......
6.1.6 Prohibiting Reverse Operation: b1-04 6 - 11.......................................
6.1.7 Selecting the Stopping Method: b1-03 6 - 12......................................
6.1.8 Multi-function Input Settings: H1-01 through H1-06 6 - 13...........................
6.2 Open-loop Vector Control 6 - 18.......................................
6.2.1 Autotuning 6 - 18...........................................................
6.2.2 Autotuning Faults 6 - 19......................................................
xiv
Table of Contents
6.3 V/f Control 6 - 21..................................................
6.3.1 Setting the Motor Constants: E1-01, E1-02, E2-01 6 - 21.............................
6.3.2 V/f Pattern Selection: E1-03 6 - 22..............................................
6.4 Flux Vector Control 6 - 26...........................................
6.4.1 PG Speed Control Card Settings 6 - 26...........................................
6.4.2 Setting the Zero-speed Operation Constants 6 - 29..................................
6.4.3 Autotuning 6 - 31...........................................................
6.4.4 Speed Control (ASR) Structure 6 - 33............................................
6.4.5 Speed Control (ASR) Gain 6 - 36...............................................
6.5 V/f Control with PG 6 - 39...........................................
6.5.1 Motor Constants: E1-01, E1-02, E2-01, E2-04 6 - 39................................
6.5.2 V/f Pattern Selection: E1-03 6 - 40..............................................
6.5.3 PG Speed Control Card Settings 6 - 41...........................................
6.5.4 Speed Control (ASR) Structure 6 - 43............................................
6.5.5 Adjusting Speed Control (ASR) Gain 6 - 44.......................................
7 Advanced Operation 7 - 1..................................
7.1 Open-loop Vector Control 7 - 2.......................................
7.1.1 Torque Limit Function 7 - 4...................................................
7.1.2 Adjusting Speed Feedback 7 - 5...............................................
7.1.3 Setting/Adjusting Motor Constants 7 - 6.........................................
7.2 Normal V/f Control 7 - 10............................................
7.2.1 Energy-saving Control Function 7 - 12...........................................
7.2.2 Hunting-prevention Function 7 - 12.............................................
7.2.3 Setting Motor Constants 7 - 13.................................................
7.3 Flux Vector Control 7 - 15...........................................
7.3.1 Droop Control Function 7 - 17.................................................
7.3.2 Zero-servo Function 7 - 18....................................................
7.3.3 Torque Control 7 - 19........................................................
7.3.4 Speed/Torque Control Switching Function 7 - 26...................................
7.3.5 Torque Limit Function 7 - 27...................................................
7.3.6 Setting/Adjusting Motor Constants 7 - 29.........................................
7.4 V/f Control with PG Feedback 7 - 33...................................
7.4.1 Energy-saving Control Function 7 - 35...........................................
7.4.2 Hunting-prevention Function 7 - 35..............................................
7.4.3 Setting Motor Constants 7 - 36..................................................
7.5 Common Functions 7 - 38............................................
7.5.1 Application Constants: b 7 - 41.................................................
7.5.2 Tuning Constants: C 7 - 50....................................................
7.5.3 Reference Constants: d 7 - 54..................................................
7.5.4 Option Constants: F 7 - 56.....................................................
7.5.5 External Terminal Functions: H 7 - 62............................................
7.5.6 Protective Functions: L 7 - 84..................................................
7.5.7 Operator Constants: o 7 - 99...................................................
8 User Constants 8 - 1.......................................
8.1 Initialize Mode Constants 8 - 3.......................................
8.2 Programming Mode Constants 8 - 4...................................
8.2.1 Application Constants: b 8 - 4.................................................
8.2.2 Autotuning Constants: C 8 - 10.................................................
8.2.3 Reference Constants: d 8 - 16..................................................
8.2.4 Motor Constant Constants: E 8 - 19..............................................
8.2.5 Options Constants: F 8 - 23....................................................
xv
8.2.6 Terminal Constants: H 8 - 26...................................................
8.2.7 Protection Constants: L 8 - 33..................................................
8.2.8 Operator Constants: o 8 - 39...................................................
8.2.9 Factory Settings that Change with the Control Method (A1-02) 8 - 41...................
8.2.10 Factory Settings that Change with the Inverter Capacity (o2-04) 8 - 42..................
9 Troubleshooting 9 - 1......................................
9.1 Protective and Diagnostic Functions 9 - 2..............................
9.1.1 Fault Detection 9 - 2........................................................
9.1.2 Minor Fault Detection 9 - 6...................................................
9.1.3 Operation Errors 9 - 8.......................................................
9.2 Troubleshooting 9 - 9..............................................
9.2.1 If Constant Constants Cannot Be Set 9 - 9........................................
9.2.2 If the Motor Does Not Operate 9 - 9............................................
9.2.3 If the Direction of the Motor Rotation is Reversed 9 - 11.............................
9.2.4 If the Motor Does Not Put Out Torque or If Acceleration is Slow 9 - 11..................
9.2.5 If the Motor Does Not Operate According to Reference 9 - 11.........................
9.2.6 If the Slip Compensation Function Has Low Speed Precision 9 - 11.....................
9.2.7 If There is Low Speed Control Accuracy at High-speed Rotation in Open-loop
9.2.8 If Motor Deceleration is Slow 9 - 12.............................................
9.2.9 If the Motor Overheats 9 - 12...................................................
9.2.10 If There is Noise When the Inverter is Started or From an AM Radio 9 - 13..............
9.2.11 If the Ground Fault Interrupter Operates When the Inverter is Run 9 - 13................
9.2.12 If There is Mechanical Oscillation 9 - 13.........................................
9.2.13 If the Motor Rotates Even When Inverter Output is Stopped 9 - 14.....................
9.2.14 If 0 V is Detected When the Fan is Started, or Fan Stalls 9 - 14........................
9.2.15 If Output Frequency Does Not Rise to Frequency Reference 9 - 14.....................
Vector Control Mode 9 - 12.................................................
10 Maintenance and Inspection 10 - 1............................
10.1 Maintenance and Inspection 10 - 3....................................
10.1.1 Daily Inspection 10 - 3......................................................
10.1.2 Periodic Inspection 10 - 3....................................................
10.1.3 Periodic Maintenance of Parts 10 - 3............................................
10.1.4 Replacement of In-panel Ventilation Fan Unit 10 - 4................................
10.1.5 Dismounting and Mounting the Module 10 - 6....................................
11 Specifications 11 - 1........................................
11.1 Standard Inverter Specifications 11 - 2.................................
11.2 Specifications of Options and Peripheral Devices 11 - 4...................
11.2.1 Selection of MCCB and Ground Fault Interrupter 11 - 4.............................
11.2.2 Module Draw-out Lift 11 - 4..................................................
11.2.3 Option Cards 11 - 6.........................................................
12 Appendix 12 - 1...........................................
12.1 Inverter Application Precautions 12 - 2................................
12.1.1 Selection 12 - 2...........................................................
12.1.2 Settings 12 - 2...........................................................
12.1.3 Handling 12 - 2..........................................................
12.2 Motor Application Precautions 12 - 3.................................
12.2.1 Using the Inverter for an Existing Standard Motor 12 - 3...........................
12.2.2 Power Transmission Mechanism (Speed Reducers, Belts, and Chains) 12 - 3............
12.3 Peripheral Device Application Precautions 12 - 4........................
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Table of Contents
12.4 Wiring Examples 12 - 5.............................................
12.4.1 Using Two Braking Units in Parallel 12 - 5.......................................
12.4.2 Using a JVOP-95-j, -96-j VS Operator 12 - 6...................................
12.4.3 Using an Open-collector Transistor for Operation Signals 12 - 7.......................
12.4.4 Using Open-collector, Contact Outputs 12 - 7.....................................
12.5 Function Block Diagram 12 - 8.......................................
12.6 Spare Parts Lists 12 - 10.............................................
12.7 User Constants 12 - 12..............................................
xvii
1
Introduction
This chapter provides an overview of the VS-616G5 Inverter and describes
its functions and components.
1.1 Outline and Functions 1 - 2....................
1.1.1 Outline of Control Methods 1 - 2.....................
1.1.2 Functions 1 - 2....................................
1.2 Nomenclature 1 - 7..........................
1.2.1 VS-616G5 Components 1 - 7........................
1.2.2 Digital Operator Components 1 - 8....................
1
1-1
1
Introduction
1.1.2 Functions
1.1 Outline and Functions
The VS-616G5 Inverters provides full-current vector control based on advanced control logic. An autotuning
function is included for easy vector control.
The Digital Operator provides a liquid crystal display that is 2 lines by 16 charactersin size. User constant settings
and monitor items are easily read in interactive operations in either Japanese or English. (The display language
can be changed by setting a user constant.)
1.1.1 Outline of Control Methods
The VS-616G5 uses four control methods.
D Open-loop vector control (factory setting)
D Flux vector control
D V/f control without PG
D V/f control with PG feedback
PG stands for pulse generator (encoder).
Vector control is a method for removing interference with magnetic flux and torque, and controlling torque
according to references.
Current vector control independently controls magnetic flux current and torque current by simultaneously
controlling the motor primary current and phases. This ensures smooth rotation, high torque, and accurate
speed/torque control at low speeds.
Vector control can be replaced by the conventional V/f control system. If the motor constants required for
vector control are not known, the motor constants can be automatically set with autotuning.
The control methods are effective for the following applications:
D Open-loop vector control: General variable-speed drive.
D Flux vector control: Simple servodrive, high-precision speed control/torque control.
D V/f control without PG: Conventional Inverter control mode. Used for multi-drive operation
(connecting multiple motors to one Inverter).
D V/f control with PG feedback:Simple speed feedback control. (For applications with the PG
connected to the machine shaft rather than the motor shaft.)
The control characteristics for each mode are shown in Table 1.1.
1.1.2 Functions
J Autotuning
Autotuning is effective for vector control. It solves problems in applicable motor restrictions and difficult
constant settings. The motor constants are automatically set by entering a value from the motor’s rating
nameplate.
Autotuning allows flux vector control to operate accurately with virtually any normal AC induction motor,
regardless of the supplier.
Always perform autotuning for motor unit separately before vector control operation.
J Torque Control
Torque control is effective for flux vector control with PG. Torque is controlled by taking multi-function
analog input signals as torque references. Torque control accuracy is ±5%. Switching is possible between
torque control and speed control.
Table 1 . 1 Control Method Characteristics
Characteristic
Open-loop Flux Vector Without PG With PG feedback
Speed Control
Range
Speed Control
Precision
Initial Drive 150% at 1 Hz 150% at 0 r/min 150% at 3 Hz
Vector Control V/f Control
1:100 1:1000 1:40 1:40
±0.2 % ±0.02 % ±2to3% ±0.03 %
1-2
J V/f Pattern Settings
V/f pattern settings are effective for V/f control. Select a V/f pattern according to the application from among
the 15 preset V/f patterns. Custom V/f patterns can also be set.
1.1 Outline and Functions
1
1-3
1
Introduction
1.1.2 Functions
J Frequency References
The following five types of frequency references can be used to control the output frequency of the Inverter.
D Numeric input from the Digital Operator
D Voltage input within a range from 0 to 10 V
D Voltageinput within a range from 0 to ±10 V (with negative voltages, rotation is in the opposite direction
from the run command.)
D Current input within a range from 4 to 20 mA
D Input from Option Card
Any of the above frequency references can be used by setting a constant.
A maximum of nine frequency references can be registered with the Inverter. With remote multi-step speed
referenceinputs, the Inverter can operate in multi-step speed operation with a maximum of nine speed steps.
J PID Control
The Inverter has a PID control function for easy follow-up control. Follow-up control is a control method
in which the Inverter varies the output frequency to match the feedback value from the sensor for a set target
value.
Follow-up control can be applied to a variety of control operations, such as those listed below, depending
on the contents detected by the sensor.
D Speed Control: With a speed sensor, such as a tachogenerator, the Inverter regulates the rotat-
ing speed of the motor regardless of the load of the motor or synchronizes the
rotating speed of the motor with that of another motor.
D Pressure Control: With a pressure sensor, the Inverter performs constant pressure control.
D Flow-rate Control: By sensing the flow rate of a fluid, the Inverter performs precise flow-rate con-
trol.
D Temperature Control: With a temperature sensor, the Inverter performs temperature control by fan
speed.
J Zero-servo Control
Zero-servo control is effective with flux vector control. Even at a motor speed of zero (r/min), a torque of
150% of the motor’s rated torque can be generated and the average servomotor holding power (stopping
power) can be obtained.
J Speed Control By Feedback
Speed control using feedback is effective with a PG. An optional PG Speed Control Card be used to enable
feedback control for speeds, thereby improving speed control accuracy.
J Dwell Function
By holding the output frequency for a constant time during acceleration and deceleration, acceleration and
deceleration can be performed without stepping out even when driving a motor with a large startup load.
J Low Noise
The output transistor of the Inverter is an IGBT (insulated gate bipolar transistor). Using sine-wave PWM
with a high-frequency carrier, the motor does not generate metallic noise.
J Monitor Function
The following items can be monitored with the Digital Operator: Frequency reference, output frequency,
output current, motor speed, output voltage reference, main-circuit DC voltage, output power, torque reference, status of input terminals, status of output terminals, operating status, total operating time, software
number, speed deviation value, PID feedback value, fault status, fault history, etc.
All types of data can be monitored even with multi-function analog output.
J Bilingual Digital Operator
The Digital Operator can display either English or Japanese. The Digital Operator’s liquid crystal display
provides a 16-character x 2-line display area.
Easy-to-readdisplays allow the advanced functions of the Inverter to be set in interactive operations to input
constants, monitoring items, etc. Change the constant setting to select the English display.
J Harmonic Countermeasures
All VS-616G5 Inverters incorporate a DC reactor in the Inverter Panel to easily handle high-frequency control guidelines.
1-4
J User Constant Structure and Three Access Levels
The VS-616G5 has a number of user constants for setting various functions. These user constants are classified into a hierarchy to make them easier to use.
The levels are as follows from top to bottom: Modes, Groups, Functions, and Constants. The access levels
for the user constants are shown in Table 1.2.
Table 1 . 2 Access Levels for User Constants
Level Contents
Mode Classified according to operation
Operation: For operating the Inverter. (All kinds of monitoring are possible.)
Initialize: For selecting the language displayed at the Digital Operator, setting
Programming: For setting user constants for operation.
Autotuning: For automatic calculation or setting motor constants. (Only under
Modified constants: For referencing or changing user constants after shipping.
Groups Classified by application.
Functions Classified by function. (See user constants.)
Constants Individual user constant settings.
The VS-616G5 allows the following three access levels to be set in order to further simplify setting user
constants. (An access level is a range of user constants that can be referenced or set.)
Quick-Start Reads/sets user constants required for trial operation. [Factory setting]
Basic Reads/sets user constants that are commonly used.
Advanced Reads/sets all the user constants that can be used.
access levels, initialization, and the control modes.
the vector control mode.)
1.1 Outline and Functions
1
In general, press the DATA/ENTER Key to move from an upper to a lower level. This varies somewhat,
however, according to the access level, as shown in Fig. 1.1. For the Quick-Start access level, which has
few user constants that can be set, pressing the DATA/ENTER Key jumps directly to the user constant level;
whereas for the Advanced access level, which has many user constants, pressing the DATA/ENTER Key
first leads to the Group level.
1-5
Introduction
1.1.2 Functions
1
MENU
Operation mode
Initialize mode
Programming mode
DATA
ENTER
(Advanced) (Basic) (Quick-Start)
Displays group level.
Application
Tuning
Reference
Displays function level.
b1 Sequence
Constant to be changed
C1 Accel/Decel
C2 S-curve Acc/Dec
Displays constant level.
b1-01 Reference source
b1-02 Run source
b1-03 Stopping method
C1-01 Accel Time 1
C1-02 Decel Time 1
(Mode)
(Groups)
Fig 1.1 Access Level Structure
(Functions)
(Constants)
1-6
1.2 Nomenclature
This section provides the names of VS-616G5 components, and the components and functions of the Digital Operator.
1.2.1 VS-616G5 Components
The appearance of Inverter and the names of its components are shown in Figure 1.2.
Inverter Module
1.2 Nomenclature
1
Control Unit
Power Supply
Unit
Fig 1.2 Appearance of VS-616G5, Model CIMR-G5A (400 V, 200 kW)
Charge lamp
1-7
Introduction
1.2.2 Digital Operator Components
1.2.2 Digital Operator Components
This section describes the component names and functions of the Digital Operator. The component names
and functions are shown in Figure 1.3 and key functions are described in Table 1.3.
1
DRIVE FWD REV REMOTE
Frequency Ref
U1--01 = 00.00 HZ
DIGITAL OPERATOR
JVOP-130
LOCAL
REMOTE
JOG
FWD
REV
RUN STOP
SEQ REF
MENU
ESC
DATA
ENTER
RESET
Operation Mode Indicators
DRIVE: Lit when in operation mode.
FWD: Lit when there is a forward reference input.
REV: Lit when there is a reverse reference input.
SEQ: Lit when an operation reference from the
REF: Lit when the frequency reference from con-
control circuit terminal is enabled.
trol circuit terminals 13 and 14 is enabled.
Data Dis play
Two-line LCD that displays data for monitoring,
user constants, and set values with 16 characters
per line.
Keys
Execute operations such as setting user constants,
monitoring, jogging, and autotuning.
Fig 1.3 Digital Operator Component Names and Functions
1-8
Table 1 . 3 Key Functions
Key Name Function
Switches between (LOCAL) operation via the Digital Operator
LOCAL
REMOTE
LOCAL/REMOTE Key
and control circuit terminal (REMOTE) operation.
This key can be enabled or disabled by setting a user constant
(o2-01).
1.2 Nomenclature
MENU
ESC
JOG
FWD
REV
RESET
DATA
ENTER
RUN
MENU Key Displays menus.
ESC Key Returns to the status before the DATA/ENTER Key was pressed.
JOG Key
FWD/REV Key
RESET Key
Increment Key
Decrement Key
DATA/ENTER Key
RUN Key
Enables jog operation when the VS-616G5 is being operated
from the Digital Operator.
Selects the rotation direction of the motor when the VS-616G5 is
being operated from the Digital Operator.
Sets the number of digits for user constant settings.
Also acts as the reset key when a fault has occurred.
Selects menu items, groups, functions, and user constant names,
and increments set values.
Selects menu items, groups, functions, and user constant names,
and decrements set values.
Enters menu items, functions, constants, and set values after they
are set.
Starts the VS-616G5 operation when the VS-616G5 is in operation with the Digital Operator.
Stops VS-616G5 operation.
STOP
STOP Key
This key can be enabled or disabled by setting a user constant
(o2-02) when operating from the control circuit terminal.
Note Except in diagrams, keys are referred to using the key names listed in the above table.
1
FWD
REV
RUN STOP
RESET
Inverter output frequency
STOP
Frequency setting
RUN
OP
ST
Lit Blinking Not lit
RUN
STOP
The RUN and STOP indicators light and blink to indicate operating status.
Fig 1.4 RUN and STOP Indicators
1-9
1
Introduction
1.2.2 Digital Operator Components
1-10
2
Handling Inverters
This chapter describes the checks required upon receiving a VS-616G5 Inverter and describes installation methods.
2.1 Confirmations upon Delivery 2 - 2..............
2.1.1 Nameplate Information 2 - 2.........................
2.2 Temporary Storage 2 - 3......................
2.2.1 Storage Location 2 - 3..............................
2.2.2 Storage Method 2 - 3...............................
2.3 Transportation 2 - 4..........................
2.3.1 Precautions During Transportation 2 - 4................
2.3.2 Lifting with Wires 2 - 4.............................
2.3.3 Transporting on Rollers 2 - 5.........................
2.4 External Dimensions and Mounting
Dimensions 2 - 6...........................
2.5 Checking and Controlling the Installation
Site 2 - 10.................................
2.5.1 Installation Site 2 - 10...............................
2.5.2 Controlling the Ambient Temperature 2 - 10..............
2.5.3 Protecting the Inverter Panel from Foreign Matter 2 - 10....
2.5.4 Floor Level 2 - 10..................................
2.5.5 Inverter Panel Connections
(Side-by-side Connection) 2 - 10....................
2.5.6 Tightening Anchor Bolts 2 - 11........................
2.6 Installation Orientation and Space 2 - 13..........
2
2.7 Removing/Attaching the Digital Operator 2 - 14....
2-1
2
Handling Inverters
2.1.1 Nameplate Information
2.1 Confirmations upon Delivery
D Never install an Inverter Panel that is damaged or missing components.
Doingsocanresult in injury.
Check the following items as soon as the Inverter is delivered.
Table 2 . 1 Checks
Item Method
Has the correct model of Inverter been
delivered?
Is the Inverter damaged in any way? Inspect the entire exterior of the Inverter to see if there are any scratches or
Are any screws or other components
loose?
If you find any irregularities in the above items, contact the agency from which you purchased the Inverter or
your Yaskawa representative immediately.
2.1.1 Nameplate Information
CAUTION
Check the model number on the nameplate on the back of the front panel of
the Inverter Panel (See 2.1.1).
other damage resulting from shipping.
Use a screwdriver or other tools to check for tightness.
J Example Nameplate
Standard domestic (Japan) Inverter: 3-phase, 400 VAC, 200 kW standards
TRANSISTOR INVERTER
Model number
Input specifications
Output specifications
Output capacity
Lot number
Serial number
MODEL CIMR--G5A4200 SPEC 42008A
RATINGS
INPUT 380 -- 460 V 385 A
OUTPUT 3PH 0 -- 460 VAC 0 -- 414 A
CODE No. 71616--G5A42008A.
SER No. MASS 800Kg DATA
YASKAWA ELECTRIC CORPORATION
J Inverter Panel Model Numbers
CIMR -G5A 4 2008 A
Inverter Panel
VS-616G5
No. Specification
A Standard domestic model
No. Voltage Class
4 AC input, 3-phase, 400 V
5 AC input, 3-phase, 575 V
KVA
JAPAN
Revision code (Specification code is entered for special specifications.)
No. Protective structure
8 Enclosed self-standing structure
No. Max. Motor Capacity
200
400
to
800
200 kW
400 kW
to
800 kW
Inverter specifications
Mass
2-2
2.2 Temporary Storage
Observe the following precautions when storing the Inverter Panel for a period of time before installation.
2.2.1 Storage Location
Store the Inverter Panel under the following conditions.
D Indoors
D In a level and flat location
D In a well-ventilated location at a low temperature and low humidity
D In a locations not subject to vibration
D In a locations not subject to dust, harmful gases, or salt
2.2.2 Storage Method
2.2 Temporary Storage
Store the Inverter Panel in the following manner.
D Place the Inverter Panel on sleepers as shown below. (Do not place it directly on the floor.)
D Cover the Inverter Panel with the polyethylene cover that is attached at the time of shipment.
Inverter Panel
Cover
Floor
Sleeper
Fig 2.1 Storage Method
2
2-3
2
Handling Inverters
2.3.1 Precautions During Transportation
2.3 Transportation
D Crane operation must be performed only by an authorized person qualified to operate cranes.
Otherwise, injury or damage caused by dropping lifted objects.
The Inverter Panel should be transported using either the lifting wires or rollers. Before transporting the Inverter
Panel, make sure that the door and internal components are secured.
2.3.1 Precautions During Transportation
D Do not push or drag the Inverter Panel on concrete floors or floors other than ones which have embedded
channel base or steel plates.
D Do not turn over or roll the Inverter Panel.
D Do not subject the Inverter Panel to vibration or shock exceeding 4.9 m/s
2.3.2 Lifting with Wires
D When lifting the Inverter Panel, use wires with sufficient strength that withstand the mass.
D When using wires to lift the Inverter Panel, route wires so as to provide a lifting angle of 60° min., as
shown in Figuure 2.2 below. If the lifting angle is less than this, allowable lifting loads will not be assured.
D Place each wire through the lifting hole provided in the lifting angle.
D Do not lift the Inverter Panel as shown in Figure 2.3.
D When lifting the Inverter Panel using a crane, first gradually lift the wires until they become taught. Lift
the Inverter Panel only after making sure that the wires are taught. Lift the Inverter Panel up or down
slowly. When placing the Inverter Panel on the floor, stop lowering it just before it reaches the floor and
then slowly lower it on the floor to avoid any shock to the Inverter Panel.
Lifting angle
CAUTION
60° min.
2
(0.5 G) during transportation.
Fig 2.2 Wire Lifting
Fig 2.3 Bad Lifting Example
2-4
Wire
Lifting angle
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