Yaskawa R1000 User Manual

YASKAWA R1000 Series

Power Regenerative Unit

Instruction Manual

Type: CIMR-RU 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: 3.5 to 105 kW 400 V Class, Three-Phase Input: 3.5 to 300 kW

MANUAL NO. TOEP C710656 08B

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

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 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Warning Label Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1. RECEIVING............................................................................................................... 17

1.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.2 Model Numbers and Nameplates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.3 Regenerative Unit Models and Enclosure Types . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2. MECHANICAL INSTALLATION ............................................................................... 23

2.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.2 Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Installation Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Installation Orientation and Spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Precautions and Instructions for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Digital Operator Remote Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Exterior and Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3. ELECTRICAL INSTALLATION ................................................................................ 35

3.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.2 Standard Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.3 Main Circuit Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2A03P5 to 2A0053, and 4A03P5 to 4A0073 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2A0073 to 2A0105, and 4A0105 to 4A0300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.4 Terminal Block Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.5 Terminal Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Models 2A03P5 to 2A0028, 4A03P5 to 4A0028 (IP20/NEMA Type 1) . . . . . . . . . . . . 45

Models 2A0035 to 2A0105, 4A0035 to 4A0300 (IP00/Open Type enclosure) . . . . . . . 46

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 3

3.6 Digital Operator and Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Removing/Reattaching the Digital Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Removing/Reattaching the Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

3.7 Top Protective Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Removing and Reattaching the Top Protective Cover . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.8 Main Circuit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Main Circuit Terminal Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Protecting Main Circuit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Wire Gauges and Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Ground Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3.9 Control Circuit Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Control Circuit Terminal Block Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Terminal Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Wiring the Control Circuit Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3.10 Control I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Terminal A2 Input Signal Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Using the Contact Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Connect to a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

3.11 Wiring Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

4. START-UP PROGRAMMING & OPERATION ......................................................... 67

4.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

4.2 Using the Digital Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

ALARM (ALM) LED Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

LO/RE LED and RUN LED Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Menu Structure for Digital Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

4.3 The Drive and Programming Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Navigating the Drive and Programming Modes (Default Setting) . . . . . . . . . . . . . . . . . 72

Changing Parameter Settings or Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Verifying Parameter Changes: Verify Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Switching Between LOCAL and REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.4 Powering Up the Regenerative Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Powering Up the Regenerative Unit and Operation Status Display . . . . . . . . . . . . . . .76

4.5 Operation with the Drive Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Drive Connection Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Timing Chart for Turning the Power Supply On and Off . . . . . . . . . . . . . . . . . . . . . . . .77

Operation Command Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

4.6 Verifying Parameter Settings and Backing Up Changes . . . . . . . . . . . . . . . . . . . . .80

Backing Up Parameter Values: o2-03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Parameter Access Level: A1-01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Password Settings: A1-04, A1-05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Copy Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

4.7 Test Run Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

4 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

5. TROUBLESHOOTING .............................................................................................. 85

5.1 Section Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

5.2 Alarms, Faults, and Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Types of Alarms, Faults, and Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Alarm and Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

5.3 Fault Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Fault Displays, Causes, and Possible Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

5.4 Alarm Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Alarm Codes, Causes, and Possible Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

5.5 Operator Programming Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Operator Programming Error Codes, Causes, and Possible Solutions . . . . . . . . . . . 109

5.6 Copy Function Related Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Tasks, Errors, and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

5.7 Diagnosing and Resetting Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Fault Reset Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

6. PERIODIC INSPECTION & MAINTENANCE ......................................................... 113

6.1 Section Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

6.2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Recommended Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Recommended Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

6.3 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

6.4 Cooling Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Number of Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Cooling Fan Component Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Cooling Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

6.5 Regenerative Unit Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Serviceable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Replacing the Regenerative Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

7. STANDARD CONFIGURATION DEVICES, PERIPHERAL DEVICES,

AND OPTIONS........................................................................................................ 135

7.1 Section Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

7.2 Regenerative Unit Options and Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . 138

7.3 Connecting Standard Configuration Devices and Peripheral Devices . . . . . . . . 139

7.4 Standard Configuration Devices Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Wire Gauges and Tightening Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Terminal Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

7.5 Installing Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Installing a Molded Case Circuit Breaker (MCCB) or Ground Fault Circuit

Interrupter (GFCI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Installing a Magnetic Contactor at the Power Supply Side . . . . . . . . . . . . . . . . . . . . 145

Connecting a Surge Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Attachment for External Heatsink Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 5

A. SPECIFICATIONS .................................................................................................. 147

A.1 Power Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

A.2 Regenerative Unit Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

A.3 Heat Loss Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150

A.4 Derating Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

Temperature Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Altitude Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

B. PARAMETER LIST ................................................................................................. 153

B.1 Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154

B.2 Parameter Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

A: Initialization Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

b: Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

C: Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

F: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

H: Multi-Function Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159

L: Protection Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164

o: Operator-Related Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166

U: Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

B.3 Defaults by Unit Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173

C. MEMOBUS/MODBUS COMMUNICATIONS .......................................................... 175

C.1 MEMOBUS/Modbus Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176

C.2 Communication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

C.3 Connecting to a Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178

Network Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178

Network Termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

C.4 MEMOBUS/Modbus Setup Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179

MEMOBUS/Modbus Serial Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

C.5 Regenerative Unit Operations by MEMOBUS/Modbus . . . . . . . . . . . . . . . . . . . . . 182

Observing the Regenerative Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Controlling the Regenerative Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182

C.6 Communications Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Command Messages from Master to Regenerative Unit . . . . . . . . . . . . . . . . . . . . . . 183

Response Messages from Regenerative Unit to Master . . . . . . . . . . . . . . . . . . . . . . 183

C.7 Message Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184

Message Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Slave Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Function Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184

Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184

Error Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

C.8 Message Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186

Reading Regenerative Unit MEMOBUS/Modbus Register Contents . . . . . . . . . . . . . 186

Loopback Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Writing to Multiple Registers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

C.9 MEMOBUS/Modbus Data Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Command Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Monitor Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Fault Trace Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Alarm Register Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197

6 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

C.10 Enter Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

Enter Command Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

C.11 Communication Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

MEMOBUS/Modbus Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Slave Not Responding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

C.12 Self-Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

D. STANDARDS COMPLIANCE ................................................................................. 201

D.1 Section Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

D.2 European Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

CE Low Voltage Directive Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

EMC Guidelines Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

D.3 UL Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

UL Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

UL Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Power Coordinating Reactor/Current Suppression Reactor . . . . . . . . . . . . . . . . . . . 217

Installing Standard Configuration Devises . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

Precautionary Notes on External Heatsink (IP00/Open Type enclosure) . . . . . . . . . 218

D.4 CSA Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Conditions of Acceptability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Installing Standard Configuration Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Main Circuit Terminal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Low Voltage Wiring for Control Circuit Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

CSA for Industrial Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

CSA for Elevator Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Revision History............................................................................................................. 220

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 7

8 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 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

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 9

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 R1000-Series Regenerative Units. Read this manual before attempting to install, operate, maintain, or inspect a regenerative unit 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 R1000 series:

YASKAWA R1000 Series Power Regenerative Unit Instruction Manual (TOEP C710656 08)

This guide is packaged together with the product and contains basic information required to install and wire the regenerative unit. It also gives an fault diagnostics, maintenance, and parameter settings. The purpose of this guide is to prepare the regenerative unit for a trial run with an application and for basic operation.

◆ Symbols

Note: Indicates a supplement or precaution that does not cause regenerative unit damage.

◆ Terms and Abbreviations

• Regenerative Unit: YASKAWA R1000 Series Power Regenerative Unit

• 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 08B YASKAWA Power Regenerative Unit - R1000 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 regenerative unit and run the regenerative unit 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 regenerative unit. The regenerative unit 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 08B YASKAWA Power Regenerative Unit - R1000 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 regenerative unit 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 regenerative unit, drive, motor and machine area before applying power to the regenerative unit. Secure covers, couplings, shaft keys and machine loads.

Electrical Shock Hazard

Do not attempt to modify or alter the regenerative unit 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 regenerative unit.

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 regenerative units.

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.

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 regenerative unit can cause a residual current with a DC component in the protective earthing conductor.

Do not operate equipment with covers removed.

Failure to comply could result in death or serious injury.

12 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

i.2 General Safety

CAUTION

NOTICE

W ARNING

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 regenerative unit 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 regenerative unit to a combustible surface. Never place combustible materials on the regenerative unit.

Crush Hazard

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

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

Do not carry the regenerative unit by the front cover or the terminal cover.

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

Do not disconnect the wiring to the regenerative unit while the regenerative unit is outputting a voltage.

Improper equipment sequencing could result in damage to the regenerative unit.

Connect a power supply with a capacity (kVA) that is larger than the rated input capacity (kW) of the regenerative unit.

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 regenerative unit.

Observe proper electrostatic discharge procedures (ESD) when handling the regenerative unit, circuit boards, and CMOSIC.

Failure to comply may result in ESD damage to the regenerative unit circuitry.

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

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

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 08B YASKAWA Power Regenerative Unit - R1000 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 regenerative unit. The regenerative unit 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 regenerative unit during regenerative unit installation and project construction.

Failure to comply could result in damage to the regenerative unit. 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 regenerative unit to overheat.

Never lift the regenerative unit 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 regenerative unit.

Do not modify the circuitry of the regenerative unit.

Failure to comply could result in damage to the regenerative unit 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 regenerative unit to halogen group disinfectants.

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

◆ General Application Precautions

■ Load Capacity

• Install the regenerative unit in one-to-one with a drive. Do not connect the multiple drives to a regenerative unit.

• Connect R1000 to a drive with same maximum applicable motor capacity (Heavy Duty rating [HD]).

• Do not connect regenerative units in parallel.

Selecting the Capacity

■

Refer to Tab le i .1 to select the regenerative unit capacity. Depending on the amount of regenerated energy, you can select an R1000 with a smaller capacity than the drive. Use the DriveSelect Inverter Capacity Selection Program to make the selection. Contact your Yaskawa representative or the nearest Yaskawa sales office.

Table i.1 Model Selection

Drive Capacity or Motor Capacity (HP)

≤ 5 2A03P5 4A03P5

7 2A0005 4A0005

10 2A0007 4A0007

15 2A0010 4A0010

20 2A0014 4A0014

25 2A0017 4A0017

30 2A0020 4A0020

40 2A0028 4A0028

50 2A0035 4A0035

200 V Class 400 V Class

Model

14 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

i.2 General Safety

Drive Capacity or Motor Capacity (HP)

74 4A0053

101 2A0073 4A0073

121

148

177 –

215 –

248 –

295 –

422 – 4A0300

200 V Class 400 V Class

2A0053

2A0105 4A0105

Model

4A0043

4A0150

4A0210

■ Installing Standard Configuration Devices

Each regenerative unit requires a corresponding set of input fuses, power coordinating reactor, and current suppression reactor. Always install the specified devices.

Installation

■

Enclosure Panels

Keep the regenerative unit in a clean environment by installing the regenerative unit 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 regenerative units to provide for cooling, and take proper measures so the ambient temperature remains within allowable limits and keep flammable materials away from the regenerative unit. Yaskawa offers protective designs for regenerative units 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 regenerative unit upright as specified in the manual. Refer to Mechanical Installation on page 23 for more

information on installation. Failure to comply may damage the regenerative unit due to improper cooling

■ General Handling

Wiring Check

NOTICE: Do not connect power supply lines to output terminals. Failure to comply will destroy the regenerative unit. 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 regenerative unit.

Inspection and Maintenance

WARNING! Electrical Shock Hazard. Capacitors in the regenerative unit do not immediately discharge after shutting off the power. Wait

for at least the amount of time specified on the regenerative unit 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.

To connect or perform maintenance for the standard configuration devices, turn off the power supply to the regenerative unit, wait for the time that is given on the regenerative unit, and then confirm that the temperature of the reactor has sufficiently decreased before you proceed.

Wiring

Yaskawa recommends using ring terminals on all models. Regenerative units require the use of ring terminals for UL/cUL compliance. Use only the tools recommended by the terminal manufacturer for crimping.

Transporting and Installing the Regenerative Unit

NOTICE: Never steam clean the regenerative unit. During transport, keep the regenerative unit 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.

Always use a three-phase power supply. The regenerative unit cannot be used with a single-phase power supply.

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 15

i.2 General Safety

YAI

◆ Precautions on Using Peripheral Devices

■ Installing a Noise Filter

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.

Wire Gauges and Wiring Distances

Use a motor cable gauge large enough to avoid unstable regenerative unit 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 regenerative unit remotely using analog signals, limit the length of the control lines between the control signals and regenerative unit 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 38 for details.

◆ Warning Label Example

Always heed the warning information in the position shown in Figure i.1.

Figure i.1

DIGITAL OPERATOR JVOP-180

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。

ALM

F2F1

LO RE

ENTERRESET

NPJT31470-1

Warning Label

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

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.

●

before inspecting, performing maintenance or wiring the converter.

Hot Surfaces

●

Top and side surfaces may become hot. Do not touch.

Figure i.1 Warning Information Position

◆ Warranty Information

■ Restrictions

The regenerative unit 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.

16 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

Receiving

This chapter explains how to inspect the regenerative unit upon receipt, and gives an overview of the different enclosure types and components.

1.1 SECTION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.2 MODEL NUMBERS AND NAMEPLATES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.3 REGENERATIVE UNIT MODELS AND ENCLOSURE TYPES . . . . . . . . . . . . . . .21

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 17

1.1 Section Safety

CAUTION

NOTICE

1.1 Section Safety

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

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

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

Failure to comply may result in ESD damage to circuitry.

18 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

1.2 Model Numbers and Nameplates

Receiving

D1000

Model

Rated output capacity

<1>

PASS

VAJ123456

CIMR-RU2A0073AAA

MODEL C/C Regenerative Capacity : 73kW

REV : A

INPUT

OUTPUT

MASS O / N

S / N

YASKAWA ELECTRIC CORPORATION

MADE IN JAPAN

2-1 Kurosaki-shiroishi, Yahatanishi-Ku, Kitakyushu 806-0004 Japan

209A 1min 25%ED 167A 80% CONT.

253A 1min 25%ED 226A 80% CONT.

: AC3PH 200-240V 50/60Hz

: :

CIMR-RU2A0073AAA

: DC270-340V

: 6W3050-2-100 : J0073D207410100

: 62kg

PRG : 1010 FILE: NO.E131457

IP00

Software version

Output specifications

Input specifications

MASS Lot number Serial number

YAI

1.2 Model Numbers and Nameplates

Perform the following tasks after receiving the regenerative unit:

• Inspect the regenerative unit for damage. If the regenerative unit 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 regenerative unit does not function properly, contact your supplier.

◆ Nameplate

<1> The address of the head office of Yaskawa Electric Corporation (responsible for product liability) is shown on the nameplate.

Figure 1.1 Regenerative Unit Nameplate Information Example

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 19

1.2 Model Numbers and Nameplates

<1>

CIMR- R A 2 A 0005 A A A

YASKAWA Power Regenerative Unit

No.

Region Code

Japan

China

Europe

India

Asia

USA

No. Voltage Class

3-phase, 380-480 Vac

3-phase, 200-240 Vac

No.

Customized

Specifications

Standard model

No. Enclosure Type

No.

Environmental Specification

Standard

Gas-resistant

Humidity- and dust-resistant

Oil-resistant

Vibration-resistant

R1000 Series

Design Revision Order

IP00/Open Type

IP20/NEMA Type 1

D1000

◆ Model Numbers

Three-Phase 200 V Class Three-Phase 400 V Class

Model

03P5 5 03P5 5

0005 7 0005 7

0007 9 0007 9

0010 13 0010 13

0014 19 0014 19

0017 23 0017 23

0020 27 0020 27

0028 38 0028 38

0035 47 0035 47

0053 71

0073 98 0053 71

0105 141 0073 98

Rated Output Capacity

(HP)

Model

Rated Output Capacity

(HP)

0043 58

0105 141

0150 201

0210 282

0300 402

<1> Regenerative units with these specifications do not guarantee complete protection for the environmental conditions indicated.

20 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

1.3 Regenerative Unit Models and Enclosure Types

Receiving

1.3 Regenerative Unit Models and Enclosure Types

Two types of enclosures are offered for R1000 regenerative units:

• IP00/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.

• IP20/NEMA Type 1 enclosure models mount to an indoor wall or in an enclosure panel. Removing the top protective cover from a IP20/NEMA Type 1 enclosure drive voids NEMA Type 1 protection while retaining IP20 conformity.

Table 1.1 describes regenerative unit 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/NEMA Type 1 IP00/Open Type

2A03P5 2A0035

2A0005 2A0053

2A0007 2A0073

2A0010 2A0105

2A0014 –

2A0017 –

2A0020 –

2A0028 –

4A03P5 4A0035

4A0005 4A0043

4A0007 4A0053

4A0010 4A0073

4A0014 4A0105

4A0017 4A0150

4A0020 4A0210

4A0028 4A0300

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 21

1.3 Regenerative Unit Models and Enclosure Types

22 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

Mechanical Installation

This chapter explains how to properly mount and install the regenerative unit.

2.1 SECTION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.2 MECHANICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 23

2.1 Section Safety

W ARNING

CAUTION

2.1 Section Safety

Fire Hazard

Ensure proper cooling when installing an IP00/IP20 regenerative unit in a closed panel or cabinet.

Ensure the air temperature entering the regenerative unit is 50 conditioner. Failure to comply could result in overheating and fire.

Crush Hazard

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

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

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

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

Only use vertical suspension to temporarily lift the unit during installation to an enclosure panel.

Do not use vertical suspension to transport the unit.

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

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

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

Do not subject the unit to vibration or impact greater than 1.96 m/s

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

Do not attempt to flip the unit over or leave the unit 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 cables.

Crush Hazard

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

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

24 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

2.2 Mechanical Installation

Mechanical Installation

2.2 Mechanical Installation

This section outlines specifications, procedures, and the environment for proper mechanical installation of the regenerative unit.

◆ Installation Environment

Install the regenerative unit in an environment matching the specifications in Tab le 2 .1 to help prolong the optimum performance life of the regenerative unit.

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/NEMA Type 1 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 151 for details.

Vibration

Orientation Install the regenerative unit vertically to maintain maximum cooling effects.

Regenerative unit reliability improves in environments without wide temperature fluctuations. When using the regenerative unit 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 regenerative unit.

-20°C to +60°C (-4°F to +140°F)

Install the regenerative unit 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

, 20 to 55 Hz at 5.9 m/s2 (2A03P5 to 2A0053, 4A03P5 to 4A0073)

, 20 to 55 Hz at 2.0 m/s2 (2A0073 to 2A0105, 4A0105 to 4A0300)

WARNING! Fire Hazard. When installing an IP00/IP20 regenerative unit 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 regenerative unit is 50 °C (122 °F) or cooler. Failure to comply could result in overheating and fire.

NOTICE: Avoid placing regenerative unit peripheral devices, transformers, or other electronics near the regenerative unit as the noise created can lead to erroneous operation. If such devices must be used in close proximity to the regenerative unit, take proper steps to shield the regenerative unit from noise.

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

◆ Installation Orientation and Spacing

Install the regenerative unit upright as illustrated in Figure 2.1 to maintain proper cooling.

Figure2.1

Figure 2.1 Correct Installation Orientation

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 25

2.2 Mechanical Installation

Side Clearance Top/Bottom Clearance

YAI

■ Single Regenerative Unit 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

A – 50 mm minimum C – 120 mm minimum B – 30 mm minimum D – Airflow direction

Figure 2.2 Correct Installation Spacing (Single)

■ Parallel Mounting with Drive

When installing the regenerative unit beside a drive, mount the devices according to Figure 2.3.

Figure 2.3

Side Clearance

Figure 2.3 Space Between Regenerative Unit and Drive (Parallel Mounting)

Line up the tops of the drive and regenerative unit.

A A

DriveRegenerative Unit

A – 50 mm minimum C – 60 mm minimum B – 30 mm minimum D – 120 mm minimum

Top/Bottom Clearance

26 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

2.2 Mechanical Installation

Mechanical Installation

Line up the tops of the drive and regenerative unit.

Side Clearance Top/Bottom Clearance

Drive

Regenerative

Unit

YAI

■ Side-by-Side Installation with Drive

Models 2A03P5 to 2A0028, 4A03P5 to 4A0028 can take advantage of Side-by-Side installation.

When installing the regenerative unit beside a drive, mount the devices according to Figure 2.4 and set L8-35, Installation Method Selection, to 1 (Side-by-Side Mounting).

When mounting regenerative units with the minimum clearance of 2 mm according to Figure 2.5, set parameter L8-35 to 1 while considering derating. Refer to Parameter Tables on page 155 for details.

Figure2.4

Note: Align the tops of the regenerative unit and the drives when installing the regenerative unit and the drives of different heights in the

same enclosure panel. Leave space between the tops and bottoms of stacked regenerative unit and drives for easier cooling fan replacement.

■ Installation Screws

Refer to Exterior and Mounting Dimensions on page 30 for the sizes of the installation screws.

◆ Precautions and Instructions for Installation

Read the following precautions and instructions before installing models 2A0073, 2A0105, and 4A0210 to 4A0300.

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

• Only use vertical suspension to temporarily lift the regenerative unit during installation to an enclosure panel.

• Do not use vertical suspension to transport the regenerative unit.

• Use screws to securely affix the regenerative unit front cover, terminal blocks, and other regenerative

unit components prior to vertical suspension.

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

• Do not attempt to flip the regenerative unit over while it is suspended by the wires.

• Do not leave the regenerative unit unattended while it is suspended by the wires.

A – 50 mm minimum C – 2 mm minimum B – 30 mm minimum D – 120 mm minimum

Figure 2.4 Space Between Regenerative Unit and Drive (Side-by-Side)

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 27

2.2 Mechanical Installation

■ Horizontal Suspension of Models 2A0073, 2A0105, and 4A0105 to 4A0300

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

NOTICE: Damage to Equipment. When lifting the regenerative unit, confirm that the spring washer is fully closed. Failure to comply may deform or damage the regenerative unit when lifted.

Figure 2.5

A – No space between regenerative

unit and washer

C – Space between regenerative

unit and washer

B – Spring washer: Fully closed D – Spring washer: Open

Figure 2.5 Details of Spring Washers

■ Vertical Suspension of Models 2A0073, 2A0105, and 4A0105 to 4A0300

When vertical suspension of the regenerative unit is required in an enclosure panel, the orientation of the eye bolts for these regenerative unit models can be easily changed by turning the eye bolts counterclockwise 90 degrees.

Figure 2.6

Figure 2.6 Adjusting Angle of Eye Bolts

1. Gradually take up the slack in the wires and hoist the regenerative unit after the wires are stretched tight.

2. Lower the regenerative unit when ready to install in the enclosure panel. Stop lowering the regenerative unit

when it is near the floor then begin lowering the regenerative unit again very slowly until the regenerative unit is placed correctly.

28 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

2.2 Mechanical Installation

Mechanical Installation

S /N : J007XE273710001

Operator

Communication Cable Connector

Regenerative Unit

D1000

S /N : J007XE273710001

7. 9

minimum

Unit: m m

12. 2

1. 6

Inst allat ion holes ( 2-M 3 sc rews , depth 5)

<1>

YAI

◆ Digital Operator Remote Usage

■ Remote Operation

The digital operator mounted on the regenerative unit can be removed and connected to the regenerative unit using an extension cable up to 3 m long to facilitate operation when the regenerative unit is installed in a location where it can not be easily accessed.

The digital operator can also be permanently mounted in remote locations such as panel doors using an extension cable and an installation support set (depending on the installation type).

■

<1> If you install the digital operator in a control panel or other enclosure, use the optional connection cable.

Digital Operator Dimensions

Figure 2.7 Digital Operator Dimensions

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 29

2.2 Mechanical Installation

■ Installation Types and Required Materials

The digital operator mounts to an enclosure two different ways:

• External/face-mount installs the operator outside the enclosure panel

• Internal/flush-mount installs the operator inside the enclosure panel

Table 2.2 Digital Operator Installation Methods and Required Tools

Installation

Method

External/ Face-Mount

Internal/ Flush-Mount

<1> If there are welding studs in the control panel, use the Installation Support Set B (for threaded studs).

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

Description

Simplified installation with the digital operator is mounted on the outside of the panel with two screws.

Encloses the digital operator in the panel. The front of the digital operator is flush with the outside of the panel.

(for mounting with screws through

(for use with threaded studs that are

Installation

Support Sets

––

Installation Support Set A

holes in the panel)

Installation Support Set B

fixed to the panel) <1>

Model Required Tools

Phillips screwdriver

(#1)

EZZ020642A

EZZ020642B

Phillips screwdriver

(#1, #2)

Phillips screwdriver (#1)

Wrench (7 mm)

◆ Exterior and Mounting Dimensions

Use Tab le 2 .3 to find the regenerative unit dimension drawings.

Table 2.3 Models and Types

Protective

Design

IP20/NEMA Type 1 Enclosure

IP00/Open Type Enclosure

Three-Phase

200 V Class

2A03P5 2A0005 2A0007 2A0010 2A0014 2A0017 2A0020 2A0028

2A0035 2A0053 2A0073 2A0105

Regenerative Unit Model

Three-Phase

400 V Class

4A03P5 4A0005 4A0007 4A0010 4A0014 4A0017 4A0020 4A0028

4A0035 4A0043 4A0053 4A0073 4A0105 4A0150 4A0210 4A0300

Page

30 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

2.2 Mechanical Installation

Mechanical Installation

1.5

4-d

Figure 1

YAI

■ IP20/NEMA Type 1 Enclosure Drives

Note: Removing the top protective cover or bottom conduit bracket from an IP20/NEMA Type 1 enclosure drive voids NEMA Type 1

protection while maintaining IP20 conformity.

Model Figure

2A03P5 1

2A0005 1

2A0007 1

2A0010 1

2A0014 1

2A0017 1

2A0020 1

2A0028 1

Table 2.4 Dimensions for IP20/NEMA Type 1 Enclosure: 200 V Class

Dimensions mm (in)

W H D W1 H0 H1 H2 H3 D1 t1 d

140

(5.5)

140

(5.5)

140

(5.5)

180

(7.1)

180

(7.1)

220

(8.7)

220

(8.7)

220

(8.7)

300

(11.8)

300

(11.8)

300

(11.8)

340

(13.4)

340

(13.4)

400

(15.8)

400

(15.8)

400

(15.8)

167

(6.6)

167

(6.6)

167

(6.6)

187

(7.4)

187

(7.4)

197

(7.8)

197

(7.8)

197

(7.8)

122

(4.8)

122

(4.8)

122

(4.8)

160

(6.3)

160

(6.3)

192

(7.6)

192

(7.6)

192

(7.6)

260

(10.2)

260

(10.2)

260

(10.2)

300

(11.8)

300

(11.8)

350

(13.8)

350

(13.8)

350

(13.8)

248

(9.8)6(0.2)40(1.6)55(2.2)5(0.2)

248

(9.8)6(0.2)40(1.6)55(2.2)5(0.2)

248

(9.8)6(0.2)40(1.6)55(2.2)5(0.2)

284

(11.2)8(0.3)40(1.6)75(3.0)5(0.2)

284

(11.2)8(0.3)40(1.6)75(3.0)5(0.2)

335

(13.2)8(0.3)50(2.0)78(3.1)5(0.2)

335

(13.2)8(0.3)50(2.0)78(3.1)5(0.2)

335

(13.2)8(0.3)50(2.0)78(3.1)5(0.2)

Weight

kg (lb)

(9)

(13)

(20)

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 31

2.2 Mechanical Installation

4-d

Max 10

Figure 1

Max 10

4-d

Max 8Max 8

Figure 2

Table 2.5 Dimensions for IP20/NEMA Type 1 Enclosure: 400 V Class

Model Figure

4A03P5 1

4A0005 1

4A0007 1

4A0010 1

4A0014 1

4A0017 1

4A0020 1

4A0028 1

W H D W1 H0 H1 H2 H3 D1 t1 d

140

(5.5)

140

(5.5)

140

(5.5)

180

(7.1)

180

(7.1)

220

(8.7)

220

(8.7)

220

(8.7)

300

(11.8)

300

(11.8)

300

(11.8)

340

(13.4)

340

(13.4)

400

(15.8)

400

(15.8)

400

(15.8)

167

(6.6)

167

(6.6)

167

(6.6)

187

(7.4)

187

(7.4)

197

(7.8)

197

(7.8)

197

(7.8)

■ IP00/Open Type Enclosure Models

122

(4.8)

122

(4.8)

122

(4.8)

160

(6.3)

160

(6.3)

192

(7.6)

192

(7.6)

192

(7.6)

Dimensions mm (in)

260

(10.2)

260

(10.2)

260

(10.2)

300

(11.8)

300

(11.8)

350

(13.8)

350

(13.8)

350

(13.8)

248

(9.8)6(0.2)40(1.6)55(2.2)5(0.2)

248

(9.8)6(0.2)40(1.6)55(2.2)5(0.2)

248

(9.8)6(0.2)40(1.6)55(2.2)5(0.2)

284

(11.2)8(0.3)40(1.6)75(3.0)5(0.2)

284

(11.2)8(0.3)40(1.6)75(3.0)5(0.2)

335

(13.2)8(0.3)50(2.0)78(3.1)5(0.2)

335

(13.2)8(0.3)50(2.0)78(3.1)5(0.2)

335

(13.2)8(0.3)50(2.0)78(3.1)5(0.2)

Weight

kg (lb)

(9)

(11)

(18)

(20)

Table 2.6 Dimensions for IP00/Open Type Enclosure: 200 V Class

Model Figure

2A0035 1

2A0053 1

2A0073 2

2A0105 2

32 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

W H D W1 H1 H2 D1 t1 d

275

(10.8)

325

(12.8)

450

(17.7)

500

(19.7)

450

(17.7)

550

(21.7)

705

(27.8)

800

(31.5)

258

(10.2)

283

(11.1)

330

(13.0)

350

(13.8)

Dimensions mm (in)

220

(8.7)

260

(10.2)

325

(12.8)

370

(14.6)

435

(17.1)

535

(21.1)

680

(26.8)

773

(30.4)

7.5

(0.3)

7.5

(0.3)

12.5

(0.5)

100

(3.9)

110

(4.3)

130

(5.1)

130

(5.1)

2.3

(0.1)

2.3

(0.1)

3.2

(0.1)

4.5

(0.2)

M10

M12

Weight

kg (lb)

(46)

(73)

(137)

(179)

2.2 Mechanical Installation

Mechanical Installation

Table 2.7 Dimensions for IP00/Open Type Enclosure: 400 V Class

Model Figure

4A0035 1

4A0043 1

4A0053 1

4A0073 1

4A0105 2

4A0150 2

4A0210 2

4A0300 2

Dimensions mm (in)

W H D W1 H1 H2 D1 t1 d

275

(10.8)

275

(10.8)

325

(12.8)

325

(12.8)

450

(17.7)

450

(17.7)

500

(19.7)

500

(19.7)

450

(17.7)

450

(17.7)

550

(21.7)

550

(21.7)

705

(27.8)

705

(27.8)

800

(31.5)

800

(31.5)

258

(10.2)

258

(10.2)

283

(11.1)

283

(11.1)

330

(13.0)

330

(13.0)

350

(13.8)

350

(13.8)

220

(8.7)

220

(8.7)

260

(10.2)

260

(10.2)

325

(12.8)

325

(12.8)

370

(14.6)

370

(14.6)

435

(17.1)

435

(17.1)

535

(21.1)

535

(21.1)

680

(26.8)

680

(26.8)

773

(30.4)

773

(30.4)

7.5

(0.3)

7.5

(0.3)

7.5

(0.3)

7.5

(0.3)

12.5

(0.5)

12.5

(0.5)

100

(3.9)

100

(3.9)

110

(4.3)

110

(4.3)

130

(5.1)

130

(5.1)

130

(5.1)

130

(5.1)

2.3

(0.1)

2.3

(0.1)

2.3

(0.1)

2.3

(0.1)

3.2

(0.1)

3.2

(0.1)

4.5

(0.2)

4.5

(0.2)

M10

M12

Weight

kg (lb)

(44)

(73)

(137)

(190)

(192)

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 33

2.2 Mechanical Installation

34 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

Electrical Installation

This chapter explains proper procedures for wiring the control circuit terminals, motor, and power supply.

3.1 SECTION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.2 STANDARD CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

3.3 MAIN CIRCUIT CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.4 TERMINAL BLOCK CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.5 TERMINAL COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

3.6 DIGITAL OPERATOR AND FRONT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

3.7 TOP PROTECTIVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.8 MAIN CIRCUIT WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3.9 CONTROL CIRCUIT WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

3.10 CONTROL I/O CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.11 WIRING CHECKLIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 35

3.1 Section Safety

DANGER

W ARNING

3.1 Section Safety

Electrical Shock Hazard

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

Failure to comply will result in death or serious injury.

Electrical Shock Hazard

Do not operate equipment with covers removed.

Failure to comply could result in death or serious injury.

The diagrams in this section may show units without covers or safety shields to show details. Be sure to reinstall covers

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

The regenerative unit can cause a residual current with a DC component in the protective earthing conductor.

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

Failure to comply could result in death or serious injury.

Remove all metal objects such as watches and rings, secure loose clothing, and wear eye protection before beginning work on the unit.

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

Failure to comply could result in death or serious injury.

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

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 this equipment.

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

Failure to comply could result in death or serious injury.

Before wiring terminals, disconnect all power to the equipment. The internal capacitor remains charged even after the power supply is turned off. After shutting off the power, wait for at least the amount of time specified on the unit before touching any components.

Fire Hazard

Tighten all terminal screws to the specified tightening torque.

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

36 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

3.1 Section Safety

Electrical Installation

CAUTION

NOTICE

W ARNING

Do not use improper combustible materials.

Failure to comply could result in death or serious injury by fire.

Do not install the unit to a combustible surface. Never place combustible materials on the unit.

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 unit matches the voltage of the incoming power supply before applying power.

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

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

Crush Hazard

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

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

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

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

Do not use unshielded cable for control wiring.

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

Do not modify the unit circuitry.

Failure to comply could result in damage to the unit and will void warranty.

Yaskawa is not responsible for any modification of the product made by the user. This product must not be modified.

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

Failure to comply could result in damage to the unit.

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

Failure to comply could result in damage to the regenerative unit.

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 37

3.2 Standard Connection Diagram

Connect the regenerative unit and peripheral devices as shown in Figure 3.1. It is possible to set and run the regenerative unit via the digital operator without connecting digital I/O wiring. This section does not discuss regenerative unit operation; Refer to Start-Up Programming & Operation on page 67 for instructions on operating the regenerative unit. Refer to Drive Connection Example on page 77 for connection with a drive.

WARNING! Sudden Movement Hazard. Ensure start/stop and safety circuits are wired properly and in the correct state before energizing the regenerative unit. Failure to comply could result in death or serious injury from moving equipment.

NOTICE: If unsuitable wiring is performed, the regenerative unit could be damaged. Implement protection for branches and short-circuits according to all national and local standards.

NOTICE: Do not connect AC control circuit ground to regenerative unit enclosure. Improper grounding can cause control circuit malfunction.

NOTICE: The minimum load for the relay outputs M1-M2, M3-M4, M5-M6 and MA-MB-MC is 10 mA.

NOTICE: When installing a noise filter on the regenerative unit power supply, use a reactor-type noise filter (without a capacitor), such

as a zero phase reactor, and install it after the MCCB on the power supply side. Do not install a filter with a built-in capacitor as the harmonic components may cause the capacitor to overheat or may damage the capacitor.

NOTICE: When installing a breaker or contactor on the regenerative unit side for an emergency shutoff, confirm that the CHARGE indicators on the drive and regenerative unit are not lit before closing the breaker or contactor on the regenerative unit output (DC) side. If the power supply is turned on while there is a voltage charge, an overcurrent will flow and the device may be damaged. Always confirm that the breaker or contactor on the regenerative unit output (DC) side is turned on before applying power to the regenerative unit.

38 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

Electrical Installation

Power Coordinating Reactor

<1>

Current Suppression Reactor

<1>

Fuse

<1>

R/L1

S/L2

T/L3

Drive

Regenerative Unit

U/T1

V/T2

W/T3

Motor

R1000

E(G)

Shield ground terminal

Forced operation command

Automatic operation command

External fault

Fault reset

(Reserved)

External Baseblock

Multi-function digital inputs (default setting)

ThreePhase Power Supply

GFCI or MCCB

<4>

CN5-A

CN5-B

CN5-C

Option card connectors

MEMOBUS/ Modbus Communication RS-422/RS-485 max. 115.2 kbps

Termination resistor (120 Ω, 1/2 W)

DIP Switch S2

R+

R-

S+

S-

(Reserved)

<2>

<5>

<3>

<5>

Control

Circuit

Ground

DIP Switch S1

shielded line main circuit terminal

twisted-pair shielded line control circuit terminal

E (G)

Multi-function analog output 1 (Power Supply Side Power)

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

Multi-function analog output 2 (Power Supply Side Current)

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

<7>

-V

Power supply +10.5 Vdc, max. 20 mA

Power supply, -10.5 Vdc, max. 20 mA

Analog Input 1

Analog Input 2

Analog Input 3

R/L1

S/L2

T/L3

r1/ 11

t1/

Ground

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

Multi-function relay output (Operation Ready) 250 Vac, max. 1 A 30 Vdc, max. 1 A (min. 5 Vdc, 10 mA)

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

Multi-function relay output (During MC on)

<3>

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

Sink

+24 V

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

<6>

YAI

3.2 Standard Connection Diagram

Figure3.1

<1> Use the specified AC reactor and fuse. Non-specified devices may cause erroneous operation. <2> Always take the power supply for the drive’s AC power supply terminals (R/L1, S/L2, and T/L3) from the secondary side of the

power coordinating reactor.

<3> Always take the power supply for the unit’s power supply voltage detection inputs (r1/ 11, 1/ 21, and t1/ 31) from the primary

side of the power coordinating reactor. <4> Do not use a DC bus line that is longer than 5 m (16.4 ft) to connect the regenerative unit and drive. <5> Do not use a line longer than 10 m (32.8 ft) to connect the power coordinating reactor and the regenerative unit. <6> This figure shows an example of a sequence input to S1 through S8 using a non-powered relay or an NPN transistor. Install the wire

link between terminals SC-SP for Sink mode and SC-SN for Source mode. Leave it out for external power supply. Never short terminals SP and SN as doing so will damage the regenerative unit.

<7> Multi-function analog outputs work with devices such as analog frequency meters, ammeters, voltmeters, and wattmeters. They are

not intended for use as a feedback-type signal.

Figure 3.1 Standard Connection Diagram (example: model 2A0007)

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 39

3.3 Main Circuit Connection Diagram

–

Relay

Fuse

Gate

board

Control

board

Operator

Current

sensor

R/L1

S/L2

T/L3

r1/ 11

1/ 21

t1/ 31

YAI

3.3 Main Circuit Connection Diagram

Refer to diagrams in this section when wiring the main circuit of the regenerative unit. Connections may vary based on regenerative unit capacity. The DC power supply for the main circuit also provides power to the control circuit.

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

–

wiring connections could damage the regenerative unit.

◆ 2A03P5 to 2A0053, and 4A03P5 to 4A0073

Figure 3.2

Figure 3.2 Connecting Main Circuit Terminals

◆ 2A0073 to 2A0105, and 4A0105 to 4A0300

Figure 3.3

Gate

board

Relay

24 V

Power

Supply

Fuse

–

R/L1

S/L2

T/L3

r1/ 11

1/ 21

t1/ 31

Current

sensor

Operator

Control

board

Figure 3.3 Connecting Main Circuit Terminals

40 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

3.4 Terminal Block Configuration

Electrical Installation

3.4 Terminal Block Configuration

Refer to the terminal block configuration diagrams in Tab le 3 .1 for the location of the main circuit terminal block.

Table 3.1 Terminal Block Configuration

Model Figure

2A03P5 Figure 3.4

2A0005 Figure 3.4

2A0007 Figure 3.4

2A0010 Figure 3.5

2A0014 Figure 3.5

200 V Class

Models

400 V Class

Models

2A0017 Figure 3.6

2A0020 Figure 3.6

2A0028 Figure 3.6

2A0035 Figure 3.7

2A0053 Figure 3.8

2A0073 Figure 3.10

2A0105 Figure 3.11

4A03P5 Figure 3.4

4A0005 Figure 3.4

4A0007 Figure 3.4

4A0010 Figure 3.5

4A0014 Figure 3.5

4A0017 Figure 3.6

4A0020 Figure 3.6

4A0028 Figure 3.6

4A0035 Figure 3.7

4A0043 Figure 3.7

4A0053 Figure 3.9

4A0073 Figure 3.9

4A0105 Figure 3.10

4A0150 Figure 3.10

4A0210 Figure 3.11

4A0300 Figure 3.11

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 41

3.4 Terminal Block Configuration

YAI

Figure 3.4

Figure 3.4 Main Circuit Terminal Block Configuration (Models 2A03P5 to 2A0007, 4A03P5 to 4A0007)

Figure 3.5

Figure 3.5 Main Circuit Terminal Block Configuration (Models 2A0010, 2A0014, 4A0010, 4A0014)

42 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

Electrical Installation

Figure3.6

YAI

RL1 SL1 TL3

D1000

r1/ℓ11 t1/ℓ31 1/ℓ21

R1000

Figure3.7

3.4 Terminal Block Configuration

Figure 3.6 Main Circuit Terminal Block Configuration (Models 2A0017 to 2A0028, 4A0017 to 4A0028)

Figure3.8

Figure 3.7 Main Circuit Terminal Block Configuration (Models 2A0035, 4A0035, 4A0043)

Figure 3.8 Main Circuit Terminal Block Configuration (Models 2A0053)

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 43

3.4 Terminal Block Configuration

r1/ℓ11 t1/ℓ31 1/ℓ21

R/L1

S/L2

T/L3

r1/ℓ11 t1/ℓ31 1/ℓ21

D1000

R/L1

S/L2

T/L3

r1/ℓ11 t1/ℓ31 1/ℓ21

D1000

R/L1

S/L2

T/L3

D1000

Figure 3.9

Figure 3.9 Main Circuit Terminal Block Configuration (Models 4A0053, 4A0073)

Figure 3.10

Figure 3.11

Figure 3.10 Main Circuit Terminal Block Configuration (Models 2A0073, 4A0105, 4A0150)

r1/ℓ11 t1/ℓ31 1/ℓ21

Figure 3.11 Main Circuit Terminal Block Configuration (Models 2A0105, 4A0210, 4A0300)

44 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

3.5 Terminal Cover

Electrical Installation

YAI

<1>

YAI

3.5 Terminal Cover

Follow the procedure below to remove the terminal cover for wiring and to reattach the terminal cover after wiring is complete.

◆ Models 2A03P5 to 2A0028, 4A03P5 to 4A0028 (IP20/NEMA Type 1)

■ Removing the Terminal Cover

Loosen the terminal cover screw using a #2 Phillips screwdriver. Screw sizes vary by regenerative unit model. Then, push in on the tab located on the bottom of the terminal cover and gently pull forward to remove the terminal cover.

Figure3.12

Figure 3.12 Removing the Terminal Cover on an IP20/NEMA Type 1 Enclosure Model

■ Reattaching the Terminal Cover

Power lines and signal wiring should pass through the opening provided. Refer to Wiring the Main Circuit Terminal on

page 56 and Wiring the Control Circuit Terminal on page 61 for details on wiring.

Reattach the terminal cover after completing the wiring to the regenerative unit and other devices.

<1> Connect ground wiring first, followed by the main circuit, and then wire the control circuit. Power lines and signal wiring

exit through the opening provided.

Figure 3.13 Reattaching the Terminal Cover on an IP20/NEMA Type 1 Enclosure Model

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 45

3.5 Terminal Cover

◆ Models 2A0035 to 2A0105, 4A0035 to 4A0300 (IP00/Open Type enclosure)

■ Removing the Terminal Cover

1. Loosen the screws on the terminal cover, then pull forward on the terminal cover to free it from the regenerative

unit.

Note: Models 2A0073, 2A0105, and 4A0105 to 4A0300 have three mounting screws above the terminal cover.

CAUTION! Do not completely remove the cover screws, just loosen them. If the cover screws are removed completely, the terminal cover may fall off causing an injury. Larger capacity regenerative units have large and heavy terminal covers. Remove and attach these covers with care.

Figure 3.13

Figure 3.14 Removing the Terminal Cover on an IP00/Open Type enclosure Model

■ Reattaching the Terminal Cover

After wiring the terminal board and other devices, double-check connections and reattach the terminal cover. Refer to

Wiring the Main Circuit Terminal on page 56 and Wiring the Control Circuit Terminal on page 61 for details on

wiring.

<1>

<1> Connect ground wiring first, followed by the main circuit, and then wire the control circuit. Power lines and signal wiring

exit through the opening provided.

Figure 3.15 Reattaching the Terminal Cover on an IP00/Open Type enclosure Model

46 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

3.6 Digital Operator and Front Cover

Electrical Installation

Removing

Reattaching

3.6 Digital Operator and Front Cover

NOTICE: Be sure to remove the digital operator prior to opening or reattaching the front cover. Leaving the digital operator plugged into

the regenerative unit when removing the front cover can result in erroneous operation caused by a poor connection. Firmly fasten the front cover back into place before reattaching the digital operator.

Detach the digital operator from the regenerative unit for remote operation or when opening the front cover to install an option card.

◆ Removing/Reattaching the Digital Operator

While pressing on the tab located on the right side of the digital operator, pull the digital operator forward to remove it from the regenerative unit. Insert the digital operator into the opening in the top cover while aligning it with the notches on the left side of the opening. Next, press gently on the right side of the operator until it clicks into place.

Figure3.14

Figure 3.16 Removing/Reattaching the Digital Operator

◆ Removing/Reattaching the Front Cover

■ Removing the Front Cover

Models 2A03P5 to 2A0028, and 4A03P5 to 4A0028

After removing the terminal cover and the digital operator, loosen the screw that affixes the front cover (models 2A03P5 to 2A0007, and 4A03P5 to 4A0007 do not use a screw to affix the front cover). Pinch in on the tabs found on each side of the front cover, then pull forward to remove it from the regenerative unit.

Figure 3.17 Remove the Front Cover (2A03P5 to 2A0028, 4A03P5 to 4A0028)

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 47

3.6 Digital Operator and Front Cover

Free hooks on both sides of the cover

Hook

Front cover installation screw

Models 2A0035 to 2A0105, and 4A0035 to 4A0300

Remove the terminal cover and the digital operator.

2. Loosen the installation screw on the front cover.

3. Use a straight-edge screwdriver to loosen the hooks on each side of the cover that hold it in place.

Figure 3.15

Figure 3.18 Remove the Front Cover (2A0035 to 2A0105, and 4A0035 to 4A0300)

4. Unhook the left side of the front cover then swing the left side towards you as shown in Figure 3.16 until the

Figure 3.16

cover comes off.

Figure 3.19 Remove the Front Cover (2A0035 to 2A0105, and 4A0035 to 4A0300)

■ Reattaching the Front Cover

Models 2A03P5 to 2A0028, 4A03P5 to 4A0028

Reverse the instructions given in Models 2A03P5 to 2A0028, 4A03P5 to 4A0028 (IP20/NEMA Type 1) on page 45 to reattach the front cover. Pinch inwards on the hooks found on each side of the front cover while guiding it back into the regenerative unit. Make sure it clicks firmly into place.

Models 2A0035 to 2A0105, and 4A0035 to 4A0300

Slide the front cover so the hooks on the top connect to the regenerative unit.

Figure 3.17

Figure 3.20 Reattach the Front Cover (2A0035 to 2A0105, and 4A0035 to 4A0300)

2. After connecting the hooks to the regenerative unit, press firmly on the cover to lock it into place.

48 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

3.7 Top Protective Cover

Electrical Installation

Protective Cover Mounting Holes

R1000

3.7 Top Protective Cover

Models 2A03P5 to 2A0028, 4A03P5 to 4A0028 are designed to IP20/NEMA Type 1 specifications with a protective cover on the top. Removing this top protective cover or the bottom conduit bracket from an IP20/NEMA Type 1 enclosure models voids the NEMA Type 1 protection while maintaining IP20 conformity.

◆ Removing and Reattaching the Top Protective Cover

Insert the tip of a straight-edge screwdriver into the small opening located on the front edge of the top protective cover. Gently apply pressure as shown in the figure below to free the cover from the regenerative unit. Insert the two small protruding hooks on the rear side of the top protective cover into the provided mounting holes near the back of the regenerative unit, then press down on the front side of the top protective cover to fasten the cover into place.

Note: Removing the top protective cover or the bottom conduit bracket from an IP20/NEMA Type 1 enclosure drive voids the NEMA

Figure3.18

Type 1 protection while maintaining IP20 conformity.

Figure 3.21 Removing and Reattaching the Top Protective Cover

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 49

3.8 Main Circuit Wiring

This section describes the functions, specifications, and procedures required to safely and properly wire the main circuit in the regenerative unit.

NOTICE: Do not switch the regenerative unit input power supply on and off frequently. Frequently switching the unit on and off shortens the life of the DC bus capacitors, and can cause premature unit failure. For the full performance life, refrain from switching the unit on and off more than once every 30 minutes.

NOTICE: Do not solder the ends of wire connections to the regenerative unit. Soldered wiring connections can loosen over time. Improper wiring practices could result in regenerative unit malfunction due to loose terminal connections.

◆ Main Circuit Terminal Functions

Table 3.2 Main Circuit Terminal Functions

Termi nal Type

400 V Class 4A03P5 to 4A0300

Model

R/L1

S/L2

T/L3

r1/ 11

1/ 21

t1/ 31

–

2A03P5 to 2A0105

Main circuit power supply input

Power supply voltage detection inputs

DC voltage input These terminals input a DC voltage –

For 200 V class: 100 Ω or less

For 400 V class: 10 Ω or less

These are the power supply input terminals that connect to the input reactor.

These terminals are to detect the power supply voltage order and voltage levels.

Grounding terminal 55

Function Page200 V Class

◆ Protecting Main Circuit Terminals

■ Insulation Caps or Sleeves

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

◆ Wire Gauges and Tightening Torque

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

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

temperature within 40°C.

2. Use terminals and when connecting the drive to the regenerative unit.

Consider the amount of voltage drop when selecting wire gauges. Increase the wire gauge when the voltage drop is greater than 2% of motor rated

voltage. Ensure the wire gauge is suitable for the terminal block. Use the following formula to calculate the amount of voltage drop:

Line drop voltage (V) =

Refer to UL Standards Compliance on page 207 for information on UL compliance.

The wire gauges listed inTab le 3 .3 and Ta bl e 3. 4 are Yaskawa recommendations. Refer to local codes for proper wire gauge selections.

+ –

× wire resistance (Ω/km) × wire length (m) × current (A) × 10

-3

50 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

Electrical Installation

■ Three-Phase 200 V Class

Table 3.3 Wire Gauge and Torque Specifications (Three-Phase 200 V Class)

3.8 Main Circuit Wiring

Model Terminal

R/L1,S/L2,T/L3 3.5 3.5 to 14 12 12 to 6 4 4 to 16 M4

–

2A03P5

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 3.5 3.5 to 14 12 12 to 6 4 4 to 16 M4

–

2A0005

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 3.5 3.5 to 14 12 12 to 6 4 4 to 16 M4

–

2A0007

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 5.5 5.5 to 14 10 10 to 6 4 4 to 16 M4

–

2A0010

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 8 8 to 14 8 8 to 6 6 6 to 16 M4

–

2A0014

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 14 14 to 38 8 8 to 1 10 10 to 25 M6

–

2A0017

r1/ 11, 1/ 21,t1/ 31

For Asia <1> For U.S.A. <2>

Recomm.

Gauge

Applicable

Gauge

Recomm.

Gauge

AWG

Applicable

Gauge

AWG

For Europe and China

<3>

Recomm.

Gauge

Applicable

Gauge

3.5 3.5 to 14 12 12 to 6 4 4 to 16 M4

2 2 14 14 2.5 2.5 M3.5

2 2 to 8 12 12 to 8 4 4 to 10 M5

3.5 3.5 to 14 10 10 to 6 4 4 to 16 M4

2 2 14 14 2.5 2.5 M3.5

2 2 to 8 12 12 to 8 4 4 to 10 M5

3.5 3.5 to 14 10 10 to 6 4 4 to 16 M4

2 2 14 14 2.5 2.5 M3.5

3.5 3.5 to 8 10 10 to 8 4 4 to 10 M5

14 14 6 6 16 16 M4

2 2 14 14 2.5 2.5 M3.5

5.5 5.5 to 14 8 8 to 6 4 4 to 16 M6

14 14 6 6 16 16 M4

2 2 14 14 2.5 2.5 M3.5

5.5 5.5 to 14 8 8 to 6 6 6 to 16 M6

14 14 to 38 4 4 to 1 16 16 to 25 M6

2 2 14 14 2.5 2.5 M3.5

5.5 5.5 to 22 8 8 to 4 10 10 to 25 M6

Screw

Size

Tightening

Tor que

Nxm

(lbxin.)

2.1 to 2.3

(18.6 to 20.4)

2.1 to 2.3

(18.6 to 20.4)

0.8 to 1.0

(7.1 to 8.9)

2.0 to 2.5

(17.7 to 22.1)

2.1 to 2.3

(18.6 to 20.4)

2.1 to 2.3

(18.6 to 20.4)

0.8 to 1.0

(7.1 to 8.9)

2.0 to 2.5

(17.7 to 22.1)

2.1 to 2.3

(18.6 to 20.4)

2.1 to 2.3

(18.6 to 20.4)

0.8 to 1.0

(7.1 to 8.9)

2.0 to 2.5

(17.7 to 22.1)

2.1 to 2.3

(18.6 to 20.4)

2.1 to 2.3

(18.6 to 20.4)

0.8 to 1.0

(7.1 to 8.9)

2.0 to 2.5

(17.7 to 22.1)

2.1 to 2.3

(18.6 to 20.4)

2.1 to 2.3

(18.6 to 20.4)

0.8 to 1.0

(7.1 to 8.9)

2.0 to 2.5

(17.7 to 22.1)

3.6 to 4.0

(31.9 to 35.4)

3.6 to 4.0

(31.9 to 35.4)

0.8 to 1.0

(7.1 to 8.9)

5.4 to 6.0

(47.8 to 53.1)

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 51

3.8 Main Circuit Wiring

–

Model Termi nal

R/L1,S/L2,T/L3 14 14 to 38 6 6 to 1 10 10 to 25 M6

2A0020

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 22 22 to 38 4 4 to 1 16 16 to 35 M6

2A0028

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 38 38 to 70 2 2 to 2/0 25 25 to 70 M8

2A0035

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 50 50 to 150 2/0 2/0 to 250 50 50 to 95 M8

2A0053

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 80 80 to 150

2A0073

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 80 × 2P 80 to 325

2A0105

r1/ 11, 1/ 21,t1/ 31

For Asia <1> For U.S.A. <2>

Recomm.

Gauge

Applicable

Gauge

Recomm.

Gauge

AWG

Applicable

Gauge

AWG

For Europe and China

<3>

Recomm.

Gauge

Applicable

Gauge

22 22 to 38 4 4 to 1 16 16 to 25 M6

2 2 14 14 2.5 2.5 M3.5

8 8 to 22 6 6 to 4 10 10 to 25 M6

30 30 to 38 2 2 to 1 25 25 to 35 M6

2 2 14 14 2.5 2.5 M3.5

14 14 to 22 6 6 to 4 16 16 to 25 M6

38 38 to 70 1/0 1/0 to 2/0 35 35 to 70 M8

2 2 to 5.5 14 14 to 10 2.5 2.5 to 6 M4

22 22 4 4 16 16 to 25 M8

80 80 to 150 4/0 4/0 to 250 70 70 to 95 M8

2 2 to 5.5 14 14 to 10 2.5 2.5 to 6 M4

22 22 to 60 3 3 to 2 25 25 to 35 M10

1/0 to 300 70 70 to 150 M12

3/0 to 300 120 120 to 150 M12

125 125 to 150

1/0

3/0

× 2P

2 2 to 5.5 14 14 to 10 2.5 2.5 to 6 M4

60 60 to 150 1/0 1/0 to 300 35 35 to 150 M12

150 × 2P 150 to 325

3/0

300

× 2P

3/0 to 600

300 to 600

95 × 2P

150 × 2P

95 to 240 M12

150 to 240 M12

2 2 to 5.5 14 14 to 10 2.5 2.5 to 6 M4

60 60 to 180 1/0 1/0 to 300 70 70 to 240 M12

Screw

Size

Tightening

Torque

Nxm

(lbxin.)

3.6 to 4.0

(31.9 to 35.4)

3.6 to 4.0

(31.9 to 35.4)

0.8 to 1.0

(7.1 to 8.9)

5.4 to 6.0

(47.8 to 53.1)

3.6 to 4.0

(31.9 to 35.4)

3.6 to 4.0

(31.9 to 35.4)

0.8 to 1.0

(7.1 to 8.9)

5.4 to 6.0

(47.8 to 53.1)

5.4 to 6.0

(47.8 to 53.1)

5.4 to 6.0

(47.8 to 53.1)

1.1 to 1.2

(9.7 to 10.6)

9.0 to 11.0

(79.7 to 97.4)

13.5 to 15.0 (119,5 to

132,8)

13.5 to 15.0 (119,5 to

132,8)

1.1 to 1.2

(9.7 to 10.6)

18.0 to 23.0

(159 to 204)

32.0 to 40.0

(283 to 354)

32.0 to 40.0

(283 to 354)

1.1 to 1.2

(9.7 to 10.6)

32.0 to 40.0

(283 to 354)

32.0 to 40.0

(283 to 354)

32.0 to 40.0

(283 to 354)

1.1 to 1.2

(9.7 to 10.6)

32.0 to 40.0

(283 to 354)

<1> Gauges listed here are for use in Japan. <2> Gauges listed here are for use in the United States. <3> Gauges listed here are for use in Europe and China.

52 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

Electrical Installation

Table 3.4 Three-Phase 400 V Class

3.8 Main Circuit Wiring

Model Terminal

R/L1,S/L2,T/L3 3.5 3.5 to 14 10 10 to 6 4 4 to 16 M4

–

4A03P5

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 3.5 3.5 to 14 10 10 to 6 4 4 to 16 M4

–

4A0005

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 3.5 3.5 to 14 12 12 to 6 4 4 to 16 M4

–

4A0007

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 3.5 3.5 to 14 12 12 to 6 4 4 to 16 M4

–

4A0010

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 3.5 3.5 to 14 10 10 to 6 4 4 to 16 M4

–

4A0014

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 8 8 to 38 10 10 to 1 10 10 to 25 M6

–

4A0017

r1/ 11, 1/ 21,t1/ 31

For Asia <1> For U.S.A. <2>

Recomm.

Gauge

Applicable

Gauge

Recomm.

Gauge

AWG

Applicable

Gauge

AWG

For Europe and China

<3>

Recomm.

Gauge

Applicable

Gauge

3.5 3.5 to 14 12 12 to 6 4 4 to 16 M4

2 2 14 14 2.5 2.5 M3.5

2 2 to 8 12 12 to 10 4 4 to 6 M5

3.5 3.5 to 14 12 12 to 6 4 4 to 16 M4

2 2 14 14 2.5 2.5 M3.5

2 2 to 8 12 12 to 10 4 4 to 6 M5

3.5 3.5 to 14 12 12 to 6 4 4 to 16 M4

2 2 14 14 2.5 2.5 M3.5

2 2 to 8 10 10 4 4 to 6 M5

5.5 5.5 to 14 10 10 to 6 6 6 to 16 M4

2 2 14 14 2.5 2.5 M3.5

3.5 3.5 to 14 10 10 to 6 4 4 to 16 M6

5.5 5.5 to 14 10 10 to 6 6 6 to 16 M4

2 2 14 14 2.5 2.5 M3.5

3.5 3.5 to 14 10 10 to 6 4 4 to 16 M6

14 14 to 38 6 6 to 1 16 16 to 25 M6

2 2 14 14 2.5 2.5 M3.5

5.5 5.5 to 22 8 8 to 6 10 10 to 16 M6

Screw

Size

Tightening

Tor que

Nxm

(lbxin.)

2.1 to 2.3

(18.6 to 20.4)

2.1 to 2.3

(18.6 to 20.4)

0.8 to 1.0

(7.1 to 8.9)

2.0 to 2.5

(17.7 to 22.1)

2.1 to 2.3

(18.6 to 20.4)

2.1 to 2.3

(18.6 to 20.4)

0.8 to 1.0

(7.1 to 8.9)

2.0 to 2.5

(17.7 to 22.1)

2.1 to 2.3

(18.6 to 20.4)

2.1 to 2.3

(18.6 to 20.4)

0.8 to 1.0

(7.1 to 8.9)

2.0 to 2.5

(17.7 to 22.1)

2.1 to 2.3

(18.6 to 20.4)

2.1 to 2.3

(18.6 to 20.4)

0.8 to 1.0

(7.1 to 8.9)

2.0 to 2.5

(17.7 to 22.1)

2.1 to 2.3

(18.6 to 20.4)

2.1 to 2.3

(18.6 to 20.4)

0.8 to 1.0

(7.1 to 8.9)

2.0 to 2.5

(17.7 to 22.1)

3.6 to 4.0

(31.9 to 35.4)

3.6 to 4.0

(31.9 to 35.4)

0.8 to 1.0

(7.1 to 8.9)

5.4 to 6.0

(47.8 to 53.1)

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 53

3.8 Main Circuit Wiring

–

Model Termi nal

R/L1,S/L2,T/L3 8 8 to 38 8 8 to 1 10 10 to 25 M6

4A0020

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 8 8 to 38 8 8 to 1 10 10 to 25 M6

4A0028

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 14 14 to 70 6 6 to 2/0 10 10 to 70 M8

4A0035

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 14 14 to 70 4 4 to 2/0 10 10 to 70 M8

4A0043

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 22 22 to 70 4 4 to 2/0 16 16 to 70 M8

4A0053

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 30 30 to 70 2 2 to 2/0 25 25 to 70 M8

4A0073

r1/ 11, 1/ 21,t1/ 31

For Asia <1> For U.S.A. <2>

Recomm.

Gauge

Applicable

Gauge

Recomm.

Gauge

AWG

Applicable

Gauge

AWG

For Europe and China

<3>

Recomm.

Gauge

Applicable

Gauge

14 14 to 38 6 6 to 1 16 16 to 25 M6

2 2 14 14 2.5 2.5 M3.5

5.5 5.5 to 22 8 8 to 6 10 10 to 16 M6

14 14 to 38 6 6 to 1 16 16 to 25 M6

2 2 14 14 2.5 2.5 M3.5

5.5 5.5 to 22 8 8 to 6 10 10 to 16 M6

14 14 to 70 3 3 to 2/0 16 16 to 70 M8

2 2 to 5.5 14 14 to 10 2.5 2.5 to 6 M4

8 8 to 22 6 6 10 10 to 16 M8

22 22 to 70 2 2 to 2/0 16 16 to 70 M8

2 2 to 5.5 14 14 to 10 2.5 2.5 to 6 M4

14 14 to 22 6 6 10 10 to 16 M8

30 30 to 70 2 2 to 2/0 25 25 to 70 M8

2 2 to 5.5 14 14 to 10 2.5 2.5 to 6 M4

14 14 to 60 6 6 to 4 16 16 to 25 M10

50 50 to 70 1/0 1/0 to 2/0 50 50 to 70 M8

2 2 to 5.5 14 14 to 10 2.5 2.5 to 6 M4

22 22 to 60 4 4 16 16 to 25 M10

Screw

Size

Tightening

Torque

Nxm

(lbxin.)

3.6 to 4.0

(31.9 to 35.4)

3.6 to 4.0

(31.9 to 35.4)

0.8 to 1.0

(7.1 to 8.9)

5.4 to 6.0

(47.8 to 53.1)

3.6 to 4.0

(31.9 to 35.4)

3.6 to 4.0

(31.9 to 35.4)

0.8 to 1.0

(7.1 to 8.9)

5.4 to 6.0

(47.8 to 53.1)

5.4 to 6.0

(47.8 to 53.1)

5.4 to 6.0

(47.8 to 53.1)

1.1 to 1.2

(9.7 to 10.6)

9.0 to 11.0

(79.7 to 97.4)

5.4 to 6.0

(47.8 to 53.1)

5.4 to 6.0

(47.8 to 53.1)

1.1 to 1.2

(9.7 to 10.6)

9.0 to 11.0

(79.7 to 97.4)

5.4 to 6.0

(47.8 to 53.1)

5.4 to 6.0

(47.8 to 53.1)

1.1 to 1.2

(9.7 to 10.6)

18.0 to 23.0

(159 to 204)

5.4 to 6.0

(47.8 to 53.1)

5.4 to 6.0

(47.8 to 53.1)

1.1 to 1.2

(9.7 to 10.6)

18.0 to 23.0

(159 to 204)

54 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

3.8 Main Circuit Wiring

Electrical Installation

Model Terminal

R/L1,S/L2,T/L3 50 50 to 150 2/0 2/0 to 300 50 50 to 150 M10

–

4A0105

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 100 100 to 150 250 250 to 300 95 95 to 240 M12

–

4A0150

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 80 × 2P 80 to 325

–

4A0210

r1/ 11, 1/ 21,t1/ 31

R/L1,S/L2,T/L3 100 × 2P 100 to 325

–

4A0300

r1/ 11, 1/ 21,t1/ 31

For Asia <1> For U.S.A. <2>

Recomm.

Gauge

Applicable

Gauge

Recomm.

Gauge

AWG

Applicable

Gauge

AWG

For Europe and China

<3>

Recomm.

Gauge

Applicable

Gauge

Screw

80 80 to 150 4/0 4/0 to 300 70 70 to 150 M10

2 2 to 5.5 14 14 to 10 2.5 2.5 to 6 M4

38 38 to 150 1 1 to 300 25 25 to 150 M10

150 150 to 325

3/0

× 2P

3/0 to 600 150 150 to 240 M12

2 2 to 5.5 14 14 to 10 2.5 2.5 to 6 M4

60 60 to 150 1/0 1/0 to 300 25 25 to 150 M12

80 × 2P 80 to 325

3/0 × 2P

× 2P

4/0

3/0 to 600

4/0 to 600

95 × 2P

95 to 240 M12

95 to 150 M12

2 2 to 5.5 14 14 to 10 2.5 2.5 to 6 M4

60 60 to 180 2/0 2/0 to 350 95 95 to 240 M12

150 × 2P 150 to 325

250 × 2P

× 2P

400

250 to 600

400 to 600

95 × 2P

120 × 2P

95 to 240 M12

120 to 150 M12

2 2 to 5.5 14 14 to 10 2.5 2.5 to 6 M4

60 × 2P 60 to 180 4/0 4/0 to 350 95 95 to 240 M12

Size

Tightening

Tor que

Nxm

(lbxin.)

18.0 to 23.0

(159 to 204)

18.0 to 23.0

(159 to 204)

1.1 to 1.2

(9.7 to 10.6)

18.0 to 23.0

(159 to 204)

32.0 to 40.0

(283 to 354)

32.0 to 40.0

(283 to 354)

1.1 to 1.2

(9.7 to 10.6)

32.0 to 40.0

(283 to 354)

32.0 to 40.0

(283 to 354)

32.0 to 40.0

(283 to 354)

1.1 to 1.2

(9.7 to 10.6)

32.0 to 40.0

(283 to 354)

32.0 to 40.0

(283 to 354)

32.0 to 40.0

(283 to 354)

1.1 to 1.2

(9.7 to 10.6)

32.0 to 40.0

(283 to 354)

<1> Gauges listed here are for use in Japan. <2> Gauges listed here are for use in the United States. <3> Gauges listed here are for use in Europe and China.

◆ Ground Wiring

Follow the precautions below when wiring the ground for one regenerative unit or a series of regenerative units.

WARNING! Electrical Shock Hazard. 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.

WARNING! Electrical Shock Hazard. Be sure to ground the regenerative unit ground terminal (200 V class: ground to 100 Ω or less; 400 V class: ground to 10 Ω or less). Improper equipment grounding could result in death or serious injury by contacting ungrounded electrical equipment.

NOTICE: Do not share the ground wire with other devices such as welding machines or large-current electrical equipment. Improper equipment grounding could result in regenerative unit or equipment malfunction due to electrical interference.

NOTICE: When using more than one regenerative unit, ground multiple regenerative units according to instructions. Improper equipment grounding could result in abnormal operation of regenerative unit or equipment.

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 55

3.8 Main Circuit Wiring

NOTICE: If devices, such as office equipment, that is sensitive to noise are installed in the same location, separate the ground wires

and use independent grounds or noise filters to prevent noise from entering the devices through the ground wire. Otherwise, the office equipment may fail.

Note: 1. Connect the regenerative units to power supply transformers on a 1:1 basis and use independent grounds. Otherwise the regenerative

units or the devices may fail to operate.

2. If other devices are installed in the same location, connect them while observing the grounding standards for each device. Otherwise the regenerative units or the devices may fail to operate.

Do not loop the ground wire of the regenerative unit and the drive.

■

Wiring the Main Circuit Terminal

WARNING! Electrical Shock Hazard. Shut off the power supply to the regenerative unit before wiring the main circuit terminals. Failure

to comply may result in death or serious injury.

Wire the main circuit terminals after the terminal board has been properly grounded.

Main Circuit Connection Diagram

■

Refer to Main Circuit Connection Diagram on page 40 when wiring terminals on the main power circuit of the regenerative unit.

56 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

3.9 Control Circuit Wiring

Electrical Installation

YAI

3.9 Control Circuit Wiring

NOTICE: Do not connect AC control circuit ground to regenerative unit enclosure. Improper regenerative unit grounding can cause

control circuit malfunction.

Figure3.19

Regenerative Unit

R1000

Option card connectors

CN5-C

CN5-B

CN5-A

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

M1 M2

Multi-function digital inputs (default setting)

Forced operation command

Automatic operation command

External fault

Fault reset

(Reserved)

External Baseblock

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

(Reserved)

MEMOBUS/ Modbus Communication RS-422/RS-485 max. 115.2 kbps

<1>

Control

Circuit

Sink

SC SP

+24 V

E(G)

Shield ground terminal

Power supply +10.5 Vdc,

max. 20 mA

Analog Input 1

Analog Input 2

Analog Input 3

A3 AC

Power supply, -10.5 Vdc,

-V

R+

R-

S+

S-

max. 20 mA

<2>

Termination resistor

（120 Ω，1/2 W）

DIP Switch S2

Multi-function relay output 1 (Operation Ready) 250 Vac, max. 1A 30 Vdc, max. 1 A (min. 5 Vdc, 10 mA)

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

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

<2>

DIP Switch S1

ＶＩ

<3>

<4>

M3 M4

<1>

M5 M6

MB MC

E(G)

Multi-function analog output 1 (Power Supply Side Power)

0 to +10 Vdc

Multi-function analog output 2 (Power Supply Current)

0 to +10 Vdc

<5>

shielded line

main circuit terminal

twisted-pair shielded line control circuit terminal

Figure 3.22 Control Circuit Wiring

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 57

3.9 Control Circuit Wiring

<1> The default setting is for Sinking Mode. Control is possible with no-voltage contacts or NPN transistors. For details, refer to

Control I/O Connections on page 63.

<2> The maximum output current capacity for the +V and -V terminals on the control circuit is 20 mA. Never short terminals +V, -V,

and AC, as it can cause erroneous operation or damage the regenerative unit.

<3> Set DIP switch S1 to select between a voltage or current input signal to terminal A2. The default setting is for current input. For

details, refer to

Terminal A2 Input Signal Selection on page 63.

<4> Set DIP switch S2 to the ON position to enable the termination resistor in a MEMOBUS/Modbus network. <5> Monitor outputs work with devices such as analog frequency meters, ammeters, voltmeters, and wattmeters. They are not intended

for use as a feedback-type signal.

◆ Control Circuit Terminal Block Functions

Parameters determine which functions apply to the multi-function digital inputs (S1 to S8), multi-function relay outputs (M1, M2, M3, M4, M5, M6), and multi-function analog monitor outputs (FM, AM). The default setting is listed next to each terminal name in Tab le 3 .5.

NOTICE: Install an MC on the power supply side of the regenerative unit when the drive should not automatically restart after power loss. To get the full performance life out of the electrolytic capacitors and circuit relays, refrain from switching the power supply off and on more than once every 30 minutes. Frequent use can damage the regenerative unit.

■ Input Terminals

Tab le 3 .5 lists the input terminals on the regenerative unit. Text in parenthesis indicates the default setting for each

multi-function input.

Table 3.5 Control Circuit Input Terminals

Typ e No. Terminal Name (Function)

S1 Multi-function input 1 (Forced operation command)

S2 Multi-function input 2 (Automatic operation command)

S3 Multi-function input 3 (External fault)

S4 Multi-function input 4 (Fault reset)

S5 Multi-function input 5 (Reserved)

S6 Multi-function input 6 (Reserved)

Multi-Function Digital Inputs

S7 Multi-function input 7 (Reserved)

S8 Multi-function input 8 (External Baseblock)

SC Multi-function input common

SP Digital input power supply +24 Vdc 24 Vdc power supply for digital inputs,

SN Digital input power supply 0 V

Function (Signal Level)

Default Setting

• Photocoupler

•24 Vdc, 8 mA

• Set the S3 jumper to select between sinking, sourcing mode, and the power supply. Refer to Control I/O

Connections on page 63.

150 mA max (only when not using digital input option DI-A3)

NOTICE: Do not jumper or short terminals SP and SN. Failure to comply will damage the regenerative unit.

Page

159

58 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

3.9 Control Circuit Wiring

Electrical Installation

Typ e No. Terminal Name (Function)

+V Analog reference input 10.5 Vdc (max allowable current 20 mA) –

-V Analog reference input -10.5 Vdc (max allowable current 20 mA) –

A1 Multi-function analog input 1 (Reserved)

A2 Multi-function analog input 2 (Reserved)

Analog Inputs

A3 Multi-function analog input 3 (Reserved)

AC Frequency reference common 0 V –

E (G) Ground for shielded lines and option cards – –

Function (Signal Level)

Default Setting

-10 to 10 Vdc, 0 to 10 Vdc (input impedance: 20 kΩ)

• -10 to 10 Vdc, 0 to 10 Vdc (input impedance: 20 kΩ)

• 4 to 20 mA, 0 to 20 mA (input impedance: 250 Ω)

• Voltage or current input must be selected by DIP switch S1 and H3-09.

• -10 to 10 Vdc, 0 to 10 Vdc (input impedance: 20 kΩ)

• Use DIP switch S4 on the terminal board to select between analog and PTC input.

Page

161

162

■ Output Terminals

Table 3.6 lists the output terminals on the regenerative unit. Text in parenthesis indicates the default setting for each

multi-function output.

Table 3.6 Control Circuit Output Terminals

Typ e

Fault Relay Output

Multi-Function Relay Output <1>

Monitor Output

<1> Refrain from assigning functions to digital relay outputs that involve frequent switching, as doing so may shorten relay performance life.

Switching life is estimated at 200,000 times (assumes 1 A, resistive load).

No. Terminal Name (Function)

MA N.O. output (Fault)

MC Fault output common

AC Monitor common 0 V –

Multi-function relay output (During MC on)

Multi-function relay output (Operation Ready)

Multi-function relay output (During Run 1)

Analog monitor output 1 (Power Supply Side Power)

Analog monitor output 2 (Power Supply Side Current)

Function (Signal Level)

Default Setting

30 Vdc, 10 mA to 1 A; 250 Vac, 10 mA to 1 A Minimum load: 5 Vdc, 10 mA

-10 to +10 Vdc, or 0 to +10 Vdc 163

Page

160MB N.C. output (Fault)

160

■ Serial Communication Terminals

Table 3.7 Control Circuit Terminals: Serial Communications

Typ e No. Signal Name Function (Signal Level) Page

Communications input (+)

MEMOBUS/

Modbus

Communication

<1>

R+

Communications input (-)

R-

Communications output (+)

S+

Communications output (-)

S-

Shield ground 0 V

MEMOBUS/Modbus communication: Use an RS-422 or RS-485 cable to connect the regenerative unit.

RS-422/RS-485 MEMOBUS/Modbus communication protocol

115.2 kbps (maximum)

178

<1> Enable the termination resistor in the last regenerative unit in a MEMOBUS/Modbus network by setting DIP switch S2 to the ON position.

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 59

3.9 Control Circuit Wiring

㪤㪘㪤㪙㪤㪚

㪤㪊㪤㪋㪤㪍

㪤㪈㪤㪉㪤㪌

㪛㪤㪄

㪠㪞㪩㪂㪩㪄㪪㪂㪪㪄㪟㪚㪟㪈㪟㪉

㪛㪤㪂

㪜㩿㪞㪀

㪘㪊㪝㪤㪘㪤㪘㪚㪤㪧㪩㪧㪘㪚㪘㪚㪭㪄㪘㪈㪘㪉㪭㪂

㪪㪈㪪㪉㪪㪊㪪㪋㪪㪌㪪㪍㪪㪎㪪㪥㪪㪚㪪㪧

㪪㪏

㪤㪘㪤㪙㪤㪚

㪤㪊㪤㪋㪤㪍

㪤㪈㪤㪉㪤㪌

㪘㪊㪝㪤㪘㪤㪘㪚㪤㪧㪩㪧㪘㪚㪘㪚㪭㪄㪘㪈㪘㪉㪭㪂

㪪㪈㪪㪉㪪㪊㪪㪋㪪㪌㪪㪍㪪㪎㪪㪥㪪㪚㪪㪧

㪪㪏

㪛㪤㪄

㪠㪞㪩㪂㪩㪄㪪㪂㪪㪄㪟㪚㪟㪈㪟㪉

㪛㪤㪂

㪜㩿㪞㪀

YAI

◆ Terminal Configuration

The control circuit terminals are arranged as shown in Figure 3.23.

Figure 3.20

Figure 3.23 Control Circuit Terminal Arrangement

■ Wire Size and Torque Specifications

Select appropriate wire type and gauges from Ta bl e 3. 8.

For simpler and more reliable wiring, use crimp ferrules on the wire ends. Refer to Tabl e 3. 9 for ferrule terminal types and sizes.

Table 3.8 Wire Gauge and Torque Specifications

Bare Wire Terminal Ferrule-Type Terminal

Recomm.

Gauge

(AWG)

0.75 (18)

1.25 (12)

Applicable

Gauge

(AWG)

0.5 to 2

(20 to 14)

0.5 to 2

(20 to 14)

Recomm.

Gauge

(AWG)

Applicable

Gauge

(AWG)

––

Stranded wire:

0.25 to 1.0

0.75 (18)

(24 to 17)

Solid wire:

0.5

(20)

0.25 to 0.5 (24 to 20)

0.25 to 1.5 (24 to 16)

Wire Type

Shielded wire,

etc.

Terminal

FM, AC, AM, SC, SP, SN, A1, A2, A3, +V, -V, S1 to S8, MA,

MB, MC, M1 to M6

E (G) M3.5

IG, R+, R-, S+, S- M2

Screw

Size

M3.5

Tightening

Torque

Nxm

(lbxin.)

0.8 to 1.0

(7.1 to 8.6)

0.8 to 1.0

(7.1 to 8.6)

0.22 to 0.25 (1.9 to 2.2)

60 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

3.9 Control Circuit Wiring

Electrical Installation

–

■ Ferrule-Type Wire Terminals

Yaskawa recommends using CRIMPFOX 6, a crimping tool manufactured by PHOENIX CONTACT, to prepare wire ends with insulated sleeves before connecting to the regenerative unit. See Tab le 3 .9 for dimensions.

Figure3.21

Figure 3.24 Ferrule Dimensions

Table 3.9 Ferrule Terminal Types and Sizes

φd1

φd2

6 mm

Size

(AWG)

Typ e

(mm)

Manufacturer

0.25 (24) AI 0.25–6YE 10.5 0.8 2

PHOENIX CONTACT0.34 (22) AI 0.34–6TQ 10.5 0.8 2

0.5 (20) AI 0.5–6WH 14 1.1 2.5

◆ Wiring the Control Circuit Terminal

This section describes the proper procedures and preparations for wiring the control terminals.

WARNING! Electrical Shock Hazard. Do not remove covers or touch the circuit boards while the power is on. Failure to comply could result in death or serious injury.

NOTICE: Separate control circuit wiring from main circuit wiring (terminals R/L1, S/L2, T/L3, r1/ 11, 1/ 21, t1/ 31, , ) and other high-power lines. Improper wiring practices could result in regenerative unit malfunction due to electrical interference.

NOTICE: Separate wiring for digital output terminals MA, MB, MC, M1 to M6 from wiring to other control circuit lines. Improper wiring practices could result in regenerative unit or equipment malfunction or nuisance trips.

NOTICE: Use a class 2 power supply (UL standard) when connecting to the control terminals. Improper application of peripheral devices could result in regenerative unit performance degradation due to improper power supply.

NOTICE: Insulate shields with tape or shrink tubing to prevent contact with other signal lines and equipment. Improper wiring practices could result in regenerative unit or equipment malfunction due to short circuit.

NOTICE: Connect the shield of shielded cable to the appropriate ground terminal. Improper equipment grounding could result in regenerative unit or equipment malfunction or nuisance trips.

Wire the control circuit only after terminals have been properly grounded and main circuit wiring is complete. Prepare the ends of the control circuit wiring as shown in Figure 3.25. Refer to Figure 3.27 for the treatment of the ends of the shield wire.

NOTICE: Do not tighten screws beyond the specified tightening torque. Failure to comply may result in erroneous operation, damage to the terminal block, or cause a fire.

NOTICE: Use shielded twisted-pair cables as indicated to prevent operating faults. Failure to comply may cause electrical interference resulting in poor system performance due to improper wiring practices. Use shielded, twisted-pair cables and ground the shield to the shield ground terminal E (G) of the regenerative unit.

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 61

3.9 Control Circuit Wiring

Preparing wire terminal ends

YAI

Connect control wires as shown in Figure 3.25 and Figure 3.26.

Figure 3.22

A – Loosen screw to insert wire. C – Avoid fraying wire strands when

B – Single wire or stranded wire D – Blade depth of 0.4 mm or less

Figure 3.25 Terminal Board Wiring Guide

Figure 3.23

stripping insulation from wire. Strip length 5.5 mm.

E – Blade width of 2.5 mm or less

Figure 3.26 Terminal Board Location Inside the Regenerative Unit

For the control circuit wires, use shielded twisted-pair wires that have been prepared as shown in Figure 3.27.

Figure 3.24

A – Regenerative unit side D – Shield sheath (insulate with tape) B – Insulation E – Shield C – Control device side

Figure 3.27 Preparing the Ends of Shielded Cables

NOTICE: The analog signal wiring between the regenerative unit and the operator station or peripheral equipment should not exceed

50 meters when using an analog signal from a remote source. Failure to comply could result in poor system performance.

62 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

3.10 Control I/O Connections

Electrical Installation

YAI

24 Vdc

YAI

24 Vdc

External

24 Vdc

YAI

DIP switch S1

3.10 Control I/O Connections

Use the wire jumper between terminals SC and SP or SC and SN to select between Sink mode, Source mode or external power supply for the digital inputs S1 to S8 as shown in Tab le 3 .1 0 (Default: Sink mode, internal power supply).

Note: Never short terminals SP and SN as doing so will damage the regenerative unit.

Table 3.10 Digital Input Sink / Source / External Power Supply Selection

Sinking Mode (NPN)

Sourcing Mode (PNP)

Regenerative Unit Internal Power Supply

(Terminal SN and SP)

24 Vdc

External 24 Vdc Power Supply

Vdc

External

Vdc

◆ Terminal A2 Input Signal Selection

Terminal A2 can be used to input either a voltage or a current signal. Select the signal type using switch S1 as explained in Tab le 3 .11 . Set parameter H3-09 accordingly as shown in Tab le 3. 12 . Refer to Figure 3.28 for locating switch S1.

To set the DIP switch, use tweezers or a tool with a tip width of approximately 0.8 mm.

Figure3.25

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 63

Figure 3.28 DIP Switch S1

3.10 Control I/O Connections

YAI

Setting Description

V (left position) Voltage input (-10 to +10 V or 0 to 10 V)

I (right position) Current input (4 to 20 mA or 0 to 20 mA): default setting

Table 3.11 DIP Switch S1 Settings

Table 3.12 Parameter H3-09 Details

No. Parameter Name Description

Selects the signal level for terminal A2. 0: 0 to 10 Vdc

H3-09 Terminal A2 signal level selection

1: -10 to 10 Vdc 2: 4 to 20 mA 3: 0 to 20 mA

◆ Using the Contact Outputs

Figure 3.29 illustrates the use of multi-function relay outputs and the fault relay outputs.

Figure 3.26

Relay

Controller

Max 250 Vac

Relay

Regenerative Unit

Fault relay output <1> 250 Vac, max. 1 A 30 Vdc, max. 1 A

Multi-function relay output <1> 250 Vac, max. 1 A 30 Vdc, max. 1 A

Fault

Through mode

Setting

Range

Default Setting

0 to 3 2

<1> Minimum load: 5 Vdc, 10 mA

Figure 3.29 Contact Outputs

64 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

3.10 Control I/O Connections

Electrical Installation

◆ Connect to a PC

This regenerative unit is equipped with a USB port (type-B). The regenerative unit can connect to a USB port on a PC using a USB 2.0, AB-type cable (sold separately). After connecting the regenerative unit to a PC, Yaskawa DriveWizard Industrial software can be used to monitor regenerative unit performance and manage parameter settings. Contact Yaskawa for more information on DriveWizard Industrial.

Figure3.27

USB Cable

(Type-AB)

(Type-B) (Type-A)

Figure 3.30 Connecting to a PC (USB)

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 65

3.11 Wiring Checklist

No. Item Page

Regenerative Unit, Peripherals, Option Cards

1 Check regenerative unit model number to ensure receipt of correct model. 19

2 Make sure you have the correct peripheral devices. –

3 Check the option card model number. –

Installation Area and Physical Setup

4 Ensure that the area surrounding the regenerative unit complies with specifications. 25

Power Supply Voltage, Output Voltage

The voltage from the power supply should be within the input voltage specification range of the

regenerative unit.

6 The total load must be within the output specifications of the regenerative unit. 20

A power supply with a capacity (kVA) that is larger than the rated input capacity of the regenerative

unit must be used.

8 The ratings must be correct. 20

Main Circuit Wiring

9 Confirm proper branch circuit protection as specified by national and local codes. –

–

10 Properly wire the regenerative unit. 41

11 Suitable wires must be used to wire the power supply and regenerative unit. 50

12 Properly ground the regenerative unit. Review page 55. 55

Tighten control circuit and grounding terminal screws.

Refer to Wire Gauges and Tightening Torque on page 50

Control Circuit Wiring

14 Use twisted-pair line for all regenerative unit control circuit wiring. 61

Ground the shields of shielded wiring to the GND terminal.

16 Properly wire any option cards. –

17 Check for any other wiring mistakes. Only use a multimeter to check wiring. –

Properly fasten regenerative unit control circuit terminal screws. Refer to Wire Size and Torque

Specifications on page 60.

19 Pick up all wire clippings. –

20 Ensure that no frayed wires on the terminal block are touching other terminals or connections. –

21 Properly separate control circuit wiring and main circuit wiring. –

The line between the input-side AC reactor and regenerative unit must be 10 m or shorter and the DC

bus line between the regenerative unit and drive must be 5 m or shorter.

–

66 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

Start-Up Programming & Operation

This chapter explains the functions of the digital operator and how to program the regenerative unit for initial operation.

4.1 SECTION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4.2 USING THE DIGITAL OPERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

4.3 THE DRIVE AND PROGRAMMING MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

4.4 POWERING UP THE REGENERATIVE UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4.5 OPERATION WITH THE DRIVE CONNECTED . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.6 VERIFYING PARAMETER SETTINGS AND BACKING UP CHANGES . . . . . . . . 80

4.7 TEST RUN CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 67

4.1 Section Safety

DANGER

W ARNING

4.1 Section Safety

Electrical Shock Hazard

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

Failure to comply will result in death or serious injury.

Electrical Shock Hazard

Do not operate equipment with covers removed.

Failure to comply could result in death or serious injury.

The diagrams in this section may show units without covers or safety shields to show details. Be sure to reinstall covers or shields before operating the unit and run the unit according to the instructions described in this manual.

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

Failure to comply could result in death or serious injury.

68 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

4.2 Using the Digital Operator

Start-Up Programming &

Operation

AC Current (OPR)

U1-55= 0A

123

U1-57= 0kW U1-58= 0.0Hz

- MODE -

DRV

Rdy

RSEQ

LREF

YAI

4.2 Using the Digital Operator

Use the digital operator to enter Run and Stop commands, edit parameters, and display data including fault and alarm information.

◆ LCD Display

Figure4.1

Table 4.1 Display and Contents

No. Name Display Content

MODE Displayed when in Mode Selection.

MONITR Displayed when in Monitor Mode.

1 Operation Mode Menus

2 Mode Display Area

3 Ready Rdy Indicates the regenerative unit is ready to run.

4 Data Display – Displays specific data and operation data.

DC Bus Voltage

Feedback Reference

Assignment

LO/RE

Display

Function Key 1

<1>

<2>

(F2)

VERIFY Indicates the Verify Menu.

PRMSET Displayed when in Parameter Setting Mode.

SETUP Displayed when in Setup Mode.

DRV Displayed when in Drive Mode.

PRG Displayed when in Programming Mode.

OPR

AI Displayed when the DC bus voltage feedback Reference is assigned to the Analog Input.

COM

RSEQ Displayed when the reference is supplied from a remote source.

LSEQ Displayed when the reference is supplied from the operator keypad.

RREF Displayed when the frequency reference is supplied from a remote source.

LREF Displayed when the frequency reference is supplied from the operator keypad.

HELP

←

HOME

ESC

Displayed when the DC bus voltage feedback Reference is assigned to the LCD Operator Option.

Displayed when the DC bus voltage feedback Reference is assigned to the MEMOBUS/Modbus Communication Inputs.

Displayed when the DC bus voltage feedback Reference is assigned to a Option regenerative unit.

Pressing displays the Help menu.

Pressing scrolls the cursor to the left.

Pressing returns to the top menu (DC bus voltage feedback Reference).

Pressing returns to the previous display.

Figure 4.1 LCD Display

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 69

4.2 Using the Digital Operator

No. Name Display Content

DATA

Function Key 2

(F1)

→

RESET

Pressing scrolls to the next display.

Pressing scrolls the cursor to the right.

Pressing resets the existing regenerative unit fault or error.

<1> Displayed when in DC bus voltage feedback Reference Mode. <2> Displayed when in DC bus voltage feedback Reference Mode and Monitor Mode.

◆ ALARM (ALM) LED Displays

Table 4.2 ALARM (ALM) LED Status and Contents

State Content Display

Illuminated When the regenerative unit detects a fault.

Flashing

• When an alarm occurs.

• When oPE is detected.

Off Normal operation (no fault or alarm).

◆ LO/RE LED and RUN LED Indications

Table 4.3 LO/RE LED and RUN LED Indications

LED Lit Flashing Off

When source of the Run command is assigned to the digital operator

–

(LOCAL)

RUN

During run Stopped for an operation interlock.

Examples

<1> The indicator flashes in the following cases:

x When REMOTE operation is restored after inputting a Run command from an external terminal during LOCAL operation. x A Run command was input from an external terminal in any mode other than Drive Mode. x The STOP key on the digital operator was pressed during REMOTE operation.

When a device other than the operator is selected for Run command control (REMOTE)

<1> During stop

70 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

Start-Up Programming &

Operation

◆ Menu Structure for Digital Operator

- MODE -

U1-55= 0A

U1-57= 0kW U1-58= 0.0Hz

DRV

AC Current (OPR)

Rdy

<3>

<1>

- MODE -

U1-55= 0A

U1-57= 0kW U1-58= 0.0Hz

DRV

Monitor Menu

Rdy

- MODE - PRG

Modified Consts

HELP

DATA

- MODE - PRG

Quick Setting

DATA

HELP

- MODE - PRG

DATA

Programming

-MONITR-

U1 -55= 0A

U1-57= 0kW U1-58= 0.0Hz

DRV

Monitor

Rdy -MONITR-

U1- 55 = 0A

U1-57= 0kW U1-58= 0.0Hz

DRV

AC Current

Rdy

-MONITR-

U1-58= 0.0Hz U1-72=

00000000

DRV

AC Power

Rdy

-MONITR-

U2 -01= oC

U2-02= oPr U2-11=

00000000

DRV

Fault Trace

Rdy

Modified

X Parameters

RSEQ LREF

YASKAWA

R1000

XXXV, X.XkW

XX.XXA

Initial Display

<4>

<5>

<2>

U1- 57

= 0kW

4.2 Using the Digital Operator

<1> Pressing will start the regenerative unit operation. <2> Flashing characters are shown as . <3> “X” characters are used as examples in this manual. The LCD Operator will display the actual setting values. <4> The DC bus voltage feedback reference appears after the initial display that shows the product name. <5> The information that appears on the display will vary depending on the regenerative unit.

Figure 4.2 Digital Operator Menu and Screen Structure

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 71

4.3 The Drive and Programming Modes

The regenerative unit has a Drive Mode and a Programming Mode.

Drive Mode: In Drive Mode the user can operate the regenerative unit, monitor operating status (DC bus voltage, DC current reference, etc.).

Programming Mode: In Programming Mode the user can edit and verify parameter settings. When the regenerative unit is in Programming Mode it will not accept a Run command unless b1-08 is set to 1.

◆ Navigating the Drive and Programming Modes (Default Setting)

NOTICE: Check the following items before you turn on the power supply.

• Is the power supply voltage correct? 200 V Class: 200 to 240 Vac 50/60 Hz 400 V Class: 380 to 480 Vac 50/60 Hz

• Are the regenerative unit and the control devices connected properly (e.g., is the phase order correct)?

• Is the phase order correct between the main circuit terminals (R/L1, S/L2, and T/L3) on the regenerative

unit and the power supply voltage detection terminals (r1/ 11, 1/ 21, and t1/ 31).

• Are the control circuit terminals on the regenerative unit connected properly to the control devices?

• Are the Run Commands for the regenerative unit and the control devices turned off?

The regenerative unit is set to operate in Drive Mode when it is first powered up. Switch between display screens by using the and keys.

Drive Mode Details

■

The following actions are possible in the Drive Mode:

• Run and stop the regenerative unit

• Monitor the operation status of the regenerative unit (DC bus voltage feedback, Power Supply Side Voltage, Power supply side current, etc.)

• View information on an alarm

• View a history of alarms that have occurred

Note: The regenerative unit must be in Drive Mode to operate. Change to another mode when the regenerative unit is stopped.

■ Programming Mode Details

The following actions are possible in the Programming Mode:

• Verify Mode: View a list of parameters that have been changed from the default values.

• Setup Mode: Access a list of commonly used parameters to simplify setup. Refer to Setup Group Parameters on

page 72.

• Parameter Setting Mode: Access and edit all parameter settings.

Setup Group Parameters

Parameters most likely to be changed are assigned to the group of User Parameters, A2-01 through A2-32. User Parameters are part of the Setup Group, which provides quicker access by eliminating the need to scroll through multiple menus.

Tab le 4 .4 lists the default settings of the A2- parameters.

Note: Parameter b1-02 is displayed in Setup Mode regardless of A2- parameter settings.

Table 4.4 Setup Group Parameters

A2- Default Name

A2-01 b1-02 Run Command Selection 1

A2-02 b1-21 Operator Operation Mode

72 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

4.3 The Drive and Programming Modes

Start-Up Programming &

Operation

- MODE - PRG

Programming

←→

-PRMSET-

Sequence

Run Source 1

PRG

b1-02=1

-PRMSET-

b1-02=1 *1*

Digital Inputs

PRG

Run Source 1

←→

-PRMSET-

b1-02=0 *0*

Operator

PRG

Run Source 1

- MODE -

U1-51= 330V

U1-52= 330V U1-03= 0.00A

DRV

Volt Ref(OPR)

Rdy

RSEQ LREF

◆ Changing Parameter Settings or Values

This example explains changing b1-02 (Run Command Selection) from 01 to 00.

Step Display/Result

1. Turn on the power to the regenerative unit. The initial display appears.

Press the or key until the Parameter Setting Mode screen appears.

- MODE -

AC Current

U1-55= 0A

U1-57= 0kW U1-58=0.0Hz

DRV

Rdy

RSEQ RREF

Press the key to enter the parameter menu tree.

Press or key to select the B parameter group.

Press two times.

Press to view the current setting value (1). “1” Flashes.

Press the key and enter 0.

-PRMSET-

A1-00=0

PRG

Initialization

Select Language

←→

-PRMSET-

b1-02=1

PRG

Sequence

Run Source 1

←→

-PRMSET-

PRG

Run Source 1

b1-02=1 *1* Digital Inputs

“1”

←→

-PRMSET-

PRG

Run Source 1

b1-02=1 *1* Digital Inputs

“1”

←→

Press and the regenerative unit will confirm the change.

9. The display automatically returns to the screen shown in Step 4.

10.

Press the key until back at the initial display.

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 73

Entry Accepted

4.3 The Drive and Programming Modes

- MODE -

U1-55= 0A

U1-57= 0kW U1-58=0.0Hz

DRV

AC Current

Rdy

RSEQ RREF

b1-02 = 0 *0*

Operator

- VERIFY -

PRG

Run Source 1

Rdy

Home DATA

b1-02 = 0 *0*

Operator

“1”

- VERIFY - PRG Run Source 1

Rdy

Home

DATA

YAI

LO RE

F2F1

ESC

RUN STOP

ENTERRESET

ALM

DIGITAL OPERATOR JVOP-180

- MODE -

U1-55= 0A

U1-57= 0kW U1-58=0.0Hz

DRV

AC Current

Rdy

RSEQ RREF

YAI

◆ Verifying Parameter Changes: Verify Mode

The Verify Mode lists edited parameters from the Programming Mode. The Verify Mode helps determine which settings have been changed, and is particularly useful when replacing a regenerative unit. If no settings have been changed, the Verify Mode will read “None”. The Verify Mode also allows users to quickly access and re-edit any parameter settings that have been changed.

Note: A1-, and A2-01 to A2-32 are not displayed even when those parameters have been changed from their default values.

Step Display/Result

1. Turn on the power to the regenerative unit. The initial display appears.

- MODE - PRG

Press or until the display shows the top of the Verify Menu.

Press to enter the list of parameters that have been edited from their original

default settings.

If parameters other than b1-02 have been changed, use the or key to scroll

until b1-02 appears.

Modified Consts

Modified

X Parameters

HELP DATA

Press the key to access the setting value.

◆ Switching Between LOCAL and REMOTE

LOCAL mode is when the regenerative unit is set to accept the Run command from the digital operator RUN key. REMOTE mode is when the regenerative unit is set to accept the Run command from an external device.

Switch the operation between LOCAL and REMOTE using the key on the digital operator or via a digital input.

Note: 1. After selecting LOCAL, the LO/RE light will remain lit.

2. The regenerative unit will not allow the user to switch between LOCAL and REMOTE during run.

■ Using the LO/RE Key on the Digital Operator

Step Display/Result

- MODE -

DRV

Rdy

RSEQ RREF

1 Turn on the power to the regenerative unit. The initial display appears.

Press . The LO/RE light will light up. The regenerative unit is now in LOCAL.

To set the regenerative unit for REMOTE operation, press the key again.

AC Current

U1-55= 0A

U1-57= 0kW U1-58=0.0Hz

74 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

4.3 The Drive and Programming Modes

Start-Up Programming &

Operation

■ Using Input Terminals S1 through S8 to Switch between LOCAL and REMOTE

It is possible to switch between LOCAL and REMOTE modes using one of the digital input terminals S1 through S8 (set the corresponding parameter H1- to “1”).

Setting H1- to 1 disables the LO/RE key on the digital operator.

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 75

4.4 Powering Up the Regenerative Unit

–

–+–

YAI

DIGITAL OPERATOR JVOP-180

ALARM

- MODE -

EF3

Ext Fault S3

DRV

RESET

YAI

4.4 Powering Up the Regenerative Unit

◆ Powering Up the Regenerative Unit and Operation Status Display

■ Powering Up the Regenerative Unit

Review the following checklist before turning the power on.

NOTICE: Equipment Damage. Check the following items before applying power to the unit. Failure to comply could result in damage to the regenerative unit.

Item to Check Description

Check the power supply voltage. 200 V class: Three-phase 200 to 240 Vac 50/60 Hz 400 V class: Three-phase 380 to 480 Vac 50/60 Hz

Power supply voltage

Regenerative unit output terminals and drive terminals

Control circuit terminals Properly connect the control circuit terminals on the regenerative unit to other control devices. Regenerative unit control terminal

status Power coordinating reactor, current

suppression reactor, and fuse connections to regenerative unit

Properly wire the power supply input terminals (R/L1, S/L2, and T/L3).

Properly wire the phase order of the power supply input terminals (R/L1, S/L2, and T/L3) and the power supply voltage detection terminals ( ).

r1/ 11, 1/ 21, and t1/ 31

Check for proper grounding of regenerative unit.

Properly connect the DC voltage output terminals ( / ) on the regenerative unit to the DC power supply input terminals ( / ) on the drive. Be particularly careful to correctly connect the and

terminals.

Turn off the Run Commands for the regenerative unit and the peripheral control devices.

Properly connect the Power coordinating reactor, current suppressoin reactor, and fuse to regenerative unit as shown in the Standard Connection Diagram.

■ Status Display

When the power supply to the regenerative unit is turned on, the digital operator lights will appear as follows:

Status Name Description

Normal

Operation

Fault

DIGITAL OPERATOR JVOP-180

- MODE -

U1-55= 0A

U1-57= 0kW U1-58=0.0Hz

Example: External Fault

AC Current

ALARM

DRV

RSEQ RREF

Rdy

The data display area displays the DC bus voltage feedback reference. is lit.

Data displayed varies by the type of fault. Refer to Troubleshooting on page 85 for more information. and are lit.

76 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

4.5 Operation with the Drive Connected

Start-Up Programming &

Operation

OFF

ON OFF

Power supply side voltage

M5-M6 (Operation Ready)

S1(Forced Operation Command

)

S2(Automatic Operation Command

)

M1-M2 (During Run 1)

Drive Run Command

Motor speed

YAI

4.5 Operation with the Drive Connected

◆ Drive Connection Example

Refer to Standard Connection Diagram on page 38 for details.

◆ Timing Chart for Turning the Power Supply On and Off

Figure 4.3 is a timing chart for turning the power supply on and off.

Figure4.2

Observe the following precautions when you perform operation with the regenerative unit connected to the drive.

• After turning on the power supply to the regenerative unit, wait for the Operation Ready signal on the multi-function contact output to turn on and then input the Run Command for the regenerative unit.

• Confirm that the regenerative unit is operating (i.e., confirm that During Run 1 is on) and then turn on the Run Command for the drive.

• To stop the regenerative unit, turn off the Run Command to the drive, confirm that the motor has stopped, and then input the Stop Command.

• Wait for the regenerative unit to stop and the During Run 1 multi-function contact output to turn off, then turn off the power supply.

◆ Operation Command Selection

The automatic operation command and forced operation command are available in the regenerative unit.

Select one of the operation commands according to the application.

Note: Select forced operation command when the motor vibrates during automatic operation.

■ Automatic Operation Command

When the multifunction input terminal S2 (H1-02 = 3D (default setting)) is “closed”, the regenerative unit detects any increase/decrease of the bus voltage and performs an automatic run/stop.

The regenerative unit stops after the minimum operation time set to C7-16 has passed when the bus voltage is less than the acceptable voltage set to the operation start/stop level.

Figure 4.3 Timing Chart for Power ON and Run Command Sequence

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 77

4.5 Operation with the Drive Connected

Run

Drive Status

Regeneration

DC Bus Voltage AC Power Supply Voltage

1.35

Automatic Operation Command

Run

Regenerative

Unit Status

Current at Power

Supply Side

Operation Start Level Operation Stop Level

Stop

Minimum Operation Time (C7-16

)

Figure 4.3

Figure 4.4 Automatic Operation Command Time Chart

■ Forced Operation Command

When the multi-function input terminal S1 (H1-01 = 3C (default setting)) is “closed”, the regenerative unit starts operation. When the terminal S1 is “open”, the regenerative unit stops operation after the minimum operation time has passed.

Note: When forced operation command is selected, use a sequence so that the operation commands of the regenerative unit and the

Figure 4.4

drive are input at the same time.

Drive Status

DC Bus Voltage

Forced Operation Command

Regenerative

Unit Status

Current at Power

Supply Side

Run

Regeneration

AC Power Supply Voltage

1.35

Minimum Operation Time (C7-16

)

Figure 4.5 Forced Operation Command Time Chart

◆ Interlocks

■ Stopping the Regenerative Unit for Faults in Peripheral Devices

If an external device fails or a fault occurs, the fault contact output on the regenerative unit is activated to stop operation. To use an external fault, set H1- (terminal S1 to S8 function selection) to one of the values from Ta bl e 4 .5 . When an external fault is input, EF is displayed on the digital operator. The  in EF is the number of the terminal where the external fault signal was input.

Example: If an external fault signal is input to the S3 terminal, EF3 is displayed.

Select the number to set for H1- according to the combination of the following three conditions:

• Use an input contact for a signal from the peripheral device.

• Use detection of an external fault.

• Stop operation (as the operation selection when an external fault is detected).

78 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

4.5 Operation with the Drive Connected

Start-Up Programming &

Operation

Table 4.5 shows the relationship between the combination of conditions and the set value of H1-.

Table 4.5 Combination of Conditions

Input Contact <1> Detection <2> Operation Selection

Setting Value

25 – {{ – { –

26 { ––{{ –

27 – { – {{ – 2C { – { ––{

2D – {{ ––{

2E { ––{ – {

2F – { – { – {

<1> When using an input contact, set whether to detect a fault when the signal opens or closes. (N.O.: External fault when closed, N.C.: External

fault when open)

<2> When using detection of a fault, set whether to always detect faults or to detect them only during operation.

N.O. Contact N.C. Contact Always Detect

{ – { – { –

Detect Only

during Operation

Stop Unit (Fault)

Continue

Operation

(Minor Fault)

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 79

4.6 Verifying Parameter Settings and Backing Up Changes

Use the Verify Mode to check all changes to parameter settings. Refer to Verifying Parameter Changes: Verify Mode on

page 74.

Save the verified parameter settings. Change the access level or set a password to the regenerative unit to prevent accidental modification of parameter settings.

◆ Backing Up Parameter Values: o2-03

Setting o2-03 to 1 saves all parameter settings to the regenerative unit internal memory. The regenerative unit can now recall all the saved parameters by performing a User Initialization (A1-03 = 1110).

No. Parameter Name Description

Lets the user create a set of default settings for a User Initialization. 0: Saved/Not Set 1: Set Defaults - Saves current parameter settings as the default

o2-03 User Defaults

A1-03 Initialize Parameters

values for a User Initialization. 2: Clear All - Clears the currently saved user settings. After saving the user parameter set value, the items of 1110 (User Initialization) are displayed in A1-03 (User Parameter Default Va l ue ) .

Selects a method to initialize the parameters. 0: No Initialize 1110: User Initialization (The user must first program and store desired settings using parameter o2-03) 2220: 2-Wire Initialization (parameter initialized prior to shipment) 5550: oPE4 Fault reset

Setting

Range

0 to 2 0

0, 0110, 2220,

5550

Default Setting

◆ Parameter Access Level: A1-01

Setting the Access Level for “Operation only” (A1-01 = 0) allows the user to access parameters A1- and U- only.

Other parameters are not displayed.

Setting the Access Level for “User Parameters” (A1-01 = 1) allows the user to access only the parameters that have been previously saved as User Parameters. This is helpful when displaying only the relevant parameters for a specific application.

No. Parameter Name Description

Selects which parameters are accessible via the digital operator. 0: Operation only. A1-01, A1-04, and A1-06 can be set and monitored, and U- parameters can also be viewed.

A1-01 Access Level Selection

80 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

1: User Parameters. Only recently changed parameters from application parameters A2-01 to A2-16 and A2-17 to A2 -32 can be set and monitored. 2: Advanced Access Level. All parameters can be set and monitored.

Setting

Range

0 to 2 2

Default Setting

4.6 Verifying Parameter Settings and Backing Up Changes

Start-Up Programming &

Operation

No. Parameter Name Description

Parameters selected by the user are saved as User Parameters, including recently viewed parameters and parameters specifically selected for quick access.

A2-01

A2-32

A2-33

User Parameters 1 to 32

User Parameter Automatic Selection

If parameter A2-33 is set to 1, recently viewed parameters will be listed between A2-17 and A2-32. Parameters A2-01 through A2-16 must be manually selected by the user. If A2-33 is set to 0, recently viewed parameters will not be saved to the group of User Parameters. A2- parameters are now available for manual programming.

0: Parameters A2-01 through A2-32 are reserved for the user to create a group of User Parameters. 1: Save history of recently viewed parameters. Recently edited parameters will be saved to A2-17 through A2-32 for quick access. The most recently changed parameter is saved to A2-17. The second most recently changed parameter is saved to A2-18, etc.

Setting

Range

A1-00 to

o4-19

0,1 0

Default Setting

–

◆ Password Settings: A1-04, A1-05

The user can set a password in parameter A1-05 to restrict access to the regenerative unit. The password must be entered to A1-04 to unlock parameter access (i.e., parameter setting A1-04 must match the value programmed into A1-05). The following parameters cannot be viewed or edited until the value entered to A1-04 correctly matches the value set to A1-05: A1-01, A1-03, and A2-01 through A2-33.

Note: Parameter A1-05 is hidden from view. To display A1-05, access parameter A1-04 and press and simultaneously.

◆ Copy Function

Parameter settings can be copied to another regenerative unit to simplify parameter restoration or multiple regenerative unit setup. The regenerative unit supports the following copy options:

• LCD Operator (standard in all models)

The LCD operator used to operate the regenerative unit supports copying, importing, and verifying parameter settings. Refer to o3: Copy Function on page 167 for details.

• LED Operator

The optional LED operator also supports copying, importing, and verifying parameter settings. Refer to the manual supplied with the LED operator for instructions.

• USB Copy Unit and CopyUnitManager

The copy unit is an external option connected to the regenerative unit to copy parameter settings from one regenerative unit and save those settings to another regenerative unit. Refer to the manual supplied with the USB Copy Unit for instructions.

Note: Connect the USB Copy Unit to the RS-422/RS-485 communication port on the regenerative unit.

CopyUnitManager is a PC software tool. It allows the user to load parameter settings from the Copy Unit onto a PC, or from the PC onto a Copy Unit. This is useful when managing parameters for various regenerative units or applications. Refer to the manual supplied with CopyUnitManager for instructions.

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 81

4.6 Verifying Parameter Settings and Backing Up Changes

■ Copying Procedure for the LCD Operator

The LCD operator can perform the following operations by changing the o3-01(Copy Function Selection) parameter in the regenerative unit.

Read (o3-01 = 1)

Copies all parameters from the regenerative unit to the LCD operator.

Note: There is a limit to the number of read operations that you can perform from the LCD operator. As a guide, do not perform more

than 100,000 read operations.

Copy (o3-01 = 2)

Copies all parameters from the LCD operator to the regenerative unit.

Verify (o3-01 = 3)

Compares the parameters in the regenerative unit with the parameter settings saved on the LCD operator for matches.

82 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

Start-Up Programming &

Operation

4.7 Test Run Checklist

LO RE

Review the checklist before performing a test run. Check each item that applies.

No. Checklist Page

1 Thoroughly read the manual before performing a test run. –

4.7 Test Run Checklist

Check the Wiring Checklist on page 66

3 Set the correct power supply voltage. 76

4 Turn on the power supply to the regenerative unit and drive. 76

5 Correctly sequence the Run commands. 77

The should light after giving a Run command.

To give Run command from the digital operator, press key to set to LOCAL.

To give Run command from the control circuit terminals, press the to set REMOTE. (The LO/

RE indicator is lit off while REMOTE is set.)

69, 74

–

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 83

4.7 Test Run Checklist

84 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

Troubleshooting

This chapter provides descriptions of the regenerative unit faults, alarms, errors, related displays, and guidance for troubleshooting. This chapter can also serve as a reference guide for tuning the regenerative unit during a trial run.

5.1 SECTION SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

5.2 ALARMS, FAULTS, AND ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

5.3 FAULT DETECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

5.4 ALARM DETECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

5.5 OPERATOR PROGRAMMING ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

5.6 COPY FUNCTION RELATED DISPLAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

5.7 DIAGNOSING AND RESETTING FAULTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 85

5.1 Section Safety

W ARNING

5.1 Section Safety

Electrical Shock Hazard

If a fuse is open or ground fault circuit interrupter GFCI is tripped, check the wiring and the selection of the peripheral devices.

Contact your supplier if the cause cannot be identified. Failure to comply may result in electrical shock by indirect or direct contact. The regenerative unit can cause a residual current with a DC component in the protective earthing conductor.

After blowing a fuse or ground fault circuit interrupter GFCI is tripped, do not attempt to restart the unit or operate peripheral devices until five minutes pass and CHARGE lamp is OFF.

Failure to comply could result in death, serious injury, and damage to the unit.

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

Failure to comply could result in death or serious injury.

Before servicing, disconnect all power to the equipment. The internal capacitor remains charged even after the power supply is turned off. The charge indicator LED will extinguish when the DC bus voltage is below 50 Vdc. To prevent electric shock, wait for at least the time specified on the warning label; after all indicators are OFF, measure for unsafe voltages to confirm the unit is safe prior to servicing.

Do not operate equipment with covers removed.

Failure to comply could result in death or serious injury.

The diagrams in this section may illustrate units without covers or safety shields to display details. Be sure to reinstall covers or shields before operating the unit and run the unit according to the instructions described in this manual.

Do not touch terminals before the capacitors have fully discharged.

Failure to comply could result in death or serious injury.

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

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 this equipment.

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

Failure to comply could result in death or serious injury.

Remove all metal objects such as watches and rings, secure loose clothing and wear eye protection before beginning work on the unit.

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

Failure to comply could result in death or serious injury.

86 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

5.2 Alarms, Faults, and Errors

Troubleshooting

5.2 Alarms, Faults, and Errors

◆ Types of Alarms, Faults, and Errors

Check the digital operator for information about possible faults if the regenerative unit fails to operate.

If problems occur that are not covered in this manual, contact the nearest Yaskawa representative with the following information:

• Regenerative unit model

• Software version

• Date of purchase

• Description of the problem

Table 5.1 contains descriptions of the various types of alarms, faults, and errors that may occur while operating the

regenerative unit.

If the regenerative unit fails, contact your Yaskawa representative or the nearest Yaskawa sales office.

Table 5.1 Types of Alarms, Faults, and Errors

Type Response

When the regenerative unit detects a fault:

• The digital operator displays text indicating the specific fault and the ALM indicator LED remains lit until the fault is reset.

Faults

Minor Faults and Alarms

Operation Errors

Copy Function Errors

• The fault interrupts regenerative unit output.

• Some faults allow the user to select the stopping method when the fault occurs.

• Fault output terminals MA-MC will close, and MB-MC will open.

• The regenerative unit will remain inoperable until the fault is cleared. Refer to Fault Reset Methods on

page 112.

When the regenerative unit detects an alarm or a minor fault:

• The digital operator displays text indicating the specific alarm or minor fault, and the ALM indicator LED flashes.

• A multi-function contact output set to be tripped by a minor fault (H2- = 10) closes. If the output is set to be tripped by an alarm, the contact will not close. Remove the cause of the problem to reset a minor fault or alarm.

An operation error occurs when parameter settings conflict or do not match hardware settings (such as with an option card). When the regenerative unit detects an operation error:

• The digital operator displays text indicating the specific error.

• Multi-function contact outputs do not operate. The regenerative unit will not operate until the error has been reset. Correct the settings that caused the operation error to clear the error.

Copy Function Errors occur when using the digital operator or the USB Copy Unit to copy, read, or verify parameter settings.

• The digital operator displays text indicating the specific error.

• Multi-function contact outputs do not operate. Pressing any key on the digital operator will clear the fault. Investigate the cause of the problem (such as model incompatibility) and try again.

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 87

5.2 Alarms, Faults, and Errors

◆ Alarm and Error Displays

■ Faults

Tab le 5 .2 gives an overview of possible fault codes. Conditions such as overvoltages can trip faults and alarms. It is

important to distinguish between faults and alarms to determine the proper corrective actions. When the regenerative unit detects a fault, the ALM indicator LED lights, the fault code appears on the digital operator, and the fault contact MA-MB-MC triggers. An alarm is present if the ALM LED blinks and the fault code on the digital operator flashes. Refer to Minor Faults and Alarms on page 89 for a list of alarm codes.

Table 5.2 Fault Displays

Digital Operator

Display

LED LCD LED LCD

<1>

Aov

AUv Power Supply Undervoltage 91 Fdv Power Supply Frequency Fault 94

bUS Option Communication Error 91 FUA AC Fuse Blowout 95

CoF Current Offset Fault 92 nSE Node Setup Error 95

CPF00,

CPF01

CPF02 A/D Conversion Error 92

CPF03

CPF06 EEPROM Memory Data Error 93

CPF07

CPF08

CPF11 to

CPF22

CPF23

CPF24 Unit Capacity Detect Fault 93 oL2 Overload 98

CPF26 to

CPF35,

CPF40 to

CPF45

Power Supply Overvoltage 91 Fan Internal Circulation Fan Fault 94

MEMOBUS/Modbus Communication Error

Control Circuit Error 92 oC Overcurrent 95

Control Board Connection Error

Terminal Board Connection Error

Control Circuit Error 92

Control Board Connection Error

Control Circuit Error 92

Name Page

92 FUd DC Fuse Blowout 95

93 oH1 Overheat 1 98

Digital Operator

Display

oFA00 to

oFA43

oFb00 to

oFb17

oFC00 to

oFC55

oH Heatsink Overheat 98

oPr Operator Connection Fault 98

ov Overvoltage 99

PF2 Input Power Supply Fault 99

PF3 Input Phase Loss Detection 99

Name Page

Option Card Fault (CN5-A) 96

Option Card Fault (CN5-B) 96

Option Card Fault (CN5-C) 97

EF0 Option Card External Fault 93 SrC Phase Order Fault 100

EF1

<1> Displayed as CPF00 when occurring at regenerative unit power up. When one of the faults occurs after successfully starting the regenerative

unit, the display will show CPF01. Displayed as CPF20 when occurring at regenerative unit power up. When one of the faults occurs after successfully starting the regenerative unit, the display will show CPF21.

88 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

EF8

Err EEPROM Write Error 94 Uv3 Soft Charge Circuit Fault 101

MECHATROLINK Watchdog Timer Error

External Fault (input terminal S1 to S8)

93 SC

Uv1 Main Circuit Undervoltage 100

Uv2

IGBT Short Circuit or Ground Fault

Control Power Supply Undervoltage

100

5.2 Alarms, Faults, and Errors

Troubleshooting

■ Minor Faults and Alarms

Refer to Tab le 5 .3 for an overview of possible alarm codes. Conditions such as overvoltages can trip faults and alarms. It is important to distinguish between faults and alarms to determine the proper corrective actions. When the regenerative unit detects an alarm, the ALM indicator LED blinks and the alarm code display flashes. Most alarms trigger a digital output programmed for alarm output (H2- = 10). A fault (not an alarm) is present if the ALM LED lights without blinking. Refer to Faults on page 88 for information on fault codes.

Table 5.3 Minor Fault and Alarm Displays

Digital Operator Display

LED LCD

AEr Station Number Setting Error YES 102

Aov

AUv Power Supply Undervoltage YES 102

bb Baseblock No output 102

bUS Option Card Communications Error YES 103

CALL Serial Communication Transmission Error YES 103

CE MEMOBUS/Modbus Communication Error YES 103

CoF Current Offset Fault YES 104

CrST Cannot Reset YES 104

CyC MECHATROLINK Communications Cycle Setting Error YES 104

E5 MECHATROLINK Watchdog Timer Error YES 104

EF0 Option Card External Fault YES 104

EF1

EF8

Fan Internal Circulation Fan Fault YES 105

Fdv Power Supply Frequency Fault YES 105

Name

Power Supply Overvoltage YES 102

External Fault (input terminal S1 to S8) YES 105

Minor Fault Output

(H2- = 10)

Page

HCA Current Alarm YES 106

LT-1 Cooling Fan Maintenance Time No output

LT-2 Capacitor Maintenance Time No output

LT-3 Capacitor Maintenance Time No output

oH Heatsink Overheat YES 106

oL2 Overload YES 107

ov Overvoltage YES 107

PAUv Power Supply Undervoltage Pre-alarm YES 107

PF3 Input Phase Loss Detection YES 107

PFDv Power Supply Frequency Pre-Alarm YES 108

SE MEMOBUS/Modbus Test Mode Fault YES 108

SRC Phase Order Fault YES 108

Uv Undervoltage YES 108

<1> Output when H2- = 2F.

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 89

<1> 106

5.2 Alarms, Faults, and Errors

■ Operation Errors

Table 5.4 Operation Error Displays

Digital Operator Display

LED LCD

Err EEPROM Write Error 109

oPE01 Unit Capacity Setting Error 109

oPE02 Parameter Setting Range Error 109

oPE03 Multi-Function Input Setting Error 109

oPE04 Terminal Board Mismatch Error 110

oPE05 Run Command Selection Error 11 0

oPE07 Multi-Function Analog Input Selection Error 110

oPE30 Incorrect Input Voltage Adjustment 110

■ Errors and Displays When Using the Copy Function

Table 5.5 Copy Errors

Digital Opera

LED LCD

CoPy Writing parameter settings (flashing) 111

CPyE Error writing data 111

CSEr Copy unit error 111

dFPS Model mismatch 111

End Task complete 111

iFEr Communication error 111

ndAT Model, voltage class, capacity mismatch 111

rdEr Error reading data 111

rEAd Reading parameter settings (flashing) 111

vAEr Voltage class, capacity mismatch 111

vFyE Parameter setting mismatch 111

vrFy Comparing parameter settings (flashing) 111

Name Page

90 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

Troubleshooting

5.3 Fault Detection

◆ Fault Displays, Causes, and Possible Solutions

Table 5.6 Detailed Fault Displays, Causes, and Possible Solutions

5.3 Fault Detection

Digital Operator

Display

Aov

Cause Possible Solution

The input power supply voltage is too high. Reduce the voltage to within the range in the power supply specifications.

Digital Operator

Display

AUv

Cause Possible Solution

The capacity of the power supply is too small. Increase the capacity of the power supply.

The AC fuse is open.

The distortion in the power supply is too large. Lower the impedance of the input power supply wiring. A phase loss occurred in the input power

supply.

Digital Operator

Display

bUS

Cause Possible Solution

No signal was received from the PLC. Faulty communications wiring or an existing

short circuit.

Communication data error occurred due to noise.

The option card is damaged. Replace the option card if there are no problems with the wiring and the error continues to occur.

The option card is not properly connected to the regenerative unit.

Fault Name Details

The input power supply voltage became equal to or higher than the Input Power Supply

Power Supply

Overvoltage

Fault Name Details

Power Supply

Undervoltage

Fault Name Details

Option Communication

Error

Overvoltage Detection Level (L8-36). 200 V Class: Approximately 277 Vac 400 V Class: Approximately 554 Vac

The input power supply voltage became equal to or lower than the Input Power Supply Undervoltage Detection Level. 200 V Class: Approximately 150 Vac 400 V Class: Approximately 300 Vac

A transistor inside the regenerative unit was destroyed. The input wiring is ground-faulted or short-circuited. Or, the drive output is ground-faulted or short-circuited, which destroyed the output transistor. Consult with your Yaskawa representative or the nearest Yaskawa sales office.

Check the input power supply for phase loss or an imbalance in the interphase voltages. Investigate and correct the cause and reset the fault.

• The connection was lost after establishing initial communication.

• Only detected when the run command frequency reference is assigned to an option card.

Check for faulty wiring.

• Correct the wiring.

• Check for disconnected cables and short circuits and repair as needed.

Check the various options available to minimize the effects of noise.

• Counteract noise in the control circuit, main circuit, and ground wiring.

• Ensure that other equipment such as switches or relays do not cause noise. Use surge absorbers if necessary.

• Use only recommended cables or other shielded line. Ground the shield on the controller side or the regenerative unit input power side.

• Separate all communication wiring from drive power lines. Install an EMC noise filter to the regenerative unit power supply input.

The connector pins on the option card do not line up properly with the connector pins on the regenerative unit. Reinstall the option card.

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 91

5.3 Fault Detection

Digital Operator

Display

Fault Name Details

MEMOBUS/Modbus

Communication Error

Cause Possible Solution

Faulty communications wiring or an existing short circuit.

Communication data error occurred due to noise.

Digital Operator

Display

Fault Name Details

CoF Current Offset Fault

Cause Possible Solution

An error occurred in the power supply detection circuit.

Digital Operator

Display

Fault Name Details

Control data was not received for the CE detection time set to H5-09.

Check for faulty wiring.

• Correct the wiring.

• Check for disconnected cables and short circuits and repair as needed.

Check the various options available to minimize the effects of noise.

• Counteract noise in the control circuit, main circuit, and ground wiring.

• Use only recommended cables or other shielded line. Ground the shield on the controller side or the regenerative unit input power side.

• Ensure that other equipment such as switches or relays do not cause noise. Use surge suppressors if required.

• Separate all communication wiring from drive power lines. Install an EMC noise filter to the regenerative unit power supply input.

A fault occurred in adjustment of the automatic current offset when the power supply was turned on.

Cycle the power supply and check operation. If the fault occurs again, replace the board or regenerative unit. For information on board replacement, consult with your Yaskawa representative or the nearest Yaskawa sales office.

CPF00,

CPF01

<1>

CPF11 to

CPF22

CPF26 to

Control Circuit Error A fault occurred in the control circuit.

<1>

CPF35

Cause Possible Solution

There is a self-diagnostic error in the control circuit.

• Cycle power to the regenerative unit.

• If the problem continues, replace the control board or the entire regenerative unit. Contact Yaskawa or a Yaskawa representative for instructions on replacing the control board.

Connector on the operator is damaged. Replace the operator.

Digital Operator

Display

CPF02

Fault Name Details

A/D Conversion Error

An A/D conversion error or control circuit error occurred.

Cause Possible Solution

Cycle power to the regenerative unit.

Control circuit is damaged.

If the problem continues, replace the control board or the entire regenerative unit. Contact Yaskawa or a Yaskawa representative for instructions on replacing the control board.

Digital Operator

Display

CPF03

Fault Name Details

Control Board

Connection Error

Connection error between the control board and the regenerative unit

Cause Possible Solution

Turn off the power and check the connection between the control board and the regenerative unit.

There is a connection error.

If the problem continues, replace the control board or the entire regenerative unit. Contact Yaskawa or a Yaskawa representative for instructions on replacing the control board.

92 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

Troubleshooting

Check the various options available to minimize the effects of noise.

• Counteract noise in the control circuit, main circuit, and ground wiring.

• Use only recommended cables or other shielded line. Ground the shield on the controller side Regenerative unit fails to operate properly due to noise interference.

Digital Operator

Display

CPF06

Cause Possible Solution

There is an error in EEPROM control circuit.

The power supply was switched off while parameters were being saved to the regenerative unit.

Digital Operator

Display

CPF07

CPF08

Cause Possible Solution

There is a faulty connection between the terminal board and the control board.

Digital Operator

Display

CPF23

Cause Possible Solution

Hardware is damaged.

Digital Operator

Display

CPF24

Cause Possible Solution

Hardware is damaged.

Digital Operator

Display

Cause Possible Solution

Data has not been received from the PLC.

Digital Operator

Display

EF0

Cause Possible Solution

An external fault was received from the PLC and F6-03 is set to a value other than 3.

Problem with the PLC program Check the PLC program and correct problems.

Fault Name Details

EEPROM Memory

Data Error

Fault Name Details

Ter m i nal Boar d

Connection Error

Fault Name Details

Control Board

Connection Error

Fault Name Details

Unit Capacity Detect

Fault

Fault Name Details

MECHATROLINK

Watchdog Timer Error

Fault Name Details

Option Card External

Fault

or the regenerative unit input power side.

• Ensure that other equipment such as switches or relays do not cause noise. Use surge

suppressors if required.

• Separate all communication wiring from regenerative unit power lines. Install an EMC noise

filter to the regenerative unit power supply input.

Error in the data saved to EEPROM

Turn off the power and check the connection between the control board and the regenerative unit. If the problem continues, replace the control board or the entire regenerative unit. Contact Yaskawa or a Yaskawa representative for instructions on replacing the control board.

Reinitialize the regenerative unit (A1-03 = 2220, 3330).

There is a faulty connection in the removable terminal block.

• Turn off the power and reconnect the terminal board.

• If the problem continues, replace the control board or the entire regenerative unit. Contact Yaskawa or a Yaskawa representative for instructions on replacing the control board.

Connection error between the control board and the regenerative unit

The regenerative unit capacity cannot be detected correctly (regenerative unit capacity is checked when the regenerative unit is powered up).

If the problem continues, replace the control board or the entire regenerative unit. Contact Yaskawa or a Yaskawa representative for instructions on replacing the control board.

The watchdog timed out.

Execute DISCONNECT or ALM_CLR, then issue a CONNECT command or SYNC_SET command and proceed to phase 3. Refer to the MECHATROLINK Option Technical Manual for more details on troubleshooting.

An external fault condition is present.

• Remove the cause of the external fault.

• Remove the external fault input from the PLC.

5.3 Fault Detection

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 93

5.3 Fault Detection

Digital Operator

Display

EF1

EF2

EF3

EF4

EF5

EF6

EF7

EF8

Cause Possible Solution

An external device tripped an alarm function. Remove the cause of the external fault and reset the fault.

Wiring is incorrect.

Multi-function contact input setting is incorrect.

Digital Operator

Display

Err

Cause Possible Solution

Electrical noise has corrupted data while writing to the EEPROM.

Hardware problem

Digital Operator

Display

Fan

Cause Possible Solution

Internal circulation fan malfunctioned. • Cycle power to the regenerative unit.

Fault detected in the internal circulation fan or magnetic contactor to the power supply.

Digital Operator

Display

Fdv

Cause Possible Solution

A momentary power loss occurred. An input power supply wiring terminal is loose. The fluctuation in the voltage of the input

power supply is too large.

The AC power supply fuse is open.

Fault Name Details

External Fault

(input terminal S1)

External Fault

(input terminal S2)

External Fault

(input terminal S3)

External Fault

(input terminal S4)

External Fault

(input terminal S5)

External Fault

(input terminal S6)

External Fault

(input terminal S7)

External Fault

(input terminal S8)

Fault Name Details

EEPROM Write Error

Fault Name Details

Internal Circulation

Fan Fault

Fault Name Details

Power Supply

Frequency Fault

External fault at multi-function input terminal S1.

External fault at multi-function input terminal S2.

External fault at multi-function input terminal S3.

External fault at multi-function input terminal S4.

External fault at multi-function input terminal S5.

External fault at multi-function input terminal S6.

External fault at multi-function input terminal S7.

External fault at multi-function input terminal S8.

• Properly connect the signal lines to the terminals assigned for external fault detection

(H1- = 20 to 2B).

• Reconnect the signal line.

• Check for unused terminals set for H1- = 20 to 2B (External Fault).

• Change the terminal settings.

Data cannot be written to the EEPROM

• Press “ENTER” on the digital operator.

• Correct the parameter setting.

• Cycle power to the regenerative unit. If the problem continues, replace the control board or the entire regenerative unit. Contact

Yaskawa or a Yaskawa representative for instructions on replacing the control board.

Fan or magnetic contactor failure

• Check for fan operation.

• Verify the cumulative operation time of the fan with monitor U4-03, and verify the cumulative

operation time of the fan maintenance timer with U4-04.

• If the cooling fan has exceeded its expected performance life or is damaged in any other way,

follow the replacement instructions in Cooling Fans on page 121.

The input power supply frequency exceeded the allowable frequency fluctuation.

Investigate and correct the cause and reset the fault. Refer to Diagnosing and Resetting Faults on page 112.

• A transistor inside the regenerative unit was destroyed.

• The input wiring or drive output has ground faulted or short circuited.

Contact your Yaskawa representative or the nearest Yaskawa sales office.

94 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

5.3 Fault Detection

Troubleshooting

r1/ 11, 1/ 21, t1/ 31

Digital Operator

Display

FUA AC Fuse Blowout The power supply fuse is open.

Cause Possible Solution

The power supply fuse is open.

Digital Operator

Display

FUd DC Fuse Blowout The DC regenerative unit output fuse is open.

Cause Possible Solution

The main transistor failed. The DC circuit fuse is open.

The drive failed.

Digital Operator

Display

nSE

Cause Possible Solution

The node setup terminal closed during run. A Run command was issued while the node

setup function was active.

Digital Operator

Display

Cause Possible Solution

A momentary power loss occurred.

One of the cables has shorted out or there is a grounding problem.

The load is too heavy.

Regenerative unit fails to operate properly due to noise interference.

The wiring of the power supply voltage detection circuits ( ) and

the wiring of the main circuit terminals (R/L1, S/L2, and T/L3) is not correct.

The voltage on the power supply side is very low.

Fault Name Details

Node Setup Error A terminal assigned to the node setup function closed during run.

Fault Name Details

Overcurrent

• A transistor inside the regenerative unit was destroyed.

• The input wiring or drive output has ground faulted or short circuited.

Contact your Yaskawa representative or the nearest Yaskawa sales office.

Replace the regenerative unit.

Replace the drive. For information on drive replacement, consult with your Yaskawa representative or the nearest Yaskawa sales office.

Stop the regenerative unit when using the node setup function.

Regenerative unit sensors detected an output current greater than the specified overcurrent level.

Investigate and correct the cause and reset the fault. Refer to Diagnosing and Resetting Faults on page 112 for details.

• Check the motor cables.

• Remove the short circuit and reapply power to the regenerative unit.

• Check the resistance between the motor cables and the ground terminal .

• Replace damaged cables.

• Measure the current flowing into the regenerative unit.

• Replace the regenerative unit with a larger capacity regenerative unit if the current value exceeds the rated current.

• Determine if there is sudden fluctuation in the current level.

• Reduce the load to avoid sudden changes in the current level or switch to a larger regenerative unit.

• Review the possible solutions provided for handling noise interference.

• Review the section on handling noise interference on page 393 and check the control circuit lines, main circuit lines, and ground wiring.

Correct the wiring.

• Check the wiring.

Correct the wiring.

• Check the load on the power supply of peripheral devices that are connected to the same power supply line.

Reduce the load.

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 95

5.3 Fault Detection

Digital Operator

Display

Fault Name Details

Option Card

oFA00

Connection Error at

Option Port CN5-A

Cause Possible Solution

The option card installed into port CN5-A is incompatible with the regenerative unit.

Digital Operator

Display

oFA01

Fault Name Details

Option Card Fault at

Option Port CN5-A

Cause Possible Solution

The option card connection to port CN5-A is faulty.

Digital Operator

Display

Fault Name Details

Same Type of Option

oFA02

Card Already

Connected

Cause Possible Solution

The same option cards or the same type of option cards are connected to CN5-A, CN5-B, and CN5-C.

Digital Operator

Display

oFA05 to

oFA06

oFA10,

Fault Name Details

Option Card Error

Occurred at Option

Port CN5-A

oFA11

oFA12 to

oFA17

oFA30 to

oFA43

Option Card

Connection Error

(CN5-A)

Communication Option

Card Connection Error

(CN5-A)

Cause Possible Solution

Option card or hardware is damaged.

Digital Operator

Display

oFb00

Fault Name Details

Option Card Fault at

Option Port CN5-B

Cause Possible Solution

The option card installed into port CN5-B is incompatible with the regenerative unit.

Digital Operator

Display

oFb01

Fault Name Details

Option Card Fault at

Option Port CN5-B

Cause Possible Solution

The option card connection to port CN5-B is faulty.

Option compatibility error

Check if the regenerative unit supports the option card to be installed. Contact Yaskawa for assistance.

Option not properly connected

Turn off the power and reconnect the option card.

The combination of the option cards that are connected is not correct.

Connect the option cards correctly.

There is a fault in the option card.

• Cycle power to the regenerative unit.

• If the problem continues, replace the control board or the entire regenerative unit. Contact Yaskawa or a Yaskawa representative for instructions on replacing the control board.

Option compatibility error

Make sure the regenerative unit supports the option card to be installed. Contact Yaskawa for assistance.

Option not properly connected

Turn off the power and reconnect the option card.

96 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

5.3 Fault Detection

Troubleshooting

Digital Operator

Display

oFb02

Cause Possible Solution

An option card of the same type is already installed in option port CN5-A.

Digital Operator

Display

oFb03 to

oFb11

to oFb12 to

oFb17

Cause Possible Solution

Option card or hardware is damaged.

Digital Operator

Display

oFC00

Cause Possible Solution

The option card installed into port CN5-C is incompatible with the regenerative unit.

Digital Operator

Display

oFC01

Cause Possible Solution

The option card connection to port CN5-C is faulty.

Digital Operator

Display

oFC02

Cause Possible Solution

An option card of the same type is already installed in option port CN5-A or CN5-B.

Digital Operator

Display

oFC03 to

oFC11

oFC12 to

oFC17

Cause Possible Solution

Option card or hardware is damaged.

Fault Name Details

Option Card Fault at

Option Port CN5-B

Fault Name Details

Option card error

occurred at Option Port

CN5-B

Option card error

occurred at Option Port

CN5-B

Fault Name Details

Option Card

Connection Error at Option Port CN5-C

Fault Name Details

Option Card Fault at

Option Port CN5-C

Fault Name Details

Option Card Fault at

Option Port CN5-C

Fault Name Details

Option Card Error

Occurred at Option

Port CN5-C

Option Card Error

Occurred at Option

Port CN5-C

Same type of option card is currently connected

Only one of each option card type can only be installed simultaneously. Make sure only one type of option card is connected.

There is a fault in the option card.

• Cycle power to the regenerative unit.

• If the problem continues, replace the control board or the entire regenerative unit. Contact Yaskawa or a Yaskawa representative for instructions on replacing the control board.

Option compatibility error

Confirm that the regenerative unit supports the option card to be installed. Contact Yaskawa for assistance.

Option not properly connected

Turn the power off and reconnect the option card.

Same type of option card is currently connected

Only one of each option card type can only be installed simultaneously. Make sure only one type of option card is connected.

There is a fault in the option card.

• Cycle power to the regenerative unit.

• If the problem continues, replace the control board or the entire regenerative unit. Contact Yaskawa or a Yaskawa representative for instructions on replacing the control board.

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 97

5.3 Fault Detection

Digital Operator

Display

oFC50 to

oFC55

Cause Possible Solution

Option card or hardware is damaged. Refer to the option manual for details.

Digital Operator

Display

Cause Possible Solution

Surrounding temperature is too high.

Load is too heavy.

Internal cooling fan is stopped.

Digital Operator

Display

oH1

Cause Possible Solution

Surrounding temperature is too high.

Load is too heavy.

Internal cooling fan is stopped.

Digital Operator

Display

oL2

Cause Possible Solution

Load is too heavy. Reduce the load. Regenerative unit capacity is too small. Replace the regenerative unit with a larger model. The regenerative unit does not operate. Start regenerative unit operation first, and then start regenerative unit operation.

Digital Operator

Display

oPr

Cause Possible Solution

External operator is not properly connected to the regenerative unit.

Fault Name Details

Option Card Error

Occurred at Option

Port CN5-C

Fault Name Details

Heatsink Overheat

Fault Name Details

Overheat 1

Fault Name Details

Overload The thermal sensor of the regenerative unit triggered the unit overload protection.

Fault Name Details

External Digital

Operator Connection

Fault

Option card is damaged

The heatsink temperature exceeded the overheat pre-alarm level set to L8-02. The default value for L8-02 is determined by o2-04 (Unit Model Selection).

• Check the temperature surrounding the regenerative unit. Verify temperature is within regenerative unit specifications.

• Improve the air circulation within the enclosure panel.

• Install a fan or air conditioner to cool the surrounding area.

• Remove anything near the regenerative unit that might be producing excessive heat.

• Measure the output current.

• Decrease the load.

• Replace the cooling fan. Refer to page 122 for details.

• After replacing the cooling fan, set parameter o4-03 to 0 to reset the cooling fan maintenance.

The heatsink temperature exceeded the regenerative unit overheat level. Overheat level is determined by o2-04 (Unit Model Selection).

• Check the temperature surrounding the regenerative unit.

• Improve the air circulation within the enclosure panel.

• Install a fan or air conditioner to cool the surrounding area.

• Remove anything near the regenerative unit that might be producing excessive heat.

• Measure the output current.

• Reduce the load.

• Replace the cooling fan. Refer to page 122 for details.

• After replacing the cooling fan, set parameter o4-03 to 0 to reset the cooling fan maintenance.

The external operator has been disconnected from the regenerative unit. Note: An oPr fault will occur when all of the following conditions are true:

• Output is interrupted when the operator is disconnected (o2-06 = 1).

• The Run command is assigned to the operator (b1-02 = 0 and LOCAL has been selected).

• Check the connection between the operator and the regenerative unit.

• Replace the cable if damaged.

• Turn off the input power and disconnect the operator. Reconnect the operator and reapply regenerative unit input power.

98 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

5.3 Fault Detection

Troubleshooting

r1/ 11, 1/ 21, t1/ 31

Digital Operator

Display

Cause Possible Solution

A momentary power loss occurred.

The regenerative load is too large. Reduce the regenerative load.

Input power voltage is too high.

Regenerative unit fails to operate properly due to noise interference.

The wiring of the power supply voltage detection circuits ( ) and

the wiring of the main circuit terminals (R/L1, S/L2, and T/L3) is not correct.

Digital Operator

Display

PF2

Cause Possible Solution

The fluctuation in the voltage of the input power supply is too large.

A phase loss occurred in the input power supply.

The capacity of the power supply is too small. The wiring is too long. The phase imbalance is too large.

Digital Operator

Display

PF3

Cause Possible Solution

The fluctuation in the voltage of the input power supply is too large.

A phase loss occurred in the input power supply.

The capacity of the power supply is too small. The wiring is too long. The phase imbalance is too large.

Digital Operator

Display

Cause Possible Solution

IGBT fault • Check the wiring to the drive.

IGBT short circuit detection circuit fault.

Fault Name Details

Voltage in the DC bus has exceeded the overvoltage detection level.

Overvoltage

Fault Name Details

Input Power Supply

Fault

Fault Name Details

Input Phase Loss

Detection

Fault Name Details

Input Short-circuit/

Main Transistor Failure

• 200 V Class: Approximately 410 V

• 400 V Class: Approximately 820 V

Investigate and correct the cause and reset the fault. Refer to Diagnosing and Resetting Faults on page 112 for details.

• Check the voltage.

• Lower input power voltage within the limits listed in the specifications.

• Review the list of possible solutions provided for controlling noise.

• Review the section on handling noise interference and check the control circuit lines, main circuit lines, and ground wiring.

Correct the wiring.

Abnormal oscillation in the main circuit DC bus continued. (Applies when L8-65 is set to 1 or 2.)

Investigate and correct the cause and reset the fault. Refer to Diagnosing and Resetting Faults on page 112.

The voltage balance in the three-phase power supply has broken down. (Detected when L8-69 =

1.)

Investigate and correct the cause and reset the fault. Refer to Diagnosing and Resetting Faults on page 112.

Short circuit or ground fault is detected.

• Turn the power supply off and then on again to check operation.

If the problem continues, contact your Yaskawa representative or nearest Yaskawa sales office.

YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual 99

5.3 Fault Detection

Digital Operator

Display

SRC Phase Order Fault

Cause Possible Solution

The power supply phase order changed during operation.

A momentary power loss occurred. An input power supply wiring terminal is loose. The fluctuation in the voltage of the input

power supply is too large.

Digital Operator

Display

Uv1

Cause Possible Solution

A phase loss occurred in the input power supply.

An input power supply wiring terminal is loose.

Fluctuation occurred in the power supply voltage.

A power loss occurred. Improve the power supply.

The main circuit capacitor circuit in the regenerative unit has deteriorated.

The operation of the relay or contactor in the inrush current protection circuit in the regenerative unit failed.

A fault occurred in the power supply device.

A fault occurred in the power supply. A fault occurred in the power supply. A fault occurred in power supply voltage

detection.

Digital Operator

Display

Uv2

Cause Possible Solution

Internal circuitry is damaged.

Fault Name Details

The phase order detection direction for the input power supply changed after the power supply was turned on.

Investigate and correct the cause and reset the fault. Refer to Diagnosing and Resetting Faults on page 112.

Fault Name Details

The following condition occurred in the regenerative unit when a Run Command was not being input.

Main Circuit

Undervoltage

Fault Name Details

Control Power Supply

Voltage Fault

The main circuit DC voltage became equal to or lower than the set value of L2-05 (Undervoltage Detection Level). 200 V Class: Approximately 190 V 400 V Class: Approximately 380 V

Check the wiring of the main circuit power supply for broken wires and wiring mistakes. Correct the wiring.

Check the terminals for looseness. Tighten the terminals to the tightening torque that is given in this manual. (See page 50.)

Check the voltage.

• Correct the voltage so that it is within the range given in the power supply specifications of the regenerative unit.

• If there is no problem with the main circuit power supply, check the magnetic contactor in the main circuit for faults.

Check the maintenance period for the capacitor in U4-05 (Capacitor Maintenance). If the value of U4-05 has exceeded 90%, replace the board or the regenerative unit. For information on board replacement, consult with your Yaskawa representative or the nearest Yaskawa sales office.

Cycle the power supply and see if the fault occurs again.

• If the fault occurs repeatedly, replace the board or the regenerative unit. For information on board replacement, consult with your Yaskawa representative or the nearest Yaskawa sales office. Check the maintenance period for the inrush prevention relay in U4-06 (Soft Charge Bypass Relay Maintenance).

• If the value of U4-06 has exceeded 90%, replace the board or the regenerative unit. For information on board replacement, consult with your Yaskawa representative or the nearest Yaskawa sales office.

Check the wiring of the power supply device. Correct the wiring.

Check the wiring. Correct the wiring.

Voltage is too low for the control regenerative unit input power.

• Cycle power to the regenerative unit. Check if the fault reoccurs.

• If the problem continues, replace either the control board or the entire regenerative unit. For instructions on replacing the control board, contact Yaskawa or a Yaskawa representative.

100 YASKAWA ELECTRIC TOEP C710656 08B YASKAWA Power Regenerative Unit - R1000 Instruction Manual

Yaskawa R1000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

i.1 Preface

◆ Applicable Documentation

◆ Symbols

◆ Terms and Abbreviations

◆ Trademarks

i.2 General Safety

◆ Supplemental Safety Information

◆ Safety Messages

◆ General Application Precautions

◆ Precautions on Using Peripheral Devices

◆ Warning Label Example

◆ Warranty Information

Receiving

1.1 Section Safety

1.2 Model Numbers and Nameplates

◆ Nameplate

◆ Model Numbers

1.3 Regenerative Unit Models and Enclosure Types

Mechanical Installation

2.1 Section Safety

2.2 Mechanical Installation

◆ Installation Environment

◆ Installation Orientation and Spacing

◆ Precautions and Instructions for Installation

◆ Digital Operator Remote Usage

◆ Exterior and Mounting Dimensions

Electrical Installation

3.1 Section Safety

3.2 Standard Connection Diagram

3.3 Main Circuit Connection Diagram

◆ 2A03P5 to 2A0053, and 4A03P5 to 4A0073

◆ 2A0073 to 2A0105, and 4A0105 to 4A0300

3.4 Terminal Block Configuration

3.5 Terminal Cover

◆ Models 2A03P5 to 2A0028, 4A03P5 to 4A0028 (IP20/NEMA Type 1)

◆ Models 2A0035 to 2A0105, 4A0035 to 4A0300 (IP00/Open Type enclosure)

3.6 Digital Operator and Front Cover

◆ Removing/Reattaching the Digital Operator

◆ Removing/Reattaching the Front Cover

3.7 Top Protective Cover

◆ Removing and Reattaching the Top Protective Cover

3.8 Main Circuit Wiring

◆ Main Circuit Terminal Functions

◆ Protecting Main Circuit Terminals

◆ Wire Gauges and Tightening Torque

◆ Ground Wiring

3.9 Control Circuit Wiring

◆ Control Circuit Terminal Block Functions

◆ Terminal Configuration

◆ Wiring the Control Circuit Terminal

3.10 Control I/O Connections

◆ Terminal A2 Input Signal Selection

◆ Using the Contact Outputs

◆ Connect to a PC

3.11 Wiring Checklist

Start-Up Programming & Operation

4.1 Section Safety

4.2 Using the Digital Operator

◆ LCD Display

◆ ALARM (ALM) LED Displays

◆ LO/RE LED and RUN LED Indications

◆ Menu Structure for Digital Operator

4.3 The Drive and Programming Modes

◆ Navigating the Drive and Programming Modes (Default Setting)

◆ Changing Parameter Settings or Values

◆ Verifying Parameter Changes: Verify Mode

◆ Switching Between LOCAL and REMOTE

4.4 Powering Up the Regenerative Unit

◆ Powering Up the Regenerative Unit and Operation Status Display

4.5 Operation with the Drive Connected

◆ Drive Connection Example

◆ Timing Chart for Turning the Power Supply On and Off

◆ Operation Command Selection

◆ Interlocks

4.6 Verifying Parameter Settings and Backing Up Changes