Yaskawa VARISPEED-616G5 User Manual

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YASKAWA

VARISPEED-616G5

INSTRUCTION MANUAL

MULTI-FUNCTION ALL-DIGITAL TYPE (VS-616G5)

MODEL: CIMR-G5A

SPEC: F 200V CLASS 0.4 to 75kW (1.2 to 110kVA) 400V CLASS 0.4 to 300kW (1.4 to 460kVA)

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference.

YA S K A WA

MANUAL NO. TOE-S616-10.30

Preface

The VARISPEED-616G5 Series of general-purpose Inverters provides V/f control and vector con-

trol as standard features along with user-friendly operation.

This manual is designed to ensure correct and suitable application of VARISPEED-616G5-series

Inverters. Read this manual before attempting to install, operate, maintain, or inspect an Inverter and

keep it in a safe, convenient location for future reference. Be sure you understand all precautions

and safety information before attempting application.

Safety Information

The following conventions are used to indicate precautions in this manual. Failure to heed precautions provided in this manual can result in serious or possibly even fatal injury or damage to the products or to related equipment and systems.

WARNING

Indicates precautions that, if not heeded, could possibly result in loss of life or serious injury.

CAUTION Indicates precautions that, if not heeded, could result in relatively serious or minor

injury, damage to the product, or faulty operation.

The warning symbols for ISO and JIS standards are different, as shown below.

ISO JIS

The ISO symbol is used in this manual. Both of thesesymbolsappearonwarninglabels on Yaskawaproducts. Please abide by thesewarninglabelsregard-

less of which symbol is used.

Yaskawa, 1998



All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of Yaskawa. No patent liability is assumed with respect to the use of the information contained herein. Moreover, because Yaskawa is constantly striving to improve its high-quality products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, Yaskawa assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication.

Visual Aids

The following aids are used to indicate certain types of information for easier reference.

Visual Aids

EXAMPLE

INFO

IMPORTANT

Indicates application examples.

Indicates supplemental information.

Indicates important information that should be memorized.

iii

General Precautions

D The diagrams in this manual may be indicated without covers or safety shields to show de-

tails. Be sure to restore covers or shields before operating the Units and run the Units according to the instructions described in this manual.

D Any illustrations, photographs, or examples used in this manual are provided as examples

only and may not apply to all products to which this manual is applicable.

D The products and specifications described in this manual or the content and presentation

of the manual may be changed without notice to improve the product and/or the manual.

D When ordering a new copy of the manual due to damage or loss, contact your Yaskawa rep-

resentatives or the nearest Yaskawa sales office and provide the manual number shown on the front cover.

D If nameplates become warn or damaged, order new ones from your Yaskawa representa-

tives or the nearest Yaskawa sales office.

Safety Precautions

Confirmations upon Delivery

D Never install an Inverter that is damaged or missing components.

Doing so can result in injury.

J Installation

D Always hold the case when carrying the Inverter.

If theInverterisheldbythefrontcover,the main body of the Inverter may fall, possibly resulting in injury.

D Attach the Inverter to a metal or other noncombustible material.

Fire can result if the Inverter is attached to a combustible material.

D Install a cooling fan or other cooling device when installing more than one Inverter in

the same enclosure so that the temperature of the air entering the Inverters is below 45_C.

Overheating can result in fires or other accidents.

Safety Precautions

CAUTION

Page 2-2

CAUTION

Page

2-6

J Wiring

WARNING

D Always turn OFF the input power supply before wiring terminals.

Otherwise, an electric shock or fire can occur.

D Wiring must be performed by an authorized person qualified in electrical work.

Otherwise, an electric shock or fire can occur.

D Be sure to ground the ground terminal.

(200 V class: Ground to 100 Ω or less, 400 V class: Ground to 10 Ω or less) Otherwise, an electric shock or fire can occur.

D Always check the operation of any emergency stop circuits after they are wired.

Otherwise, there is the possibility of injury. (Wiring is the responsibility of the user.)

D Never touch the output terminals directly with your hands or allow the output lines to

come into contact with the Inverter case. Never short the output circuits.

Otherwise, electric shock or grounding can occur.

CAUTION

D Check to be sure that the voltage of the main AC power supply satisfies the rated

voltage of the Inverter.

Injury or fire can occur if the voltage is not correct.

D Do not perform voltage withstand tests on the Inverter.

Otherwise, semiconductor elements and other devices can be damaged.

D Connect braking resistors, Braking Resistor Units, and Braking Units as shown in the

I/O wiring examples.

Otherwise, a fire can occur.

D Tighten all terminal screws to the specified tightening torque.

Otherwise, a fire may occur.

Page

3-2

Page

3-2

D Do not connect AC power to output terminals U, V, and W.

The interior parts of the Inverter will be damaged if voltage is applied to the output terminals.

D Do not connect phase-advancing capacitors or LC/RC noise filters to the output cir-

cuits.

The Inverter can be damaged or internal parts burnt if these devices are connected.

D Do not connect electromagnetic switches or contactors to the output circuits.

If a load is connected while the Inverter is operating, surge current will cause the overcurrent protection circuit inside the Inverter to operate.

J Setting User Constants

D Disconnect the load (machine, device) from the motor before autotuning.

The motor may turn, possibly resulting in injury or damage to equipment. Also, motor constants cannot be correctly set with the motor attached to a load.

J Trial Operation

D Check to be sure that the front cover is attached before turning ON the power supply.

Do not remove the front cover during operation.

An electric shock may occur.

D Do not come close to the machine when the fault reset function is used. If the alarmed

is cleared, the machine may start moving suddenly.

Also, design the machine so that human safety is ensured even when it is restarted. Injury may occur.

D Provide a separate emergency stop switch; the Digital Operator STOP Key is valid

only when its function is set.

Injury may occur.

D Reset alarms only after confirming that the RUN signal is OFF.Ifanalarmis reset with

the RUN signal turned ON, the machine may suddenly start.

Injury may occur.

CAUTION

Page

3-2

CAUTION

Page

4-30

WARNING

Page

5-2

CAUTION

D Don’t touch the radiation fins (heat sink), braking resistor, or Braking Resistor Unit.

These can become very hot.

Otherwise, a burn injury may occur.

D Be sure that the motor and machine is within the applicable ranges before starting

operation.

Otherwise, an injury may occur.

D Provide a separate holding brake if necessary.

Always construct the external sequence to confirm that the holding brake is activated in the event of an emergency,a power failure, or an abnormality in the inverter occuring.

Failure to observe this caution can result in personal injury.

D If using with an elevator, take safety measures on the machine’s side to prevent the

elevator from dropping.

Failure to observe this caution can result in personal injury.

Page

5-2

CAUTION

Safety Precautions

D Don’t check signals while the Inverter is running.

Otherwise, the equipment may be damaged.

D Be careful when changing Inverter settings. The Inverter is factory set to suitable set-

tings.

Otherwise, the equipment may be damaged. You must, however, you must set the power supply voltage jumper for 400 V class Inverters of 18.5 kW or higher (see 5.2.4).

J Maintenance and Inspection

D Do not touch the Inverter terminals. Some of the terminals carry high voltages and

are extremely dangerous.

Doing so can result in electric shock.

D Always have the protective cover in place when power is being supplied to the Invert-

er. When attaching the cover, always turn OFF power to the Inverter through the MCCB.

Doing so can result in electric shock.

D After turning OFF the main circuit power supply, wait until the CHARGE indicator light

goes out before performing maintenance or inspections.

The capacitor will remain charged and is dangerous.

D Maintenance, inspection, and replacement of parts must be performed only by au-

thorized personnel. Remove all metal objects, such as watches and rings, before starting work. Always

use grounded tools.

Failure to heed these warning can result in electric shock.

5-2

WARNING

Page

10-2

J Other

CAUTION

Page

D A CMOS IC is used in the control board. Handle the control board and CMOS IC care-

fully. The CMOS IC can be destroyed by static electricity if touched directly.

D Do not change the wiring, or remove connectors or the Digital Operator, during op-

eration.

Doing so can result in personal injury.

10-2

WARNING

D Do not attempt to modify or alter the Inverter.

Doing so can result in electric shock or injury.

CAUTION

D Do not subject the Inverter to halogen gases, such as fluorine, chlorine, bromine, and iodine, at

any time even during transportation or installation.

Otherwise, the Inverter can be damaged or interior parts burnt.

vii

Warning Label Contents and Position

There is a warning label on the Inverter in the position shown in the following illustration. Always heed the warnings given on this label.

Warning label position

Illustration shows the CIMR-G5A23P7

Warning Label Contents

viii

How to Change the Digital Operator Display from Japanese to English

If the Digital Operator displays messages in Japanese, change to the English mode using the follow-

ing steps.

(This manual provides descriptions for the English mode.)

Warranty Information

J Free Warranty Period and Scope

Warranty Period

This product is warranted for twelve months after being delivered to Yaskawa’s customer or if appli-

cable eighteen months from the date of shipment from Yaskawa’s factory whichever comes first.

Scope of Warranty

Inspections

Periodic inspections must be conducted by the customer. However, upon request, Yaskawa or one

of Yaskawa’s Service Centers can inspect the product for a fee. In this case, if after conferring with

the customer, a Yaskawa product is found to be defective due to Yaskawa workmanship or materials

and the defect occurs during the warranty period, then this fee will be waived and the problem reme-

died free of charge.

Repairs

If a Yaskawa product is found to be defective due to Yaskawa workmanship or materials and the de-

fect occurs during the warranty period, Yaskawa will provide a replacement, repair the defective

product, and provide shipping to and from the site free of charge.

However, if the Yaskawa Authorized Service Center determines that the problem with a Yaskawa

product is not due to defects in Yaskawa’s workmanship or materials, then the customer will be re-

sponsible for the cost of any necessary repairs. Some problems that are outside the scope of this war-

ranty are:

D Problems due to improper maintenance or handling, carelessness, or other reasons where

the customer is determined to be responsible.

D Problems due to additions or modifications made to a Yaskawa product without Yaskawa’s

understanding.

D Problems due to the use of a Yaskawa product under conditions that do not meet the recom-

mended specifications.

D Problems caused by natural disaster or fire.

D Or other problems not due to defects in Yaskawa workmanship or materials.

Warranty service is only applicable within Japan.

However, after−sales service is available for customers outside of Japan for a reasonable fee. Contact

your local Yaskawa representative for more information.

J Exceptions

Any inconvenience to the customer or damage to non−Yaskawa products due to Yaskawa’s defective

products whether within or outside the warranty period are NOT covered by this warranty.

J Restrictions

D The Varispeed F7 was not designed or manufactured for use in devices or systems that may

directly affect or threaten human lives or health.

D Customers who intend to use the product described in this manual for devices or systems

relating to transportation, health care, space aviation, atomic or electric power, or underwater use must contact their Yaskawa representatives or the nearest Yaskawa sales office beforehand.

D 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.

Before Reading This Manual

This manual explains both the conventional VS-616G5 Inverters and the G5-series Inverters for SPEC:F.

The shaded sections or those specified as being for SPEC:F apply only to G5-series Inverters for SPEC:F ( Inverters with revised version letters of F or later.)

Be certain to check the specification on the Inverter nameplate.

Example of Inverter Nameplate

Version code

MODEL : CIMR−G5A20P4 SPEC : 20P41F

INPUT : AC 3PH 200-220 V 50Hz

OUTPUT: AC 3PH 0-230 V 1.2kVA 3.2 A

LOT NO : MASS : 3.0kg

SER NO :

YASKAWA ELECTRIC CORPORATION

200-230 V 60Hz

JAPAN

11 Introduction

12 Handling Inverters

13 Wiring

14 Setting User Constants

15 Trial Operation

16 Basic Operation

17 Advanced Operation

xiii

18 User Constants

19 Troubleshooting

10 Maintenance and Inspection

11 Specifications

12 Appendix

Table of Contents

Safety Information ii..................................................

Visual Aids iii........................................................

General Precautions iv................................................

Safety Precautions v.................................................

Warning Label Contents and Position viii.................................

How to Change the Digital Operator Display from Japanese to English ix....

Warranty Information x...............................................

Before Reading This Manual xi.........................................

1 Introduction 1 - 1........................................

1.1 Outline and Functions 1 - 2........................................

1.1.1 VS-616G5 Inverter Models 1 - 2............................................

1.1.2 Outline of Control Methods 1 - 4............................................

1.1.3 Functions 1-4...........................................................

1.2 Nomenclature 1 - 7...............................................

1.2.1 VS-616G5 Components 1 - 7...............................................

1.2.2 Digital Operator Components 1 - 8..........................................

2 Handling Inverters 2 - 1..................................

2.1 Confirmations upon Delivery 2 - 2..................................

2.1.1 Nameplate Information 2 - 2................................................

2.2 Exterior and Mounting Dimensions 2 - 4.............................

2.3 Checking and Controlling the Installation Site 2 - 6...................

2.3.1 Installation Site 2 - 6......................................................

2.3.2 Controlling the Ambient Temperature 2 - 6...................................

2.3.3 Protecting the Inverter from Foreign Matter 2 - 6..............................

2.4 Installation Orientation and Space 2 - 7.............................

2.5 Removing/Attaching the Digital Operator and Front Cover 2 - 8........

2.5.1 Inverters of 15 kW or Less 2 - 8............................................

2.5.2 Inverters of 18.5 kW or Higher 2 - 9.........................................

3 Wiring 3 - 1.............................................

3.1 Connections to Peripheral Devices 3 - 3............................

3.2 Connection Diagram 3 - 4.........................................

3.3 Terminal Block Configuration 3 - 5..................................

3.4 Wiring Main Circuit Terminals 3 - 6.................................

3.4.1 Applicable Wire Sizes and Closed-loop Connectors 3 - 6.......................

3.4.2 Main Circuit Terminal Functions 3 - 9........................................

3.4.3 Main Circuit Configurations 3 - 10............................................

3.4.4 Standard Connection Diagrams 3 - 12........................................

3.4.5 Wiring the Main Circuits 3 - 13...............................................

3.5 Wiring Control Circuit Terminals 3 - 20...............................

3.5.1 Wire Sizes and Closed-loop Connectors 3 - 20................................

3.5.2 Control Circuit Terminal Functions 3 - 21......................................

3.5.3 Control Circuit Terminal Connections (All Models) 3 - 22........................

3.5.4 Control Circuit Wiring Precautions 3 - 23......................................

3.6 Wiring Check 3 - 23...............................................

3.7 Installing and Wiring PG Speed Control Cards 3 - 24..................

3.7.1 Installing a PG Speed Control Card 3 - 24.....................................

3.7.2 PG Speed Control Card Terminal Blocks 3 - 25................................

3.7.3 Wiring a PG Speed Control Card 3 - 27.......................................

3.7.4 Wiring PG Speed Control Card Terminal Blocks 3 - 31..........................

3.7.5 Selecting the Number of PG (Encoder) Pulses 3 - 33...........................

4 Setting User Constants 4 - 1..............................

4.1 Using the Digital Operator 4 - 2....................................

4.2 Modes 4 - 5.....................................................

4.2.1 Inverter Modes 4 - 5......................................................

4.2.2 Switching Modes 4 - 6.....................................................

4.2.3 User Constant Access Levels 4 - 7..........................................

4.2.4 Operation Mode 4 - 12.....................................................

4.2.5 Initialize Mode 4 - 20.......................................................

4.2.6 Programming Mode 4 - 27..................................................

4.2.7 Autotuning Mode 4 - 31.....................................................

4.2.8 Modified Constants Mode 4 - 33.............................................

5 Trial Operation 5 - 1......................................

5.1 Procedure 5 - 3..................................................

5.2 Trial Operation Procedures 5 - 4...................................

5.2.1 Power ON 5-4...........................................................

5.2.2 Checking the Display Status 5 - 4...........................................

5.2.3 Initializing Constants 5 - 4.................................................

5.2.4 Setting Input Voltage 5 - 5.................................................

5.2.5 Autotuning 5 - 6..........................................................

5.2.6 No-load Operation 5 - 9...................................................

5.2.7 Loaded Operation 5 - 10....................................................

6 Basic Operation 6 - 1....................................

6.1 Common Settings 6 - 2...........................................

6.1.1 Setting the Access Level and Control Method: A1-01, A1-02 6 - 2...............

6.1.2 Frequency Reference Settings: b1-01, H3-01, H3-08, H3-09 6 - 4...............

6.1.3 Frequency Reference from Digital Operator: b1-01, o1-03, d1-01 to d1-09 6 - 7...

6.1.4 Run Source and Sequence Input Responsiveness: b1-02, b1-06, b1-07 6 - 9.....

6.1.5 Acceleration/Deceleration Times: C1-01 through C1-08, C1-09, C1-10, C1-11 6 - 10

6.1.6 Prohibiting Reverse Operation: b1-04 6 - 11...................................

6.1.7 Selecting the Stopping Method: b1-03 6 - 12..................................

6.1.8 Multi-function Input Settings: H1-01 through H1-06 6 - 13.......................

6.2 Open-loop Vector Control 6 - 18.....................................

6.2.1 Autotuning 6 - 18..........................................................

6.2.2 Autotuning Faults 6 - 19....................................................

6.3 V/f Control 6 - 21..................................................

6.3.1 Setting the Motor Constants: E1-01, E1-02, E2-01 6 - 21........................

6.3.2 V/f Pattern Selection: E1-03 6 - 22...........................................

xvi

Table of Contents

6.4 Flux Vector Control 6 - 28..........................................

6.4.1 PG Speed Control Card Settings 6 - 28.......................................

6.4.2 Setting the Zero-speed Operation Constants 6 - 31.............................

6.4.3 Autotuning 6 - 33..........................................................

6.4.4 Speed Control (ASR) Structure 6 - 36........................................

6.4.5 Speed Control (ASR) Gain 6 - 38............................................

6.5 V/f Control with PG 6 - 40..........................................

6.5.1 Motor Constants: E1-01, E1-02, E2-01, E2-04 6-40..........................

6.5.2 V/f Pattern Selection: E1-03 6 - 41...........................................

6.5.3 PG Speed Control Card Settings 6 - 42.......................................

6.5.4 Speed Control (ASR) Structure 6 - 44........................................

6.5.5 Adjusting Speed Control (ASR) Gain 6 - 45....................................

7 Advanced Operation 7 - 1................................

7.1 Open-loop Vector Control 7 - 2.....................................

7.1.1 Torque Limit Function 7 - 4.................................................

7.1.2 Adjusting Speed Feedback 7 - 5............................................

7.1.3 Setting/Adjusting Motor Constants 7 - 6......................................

7.1.4 Operation Selection when Output Voltage Saturated 7 - 8......................

7.1.5 Starting Torque Compensation Function (for SPEC:F) 7 - 9.....................

7.2 V/f Control without PG 7 - 11.......................................

7.2.1 Energy-saving Control Function 7 - 13........................................

7.2.2 Hunting-prevention Function 7 - 13...........................................

7.2.3 Setting Motor Constants 7 - 14..............................................

7.3 Flux Vector Control 7 - 16..........................................

7.3.1 Droop Control Function 7 - 18...............................................

7.3.2 Zero-servo Function 7 - 19..................................................

7.3.3 Torque Control 7 - 21.......................................................

7.3.4 Speed/Torque Control Switching Function 7 - 27...............................

7.3.5 Torque Limit Function 7 - 30.................................................

7.3.6 Setting/Adjusting Motor Constants 7 - 31......................................

7.3.7 Operation Selection when Output Voltage Saturated 7 - 34......................

7.4 V/f Control with PG 7 - 36..........................................

7.4.1 Energy-saving Control Function 7 - 38........................................

7.4.2 Hunting-prevention Function 7 - 38...........................................

7.4.3 Setting Motor Constants 7 - 39...............................................

7.5 Common Functions 7 - 41..........................................

7.5.1 Application Constants: b 7 - 43..............................................

7.5.2 Tuning Constants: C 7 - 52..................................................

7.5.3 Reference Constants: d 7 - 57...............................................

7.5.4 Option Constants: F 7 - 59..................................................

7.5.5 External Terminal Functions: H 7 - 64.........................................

7.5.6 Protective Functions: L 7 - 84...............................................

7.5.7 Operator Constants: o 7 - 97................................................

8 User Constants 8 - 1.....................................

8.1 Initialize Mode Constants 8 - 3.....................................

8.2 Programming Mode Constants 8 - 5................................

8.2.1 Application Constants: b 8 - 5..............................................

8.2.2 Autotuning Constants: C 8 - 11..............................................

8.2.3 Reference Constants: d 8 - 17...............................................

8.2.4 Motor Constant Constants: E 8 - 20..........................................

8.2.5 Options Constants: F 8 - 24.................................................

xvii

8.2.6 Terminal Constants: H 8 - 28................................................

8.2.7 Protection Constants: L 8 - 35...............................................

8.2.8 Operator Constants: o 8 - 43................................................

8.2.9 Factory Settings that Change with the Control Method (A1-02) 8 - 45.............

8.2.10 Factory Settings that Change with the Inverter Capacity (o2-04) 8 - 47...........

9 Troubleshooting 9 - 1....................................

9.1 Protective and Diagnostic Functions 9 - 2...........................

9.1.1 Fault Detection 9 - 2......................................................

9.1.2 Minor Fault Detection 9 - 6.................................................

9.1.3 Operation Errors 9 - 8.....................................................

9.2 Troubleshooting 9 - 9.............................................

9.2.1 If Constant Constants Cannot Be Set 9 - 9...................................

9.2.2 If the Motor Does Not Operate 9 - 9.........................................

9.2.3 If the Direction of the Motor Rotation is Reversed 9 - 11.........................

9.2.4 If the Motor Does Not Put Out Torque or If Acceleration is Slow 9 - 11.............

9.2.5 If the Motor Does Not Operate According to Reference 9 - 11....................

9.2.6 If the Slip Compensation Function Has Low Speed Precision 9 - 11...............

9.2.7 If There is Low Speed Control Accuracy at High-speed Rotation in Open-loop

9.2.8 If Motor Deceleration is Slow 9 - 12..........................................

9.2.9 If the Motor Overheats 9 - 12................................................

9.2.10 If There is Noise When the Inverter is Started or From an AM Radio 9 - 13.......

9.2.11 If the Ground Fault Interrupter Operates When the Inverter is Run 9 - 13.........

9.2.12 If There is Mechanical Oscillation 9 - 13.....................................

9.2.13 If the Motor Rotates Even When Inverter Output is Stopped 9 - 14...............

9.2.14 If 0 V is Detected When the Fan is Started, or Fan Stalls 9 - 14.................

9.2.15 If Output Frequency Does Not Rise to Frequency Reference 9 - 14..............

Vector Control Mode 9 - 11................................................

10 Maintenance and Inspection 10 - 1.........................

10.1 Maintenance and Inspection 10 - 3.................................

10.1.1 Daily Inspection 10 - 3....................................................

10.1.2 Periodic Inspection 10 - 3..................................................

10.1.3 Periodic Maintenance of Parts 10 - 3........................................

11 Specifications 11 - 1......................................

11.1 Standard Inverter Specifications 11 - 2..............................

11.2 Specifications of Options and Peripheral Devices 11 - 5...............

12 Appendix 12 - 1...........................................

12.1 Inverter Application Precautions 12 - 2..............................

12.1.1 Selection 12 - 2..........................................................

12.1.2 Installation 12 - 2........................................................

12.1.3 Settings 12 - 3...........................................................

12.1.4 Handling 12 - 3..........................................................

12.2 Motor Application Precautions 12 - 4...............................

12.2.1 Using the Inverter for an Existing Standard Motor 12 - 4.......................

12.2.2 Using the Inverter for Special Motors 12 - 5.................................

12.2.3 Power Transmission Mechanism (Speed Reducers, Belts, and Chains) 12 - 5....

12.3 Peripheral Device Application Precautions 12 - 6.....................

xviii

12.4 Wiring Examples 12 - 8...........................................

12.4.1 Using a Braking Resistor Unit 12 - 8.........................................

12.4.2 Using a Braking Unit and Braking Resistor Unit 12 - 8..........................

12.4.3 Using Braking Units in Parallel 12 - 11........................................

12.4.4 Using a Braking Unit and Three Braking Resistor Units in Parallel 12 - 12..........

12.4.5 Using a JVOP-95-j, -96-j VS Operator 12 - 13...............................

12.4.6 Using an Open-collector Transistor for Operation Signals 12 - 14.................

12.4.7 Using Open-collector, Contact Outputs 12 - 14.................................

12.5 User Constants 12 - 15............................................

12.6 Function Block Diagram 12 - 20.....................................

INDEX

Table of Contents

xix

Introduction

This chapter provides an overview of the VS-616G5 Inverter and describes its functions and components.

1.1 Outline and Functions 1 - 2..................

1.1.1 VS-616G5 Inverter Models 1 - 2....................

1.1.2 Outline of Control Methods 1 - 4...................

1.1.3 Functions 1 - 4..................................

1.2 Nomenclature 1 - 7.........................

1.2.1 VS-616G5 Components 1 - 7......................

1.2.2 Digital Operator Components 1 - 8.................

1-1

Introduction

Maximum

listedatthe

right

1.1.1 VS-616G5 Inverter Models

1.1 Outline and Functions

The VS-616G5 Inverters provides full-current vector control based on advanced control logic. An autotuning function is included for easy vector control.

The Digital Operator provides a liquid crystal display that is 2 lines by 16 characters in size. User constant settings and monitor items are easily read in interactive operations in either Japanese or English. (The display language can be changed by setting a user constant.)

Voltage

Class

200 V class

1.1.1 VS-616G5 Inverter Models

VS-616G5 Inverters are available in 200 and 400 V class models. These are listed in the following table. A total of 37 models is available for motor capacities of 0.4 to 300 kW.

Table 1.1 VS-616G5 Inverter Models

Maximum

Applicable

Motor Out-

put [kW]

0.4

0.75

1.5

2.2

3.7

5.5

7.5

18.5

Output Ca-

pacity [kVA]

1.2 CIMR-G5A20P4 20P41j *

2.3 CIMR-G5A20P7 20P71j *

3.0 CIMR-G5A21P5 21P51j *

4.2 CIMR-G5A22P2

6.7 CIMR-G5A23P7

9.5 CIMR-G5A25P5

13 CIMR-G5A27P5 27P51j *

19 CIMR-G5A2011 20111j *

24 CIMR-G5A2015 20151j *

30 CIMR-G5A2018 20180j * 20181j ‡

37 CIMR-G5A2022 20220j * 20221j ‡

50 CIMR-G5A2030 20300j † 20301j ‡

61 CIMR-G5A2037 20370j † 20371j ‡

70 CIMR-G5A2045 20450j † 20451j ‡

85 CIMR-G5A2055 20550j † 20551j ‡

110 CIMR-G5A2075 20750j ‡ 20751j ‡

VS-616G5

Model Number

(Specify all required standards when ordering.)

Open Chassis Type

(IEC IP 00)

CIMR-G5Ajjjjjj

Remove the top and bottom covers from the models listed at the ri

Inverter Specifications

ht.

Enclosed Wall-mounted

(IEC IP 20, NEMA 1)

CIMR-G5Ajjjjjj

Type

22P21j *

23P71j *

25P51j *

1-2

1.1 Outline and Functions

listedatthe

right

Voltage

Class

400 V class

Maximum

Applicable

Applicable Motor Out-

Motor Out-

put [kW]

0.4

0.75

1.5

2.2

3.7

5.5

7.5

18.5

110

160

185

220

300

VS-616G5

Output Ca-

pacity [kVA]

1.4 CIMR-G5A40P4 40P41j *

2.6 CIMR-G5A40P7 40P71j *

3.7 CIMR-G5A41P5 41P51j *

4.7 CIMR-G5A42P2

6.1 CIMR-G5A43P7

11 CIMR-G5A45P5

14 CIMR-G5A47P5 47P51j *

21 CIMR-G5A4011 40111j *

26 CIMR-G5A4015 40151j *

31 CIMR-G5A4018 40180j * 40181j ‡

37 CIMR-G5A4022 40220j * 40221j ‡

50 CIMR-G5A4030 40300j * 40301j ‡

61 CIMR-G5A4037 40370j * 40371j ‡

73 CIMR-G5A4045 40450j * 40451j ‡

98 CIMR-G5A4055 40550j † 40551j ‡

130 CIMR-G5A4075 40750j † 40751j ‡

170 CIMR-G5A4110 41100j † 41101j ‡

230 CIMR-G5A4160 41600j † 41601j ‡

260 CIMR-G5A4185 41850j ‡

340 CIMR-G5A4220 42200j ‡

460 CIMR-G5A4300 43000j ‡

Model Number

(Specify all required standards when ordering.)

Open Chassis Type

(IEC IP 00)

CIMR-G5Ajjjjjj

Remove the top and bottom covers from the models listed at the ri

Inverter Specifications

ht.

Enclosed Wall-mounted

(IEC IP 20, NEMA 1)

CIMR-G5Ajjjjjj

Type

42P21j *

43P71j *

45P51j *



*: Immediate delivery †: Available from factory ‡: Manufactured upon order

1-3

Introduction

1.1.2 Outline of Control Methods

The VS-616G5 uses four control methods.

Open-loop vector control (factory setting)

Flux vector control

V/f control without PG

V/f control with PG feedback

PG stands for pulse generator (encoder).

Vector control is a method for removing interference with magnetic flux and torque, and controlling torque according to references.

Current vector control independently controls magnetic flux current and torque current by simultaneously controlling the motor primary current and phases. This ensures smooth rotation, high torque, and accurate speed/torque control at low speeds.

Vector control can be replaced by the conventional V/f control system. If the motor constants required for vector control are not known, the motor constants can be automatically set with autotuning.

The control methods are effective for the following applications:

Open-loop vector control: General variable-speed drive.

Flux vector control: Simple servodrive, high-precision speed control/torque control.

V/f control without PG: Conventional Inverter control mode. Used for multi-drive operation

(connecting multiple motors to one Inverter).

V/f control with PG feedback:Simple speed feedback control. (For applications with the PG

connected to the machine shaft rather than the motor shaft.)

The control characteristics for each mode are shown in Table 1.2.

Table 1.2 Control Method Characteristics

1.1.3 Functions

J Autotuning

Autotuning is effective for vector control. It solves problems in applicable motor restrictions and difficult constant settings. The motor constants are automatically set by entering a value from the motor’s rating nameplate.

Autotuning allows flux vector control to operate accurately with virtually any normal AC induction motor, regardless of the supplier.

Always autotune the motor separately before operating using vector control. Refer to 5.2.5 Autotuning and

6.4.3 Autotuning for details.

J Torque Control

Torque control is effective for flux vector control with PG. Torque is controlled by taking multi-function analog input signals as torque references. Torque control accuracy is ±5%. Switching is possible between torque control and speed control.

V/f Pattern Settings

V/f pattern settings are effective for V/f control. Select a V/f pattern according to the application from among the 15 preset V/f patterns. Custom V/f patterns can also be set.

Characteristic

Speed Control

Range

Speed Control

Precision

Initial Drive

Vector Control V/f Control

Open-loop Flux Vector Without PG With PG feedback

1:100 1:1000 1:40 1:40

±0.2 % ±0.02 % ±2to3% ±0.03 %

150% at 1 Hz 150% at 0 r/min 150% at 3 Hz

J Frequency References

The following five types of frequency references can be used to control the output frequency of the Inverter.

Numeric input from the Digital Operator

Voltage input within a range from 0 to 10 V

Voltage input within a range from 0 to ±10 V (with negative voltages, rotation is in the opposite direc-

tion from the run command.)

1-4

Current input within a range from 4 to 20 mA

Input from Option Card

Any of the above frequency references can be used by setting a constant.

A maximum of nine frequency references can be registered with the Inverter. With remote multi-step speed reference inputs, the Inverter can operate in multi-step speed operation with a maximum of nine speed steps.

PID Control

The Inverter has a PID control function for easy follow-up control. Follow-up control is a control method in which the Inverter varies the output frequency to match the feedback value from the sensor for a set target value.

Follow-up control can be applied to a variety of control operations, such as those listed below, depending on the contents detected by the sensor.

Speed Control: With a speed sensor, such as a tacho-generator,the Inverter regulates the rotat-

Pressure Control: With a pressure sensor, the Inverter performs constant pressure control.

Flow-rate Control: By sensing the flow rate of a fluid, the Inverter performs precise flow-rate

Temperature Control: With a temperature sensor, the Inverter performs temperature control by fan

J Zero-servo Control

Zero-servo control is effective with flux vector control. Even at a motor speed of zero (r/min), a torque of 150% of the motor’s rated torque can be generated and the average servomotor holding power (stopping power) can be obtained.

1.1 Outline and Functions

ing speed of the motor regardless of the load of the motor or synchronizes the rotating speed of the motor with that of another motor.

control.

speed.

Speed Control By Feedback

Speed control using feedback is effective with a PG. An optional PG Speed Control Card be used to enable feedback control for speeds, thereby improving speed control accuracy.

J Dwell Function

By holding the output frequency for a constant time during acceleration and deceleration, acceleration and deceleration can be performed without stepping out even when driving a motor with a large startup load.

J Low Noise

The output transistor of the Inverter is an IGBT (insulated gate bipolar transistor). Using sine-wave PWM with a high-frequency carrier, the motor does not generate metallic noise.

J Monitor Function

The following items can be monitored with the Digital Operator: Frequency reference, output frequency, output current, motor speed, output voltage reference, main-circuit DC voltage, output power, torque reference, status of input terminals, status of output terminals, operating status, total operating time, software number, speed deviation value, PID feedback value, fault status, fault history, etc.

All types of data can be monitored even with multi-function analog output.

J Multilingual Digital Operator (SPEC:F)

The Digital Operator can display in seven languages (Japanese, English, German, French, Italian, Spanish, and Portuguese). The Digital Operator’s liquid crystal display provides a 16-character x 2-line display area.

Easy-to-read displays in each language allow the advanced functions of the Inverter to be set in interactive operations to input constants, monitoring items, etc. Change the constant setting to select the display language.

J Harmonic Countermeasures (0.4 to 160 kW Models)

The VS-616G5 Inverters up to 160 kW support DC reactors to easily handle high-frequency control guidelines.

DC reactors (optional) can be connected to 0.4 to 15 kW models.

Models from 18.5 to 160 kW have a built-in DC reactor.

An optional AC reactor can be connected to Inverters from 185 to 300 kW.

1-5

Introduction

1.1.3 Functions

User Constant Structure and Three Access Levels

The VS-616G5 has a number of user constants for setting various functions. These user constants are classified into a hierarchy to make them easier to use.

The levels are as follows from top to bottom: Modes, Groups, Functions, and Constants. The access levels for the user constants are shown in Table 1.3.

Table 1.3 Access Levels for User Constants

Level Contents

Mode

Groups

Functions

Constants

Classified according to operation

Operation: For operating the Inverter. (All kinds of monitoring are possible.)

Initialize: For selecting the language displayed at the Digital Operator, set-

ting access levels, initialization, and the control modes.

Programming: For setting user constants for operation.

Autotuning: For automatic calculation or setting motor constants. (Only under

the vector control mode.)

Modified constants: For referencing or changing user constants after shipping.

Classified by application.

Classified by function. (See user constants.)

Individual user constant settings.

The VS-616G5 allows the following three access levels to be set in order to further simplify setting user constants. (An access level is a range of user constants that can be referenced or set.)

Quick-Start

Basic

Advanced

Reads/sets user constants required for trial operation. [Factory setting]

Reads/sets user constants that are commonly used.

Reads/sets all the user constants that can be used.

In general, press the DATA/ENTER Key to move from an upper to a lower level. This varies somewhat, however, according to the access level, as shown in Fig. 1.1. For the Quick-Start access level, which has few user constants that can be set, pressing the DATA/ENTER Key jumps directly to the user constant level; whereas for the Advanced access level, which has many user constants, pressing the DATA/ENTER Key first leads to the Group level.

Operation mode

Initialize mode

Programming mode

DATA

ENTER

[Advanced] [Basic] [Quick-Start]

Displays group level.

Application

Displays function level.

b1 Sequence

Constant to be changed

Displays constant level.

b1-01 Reference source

b1-02 Run source

b1-03 Stopping method

Tuning

Reference

[Mode]

[Groups]

Fig 1.1 Access Level Structure

1-6

C1 Accel/Decel

C2 S-curve Acc/Dec

[Functions]

C1-01 Accel Time 1

C1-02 Decel Time 1

[Constants]

1.2 Nomenclature

This section provides the names of VS-616G5 components, and the components and functions of the Digital Operator.

1.2.1 VS-616G5 Components

The appearance of Inverter and the names of its components are shown in Figure 1.2.

1.2 Nomenclature

Protective cover (top)

Mounting hole

Front cover

Digital Operator JVOP-130

Die-cast case

Protective cover (bottom)

Fig 1.2 Appearance of VS-616G5, Model CIMR-G5A20P4 (200 V, 0.4 kW)

A 200 V Class Inverter with 0.4 kW Output is shown below with the front cover removed.

Control circuit terminals

11 12(G) 13 14 15 16 17 25 26 27 33 18 19 20

1234567821 22 23 9

Power input

¨1

¨2B1

Braking Resistor

Motor output

W/T3

CHARGE

Fig 1.3 Terminal Arrangement

Main circuit terminals

1-7

Introduction

1.2.2 Digital Operator Components

This section describes the component names and functions of the Digital Operator. The component names and functions are shown in Figure 1.4 and key functions are described in Table 1.4.

DRIVE FWD REV REMOTE

Frequency Ref

U1−01 = 00.00 HZ

DIGITAL OPERATOR JVOP−130

LOCAL

REMOTE

JOG

FWD

REV

RUN STOP

SEQ REF

ESC

DATA

ENTER

RESET

Operation Mode Indicators

DRIVE: Lit when in operation mode. FWD: Lit when there is a forward reference input. REV: Lit when there is a reverse reference input. SEQ: Lit when an operation reference from the

control circuit terminal is enabled.

REF: Lit when the frequency reference from con-

trol circuit terminals 13 and 14 is enabled.

Data Display

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

Keys

Execute operations such as setting user constants, monitoring, jogging, and autotuning.

Fig 1.4 Digital Operator Component Names and Functions

1-8

Table 1.4 Key Functions

Key Name Function

Switches between (LOCAL) operation via the Digital Operator

LOCAL

REMOTE

LOCAL/REMOTE Key

and control circuit terminal (REMOTE) operation.

This key can be enabled or disabled by setting a user constant (o2-01).

1.2 Nomenclature

ESC

JOG

FWD REV

RESET

DATA

ENTER

RUN

MENU Key Displays menus.

ESC Key

JOG Key

FWD/REV Key

RESET Key

Increment Key

Decrement Key

DATA/ENTER Key

RUN Key

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

Enables jog operation when the VS-616G5 is being operated from the Digital Operator.

Selects the rotation direction of the motor when the VS-616G5 is being operated from the Digital Operator.

Sets the number of digits for user constant settings.

Also acts as the reset key when a fault has occurred.

Selects menu items, groups, functions, and user constant names, and increments set values.

Selects menu items, groups, functions, and user constant names, and decrements set values.

Enters menu items, functions, constants, and set values after they are set.

Starts the VS-616G5 operation when the VS-616G5 is in operation with the Digital Operator.

Stops VS-616G5 operation.

STOP

STOP Key

This key can be enabled or disabled by setting a user constant (o2-02) when operating from the control circuit terminal.

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

FWD

REV

RUN STOP

RESET

Inverter output frequency

STOP

Frequency setting

RUN

Blinking:Not lit

Lit

RUN

The RUN and STOP indicators light and blink to indicate operating status. During DB (initial excitation), RUN blinks and STOP is turned ON.

Fig 1.5 RUN and STOP Indicators

STOP

1-9

Handling Inverters

This chapter describes the checks required upon receiving a VS-616G5 Inverter and describes installation methods.

2.1 Confirmations upon Delivery 2 - 2............

2.1.1 Nameplate Information 2 -

2.2 Exterior and Mounting Dimensions 2 - 4.......

2.3 Checking and Controlling the

Installation Site 2 - 6.......................

2.3.1 Installation Site 2 - 6..............................

2.3.2 Controlling the Ambient Temperature 2 - 6...........

2.3.3 Protecting the Inverter from Foreign Matter 2 - 6......

2.4 Installation Orientation and Space 2 - 7.......

2.5 Removing/Attaching the Digital Operator

and Front Cover 2 - 8......................

2.5.1 Inverters of 15 kW or Less 2 - 8....................

2.5.2 Inverters of 18.5 kW or Higher 2 - 9.................

.......................

2-1

 



Handling Inverters

2.1.1 Nameplate Information

2.1 Confirmations upon Delivery

D Never install an Inverter that is damaged or missing components.

Doing so can result in injury.

Check the following items as soon as the Inverter is delivered.

Table 2.1 Checks

Item Method

Has the correct model of Inverter been delivered?

Is the Inverter damaged in any way? Inspect the entire exterior of the Inverter to see if there are any scratches or

Are any screws or other components loose?

If you find any irregularities in the above items, contact the agency from which you purchased the Inverter or your Yaskawa representative immediately.

CAUTION

Check the model number on the nameplate on the side of the Inverter (See

2.1.1).

other damage resulting from shipping.

Use a screwdriver or other tools to check for tightness.

2.1.1 Nameplate Information

Example Nameplate

Standard domestic (Japan) Inverter: 3-phase, 200 VAC, 0.4 kW, IEC IP20 and NEMA 1 standards

Model number

Input specifications

Output specifications

Lot number

Serial number

J Inverter Model Numbers

Inverter

VS-616G5

No. Specification

A Standard domestic model V UL/C-UL model

No. Voltage Class

2 AC input, 3-phase, 200 V 4 AC input, 3-phase, 400 V D DC input, 3-phase, 200 V E DC input, 3-phase, 400 V

MODEL : CIMR-G5A20P4 SPEC: 20P41F

INPUT : AC 3PH 200-220 V 50Hz

OUTPUT: AC 3PH 0-230 V 1.2kVA 3.2 A

LOT NO : MASS : 3.0kg

SER NO :

YASKAWA ELECTRIC CORPORATION

200-230 V 60Hz

JAPAN

CIMR -G5A 2 0P4

No. Max. Motor Capacity

0P4 0P7

075

“P” indicates the decimal point.

Inverter specifications

Mass

0.4 kW

0.75 kW to

75kW

2-2

Inverter Specifications

2.1 Confirmations upon Delivery

2 0P4 1 F

No. Voltage Class

2 AC input, 3-phase, 200 V 4 AC input, 3-phase, 400 V D DC input, 3-phase, 200 V E DC input, 3-phase, 400 V

No. Max. Motor Capacity

0P4 0P7

075

“P” indicates the decimal point.

Open Chassis Type (IEC IP00)

0.4 kW

0.75 kW to

75kW

Protected so that parts of the human body cannot reach electrically charged parts from the front when the Inverter is mounted in a control panel.

Enclosed Wall-mounted Type (IEC IP20, NEMA 1)

The Inverter is structured so that the Inverter is shielded from the exterior, and can thus be mounted to the interior wall of a standard building (not necessarily enclosed in a control panel). The protective structure conforms to the standards of NEMA 1 in the USA.

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

No. Protective Structure

0 1

Enclosed wall-mounted (IEC IP20, NEMA 1)

Open chassis (IEC IP00)

2-3

Handling Inverters

2.2 Exterior and Mounting Dimensions

200 V/400 V Class Inverters of 15 kW and Lower

The following diagram shows a 200 V class, 1.5 kW Inverter.

Remove the top and bottom covers when mounting 200 V/400 V class Inverters of 15 kW or lower in a control panel.

200 V/400 V Class Inverters of 18.5 kW and Higher

4-d

The following diagram shows a 200 V class, 18.5 kW Inverter.

4-d

J Mounting Dimensions for 400 V Class Inverters of 185 to 300 kW

W2 W3

Max. Applicable Motor

Capacity

[kW]

185, 220

300

2-4

W1 W2 W3 W4 W5 W6

750 440 310 850 285 565

750 440 310 873 298 575

Volt-

tion

200

tion

class

age

class

200 V class

400 V

Max. Ap-

plicable

Motor Out-

put

[kW]

0.4

0.75

1.5

2.2

3.7

5.5

7.5

18.5

0.4

0.75

1.5

2.2

3.7

5.5

7.5

18.5

110

160

185

220

300

2.2 Exterior and Mounting Dimensions

Table 2.2 VS-616G5 External Dimensions (mm) and Approx. Masses (kg)

Open Chassis (IP00) Enclosed Wall-mounted (NEMA1)

W H D W1 H1 H2

Approx.

Mass

W H D W1 H1 H2

140 280 160 126 266 7.0 3 140 280 160 126 266 7.0 3 M5

140 280 180 126 266 7.0 4.5 140 280 180 126 266 7.0 4.5 M5

5.5

200 300 205 186 285 8.0

250 380 225 236 365 7.5 11 250

325 450 285 275 435 7.5 28 330

200 300 205 186 285 8.0

380

225 236 365

400

610

285 275 435

675

7.5

27.5

87.5

152.5

425 675 350 320 650 12.5

430 985 350 320 650 212.5

475 800 350 370 775 12.5 80 480 1110 350 370 775 212.5 87 M10

575 925 400 445 895 15.0 135 580 1290 400 445 895 270 145 M12

140 280 160 126 266 7.0 3 140 280 160 126 266 7.0 3 M5

4 4

140 280 180 126 266 7.0

4.5 4.5

200 300 205 186 285 8.0 6 200 300 205 186 285 8.0 6 M6

250 380 225 236 365 7.5 11 250 380 225 236 365 7.5 11 M6

325 450 285 275 435 7.5

325 625 285 275 610 7.5 44 330

330 610 285 275 435 87.5

785

285 275 610

87.5

850 152.5

455 820 350 350 795 12.5

375

575 925

445 895 15.0

400

950 1450 435 *21400 25 360

460 1130 350 350 795 212.5

135

145

580 1290

375

445 895 270

400



960 1600 455 *21550 25 420

Approx.

Mass

5.5

11 M6

32 M6

48 M6

145

155

Mounting

Holes

d*1

M10

M12

Reac-

tor

Op-

Built-

Op-

Built-



* 1. Same for open chassis and enclosed wall-mounted types.

* 2. See page 2 - 4 for mounting dimensions.

Note An attachment is required to mount the cooling fins (fin section) on the outside of the control panel for 200 V/400 V class

Inverters of 15 kW or less. Please contact your Yaskawa representative for details. Dimensional drawings for models with externally mounted cooling fins and other special requirements are also available from your Yaskawa representative.

2-5

Handling Inverters

2.3.1 Installation Site

2.3 Checking and Controlling the Installation Site

CAUTION

D Always hold the case when carrying the Inverter.

If the Inverter is held by the front cover,the main body of the Inverter may fall, possibly resulting in injury.

D Attach the Inverter to a metal or other noncombustible material.

Fire can result if the Inverter is attached to a combustible material.

D Install a cooling fan or other cooling device when installing more than one Inverter in the same

enclosure so that the temperature of the air entering the Inverters is below 45_C.

Overheating can result in fires or other accidents.

Install the VS-616G5 in the installation site described below and maintain optimum conditions.

2.3.1 Installation Site

Install the Inverter under the following conditions.

Type Ambient Operating Temperature Humidity

Enclosed wallmounted

Open chassis

−10 to 40_C

−10 to 45_C 90% RH or less (no condensation)

90% RH or less (no condensation)

Protection covers are attached to the top and bottom of the Inverter. Be sure to remove the protection covers before installing a 200 or 400 V Class Inverter with an output of 15 kW or less in a panel.

Install the Inverter in a clean location free from oil mist and dust. It can be installed in a totally enclosed

panel that is completely shielded from floating dust.

When installing or operating the Inverter, always take special care so that metal powder, oil, water, or

other foreign matter does not get into the Inverter.

Do not install the Inverter on combustible material, such as wood.

Install the Inverter in a location free from radioactive materials and combustible materials.

Install the Inverter in a location free from harmful gasses and liquids.

Install the Inverter in a location without excessive oscillation.

Install the Inverter in a location free from chlorides.

Install the Inverter in a location not in direct sunlight.

2.3.2 Controlling the Ambient Temperature

To enhance the reliability of operation, the Inverter should be installed in an environment free from extreme temperature increases. If the Inverter is installed in an enclosed environment, such as a box, use a cooling fan or air conditioner to maintain the internal air temperature below 45°C.

2.3.3 Protecting the Inverter from Foreign Matter

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

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

2-6

2.4 Installation Orientation and Space

Install the Inverter on a vertical surface so as not to reduce the cooling effect. When installing the Inverter, always provide the following installation space to allow normal heat dissipation.

2.4 Installation Orientation and Space

IMPORTANT

50 mm min.

120 mm min.

30 mm min.30 mm min.

50 mm min.

(a) Horizontal Space

Fig 2.1 VS-616G5 Installation Orientation and Space

S The same space is required horizontally and vertically for both open chassis (IP00) and enclosed

wall-mounted (IP20, NEMA 1) Inverters.

Always remove the protection covers before installing a 200 or 400 V Class Inverter with an output

of 15 kW or less in a panel.

Always provide enough space for suspension eye bolts and the main circuit lines when installing a

200 or 400 V Class Inverter with an output of 30 kW or more in a panel.

120 mm min.

(b) Vertical Space

Air

2-7

Handling Inverters

2.5.1 Inverters of 15 kW or Less

2.5 Removing/Attaching the Digital Operator and Front Cover

Remove the front cover to wire the terminals.

For models of 15 kW or less (both 200 V and 400 V class), do not remove or mount the front cover without first removing the Digital Operator; otherwise, the Digital Operator may malfunction due to imperfect contact. Use the following procedures to remove or attach the front cover.

2.5.1 Inverters of 15 kW or Less

Removing the Digital Operator

Press the lever on the side of the Digital Operator in the direction of arrow 1 to unlock the Digital Operator and lift the Digital Operator in the direction of arrow 2 to remove the Digital Operator as shown in the following illustration.

Front cover

Digital Operator

Fig 2.2 Removing the Digital Operator

J Removing the Front Cover

Press the left and right sides of the front cover in the directions of arrows 1 and lift the bottom of the cover in the direction of arrow 2 to remove the front cover as shown in the following illustration.

Front cover

Fig 2.3 Removing the Front Cover

J Mounting the Front Cover

After wiring the terminals, mount the front cover to the Inverter by performing in reverse order to the steps to remove the front cover.

Do not mount the front cover with the Digital Operator attached to the front cover; otherwise, Digital

Operator may malfunction due to imperfect contact.

Insert the tab of the upper part of the front cover into the groove of the Inverter and press the lower

part of the front cover onto the Inverter until the front cover snaps shut.

2-8

Mounting the Digital Operator

Hook the Digital Operator at A (two locations) on the front cover in the direction of arrow 1 as shown

in the following illustration.

Press the Digital Operator in the direction of arrow 2 until it snaps in place at B (two locations).

Digital Operator

Front cover

2.5 Removing/Attaching the Digital Operator and Front Cover

Fig 2.4 Mounting the Digital Operator

IMPORTANT

1. Do not remove or attach the Digital Operator or mount or remove the front cover using methods other than those described above, otherwise the Inverter may break or malfunction due to imperfect contact.

2. Never attach the front cover to the Inverter with the Digital Operator attached to the front cover. Imperfect contact can result.

Always attach the front cover to the Inverter by itself first, and then attach the Digital Operator to the front cover.

2.5.2 Inverters of 18.5 kW or Higher

The front cover can be removed without removing the Digital Operator from the Inverter provided that the Inverter has an output of 18.5 kW or higher.

Loosen the four screws of the front cover and move the front cover slightly upwards to remove the front cover.

2-9

Wiring

This chapter describes wiring terminals, main circuit terminal connections, main circuit terminal wiring specifications, control circuit terminals, and control circuit wiring specifications.

3.1 Connections to Peripheral Devices 3 - 3......

3.2 Connection Diagram 3 - 4...................

3.3 Terminal Block Configuration 3 - 5............

3.4 Wiring Main Circuit Terminals 3 - 6...........

3.4.1 Applicable Wire Sizes and Closed-loop

Connectors 3 - 6...............................

3.4.2 Main Circuit Terminal Functions 3 - 9...............

3.4.3 Main Circuit Configurations 3 - 10...................

3.4.4 Standard Connection Diagrams 3 - 12...............

3.4.5 Wiring the Main Circuits 3 - 13......................

3.5 Wiring Control Circuit Terminals 3 - 20.........

3.5.1 Wire Sizes and Closed-loop Connectors 3 - 20........

3.5.2 Control Circuit Terminal Functions 3 - 21.............

3.5.3 Control Circuit Terminal Connections (All Models) 3 - 22

3.5.4 Control Circuit Wiring Precautions 3 - 23.............

3.6 Wiring Check 3 - 23.........................

3.7 Installing and Wiring PG Speed Control

Cards 3 - 24...............................

3.7.1 Installing a PG Speed Control Card 3 - 24............

3.7.2 PG Speed Control Card Terminal Blocks 3 - 25........

3.7.3 Wiring a PG Speed Control Card 3 - 27..............

3.7.4 Wiring PG Speed Control Card Terminal Blocks 3 - 31.

3.7.5 Selecting the Number of PG (Encoder) Pulses 3 - 33...

3-1

Wiring

WARNING

D Always turn OFF the input power supply before wiring terminals.

Otherwise, an electric shock or fire can occur.

D Wiring must be performed by an authorized person qualified in electrical work.

Otherwise, an electric shock or fire can occur.

D Be sure to ground the ground terminal.

(200 V class: Ground to 100 Ω or less, 400 V class: Ground to 10 Ω or less) Otherwise, an electric shock or fire can occur.

D Always check the operation of any emergency stop circuits after they are wired.

Otherwise, there is the possibility of injury. (Wiring is the responsibility of the user.)

D Never touch the output terminals directly with your hands or allow the output lines to come into

contact with the Inverter case. Never short the output circuits.

Otherwise, electrical shock or grounding can occur.

CAUTION

D Check to be sure that the voltage of the main AC power supply satisfies the rated voltage of the

Inverter.

Injury or fire can occur if the voltage is not correct.

D Do not perform voltage withstand tests on the Inverter.

Otherwise, semiconductor elements and other devices can be damaged.

D Connect braking resistors, Braking Resistor Units, and Braking Units as shown in the I/O wiring

examples.

Otherwise, a fire can occur.

D Tighten all terminal screws to the specified tightening torque.

Otherwise, a fire may occur.

D Do not connect AC power to output terminals U, V, and W.

The interior parts of the Inverter will be damaged if voltage is applied to the output terminals.

D Do not connect phase-advancing capacitors or LC/RC noise filters to the output circuits.

The Inverter can be damaged or internal parts burnt if these devices are connected.

D Do not connect electromagnetic switches or contactors to the output circuits.

If a load is connected while the Inverter is operating, surge current will cause the overcurrent protection circuit inside the Inverter to operate.

3-2

3.1 Connections to Peripheral Devices

Examples of connections between the VS-616G5 and typical peripheral devices are shown in Figure 3.1. Use this illustration to gain an understanding of the overall equipment configuration.

Power supply

Molded-case circuit breaker or ground fault interrupter

Magnetic contactor

3.1 Connections to Peripheral Devices

AC reactor for power factor improvement

Input noise filter

VS-616G5

Ground

DC reactor for power factor improvement

Output noise filter

Motor

Ground

Fig 3.1 Example Connections to Peripheral Devices

3-3

Wiring

3.2 Connection Diagram

The connection diagram of the VS-616G5 is shown in Figure 3.2.

When using the Digital Operator, the motor can be operated by wiring only the main circuits.

External frequency references

3-phase power 200 to 230 V 50/60 Hz

Factorypreset functions

2kΩ

MCCB

Forward Run/Stop

Reverse Run/Stop

External fault

Fault reset

Multi-step speed setting 1 (Master/auxiliary switch)

Multi-step speed setting 2

Jog frequency reference

External baseblock command

2kΩ

0to10V

4to20mA

0to10V

DC reactor to improve input power factor (optional)

Short-circuit bar

¨ 1B1B2

¨ 2

R (L1)

S (L2)

T (L3)

VS-616G5

Forward run command (forward when closed)

Reverse run command (reverse when closed)

Multi-function contact inputs

Sequence common

(Insulated from 0 V terminal)

12 Shield wire connection terminal

15 Frequency setting power

15 V, 20 mA

13 Master speed reference

−10 to 10 V (20 kΩ) (Default: 0 to 10 V/100%)

14 Master speed reference

4 to 20 mA (250 Ω)

16 Multi-function analog input

(−10 to 10 V (20 kΩ)

(Default: Auxiliary frequency

33 Frequency setting

power:

−15 V, 20 mA

Analog monitor 2

Analog monitor 1

reference 0 to 10 V/100%)

Braking Resistor Unit (Optional)

U (T1)

V (T2)

W (T3)

(12)

Motor

(Ground to 100 Ω max.)

−

Fault contact output 250 VAC, 1 A max. 30 VDC, 1 A max.

Multi-function contact output 250 VAC, 1 A max. 30 VDC, 1 A max. (Default: Running signal)

Open collector 1 (Default: Zero speed signal)

Open collector 2 (Default: Speed agree signal)

Multi-function output common

Multi-function analog output

−10 to 10 V (Default: Output current

−

5 V/Inverter rated current)

Multi-function analog output

−10 to10 V (Default: Output frequency

0 to 10 V/100% frequency)

Multi-function open-collector output 48 V , 50 mA max.

* Shield

* Twisted-pair wires

Fig 3.2 Connection Diagram (Model CIMR-G5A27P5 Shown Above)

3-4

3.3 Terminal Block Configuration

IMPORTANT

1. Control circuit terminals 1 to 33 are not arranged in order of terminal numbers; they are arranged as shown below. Be sure to wire them correctly.

123 4567 8

13 14 15 16 17

2. Do not use control circuit terminals 13 and 14 at the same time. (The two signals will be added inside the Inverter if they are input at the same time.)

3. The maximum output current capacity of the +15 V/−15 V output from control circuit terminals 15 and 33 is 20 mA.

4. The multi-function analog output is a dedicated meter output for a frequency meter, ammeter, etc. Do not use this output for feedback control or for any other control purpose. Use one of the optional Analog Monitor Cards (AO-08 or AO-012) for analog outputs to the control system.

5. Disable the stall prevention during deceleration (set constant L3-04 to 0) when using a Braking Resistor Unit. If this user constant is not changed to disable stall prevention, the system may not stop during deceleration.

6. Enable protection for the internal DB resistor (model ERF) (set constant L8-01 to 1) when using an internal braking resistor. The braking resistor will not be protected unless this setting is changed to enable protection.

7. DC reactors to improve the input power factor can be connected as an option only to Inverters for 15 kW or less. Remove the short bar from between ¨1 and ¨2 when connecting a DC reactor.

8. There is no DC power supply input terminals for 200 V class Inverters of 30 to 75 kW and 400 V class Inverters of 55 to 160 kW, and DC power cannot be input to these Inverters.

3.3 Terminal Block Configuration

25 26 27 33 18 19 2011 12(G)

21 22 23 9 10

The terminal block for a 200 V class Inverter with an output of 0.4 kW is shown in Figure 3.3.

11 12(G) 13 14 15 16 17 25 26 27 33 18 19 20

CHARGE

W/T3

1234567821 22 23 9

Power input Braking resistor Motor output

¨ 1

¨ 2B1

Fig 3.3 Terminal Arrangement

Control circuit terminals

Main circuit terminals

3-5

G5A20P4

2to5.5

G5A20P7

2to5.5

G5A22P2

3.5to5.5

G5A23P7

5.5

G5A2018

Mai

600Vvinyl

Circuits

G5A2022

cables

Wiring

3.4.1 Applicable Wire Sizes and Closed-loop Connectors

3.4 Wiring Main Circuit Terminals

3.4.1 Applicable Wire Sizes and Closed-loop Connectors

Select the appropriate wires and crimp terminals from Table 3 .1 to Table 3 . 3 . Refer to instruction manual TOE-C726-2j for wire sizes for Braking Resistor Units and Braking Units.

Table 3.1 200 V Class Wire Sizes

Circuit

Circuits

Control Circuits

Note The wire thickness is set for copper wires at 75°C.

VS-616G5 Model

CIMR-

G5A21P5

G5A25P5

G5A27P5

G5A2011

G5A2015

G5A2018

G5A2022

G5A2030

G5A2037

G5A2045

G5A2055

G5A2075

All models

Terminal Symbol

R, S, T, © , ¨ 1,¨ 2, B1, B2, U, V, W

R, S, T, © , ¨ 1,¨ 2, ¨ 3, U, V, W

R, S, T, © , ¨ 1,¨ 2, ¨ 3, U, V, W M8 30

R, S, T, © , ¨ 1,¨ 2, ¨ 3, U, V, W

r, M4 0.5 to 5.5

R, S, T, © , ¨ 1,¨ 2, ¨ 3, U, V, W

r, M4 0.5 to 5.5

R, S, T, U, V, W M10 38 to 100

r, M4 0.5 to 5.5

R, S, T, U, V, W M10 38 to 100

r, M4 0.5 to 5.5

R, S, T, U, V, W M10 60 to 100

r, M4 0.5 to 5.5

R, S, T, U, V, W M10 100

r, M4 0.5 to 5.5

R, S, T, U, V, W M12 100 to 200

r, M4 0.5 to 5.5

1to33 M3.5 0.5 to 2 Shielded twisted-pair wires

Termi-

Screws

Wire Thickness

nal

M6 8

M8 22

M8 30

M8 50

(see note)

2 to 5.5

3.5 to 5.5

5.5 to 8



Wire Type

Power cables, e.g., er cables

pow-

3-6

Table 3.2 400 V Class Wire Sizes

G5A40P4

G5A40P7

G5A41P5

G5A42P2

G5A45P5

G5A47P5

G5A4018

G5A4022

G5A4030

G5A4037

G5A4045

G5A4185

G5A4220

Main

VS-616G5 Model

CIMR-

G5A43P7

G5A4011

G5A4015

G5A4018

G5A4022

G5A4030

G5A4037

G5A4045

G5A4055

G5A4075

G5A4110

G5A4160

G5A4185

G5A4220

G5A4300

All models

Terminal Symbol

R, S, T, © , ¨ 1,¨ 2, B1, B2, U, V, W

R, S, T, © , ¨ 1,¨ 2, B1, B2, U, V,W

R, S, T, © , ¨ 1,¨ 2, B1, B2, U, V, W

R, S, T, © , ¨ 1,¨ 2, B1, B2, U, V, W M5 8to14

R, S, T, © , ¨ 1,¨ 2, ¨ 3, U, V, W M6 14

r, M4 0.5 to 5.5

R, S, T, © , ¨ 1,¨ 2, ¨ 3, U, V, W M6 22

r, M4 0.5 to 5.5

R, S, T, © , ¨ 1,¨ 2, ¨ 3, U, V, W

r, M4 0.5 to 5.5

R, S, T, © , ¨ 1,¨ 2, ¨ 3, U, V, W

r, M4 0.5 to 5.5

R, S, T, © , ¨ 1,¨ 2, ¨ 3, U, V, W

r, M4 0.5 to 5.5

R, S, T, U, V, W M10 38 to 100

r , 200, 400 M4 0.5 to 5.5

R, S, T, U, V, W M10 38 to 100

r , 200, 400 M4 0.5 to 5.5

R, S, T, U, V, W M10 60 to 100

r , 200, 400 M4 0.5 to 5.5

R, S, T, U, V, W M12 100 to 200

r , 200, 400 M4 0.5 to 5.5

R, S, T, © , ¨ 1,¨ 3, U, V, W M16 250 to 325

r , 200, 400 M4 0.5 to 5.5

R, S, T, © , ¨ 1,¨ 3, U, V, W M16 325 or 200×2P

r , 200, 400 M4 0.5 to 5.5

R, S, T, © , ¨ 1,¨ 3, U, V, W M16

r , 200, 400 M4 0.5 to 5.5

1to33 M3.5 0.5 to 2

Circuit

Circuits

Control Circuits

Note The wire thickness is set for copper wires at 75°C.

Termi-

nal

Wire Thickness

(see note)

Screws

M4 2 to 5.5

M4 3.5 to 5.5

M5 5.5

M6 8

M8 8

M8 22

M8 30

M8 50

M8 60

2 to 5.5

3.5 to 5.5

250 × 2P or 325



× 2P

3.4 Wiring Main Circuit Terminals

Wire Type

Power cables, e.g., 600 V vinyl power cables

Shielded twisted-pair wires

3-7

Wiring

3.4.1 Applicable Wire Sizes and Closed-loop Connectors

Table 3.3 Closed-loop Connector Sizes (JIS C 2805) (For 200 V/400 V Classes)

Wire Thickness mm

0.5

0.75

1.25

3.5/5.5

30/38 M8 38 to 8

50/60

100

100 100 to 12

150

200 200 to 12

325

Terminal Screws Size

M3.5 1.25 to 3.5

M4 1.25 to 4

M3.5 1.25 to 3.5

M4 1.25 to 4

M3.5 1.25 to 3.5

M4 1.25 to 4

M3.5 2 to 3.5

M4 2to4

M5 2to5

M6 2to6

M8 2to8

M4 5.5 to 4

M5 5.5 to 5

M6 5.5 to 6

M8 5.5 to 8

M5 8to5

M6 8to6

M8 8to8

M6 14 to 6

M8 14 to 8

M6 22 to 6

M8 22 to 8

M8 60 to 8

M10 60 to 10

M10

M12

M12 × 2 325 to 12

M16 325 to 16

80 to 10

100 to 10

150 to 12

IMPORTANT

Determine the wire size for the main circuit so that line voltage drop is within 2% of the rated voltage.

Line voltage drop is calculated as follows:

(If there is the possibility of excessive voltage drop, use a larger wire suitable to the required length.) Line voltage drop



(V) = 3

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

3-8

−3

3.4.2 Main Circuit Terminal Functions

Main circuit terminal functions are summarized according to terminal symbols in Table 3.4 and Table

3.5. Wire the terminals correctly for the desired purposes.

Table 3.4 200 V Class Main Circuit Terminal Functions

Purpose Terminal Symbol

Main circuit power input

Inverter outputs

DC power input

Braking Resistor Unit connection

DC reactor connection

Braking Unit connection

Cooling fan power input

Cooling fan power input (control power input)

Ground

Note 1.Models CIMR-G5A2030 to 2075 do not support DC power input.

2. When using this terminal as an input for DC power supply, special considerations are required. Be sure to consult our sales representative.

Table 3.5 400 V Class Main Circuit Terminal Functions

Purpose Terminal Symbol

Main circuit power input

Inverter outputs

DC power input

Braking Resistor Unit connection

DC reactor connection

Braking Unit connection

Cooling fan power input

Cooling fan power input (control power input)

Ground

r − 200: 200 to 230 VAC input

r − 400: 380 to 460 VAC input

3.4 Wiring Main Circuit Terminals

Model: CIMR-G5A

R (L1), S (L2), T (L3) 20P4 to 2075

U (T1), V (T2), W (T3) 20P4 to 2075, D030 to D075 (all models)

¨ 1 − ©

B1, B2 20P4 to 27P5

¨ 1 − ¨ 2

¨ 3 − © (see note 2)

R (L1), S (L2), T (L3) 40P4 to 4300

U (T1), V (T2), W (T3) 40P4 to 4300, E055 to E160 (all models)

¨ 1 − ©

B1, B2 40P4 to 4015

¨ 1 − ¨ 2

¨ 3 − © (see note 2)

20P4 to 2022, D030 to D075

20P4 to 2015

2011 to 2075, D030 to D075

2018 to 2022

2030 to 2075, D030 to D075

20P4 to 2075, D030 to D075 (all models)

Model: CIMR-G5A

40P4 to 4045, 4185 to 4300, E055 to E160

40P4 to 4015

4018 to 4300, E055 to E160

4018 to 4045

4055 to 4300, E055 to E160

40P4 to 4300, E055 to E160 (all models)

Note 1.Models CIMR-G5A4055 to 4160 do not support DC power input.

2. When using this terminal as an input for DC power supply, special considerations are required. Be sure to consult our sales representative.

3-9

Wiring

3.4.3 Main Circuit Configurations

200 V Class

The main circuit configurations are shown in Figure 3.4 and Figure 3.5.

CIMR-G5A20P4 to 21P5 (0.4 to 1.5 kW)

B2B1

U(T1)

Control circuits

V(T2)

W(T3)

(DCL

option)

¨1 ¨2

R(L1)

S(L2)

T(L3)

Power supply (RCC)

CIMR-G5A2011 to 2015 (11, 15 kW)

¨3

Fin cooling fan

Control circuits

U(T1)

V(T2)

W(T3)

(DCL option)

¨1

¨2

R(L1)

S(L2)

T(L3)

Power supply (RCC)

CIMR-G5A22P2 to 27P5 (2.2 to 7.5 kW)

B2B1

U(T1)

Control circuits

V(T2)

W(T3)

(DCL option)

¨1 ¨2

R(L1)

S(L2)

T(L3)

Power supply (RCC)

Fin cooling fan

CIMR-G5A2018 to 2022 (18.5, 22 kW)

¨1 ¨2

Fin cooling fan

Power supply (RCC)

¨3

Internal cooling fan

Control circuits

CIMR-G5A2030 to 2075 (30 to 75 kW)

¨3

Fin cooling fan

Power supply (RCC)

Internal cooling fan

Control circuits

CIMR-G5AD030 to D075 (30 to 75 kW)

¨1

* 1 Prewired at the factory.

* 2 Remove the short-circuit bar from between ¨1 and ¨2 when connecting a DC

reactor to Inverters of 15 kW or less.

* 3 Prewired at the factory. When supplying power to the main circuits from the DC

power supply, remove the wiring from R-r and S- .

Fig 3.4 200 V Class Inverter Main Circuit Configurations

¨3

Power supply (RCC)

Fin cooling fan

Control circuits

3-10

400 V Class

3.4 Wiring Main Circuit Terminals

CIMR-G5A40P4 to 41P5 (0.4 to 1.5 kW)

B2B1

U(T1)

Control circuits

V(T2)

W(T3)

(DCL option)

¨1 ¨2

R(L1)

S(L2)

T(L3)

Power supply (RCC)

CIMR-G5A45P5 to 43P7 (5.5 to 3.7 kW)

B2B1

Control circuits

U(T1)

V(T2)

W(T3)

(DCL option)

¨1 ¨2

R(L1)

S(L2)

T(L3)

Power supply (RCC)

Fin cooling fan

CIMR-G5A42P2 to 43P7 (2.2 to 3.7 kW)

B2B1

U(T1)

Control circuits

V(T2)

W(T3)

(DCL option)

¨1 ¨2

R(L1)

S(L2)

T(L3)

Power supply (RCC)

Fin cooling fan

CIMR-G5A4018 to 4045 (18.5 to 45 kW)

¨1 ¨2

Fin cooling fan

Power supply (RCC)

¨3

Control circuits

Internal cooling fan

CIMR-G5A4055 to 4160 (55 to 160 kW)

¨3

200 400

Fin cooling fan

Power supply (RCC)

Internal cooling fan

Control circuits

CIMR-G5AE055 to E160 (55 to 160 kW)

¨3

¨1

200 400

Fin cooling fan

Power supply (RCC)

Control circuits

CIMR-G5A4185 to 4300 (185 to 300 kW)

Power supply (RCC)

¨3

¨1

200 400

Fin cooling fan

Control circuits

* 1 Prewired at the factory.

* 2 Remove the short-circuit bar from between ¨1 and ¨2 when connecting a DC

reactor to Inverters of 15 kW or less.

* 3 Prewired at the factory. When supplying power to the main circuits from the DC

power supply, remove the wiring from R-r and S- .

Fig 3.5 400 V Class Inverter Main Circuit Configurations

3-11

Wiring

3.4.4 Standard Connection Diagrams

CIMR-G5A20P4 to 27P5, 40P4 to 4015

DC reactor (optional)

©¨1 ¨2B1 B2

3-phase 200 VAC (400 VAC)

Be sure to remove the short-circuit bar before connecting a DC reactor.

Braking Resistor Unit (optional)

CIMR-G5A2018, 2022, 4018 to 4045

Braking Resistor Unit (optional)

Braking Unit (optional)

©¨1 ¨2

¨3

3-phase 200 VAC (400 VAC)

CIMR-G5A2011, 2015

Braking Resistor

¨3

Unit (optional)

Braking Unit (optional)

©¨1 ¨2

DC reactor (optional)

3-phase 200 VAC

Be sure to remove the short-circuit bar before connecting a DC reactor.

CIMR-G5A2030 to 2075

Braking Resistor Unit (optional)

Braking Unit (optional)

3-phase 200 VAC

r*1

©¨3

The DC reactor is built in.

CIMR-G5A4055 to 4160

3-phase 400 VAC

r*1

200

400 *2

¨3

Braking Resistor Unit (optional)

Braking Unit (optional)

The DC reactor is built in.

CIMR-G5A4185 to 4300

¨1

3-phase 400 VAC

r*1

200

400 *2

Braking Resistor Unit (optional)

Braking Unit (optional)

©¨3

The DC reactor is built in.

* 1 Input the control circuit power supply from r− for 200 V class Inverters of 30 to 75 kW (B2030 to B2075) and

from r- 400 for 400 V class Inverters of 55 to 300 kW (B4055 to B4300). (For other models, the control power supply is supplied internally from the main circuit DC power supply.)

* 2 The r−R, ( 400)-Sterminals are short-circuited for shipping. Remove the short wiring from the 2018, 2022,

4018 to 4045 and 4185 to 4300 when supplying power to the main circuits from the DC power supply.

Fig 3.6 Main Circuit Terminal Connections

3-12

3.4.5 Wiring the Main Circuits

200 V class: 3-phase,

200 to 230 VAC, 50/60 Hz

400 V class: 3-phase,

380 to 460 VAC, 50/60 Hz

3.4 Wiring Main Circuit Terminals

This section describes wiring connections for the main circuit inputs and outputs.

Wiring Main Circuit Inputs

Installing a Molded-case Circuit Breaker

Always connect the power input terminals (R, S, and T) and power supply via a molded-case circuit breaker (MCCB) suitable for the Inverter.

Choose an MCCB with a capacity of 1.5 to 2 times the Inverter’s rated current.

For the MCCB’s time characteristics, be sure to consider the Inverter’s overload protection (one min-

ute at 150% of the rated output current).

If the same MCCB is to be used for more than one Inverter, or other devices, set up a sequence so that

the power supply will be turned OFF by a fault output, as shown in Figure 3.7.

Power supply

MCCB

OFF

VS-616G5

Fault output (NC)

* For 400 V class Inverters, connect a 400/200 V transformer.

Fig 3.7 MCCB Installation

Installing a Ground Fault Interrupter

Inverter outputs use high-speed switching, so high-frequency leakage current is generated. Therefore, at the Inverter primary side, use a ground fault interrupter that detects only the leakage current in the frequency range that is hazardous to humans and excludes high-frequency leakage current.

For the special-purpose ground fault interrupter for Inverters, choose a ground fault interrupter with

a sensitivity amperage of at least 30 mA per Inverter.

When using a general ground fault interrupter, choose a ground fault interrupter with a sensitivity am-

perage of 200 mA or more per Inverter and with an operating time of 0.1 s or more.

Installing a Magnetic Contactor

If the power supply for the main circuit is to be shut off during a sequence, a magnetic contactor can be used instead of a molded-case circuit breaker.

When a magnetic contactor is installed on the primary side of the main circuit to forcibly stop the Inverter, however, the regenerative braking does not work and the Inverter will coast to a stop.

The Inverter can be started and stopped by opening and closing the magnetic contactor on the primary

side. Frequently opening and closing the magnetic contactor, however, may cause the Inverter to break down.

When the Inverter is operated with the Digital Operator, automatic operation cannot be performed after

recovery from a power interruption.

If the Braking Resistor Unit is used, program the sequence so that the magnetic contactor is turned OFF

by the contact of the Unit’s thermal overload relay.

Connecting Input Power Supply to the Terminal Block

Input power supply can be connected to any terminal R, S or T on the terminal block; the phase sequence of input power supply is irrelevant to the phase sequence.

3-13

Wiring

3.4.5 Wiring the Main Circuits

Installing an AC Reactor or DC Reactor

If the Inverter is connected to a large-capacity power transformer (600 kW or more) or the phase advancing capacitor is switched, an excessive peak current may flow through the input power circuit, causing the converter unit to break down.

To prevent this, install an optional AC Reactor on the input side of the Inverter or a DC reactor to the DC reactor connection terminals.

This also improves the power factor on the power supply side.

Installing a Surge Absorber

Always use a surge absorber or diode for inductive loads near the Inverter. These inductive loads include magnetic contactors, electromagnetic relays, solenoid valves, solenoids, and magnetic brakes.

Wiring the Power Terminals of Inverters with 18.5 to 300 kW Outputs

For 200 V class Inverters of 18.5 to 75 kW or 400 V class Inverters of 18.5 to 45 kW, connect the r

and

terminals to the R and S terminals respectively. (These are shorted by a short-circuit bar for ship-

ping.)

For 400 V class, 55 to 300 kW, connect the r and 400 terminals to the R and S terminals respectively.

(These are shorted by a short-circuit bar for shipping.)

Installing a Noise Filter on Power Supply Side

Install a noise filter to eliminate noise transmitted between the power line and the Inverter.

Wiring Example 1

Power supply

MCCB

Noise filter

VS-616G5

Other controllers

Use a special-purpose noise filter for Inverters.

Fig 3.8 Correct Power supply Noise Filter Installation

Wiring Example 2

Power supply

MCCB

Generalpurpose noise filter

VS-616G5

Other controllers

Power supply

MCCB

Generalpurpose noise filter

VS-616G5

Other controllers

Do not use general-purpose noise filters. No general-purpose noise filter can effectively suppress noise generated from the Inverter.

Fig 3.9 Incorrect Power supply Noise Filter Installation

3-14

Wiring on the Output Side of Main Circuit

Connecting the Inverter and Motor

Connect output terminals U, V, and W to motor lead wires U, V, and W, respectively.

Check that the motor rotates forward with the forward run command. Switch over any two of the output terminals to each other and reconnect if the motor rotates in reverse with the forward run command.

Never Connect a Power Supply to Output Terminals

Never connect a power supply to output terminals U, V, and W.If voltage is applied to the output terminals, the internal circuits of the Inverter will be damaged.

Never Short or Ground Output Terminals

If the output terminals are touched with bare hands or the output wires come into contact with the Inverter casing, an electric shock or grounding will occur. This is extremely hazardous. Do not short the output wires.

Do Not Use a Phase Advancing Capacitor or Noise Filter

Never to connect a phase advancing capacitor or LC/RC noise filter to an output circuit. Doing so may result in damage to the Inverter or cause other parts to burn.

3.4 Wiring Main Circuit Terminals

Do Not Use an Electromagnetic Switch or Magnetic Contactor

Do not connect an electromagnetic switch or magnetic contactor to an output circuit. If a load is connected to the Inverter during operation, a surge current will actuate the overcurrent protective circuit in the Inverter.

Installing a Thermal Overload Relay

This Inverter has an electronic thermal protection function to protect the motor from overheating. If, however, more than one motor is operated with one Inverter or a multi-polar motor is used, always install a thermal relay (THR) between the Inverter and the motor and set L1-01 to 0 (no motor protection).

Set the thermal overload relay to the value on the motor nameplate when operating at 50 Hz and to 1.1 times the value on the nameplate when operating at 60 Hz. The sequence should be designed so that the contacts of the thermal overload relay turn OFF the magnetic contactor on the main circuit inputs.

Installing a Noise Filter on Output Side

Connect a noise filter to the output side of the Inverter to reduce radio noise and inductive noise.

Power supply

MCCB

VS-616G5

Noise filter

Signal line

Inductive noise

Controller

Radio noise

AM radio

Inductive Noise: Electromagnetic induction generates noise on the signal line, causing the control-

ler to malfunction.

Radio Noise: Electromagnetic waves from the Inverter and cables cause the broadcasting radio

receiver to make noise.

Fig 3.10 Installing a Noise Filter on the Output Side

Countermeasures Against Inductive Noise

As described previously, a noise filter can be used to prevent inductive noise from being generated on the output side. Alternatively, cables can be routed through a grounded metal pipe to prevent inductive noise. Keeping the metal pipe at least 30 cm away from the signal line considerably reduces inductive noise.

Power supply

MCCB

VS-616G5

Metal pipe

30 cm min.

Signal line

Controller

Fig 3.11 Countermeasures Against Inductive Noise

3-15

Wiring

3.4.5 Wiring the Main Circuits

Countermeasures Against Radio Interference

Radio noise is generated from the Inverter as well as from the input and output lines. To reduce radio noise, install noise filters on both input and output sides, and also install the Inverter in a totally enclosed steel box.

The cable between the Inverter and the motor should be as short as possible.

Power supply

MCCB

Noise filter

Fig 3.12 Countermeasures Against Radio Interference

Cable Length between Inverter and Motor

If the cable between the Inverter and the motor is long, the high-frequency leakage current will increase, causing the Inverter output current to increase as well. This may affect peripheral devices. To prevent this, adjust the carrier frequency (set in C6-01 to C6-03) as shown in Table 3.6 . (For details, refer to the user constant settings.)

Table 3.6 Cable Length between Inverter and Motor

Cable length 50 m max. 100 m max. More than 100 m

Carrier frequency

(Set value: C6-01)

(Set value: C6-02)

(Set value: C6-03)

Ground Wiring

Always use the ground terminal of the 200 V Inverter with a ground resistance of less than 100 Ω and

that of the 400 V Inverter with a ground resistance of less than 10 Ω.

Do not share the ground wire with other devices, such as welding machines or power tools.

Always use a ground wire that complies with technical standards on electrical equipment and mini-

mize the length of the ground wire. Leakage current flows through the Inverter. Therefore, if the distance between the ground electrode

and the ground terminal is too long, potential on the ground terminal of the Inverter will become unstable.

When using more than one Inverter, be careful not to loop the ground wire.

Steel box

VS-616G5

15 kHz max. 10 kHz max. 5 kHz max.

Noise filter

(15.0) (10.0) (5.0)

(0) (0) (0)

Metal pipe

NO!

Fig 3.13 Ground Wiring

3-16

Connecting the Braking Resistor (ERF)

tion)

Connect the braking resistor as shown in Figure 3.14.

L8-01 (Overheat protection of braking resistor)

L3-04 (Stall prevention during decelera-

3.4 Wiring Main Circuit Terminals

1 (Enables overheat protection)

0 (Disables stall prevention function)

(Select either one of them.)

VS-616G5

3 (Enables stall prevention function with braking resistor)

Braking resistor

The braking resistor connection terminals are B1 and B2. Do not connect to any other terminals. Connecting to any terminals other than B1 or B2 can cause the resistor to overheat, resulting in damage to the equipment.

Fig 3.14 Connecting the Braking Resistor

Connecting the Braking Resistor Unit (LKEB) and Braking Unit (CDBR)

Connect the Braking Resistor Unit and Braking Unit to the Inverter as shown in the Figure 3.15.

L8-01 (Overheat protection of braking resistor)

L3-04 (Stall prevention during decelera-

(Select either one of them.)

0 (Disables overheat protection)

0 (Disables stall prevention function)

3 (Enables stall prevention function with braking resistor)

Set L8-01 to “1” before operating the Inverter with the braking resistor without thermal overload relay trip contacts.

The Braking Resistor Unit cannot be used and the deceleration time cannot be shortened by the Inverter if L3-04 is set to “1” (i.e., if stall prevention is enabled for deceleration).

To prevent the Unit from overheating, design the sequence to turn OFF the power supply for the thermal overload relay trip contacts of the Unit as shown in Figure 3.15.

200 V Class Inverters with 3.7 to 7.5 kW Output and 400 V Class Inverters with 3.7 to 15 kW Output

LKEB Braking Re-

sistor Unit

VS-616G5

Thermal overload relay trip contact

3-17

Wiring

3.4.5 Wiring the Main Circuits

200 V Class Inverters with 11 kW or higher Output and 400 V Class Inverters with 18.5 or higher Output

LKEB Braking Re-

sistor Unit

VS-616G5

¨3

CDBR Brak-

ing Unit

Thermal overload relay trip contact

Fig 3.15 Connecting the Braking Resistor Unit and Braking Unit

Thermal protector trip contact

3-18

3.4 Wiring Main Circuit Terminals

Connecting Braking Units in Parallel

When connecting two or more Braking Units in parallel, use the wiring and connectors shown in Figure

3.16. There are connectors for selecting whether each Braking Unit is to be a Master or Slave. Select “Mas- ter” for the first Braking Unit only, and select “Slave” for all other Braking Units (i.e., from the second Unit onwards).

Braking resistor overheating contacts (Thermal

¨ 3 ©

protector contacts)

Braking Resistor Unit

©¨0 ©0

MASTER

VS-616G5

Braking Unit #1

Level

detector

SLAVE

+15

434343

Cooling fin overheating contacts (thermoswitch contacts)

Fig 3.16 Connecting Braking Units in Parallel

Power Supply Sequence

MCCB

Three-phase power: 200 to 230 V, 50/60 Hz or 380 to 460 V, 50/60 Hz

T T (L3)

* 400/200 V

Braking resistor overheating contacts (Thermal protector contacts)

Braking Resistor Unit

¨©¨0 ©0 ¨©¨0 ©0

MASTER

SLAVE

Braking Unit #2

Cooling fin overheating contacts (thermoswitch contacts)

Braking Unit #3

Cooling fin overheating contacts (thermoswitch contacts)

R (L1)

S (L2)

Braking resistor overheating contacts (Thermal protector contacts)

Braking Resistor Unit

MASTER

SLAVE

THRX OFF ON MC

Overload relay trip contact of Braking Resistor Unit

20 18

* Use a transformer with 200 and 400 V outputs for the power supply of the

400 V Inverter.

Fig 3.17 Power Supply Sequence

THRX

TRX

Fault contacts

VS-616G5

3-19

Wiring

3.5.1 Wire Sizes and Closed-loop Connectors

3.5 Wiring Control Circuit Terminals

A control signal line must not be longer than 50 m and must be separated from power lines.

The frequency reference must be input to the Inverter through twisted-pair wires.

3.5.1 Wire Sizes and Closed-loop Connectors

Terminal numbers and wire sizes are shown in Table 3.7.

Table 3.7 Terminal Numbers and Wire Sizes (Same for all Models)

Terminals

1 to 11, 13 to 33 M3.5

12 (G) M3.5 0.5 to 2

The closed-loop connectors and tightening torques for various wire sizes are shown in Table 3.8.

Terminal

Screws

Wire Thickness

Stranded wire: 0.5 to

1.25

Single wire: 0.5 to 1.25

[mm

]

Wire Type

S Shielded, twisted-pair wire

S Shielded,polyethylene-covered, vinyl sheath

cable

Table 3.8 Closed-loop Connectors for Ground Terminal

Wire Thickness

]

[mm

0.5 1.25 to 3.5

0.75

1.25

2 2 to 3.5

Terminal

Screws

M3.5

Crimp Size Tightening Torque (N⋅m)

1.25 to 3.5

0.8

3-20

3.5 Wiring Control Circuit Terminals

(

)

Phot

H1-06.)

Analog

Master

speed

frequence

refer-

sg as

Running

signal

(1NO

contact)

Contact

capacity:

Open-collector

output

signals

pg()

FaultwhenOPEN

d201

250VAC

Analog

2mA

3.5.2 Control Circuit Terminal Functions

The functions of the control circuit terminals are shown in Table 3.9 . Use the appropriate terminals for the correct purposes.

Table 3.9 Control Circuit Terminals

Type No. Signal Name Function Signal Level

Forward run/stop command Forward run when CLOSED; stopped when OPEN.

Reverse run/stop command Reverse run when CLOSED; stopped when OPEN.

External fault input

Se-

quence

npu

signals

input

signals

Se-

quence

output

signals

* When driving an L load, such as a relay coil, always insert a flywheel diode as shown in Figure 3.18.

Fault reset Reset when CLOSED

Multi-step speed reference 1

(Master/auxiliary switch)

Multi-step speed reference 2

Jog frequency reference Jog run when CLOSED.

External baseblock

Sequence input common

15 V power output 15 V power supply for analog references

−15 V power output −15 V power supply for analog references

Master speed frequence reference

Multi-function analog input

Control common

Shield wire, optional ground

line connection point

Running signal (1NO contact)

Zero speed detection

Speed agree detection

Open-collector output common

Fault output signal (SPDT)

Frequency output 0 to 10 V/100% frequency

Common

Current monitor 5 V/Inverter’s rated current

Fault when CLOSED; normal when OPEN.

Auxiliary frequency reference when CLOSED.

Multi-step setting 2 when CLOSED.

Inverter output stopped when CLOSED.

−10 to 10 V/−100% to 100% 0 to 10 V/100%

4 to 20 mA/100%, −10 to +10 V/−100% to 100% 0 to +10 V/100%

−10 to 10 V/−100% to 100%

0 to 10 V/100%

Operating when CLOSED.

Zero level (b2-01) or below when CLOSED

Within ±2 Hz of set frequency when CLOSED.

Fault when CLOSED across 18 and 20

across19an

Multi-function contact inputs

Command signals can be selected by setting H1-01 to H1-06.



Auxiliary analog input (H3-05)

 

Multi-function outputs



Multi-function analog monitor 1 (H4-01, H4-02)



Multi-function analog monitor 2 (H4-04,H4-05)

24 VDC, 8 mA

ocouplerisolation

15 V (Max. current: 20 mA)

−15 V (Max. current: 20 mA)

−10 to 10 V (20 kΩ), 0to10V(20kΩ)

4 to 20 mA (250 Ω)

−10 to 10 V (20 kΩ), 0to10V(20kΩ)

Dry contacts Contact ca 1 A max. at 250 VAC 1 A max. at 30 VDC

Open-collector output 50 mA max. at 48 V*

Dry contacts Contact capacity:

1 A max. at 30 VDC

0to±10 V max. ±5%

acity:

max. a

max.

External power: 48 V max.

Coil

50 mA max.

Fig 3.18 Flywheel Diode Connection

3-21

Flywheel diode

The rating of the flywheel diode must be at least as high as the circuit voltage.

Wiring

3.5.3 Control Circuit Terminal Connections (All Models)

123 4567 8

3.5.3 Control Circuit Terminal Connections (All Models)

Forward run/stop

Reverse run/stop

Multi-function contact input 1

Multi-function contact input 2

Multi-function contact input 3

Multi-function contact input 4

Multi-function contact input 5

Multi-function contact input 6

Sequence input common

Frequency reference power supply +15 V

Frequency reference power supply −15 V

Frequency reference input (voltage) Frequency reference input (current)

Multi-function analog input

Frequency reference input common

13 14 15 16 17

25 26 27 33 18 19 2011 12(G)

21 22 23 9 10

Fig 3.19 Control Circuit Terminal Arrangement

Connections to VS-616G5 control circuit terminals are shown in Figure 3.20.

3 (External fault)

4 (Fault reset)

5 (Multi-step speed reference 1)

6 (Multi-step speed reference 2)

7 (Jog frequency reference)

8 (External baseblock)

12 (G)

16 (Auxiliary frequency reference)

Fault output (NO)

Fault output (NC)

Fault output common

Multi-function contact output

Multi-function contact output common

Multi-function output 1 (Zero speed signal)

Multi-function output 2 (Speed agree signal)

Multi-function output common

(Running signal)

Multi-function analog output 1

Voltmeter

(Output frequency)

Multi-function analog output 2

Voltmeter (Output current)

Multi-function analog output common

Factory presets are shown in parentheses. When driving an L load, such as a relay coil, always insert a flywheel diode as shown in Figure 3.18.

Fig 3.20 Control Circuit Terminal Connections

3-22

3.5.4 Control Circuit Wiring Precautions

Separate control circuit wiring (terminals 1 to 33) from main circuit wiring (terminals R, S, T, B1, B2, U, V, W, ©, ¨1, ¨2, and ¨3) and other high-power lines.

Separate wiring for control circuit terminals 9, 10, 18, 19, and 20 (contact outputs) from wiring for

terminals 1 to 8, 21, 22, 23, 25, 26, 27, 33 and 11 to 17.

Use shielded twisted-pair cables for control circuits to prevent operating faults. Process cable ends as

shown in Figure 3.21.

Connect the shield wire to terminal 12(G).

Insulate the shield with tape to prevent contact with other signal lines and equipment.

Shield sheath

Connect to shield sheath terminal at VS-616G5 (terminal 12)

Fig 3.21 Processing the Ends of Twisted-pair Cables

Insulate with tape

3.6 Wiring Check

Armor

Do not connect here.

3.6 Wiring Check

Check all wiring after wiring has been completed. Do not perform a buzzer check on control circuits.

Is all wiring correct?

Have any wire clippings, screws, or other foreign material been left?

Are all screws tight?

Are any wire ends contacting other terminals?

3-23

Wiring

3.7.1 Installing a PG Speed Control Card

3.7 Installing and Wiring PG Speed Control Cards

PG Speed Control Cards are used for executing speed control using a pulse generator (PG). There are four types of PG speed control, as shown below. Select the type that fits the application and control method.

PG-A2

PG-B2

PG-D2

PG-X2

A-phase (single) pulse input for open collector output or complementary outputs, for V/f control

A/B-phase pulse input for open collector output or complementary outputs, for vector control

A-phase (single) pulse input for line driver input, for V/f control

A/B/Z-phase pulse input for line driver input, for vector control

3.7.1 Installing a PG Speed Control Card

Use the following procedure to install a PG Speed Control Card.

1. Turn off the main-circuit power supply.

2. Leave it off for at least one minute before removing the front cover of the Inverter (or at least three minutes for Inverters of 30 kW or more). Check to be sure that the CHARGE indicator is OFF.

3. Insert the spacer (which is provided) into the spacer hole in the Inverter’s mounting base.

For Inverters of 3.7 kW or lower, there are two adjacent holes. Insert the spacer into the 7CN hole. The spacer cannot be easily removed if inserted into the wrong hole. Be very careful to insert the spacer into the correct hole, and in the proper direction.

4. Referring to the enlarged illustration in the following diagram, align the PG Speed Control Card with the catch position as shown by (a) and (b) and fit it precisely to the Option-A connector. Insert at (a) first.

5. Pass the spacer through the spacer hole at the Card. (Refer to A in the illustration.) Check to be sure that it is precisely aligned with the 4CN position, and snap it into the proper position. Be sure to press it in firmly until you hear it snap into place.

PG Speed Control Card

4CN Option-A Connector

2CN Option-C Connector

3CN Option-D Connector

Spacer mounting hole

Option A

Top

7CN

Option C

Control board

Option D

Option A mounting spacer (Accessory: SRNT41028-9)

PG Speed Control Card

Inverter mounting base

Control board

Mounting base side

Option A side

Spacer mounting hole

Spacer

Connection terminals

Ground terminal 12

Bottom

[Front]

Fig 3.22 Installing a PG Speed Control Card

3-24

(b)

(a)

Enlargement

Spacer mounting

[Side]

3.7.2 PG Speed Control Card Terminal Blocks

+12

V/open

collector

switching

ter-

Pulse

input

terminal

pp y

)

Line

driver

input

(RS-422

level

input)

)

The terminal specifications for each PG Speed Control Card are given in the following tables.

PG-A2 (For V/f with PG Feedback Mode Only)

Table 3.10 PG-A2 Terminal Specifications

Terminal No. Contents Specifications

Power supply for pulse generator

+12 V/open collector switchingterminal

TA1

TA2 (E)

PG-B2 (For Flux Vector Control Mode Only)

Pulse input terminal

Pulse motor output terminal

Shield connection terminal

3.7 Installing and Wiring PG Speed Control Cards

12 VDC (±5%), 200 mA max.

0 VDC (GND for power supply)

Terminal for switching between12 V voltage input and open collector input. For open collector input, short across 3 and 4.

H: +4 to 12 V; L: +1 V max. (Maximum response frequency: 30 kHz)

Pulse input common

12 VDC (+10%), 20 mA max.

Pulse monitor output common



Table 3.11 PG-B2 Terminal Specifications

Terminal No. Contents Specifications

TA1

TA2

TA3 (E)

Power supply for pulse generator

A-phase pulse input terminal

B-phase pulse input terminal

A-phase monitor output terminal

B-phase monitor output terminal

Shield connection terminal

12 VDC (±5%), 200 mA max.

0 VDC (GND for power supply)

H: +8 to 12 V L: +1 V max. (Maximum response frequency: 30 kHz)

Pulse input common

H: +8 to 12 V L: +1 V max. (Maximum response frequency: 30 kHz)

Pulse input common

Open collector output, 24 VDC, 30 mA max.

A-phase monitor output common

Open collector output, 24 VDC, 30 mA max.

B-phase monitor output common

J PG-D2 (For V/f with PG Feedback Mode Only)

Table 3.12 PG-D2 Terminal Specifications

Terminal No. Contents Specifications

TA1

TA2 (E)

Power supply for pulse generator

Pulse input + terminal

Pulse input − terminal

Common terminal

Pulse monitor output + terminal

Pulse monitor output − terminal

Shield connection terminal

12 VDC (±5%), 200 mA max. (see note)

0 VDC (GND for power supply)

5 VDC (±5%), 200 mA max. (see note)

Line driver input(RS-422 level input Maximum response frequency: 300 kHz

Line driver output(RS-422 level output



Note 5 VDC and 12 VDC cannot be used at the same time.

3-25

pp y

)

Line

driver

input

(RS-422

level

input)

)

Wiring

3.7.2 PG Speed Control Card T erminal Blocks

PG-X2 (For Flux Vector Control Mode Only)

Table 3.13 PG-X2 Terminal Specifications

Terminal No. Contents Specifications

TA1

TA2

TA3 (E)

Power supply for pulse generator

A-phase + input terminal

A-phase − input terminal

B-phase + input terminal

B-phase − input terminal

Z-phase + input terminal

Z-phase − input terminal

Common terminal 0 VDC (GND for power supply)

A-phase + output terminal

A-phase − output terminal

B-phase + output terminal

B-phase − output terminal

Z-phase + output terminal

Z-phase − output terminal

Control circuit common Control circuit GND

Shield connection terminal

12 VDC (±5%), 200 mA max. (see note)

0 VDC (GND for power supply)

5 VDC (±5%), 200 mA max. (see note)

Line driver input(RS-422 level input Maximum response frequency: 300 kHz

Line driver output(RS-422 level output



Note 5 VDC and 12 VDC cannot be used at the same time.

3-26

3.7.3 Wiring a PG Speed Control Card

Three-phase, 200 VAC (400 VAC)

Wiring examples are provided in the following illustrations for the PG Speed Control Cards.

PG-A2 (For V/f with PG Feedback Mode Only)

12 V Voltage Input

VS-616G5

4CN

PG-A2

TA1

4CN

TA2 (E)

3.7 Installing and Wiring PG Speed Control Cards

+12 V power supply

0 V power supply

12 V voltage output (A/B phase)

Pulse 0 V

Pulse monitor output

Three-phase, 200 VAC (400 VAC)

Fig 3.23 Wiring a 12 V Voltage Input

Open Collector Input

VS-616G5

4CN

PG-A2

4CN

TA2 (E)

D Shielded twisted-pair wires must be used for signal lines. D Do not use the pulse generator’s power supply for anything other than the

pulse generator (encoder). Using it for another purpose can cause malfunctions due to noise.

D The length of the pulse generator’s wiring must not be more than 100 meters.

Fig 3.24 Wiring an Open-collector Input

TA1

+12 V power supply

0 V power supply

Open collector output (A/B phase)

Pulse 0 V

Pulse monitor output

3-27

Wiring

3.7.3 Wiring a PG Speed Control Card

PG power supply +12 V

Short for open-collector input

Pulse input

TA1

I/O Circuit Configuration

+12 V

3.9 k

Pulse input

+12 V

Pulse monitor output

TA1

Fig 3.25 I/O Circuit Configuration of the PG-A2

3-28

PG-B2 (For Flux Vector Control Mode Only)

3.7 Installing and Wiring PG Speed Control Cards

Three-phase 200 VAC (400 VAC)

VS-616G5

4CN

PG-B2

TA1

4CN

TA2

TA3 (E)

Power supply +12 V

Power supply 0 V

A-phase pulse output (+)

A-phase pulse output (−)

B-phase pulse output (+)

B-phase pulse output (−)

A-phase pulse monitor output

B-phase pulse monitor output

D Shielded twisted-pair wires must be used for signal lines. D Do not use the pulse generator’s power supply for anything other than the

pulse generator (encoder). Using it for another purpose can cause malfunctions due to noise.

D The length of the pulse generator’s wiring must not be more than 100 meters. D The direction of rotation of the PC can be set in user constant F1-05. The

factory preset if for forward rotation, A-phase advancement.

PG power supply +12 V

A-phase pulse input

B-phase pulse input

Fig 3.26 PG-B2 Wiring

I/O Circuit Configuration

TA1

+12 V

150

150 180 150

150

180

470

180

470

180

Division rate circuit

A-phase pulses

B-phase pulses

D When connecting to a voltage-output-type PG (encoder), select a PG

that has an output impedance with a current of at least 12 mA to the input circuit photocoupler (diode).

D The pulse monitor dividing ratio can be changed using constant

F1-06.

D The pulse monitor emitter is connected to common inside the PG-B2.

The emitter common must be used for external circuits.

Fig 3.27 I/O Circuit Configuration of the PG-B2

TA2

A-phase pulse monitor

output

B-phase pulse monitor

output

A-phase pulses

B-phase pulses

3-29

Wiring

3.7.3 Wiring a PG Speed Control Card

PG-D2 (For V/f with PG Feedback Mode Only)

Three-phase 200 VAC (400 VAC)

VS-616G5

4CN

PG-D2

4CN

TA1

TA2 (E)

D Shielded twisted-pair wires must be used for signal lines. D Do not use the pulse generator’s power supply for anything other than the pulse

generator (encoder). Using it for another purpose can cause malfunctions due to noise.

D The length of the pulse generator’s wiring must not be more than 100 meters.

Fig 3.28 PG-D2 Wiring

PG-X2 (For Flux Vector Control Mode Only)

VS-616G5

4CN

PG-X2

TA1

Power supply +12 V

Power supply 0 V

Power supply +5 V

Pulse input + (A/B phase)

Pulse input − (A/B phase)

Pulse monitor output

Power supply +12 V Power supply 0 V

Power supply +5 V

A-phase pulse input (+)

A-phase pulse input (−)

B-phase pulse input (+)

B-phase pulse input (−)

TA2

TA3 (E)

A-phase pulse monitor output

B-phase pulse monitor output

Z-phase pulse monitor output

D Shielded, twisted-pair wire must be used for signal lines. D Do not use the pulse generator’s power supply for anything other than the

pulse generator (encoder). Using it for another purpose can cause malfunctions due to noise.

D The length of the pulse generator’s wiring must not be more than 100 meters. D The direction of rotation of the PC can be set in user constant F1-05. The

factory preset if for forward rotation, A-phase advancement.

Fig 3.29 PG-X2 Wiring

3-30

3.7 Installing and Wiring PG Speed Control Cards

3.7.4 Wiring PG Speed Control Card Terminal Blocks

Use no more than 100 meters of wiring for PG (encoder) signal lines, and keep them separate from power lines.

Use shielded, twisted-pair wires for pulse inputs and pulse output monitor wires, and connect the shield to the shield connection terminal.

J Wire Sizes (Same for All Models)

Terminal wire sizes are shown in Table 3.14 .

Table 3.14 Wire Sizes

Terminal

Pulse generator power supply

Pulse input terminal

Pulse monitor output terminal

Shield connection terminal M3.5 0.5 to 2

Solderless Terminals for Control Circuit Terminals

Terminal

Screws



The use of solderless terminals for the control circuit terminals is recommended because solderless terminals are easy to connect securely.

Table 3.15 Straight Solderless Terminal Sizes

Wire Thickness Model d1 d2 Manufacturer

0.5 mm

0.75mm

1mm

1.5 mm

A1 0.5-8 WH 1.00 2.60

A1 0.75-8 GY 1.20 2.80

A1 1-8 RD 1.40 3.00

A1 1.5-8 BK 1.70 3.50

Wire Thickness

(mm

Stranded wire: 0.5 to

1.25

Single wire: 0.5 to 1.25

)

S Shielded, twisted-pair wire

S Shielded, polyethylene-cov-

Wire Type

ered,vinylsheathcable

Phoenix Contact

IMPORTANT

φd1

8mm

14 mm

φd2

Fig 3.30 Straight Solderless Terminal Sizes

Do not solder wires with the control circuit terminals if wires are used instead of solderless terminals.

Wires may not contact well with the control circuit terminals or the wires may be disconnected from the control circuit terminals due to oscillation if the wires are soldered.

3-31

Wiring

3.7.4 Wiring PG Speed Control Card Terminal Blocks

Closed-loop Connector Sizes and Tightening Torque

The closed-loop connectors and tightening torques for various wire sizes are shown in Table 3.16 .

Table 3.16 Closed-loop Connectors and Tightening Torques

Wire Thickness [mm2]

0.5 1.25 to 3.5

0.75

1.25

2 2 to 3.5

Wiring Method

Use the following procedure to connect wires to the terminal block.

1. Loosen the terminal screws with a thin-slot screwdriver.

2. Insert the wires from underneath the terminal block.

3. Tighten the terminal screws firmly.

Terminal

Screws

M3.5

Thin-slot screwdriver

Crimp Terminal Size Tightening Torque (N⋅m)

1.25 to 3.5

0.8

Blade of screwdriver

IMPORTANT

Control circuit terminal block

Strip the end for

5.5 mm if no

solderless terminal is used.

Wires

Solderless terminal or wire without soldering

Blade thickness: 0.6 mm max.

3.5 mm max.

Fig 3.31 Connecting Wires to Terminal Block

Wiring Precautions

1. Separate PG Speed Control Card control circuit wiring (terminals TA1 and TA2) from main circuit wiring and other high-power lines.

2. Use twisted-pair or shielded twisted-pair cables to connect the PG to prevent operating faults. Process cable ends as shown in Figure 3.32. The maximum cable length is 100 m.

Shield sheath

Armor

Do not connect here.

Connect to terminal TA3 on the VS-616G5.

Insulate with tape.

Fig 3.32 Processing the Ends of Twisted-pair Cables

3. Connect the shield to the ground terminal.

4. Do not solder the wires to the control circuit terminals. The wires may not contact well with the control circuit terminals if the wires are soldered.

5. The end of each wire connected to the control circuit terminals must be stripped for approximately

5.5 mm.

3-32

3.7 Installing and Wiring PG Speed Control Cards

3.7.5 Selecting the Number of PG (Encoder) Pulses PG-A2/PG-B2

The maximum response frequency is 32,767 Hz.

Use a PG that outputs a maximum frequency of approximately 20 kHz for the rotational speed of the motor.

Motor speed at maximum frequency output (

r∕min

)

rating (

p∕rev

= 20, 000 Hz

)

Some examples of PG output frequency (number of pulses) for the maximum frequency output are shown in Table 3.17 .

Table 3.17 PG Pulse Selection Examples

Motor’s Maximum Speed (r/min) PG Rating

1800 600 18,000

1500 800 20,000

1200 1000 20,000

900 1200 18,000

Note 1.The motor speed at maximum frequency output is expressed as the sync rotation speed.

2. The PG power supply is 12 V.

3. A separate power supply is required if the PG power supply capacity is greater than 200 mA. (If momentary power loss must be handled, use a backup capacitor or other method.)

PG power supply

Capacitor for power momentary power loss

(p/rev)

Signals

PG Output Frequency for Maximum

Frequency Output (Hz)

Fig 3.33 PG-B2 Connection Example

J PG-D2/PG-X2

There are 5 V and 12 V PG power supplies. Check the PG power supply specifications before connecting.

The maximum response frequency is 300 kHz.

Use the following equation to computer the output frequency of the PG (fPG).

(Hz) =

A separate power supply is required if the PG power supply capacity is greater than 200 mA. (If momentary power loss must be handled, use a backup capacitor or other method

Motor speed at maximum frequency output (

PG power 0 V 12V

Capacitor for momentary power loss

r∕min

)

×PGrating (

p∕rev

)

Fig 3.34 PG-X2 Connection Example (for 12 V PG power supply)

3-33

Setting User Constants

This chapter describes setting user constants using the Digital Operator.

4.1 Using the Digital Operator 4 - 2..............

4.2 Modes 4 - 5...............................

4.2.1 Inverter Modes 4 - 5..............................

4.2.2 Switching Modes 4 - 6............................

4.2.3 User Constant Access Levels 4 - 7.................

4.2.4 Operation Mode 4 - 12.............................

4.2.5 Initialize Mode 4 - 20..............................

4.2.6 Programming Mode 4 - 27..........................

4.2.7 Autotuning Mode 4 - 31............................

4.2.8 Modified Constants Mode 4 - 33.....................

4-1

Setting User Constants

4.1 Using the Digital Operator

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

DRIVE FWD REV REMOTE

Frequency Ref

U1−01 = 00.00 HZ

DIGITAL OPERATOR JVOP-130

LOCAL

REMOTE

JOG

FWD

REV

RUN STOP

SEQ REF

ESC

DATA

ENTER

RESET

Operation Mode Indicators

DRIVE: Lit when in operation mode. FWD: Lit when there is a forward run command input. REV: Lit when there is a reverse run command input. SEQ: Lit when the run command from the control cir-

cuit terminal is enabled.

REF: Lit when the frequency reference from control

circuit terminals 13 and 14 is enabled.

Data Display

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

Keys

Execute operations such as setting user constants, monitoring, JOG, and autotuning.

Fig 4.1 Digital Operator Component Names and Functions

4-2

Table 4.1 Key Functions

Key Name Function

LOCAL

REMOTE

LOCAL/REMOTE Key

Switches between operation (LOCAL) via the Digital Operator and control circuit terminal (REMOTE) operation.

This Key can be enabled or disabled by setting a user constant (o2-01).

4.1 Using the Digital Operator

ESC

JOG

FWD

REV

RESET

MENU Key Displays menus.

ESC Key

JOG Key

FWD/REV KeyJ

RESET Key

Increment Key

Decrement Key

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

Enables jog operation when the VS-616G5 is being operated from the Digital Operator.

Selects the rotation direction of the motor when the VS-616G5 is being operated from the Digital Operator.

Sets the number of digits for user constant settings.

Also acts as the reset Key when a fault has occurred.

Selects menu items, groups, functions, and user constant names, and increments set values.

Selects menu items, groups, functions, and user constant names, and decrements set values.

Enters menu items, functions, constants, and set values after

DATA

ENTER

DATA/ENTER Key

they are set.

Constants cannot be changed when Undervoltage (UV) is detected.

RUN

RUN Key

Starts the VS-616G5 operation when the VS-616G5 is in operation with the Digital Operator.

Stops VS-616G5 operation.

STOP

STOP Key

This Key can be enabled or disabled by setting a user constant (o2-02) when operating from the control circuit terminal.

Note Except in diagrams, Keys are referred to using the Key names listed in the above table.

FWD

REV

RUN STOP

RESET

Inverter output frequency

STOP

Frequency setting

RUN

Lit:Blinking

Not lit

RUN

The RUN and STOP indicators light and blink to indicate operating status. During DB (initial excitation), RUN blinks and STOP is turned ON.

Fig 4.2 RUN and STOP Indicators

STOP

4-3

Setting User Constants

The following table shows the relationship between the indicators on the RUN and STOP Keys and the Inverter conditions.

The indicators are lit, unlit or blinking reflecting the order of priority.

Priority

Table 4.2 Relation of Inverter to RUN and STOP Indicators

RUN

Indica-

tor

STOP

Indica-

tor

Inverter

Status

Stopped

Stopped*

Stopped

Running

Conditions

Power supply is shut down.

Emergency stop

S Stop Command is sent from the Digital Operator when the control circuit

terminals were used to operate the Inverter.

S Emergency Stop Command is sent from the control circuit terminal.

Switched from LOCAL (operation using the Digital Operator) to REMOTE (operation using the control circuit terminals) when the Run Command is sent from the external terminal.

Switched from the Quick or Advanced Quick programming mode to the Drive mode when the Run Command is sent from the external terminal.

The Inverter is run at a frequency below the minimum output frequency. The Run Command is carried out when the External Baseblock Command

using the multi−function contact input terminal is issued.

Stopped

During deceleration to a stop During DC injection braking when using the multi−function contact input

terminal. During initial excitation of DC injection braking while the Inverter is

stopped.

During emergency deceleration

S Stop Command is sent from the Digital Operator when operating the Invert-

er using the control circuit terminals.

S Emergency Stop Command is sent from the control circuit terminal.

Run Command is issued. During initial excitation of DC injection braking when starting the Inverter.

Note

: Lit : Blinking : Not lit

If planning to run the Inverter again, first turn OFF the Run Command and Emergency Stop Command

from the control circuit terminal and send the Run Command.

4-4

4.2 Modes

4.2.1 Inverter Modes

4.2 Modes

This section describes the VS-616G5’s monitor modes, switching between modes, and accessing/setting user constants.

The VS-616G5 Inverter’s user constants and monitoring functions have been organized in groups called modes that make it easier to read and set user constants.

The VS-616G5 is equipped with 5 modes, as shown in the Table 4.3 .

Table 4.3 Modes

Mode Primary function(s)

The Inverter can be run in this mode.

Operation mode

Initialize mode

Programming mode

Autotuning mode (See note)

Modified constants mode

Use this mode when monitoring values such as frequency references or output current, displaying fault information, or displaying the fault history.

Use this mode when selecting the language displayed on the Digital Operator, selecting the access level for reading/setting user constants, selecting the control mode, or initializing the user constants.

Use this mode when reading/setting the user constants required for operation.

The program-mode functions are subdivided into the following groups:

S Application: Operation mode selection, DC control, speed search, etc. S Tuning: Acceleration/deceleration times, S-curve characteristics, carrier

frequencies, etc.

S Reference: Settings related to frequency control S Motor: V/f characteristics and motor constants S Option: Settings for Optional Cards S Terminal: Settings for sequential I/O and analog I/O S Protection: Settings for the motor and inverter protection functions S Operator: Selects the Digital Operator’s display and Key functions

(Usable only with in vector control mode)

Use this mode when running a motor with unknown motor constants in the vector control mode. The motor constants are calculated and set automatically.

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

Note Always perform autotuning before operating in vector control mode. Refer to

tuning and 6.4.3 Autotuning for details.

5.2.5 Auto-

4-5

Setting User Constants

4.2.2 Switching Modes

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

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

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

All modes/constant status

SOperation mode

Main Menu

Operation

SInitialize mode

Main Menu

Initialize

SProgramming mode

G5:Main Menu

Programming

SAutotuning mode

(Open loop vector control at factory setting.)

Main Menu

Autotuning

DATA

ENTER

ESC

DATA

ENTER

ESC

DATA

ENTER

ESC

DATA

ENTER

ESC

Power ON

Monitor (Frequency reference value)

Frequency Ref

U1−01 = 0.00 HZ

Operator display language selection

Select Language

English

Frequency reference input method selection

Display contents differ depending on the access level (A1-01)

Reference Source

Terminal

(Access level: Quick-start)

Autotuning (Rated voltage setting)

Rated Voltage

200.0 VAC

DATA

ENTER

ESC

DATA

ENTER

ESC

DATA

ENTER

ESC

A1−00 = 1

English

Function b1

Sequence

Rated Voltage

200.0 VAC

:::

SModified constant mode

Modified Consts

(Mode Display)

IMPORTANT

Displays constants changed from factory settings

Main Menu

DATA

ENTER

None Modified

ESC

Function

(Constant Reading)

Constant Display

(Constant Setting)

Fig 4.3 Mode Transitions

When running the Inverter after using digital operator, press the MENU Key to enter the operation mode and then press the DATA/ENTER Key from the operation mode display to bring up the monitor display. Run commands can’t be received from any other display. (Monitor display in the operation mode appears when the power is turned ON.)

4-6

4.2.3 User Constant Access Levels

The VS-616G5 has three access levels which divide the various user constants based on their applications, as shown below. The access level restricts which user constants can be set or displayed.

4.2 Modes

Quick-start

Basic

Advanced

Allows reading/setting of user constants required for simple operation. (factory preset)

Allows reading/setting of Basic user constants.

Allows reading/setting of all user constants.

Set the access level in initialize mode with user constant A1-01.

J Changing the Access Level from Quick-start to Basic

The Inverter is set at the factory to start in the Quick-start access level. Use the following procedure to change from the Quick-start level to the Basic level.

Step Key Sequence Digital Operator Display Remarks

DATA

ENTER

DATA

ENTER

DATA

ENTER

G5: Main Menu

Operation

G5: Main Menu

Initialize

Select Language

English

Access Level

QUICK−START

A1−01 = 2

:::

QUICK−START

A1−01 = 3

Basic

Entry Accepted

G5:Main Menu

Operation

G5:Main Menu

Initialize

Access Level

Basic

As shown above, Quick-start has changed to Basic.

These seven steps can be illustrated as when in Figure 4.4.

DATA

ENTER

Select Language

English

Access Level

QUICK−START

Access Level

Basic

After approx. 3 seconds, the Operator display is as shown on the left.

DATA

ENTER

A1−01 = 2

QUICK−START

A1−01 = 3

Basic

DATA

ENTER

Entry Accepted

:::

Fig 4.4 Changing Quick-start to Basic

4-7

Setting User Constants

4.2.3 User Constant Access Levels

Setting User Constants in Each Access Level

The displayed access level will change when programming mode is selected. The display will not change for access levels in operation mode, initialize mode, autotuning mode, and modified constants mode.

This section provides the procedure to change the acceleration time to 20.0 s in each access level. The acceleration time (C1-01) is a user constant in programming mode.

If the new user constant setting is not written to the Unit by pressing the DATA/ENTER Key within one minute after starting the procedure, the display will automatically revert to the original user constant setting. In this case, the procedure must be started again.

Operation mode

Initialize mode

Programming mode

DATA

ENTER

[Advanced] [Basic] [Quick-start]

Displays group level.

Application

Tuning

Reference

Displays function level.

b1 Sequence

Constant to be changed

C1 Accel/Decel

C2 S-curve Acc/Dec

Displays constant level.

b1-01 Reference Source

b1-02 Run Source

b1-03 Stopping Method

C1-01 Accel Time 1

C1-02 Decel Time 1

[Mode]

[Group]

Fig 4.5 Constant Access Levels

[Function]

[Constant]

4-8

4.2 Modes

EXAMPLE

Setting a User Constant in the Quick-start Access Level

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

Use the following display to set the acceleration time to 20.0 s.

Step Key Sequence Digital Operator Display Remarks

Press twice.

DATA

ENTER

DATA

ENTER

RESET

Press twice.

G5:Main Menu

Operation

G5:Main Menu

Programming

Reference source

Terminals

Run Source

Terminals

Stopping Method

Ramp to Stop

Accel Time 1

C1−01 = 10.0 Sec

Accel Time 1

0010.0 Sec

Accel Time 1

0010.0 Sec

Accel Time 1

0020.0 Sec

Changed to constant setting level.

Selects the user constant so that the leading 0 blinks. The digit that is

blinking can be changed.

Blinking digit moves 2 places to the right.

Changes 1 to 2.

DATA

ENTER

Entry Accepted

Accel Time 1

C1−01 = 20.0 Sec

After approx. 3 seconds, the Operator display is as shown on the left.

The acceleration time has been set to 20.0 seconds.

Step Key Sequence Digital Operator Display Remarks

ESC

G5:Main Menu

Programming

Returns to programming mode display.

4-9

Setting User Constants

4.2.3 User Constant Access Levels

EXAMPLE

Setting a User Constant in the Basic Access Level

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

Use the following display to set the acceleration time to 20.0 s.

Step Key Sequence Digital Operator Display Remarks

Press twice.

DATA

ENTER

DATA

ENTER

DATA

ENTER

RESET

Press twice.

G5:Main Menu

Operation

G5:Main Menu

Programming

Function b1

Sequence

Function b2

DC Braking

Function C1 Accel/Decel

Accel Time 1

C1−01 = 10.0 Sec

Accel Time 1

0010.0 Sec

Accel Time 1

0010.0 Sec

Accel Time 1

0020.0 Sec

Changed to constant reading (function) level.

Changed to constant setting level,.

Selects the user constant so that the leading 0 blinks. The blinking digit can be changed.

Blinking digit moves 2 places to the right and the “1” blinks.

Changes 1 to 2.

DATA

ENTER

Entry Accepted

Accel Time 1

C1−01 = 20.0 Sec

ESC

Function C1 Accel/Decel

Returns to “Function C1 Accel/Decel” display.

Writes-in the new setting.

The Operator display is as shown on the left.

4-10

4.2 Modes

EXAMPLE

Setting a User Constant in the Advanced Access Level

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

Use the following procedure to set a constant.

Step Key Sequence Digital Operator Display Remarks

Press twice.

DATA

ENTER

DATA

ENTER

DATA

ENTER

DATA

ENTER

RESET

Press twice.

G5:Main Menu

Operation

G5:Main Menu

Programming

Group b

Application

Group C

Tuning

Function C1 Accel/Decel

Accel Time 1

C1−01 = 10.0 Sec

Accel Time 1

0010.0 Sec

Accel Time 1

0010.0 Sec

Accel Time 1

0020.0 Sec

Changed to constant reading (function) level.

Selects the user constant so that the leading 0 blinks. The blinking digit can be changed.

Blinking digit moves 2 places to the right and the “1” blinks.

Changes 1 to 2.

DATA

ENTER

Entry Accepted

Accel Time 1

C1−01 = 20.0 Sec

ESC

Function C1 Accel/Decel

Writes-in the new setting, 20.0 s.

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

The constant setting in Advanced level (acceleration time change from 10.0 to 20.0 s) has been completed.

4-11

Setting User Constants

4.2.4 Operation Mode

Operation mode is the mode in which the Inverter can be operated.

Many user constants can’t be changed when the Inverter is operating. Refer to User Constant List for details.

The following monitor displays are possible in operation mode: The frequency reference, output frequency, output current, and output voltage, as well as fault information and the fault history.

IMPORTANT

All modes/constants status

SOperation Mode

When running the Inverter after using digital operator, press the MENU Key to enter the operation mode and then press the DATA/ENTER Key from the operation mode display to bring up the monitor display.Run commands can’t be received from any other display. (Monitor display in the operation mode appears when the power is turned ON.)

Operations in Operation Mode

Key operations in operation mode are shown in Figure 4.6.

Power ON (when o1-o2=1)

Main Menu

Operation

DATA

ENTER

ESC

Frequency reference setting/display

Frequency Ref

U1−01 = 0.00 HZ

Output frequency display

Output Freq

U1−02 = 0.00 Hz

Output current display

Output Current

U1−03 = 0.00 A

Power ON (when o1-02=12)

Power ON (when o1-02=3)

Output voltage display

Output Voltage

U1−06 = 0.0 VAC

Function selection U2 (fault trace)

Function U2

Fault Trace

Function selection U3 (fault history)

Function U3

Fault History

Function selection U1 (Monitor)

Function U1

Monitor

Fig 4.6 Operations in Operation Mode

This item can be changed using o1-01

Power ON (when o1-02=4)

DATA

ENTER

ESC

DATA

ENTER

ESC

DATA

ENTER

ESC

Contents of fault trace

Contents of fault history

Various monitors

U1−01 = 0.00 HZ

Current Fault

None

Last Fault

None

Frequency Ref

4-12

Func-

U1 01

(

)

QQQ

10V:

Max.

frequency

0.01

10V:

Rated

current

Shows

which

control

mode

10V:

Max.

frequency

0.01

Monitors

the

Inverter

internal

10V:

200

(400)VAC

Monitors

theDCvoltage

the

10V:

400

(800)

VDC

Moni

(

10V:

Max.

motor

capacity

10V:

Rated

torque

U1 10

Cantbe

output

QQQ

U1 1

1:T

l25ON

Cantbe

output

QQQ

tion

Status

tor

4.2 Modes

Conditions for Monitoring

Table 4.4 shows the items that can be monitored in operation mode.

The “Valid access levels” column in the table indicates whether an item can be monitored in a particular access level and control method. The codes in this column have the following meanings.

Items that can be monitored in all access levels. (Quick-start, Basic, and Advanced)

Items that can be monitored in the Advanced and Basic access levels.

Items that can be monitored only in the Advanced access level.

Items that cannot be monitored in the control mode shown.

The output signal levels for multi-function analog outputs shown in the table are for a gain of 100.0 and a bias of 0.00.

Table 4.4 Constants Monitored in Operation Mode

Constant

No.

U1-01

U1-02

U1-03

U1-04

U1-05

U1-06

U1-07

U1-08

U1-09

Digital Operator

Display

Frequency reference

Frequency Ref

Output frequency

Output Freq

Output current

Output Current

Control method

Control Method

Motor speed

Motor Speed

Output voltage

Output Voltage

DC bus voltage

DC Bus Voltage

Output power

Output kWatts

Torque reference

Torque Reference

Monitors/sets the frequency reference value.

The display units can be set with user constant o1-03.

Monitors the output frequency.

The display units can be set with user constant o1-03.

Monitors the output current.

Shows which control mode is set.

Monitors the motor speed.

The display unit setting can be changed using o1-03.

Monitors the Inverter’s internal output voltage reference value.

Monitors the DC voltage of the Inverter’s internal main circuit.

Monitors the output power.

This is an internally detected

value.)

Monitors the internal torque reference value when vector control is used.

Function

Output Signal Levels for

Multi-function Analog Out-

puts

10 V: Max. frequency

0to±10 V possible

10 V: Max. frequency

(0 to ±10 V possible)

10 V: Rated current

(0 to +10 V output)

’

Can’t be output.

10 V: Max. frequency

(0 to ±10 V possible)

10 V: 200 (400) VAC

(0 to +10 V output)

10 V: 400 (800) VDC

(0 to +10 V output)

10 V: Max. motor capacity

(0 to ±10 V possible)

10 V: Rated torque

(0 to ±10 V possible)

Min.

Unit

0.01

0.1 A

0.01

0.1 V

0.1 kW

0.1 %

Shows input ON/OFF status.

Name

Input terminal status

U1-10

Input Term Sts

U1-10 = 00000000

1: Terminal 1 ON

1: Terminal 2 ON

1: Terminal 3 ON

1: Terminal 4 ON

1: Terminal 5 ON

1: Terminal 6 ON

1: Terminal 7 ON

1: Terminal 8 ON

Can’t be output.

Shows output ON/OFF status.

Output terminal status

U1-11

Output Term Sts

U1-11 = 00000000

1: Terminals 9−10 ON

ermina

1: Terminal 26 ON

Not used. (always 0)

1: Terminals 18/19−20

Can’t be output.

Valid Access Levels

V/f

Q Q Q Q



Q Q Q Q

× ×

Q Q Q Q



Q Q Q Q



Open

V/f w/

-loop

Vec-

tor

Q Q Q

Q Q

Flux Vec-

tor

4-13

Setting User Constants

U1 13

Cantbe

output

QQQ

U1 15

(

)

0.1

BBB

U1 16

(

)

0.1

BBB

Moni

U1 17

(

)

0.1

BBB

U1 18

(q)

(

)

0.1

BBB

U1 19

()

(

)

0.1

U1 20

(

)

AAA

control

loop.

10V:

Max.

frequency

speed

control

loop.

10V:

Rated

secondary

current

within

the

speed

control

loop.

10V:

Max.

frequency

4.2.4 Operation Mode

Table 4.4 Constants Monitored in Operation Mode (Continued)

Func-

tion

Status Monitor

Constant

No.

U1-12

U1-13

U1-14

U1-15

U1-16

U1-17

U1-18

U1-19

U1-20

U1-21

U1-22

U1-23

Name

Digital Operator

Display

Operation status

Int Ctl Sts 1

Cumulative operation time

Elapsed Time

Software No.

FLASH ID

Terminal 13 input voltage level

Term 13 Level

Terminal 14 input current level

Term 14 Level

Terminal 16 input voltage level

Term 16 Level

Motor secondary current (lq)

Mot SEC Current

Motor exciting current (ld)

Mot EXC Current

Output frequency after soft-start

SFS Output

ASR input

ASR Input

ASR output

ASR Output

Speed deviation

Speed Deviation

Function

Multi-function Analog Out-

puts

Inverter operating status.

Output Signal Levels for

U1-12 = 00000000

1: Running

1: Zero-speed level

1: Reverse

1: Reset input ON

1: F.ref/F.out agree

1: Inverter ready

1: Minor fault detected

1: Major fault detected

’

Can’t be output.

Monitors the Inverter’s elapsed operating time.

The initial value and running/ power-on time selection can be

Can’t be output. 1hr

set with user constants o2-07 and o2-08.

Manufacturer’s ID number Can’t be output.

’

Monitors the input voltage of the frequency reference (voltage).

An input of 10 V corresponds to

10 V: 100% (10 V)

0to±10 V possible

100%.

Monitors the input current of the frequency reference (current).

An input of 20 mA corresponds

20 mA: 100% (20 mA)

0 to +10 V output

to 100%.

Monitors the input voltage of the multi-function analog input.

An input of 10 V corresponds to

10 V: 100% (10 V)

0to±10 V possible

100%.

Monitors the calculated value of the motor’s secondary current (Iq).

The motor’s rated secondary

10 V: Rated secondary current

0 to +10 V output

current corresponds to 100%.

Monitors the calculated value of the motor’s excitation current (Id).

The motor’s rated secondary

10 V: Rated secondary current

0 to +10 V output

current corresponds to 100%.

Monitors the output frequency after a soft start.

The display shows the frequency without the correction from

10 V: Max. frequency

0to±10 V possible compensation functions such as slip compensation.

Monitors the input to the speed control loop.

The max. frequency corresponds

10 V: Max. frequency

(0 to ±10 V possible)

to 100%.

Monitors the output from the speed control loop.

The motor’s rated secondary

10 V: Rated secondary current

(0 to ±10 V possible)

current corresponds to 100%.

Monitors the speed deviation within the speed control loop.

The max. frequency corresponds

10 V: Max. frequency

(0 to ±10 V possible)

to 100%.

Valid Access Levels

Min.

Unit

0.1 %

0.01

0.01 %

V/f

Q Q Q Q



Q Q Q Q



B B B B

× ×

A A A A

V/f w/

Open

-loop Vec-

tor

B B

Flux

Vec-

tor

4-14

4.2 Modes

U1 24

(

)

0.01

AAA

U1 25

Cantbe

output

AAA

U1 26

(

)

0.1

U1 27

(

)

0.1

U1 28

Cantbe

output

0.1

AAA

U1 32

value

for

motorssecondary

cur-

10V:

100%

0.1

Moni

U1 33

value

for

motorsexcitation

cur-

10V:

100%

0.1

U1 34

Cantbe

output

AAA

bias

PID

feedback

volume.

bias.

Func-

tion

Status Monitor

Con-

Constant

stant

No.

U1-24

U1-25

U1-26

U1-27

U1-28

U1-32

U1-33

U1-34

U1-35

Name

Digital Operator

Display

PID feedback value

PID Feedback

DI-16H2 input status

DI-16 Reference

Output voltage reference (Vq)

Voltage Ref (Vq)

Output voltage reference (Vd)

Voltage Ref (Vd)

Software No. (CPU)

CPU ID

ACR output of q axis

ACR (q) Output

ACR output of d axis

ACR (d) Output

OPE fault constant

OPE Detected

Zero servo movement pulses

Function

Monitors the feedback value when PID control is used.

The input for the max. frequency corresponds to 100%.

Monitors the reference value from a VS-616G5-DI16H2 Digital Reference Card.

The value will be displayed in binary or BCD depending on user constant F3-01.

Monitors the Inverter’s internal voltage reference value for the

’

motor’s secondary current control.

Monitors the Inverter’s internal voltage reference value for the

’

motor’s excitation current control.

Manufacturer’s CPU software ID number

Monitors current control output value for motor’s secondar

cur-

rent.

Monitors current control output value for motor’s excitation current.

Shows the first constant number where an OPE fault is detected.

Shows the number of PG pulses for the movement range at the stop point for a zero servo times

Output Signal Levels for

Multi-function Analog Out-

puts

10 V: Max. frequency

0to±10 V possible

Can’t be output.

10 V: 200 (400) VAC

0to±10 V possible

10 V: 200 (400) VAC

0to±10 V possible

Can’t be output. 0.1 V

Min.

Unit

0.01 %



0.1 V

10 V: 100% 0.1 %

Can’t be output.



Can’t be output. 1

Valid Access Levels

Open

V/f w/

-loop Vec-

tor

V/f

A A A A

× ×

A A

A A A A

× ×

A A

A A A A

× × ×

Flux

Vec-

tor

U1-36

U1-37

U1-38

PID input volume

PID Input

PID output volume

PID Output

PID command

PID Setpoint

PID command + PID command bias − PID feedback volume.

The input for the max. frequency corresponds to 100%.

PID control output.

The input for the max. frequency corresponds to 100%.

PID command + PID command bias.

The input for the max. frequency corresponds to 100%.

10V: Max. frequency 0.01%

A A A A

4-15

Setting User Constants

U2 03

QQQ

U2 04

QQQ

U2 05

0.1

QQQ

U2 06

QQQ

U2 07

0.1

QQQ

Fault

)

U2 08

QQQ

U2 09

0.1

QQQ

U2 10

fault

occurred.

0.1

U2 1

last

fault

occurred.

QQQ

U2 12

last

fault

occurred.

QQQ

U2 13

the

last

fault

occurred.

QQQ

U2 14

time

when

the

last

fault

oc-

QQQ

4.2.4 Operation Mode

Table 4.4 Constants Monitored in Operation Mode (Continued)

Func-

tion

Fault trace (See note.

Const

ant

No.

U2-01

U2-02

U2-03

U2-04

U2-05

U2-06

U2-07

U2-08

U2-09

U2-10

U2-11

U2-12

U2-13

U2-14

Name

Digital Operator

Display

Current fault

Current Fault

Last fault

Last Fault

Frequency reference at fault

Frequency Ref

Output frequency at fault

Output Freq

Output current at fault

Output Current

Motor speed at fault

Motor Speed

Output voltage reference at fault

Output Voltage

DC bus voltage at fault

DC Bus Voltage

Output power at fault

Output kWatts

Torque reference at fault

Torque Reference

Input terminal status at fault

Input Term Sts

Output terminal status at fault

Output Term Sts

Operation status at fault

Inverter status

Cumulative operation time at fault

Elapsed time

Function

Multi-function Analog Out-

puts

Information on the current fault

Information on the last fault

Frequency reference value when

Output Signal Levels for

“

the “last fault” occurred. Hz

”

Output frequency when the “last

”

fault” occurred. Hz

Output current when the “last

”

fault” occurred.

Motor speed when the “last

”

fault” occurred. Hz

Output voltage when the “last

”

fault” occurred.

The main circuit DC voltage when the “last fault” occurred.

“

”

Can’t be output.

Output power when the “last

”

fault” occurred.

Min.

Units



0.01

0.1 A

0.01

0.1 V

0.1 kW

Torque reference when the “last fault” occurred.

0.1 %

(The rated torque = 100%.)

Input terminal status when the “last fault” occurred.



(Same format as U1-10.)

Output terminal status when the “last fault” occurred.



(Same format as U1-11.)

Inverter operating status when the “last fault” occurred.



(Same format as U1-12.)

Elapsed operating or power-on time when the “last fault” oc-

1hr

curred.

Valid Access Levels

Open

-loop Vec-

tor

Flux

Vec-

V/f w/

V/f

Q Q Q Q

Q Q Q

Q Q Q Q

× ×

Q Q

Q Q Q Q

tor

Note When faults CPF00, 01, 02, 03, UV1 and UV2 occur, a fault trace is not performed.

4-16

4.2 Modes

U3 02

QQQ

U3 03

QQQ

Information

the4to

last

Fault

)

U3 05

time

when

the

last

fault

oc-

QQQ

note.)

U3 06

time

when

the2to

last

fault

QQQ

U3 07

time

when

the3to

last

fault

QQQ

User

Func-

tion

Fault history (See note.

Const

ant

No.

U3-01

U3-02

U3-03

U3-04

U3-05

U3-06

U3-07

U3-08

Name

Digital Operator

Function

Display

Most recent fault

Last Fault

Second most recent fault

Fault Message 2

Third most recent fault

Fault Message 3

Fourth/oldest fault

Fault Message 4

Cumulative operation time at fault

Elapsed Time 1

Accumulated time of second fault

Elapsed Time 2

Accumulated time of third fault

Elapsed Time 3

Accumulated time of fourth/oldest fault

Elapsed Time 4

Information on the last fault.

Information on the 2ndto last fault.

Information on the 3rdto last fault.

Information on the 4thto last fault.

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

Elapsed running or power-on time when the 2 occurred.

Elapsed running or power-on time when the 3 occurred.

Elapsed running or power-on time when the 4 occurred.

Note Faults CPF00, 01, 02, 03, UV1 and UV2 are not recorded in the fault history.

J Monitoring at Startup

In operation mode, the frequency reference, output frequency, output current, and output voltage can be monitored immediately if the factory presets are being used. One of these four values, the output voltage, can be changed to a different monitor item. When an item other than the output voltage is to be monitored, set that value in user constant o1-01 (Monitor selection). Refer to the example procedure given later in this manual.

When the power is turned ON, the frequency reference will appear in the Unit’s data display if the factor presets are being used. Any one of the four values monitored at startup (frequency reference, output frequency, output current, or the value set in user constant o1-01) can be selected to appear when the power is turned ON.

The value that appears at startup is determined by user constant o1-02 (Monitor selection after power up). User constants o1-01 and o1-02 can be changed in the Basic or Advanced access levels. These user

constants can be changed during operation.

to last fault

Output Signal Levels for

Multi-function Analog Out-

puts

Can’t be output.

Min.

Units



1hr

Valid Access Levels

Open

V/f w/

-loop Vec-

tor

V/f

Q Q Q Q

Flux Vec-

tor

User

Constant

Number

o1-01

J Monitor Displays

Display Name

Monitor selection

The following notation is used in this manual when describing user constants.

Change during

Operation

Use the last two digits from the U1 Monitor list (U1-

Setting Range

4to38

Unit Factory Setting



) to select a value. For example, the torque refer-

V/f

Control

B B B B

ence is U1-09, so input 9 to select the torque reference.

Change during

peration

Setting Range

Units

Factory Setting

Indicates whether or not the constant can be changed during operation.

Can be changed during operation.

Cannot be changed during operation.

The setting range for the constant.

The unit used to set the constant (“−” indicates that no unit is used).

The value preset at the factory. (There are different factory settings for each control method, i.e., if the control method is changed, the factory setting can also change.)

4-17

Valid Access Levels

Open

Loop

Vector

V/f with

Flux

Vector

Setting User Constants

alid

Access

User

4.2.4 Operation Mode

Levels

Indicates the control methods and access levels under which the constant can be accessed and set.

Accessible/settable under all access levels (Quick-start, Basic, and Advanced).

Accessible/settable under Advanced or Basic access levels.

Accessible/settable under Advanced access level.

Not accessible/settable in the specified control method.

EXAMPLE

User

Constant

Number

o1-02

Name

Monitor selection after power up

Change

during

Opera-

tion

Setting

Range

Unit

1to4 − 1

Use constant o1-02 to indicate which value will be displayed when the Inverter is started. Refer to the following table.

Monitor Display Contents at Startup

Setting Contents

Changing Monitor Display to Output Power at Startup in Basic Access Level

Indicates the frequency reference at startup.

Indicates the output frequency at startup.

Indicates the output current at startup.

Indicates the value set in user constant o1-01 at startup.

Change the access level to Basic if it is n o t already set there. Refer to Figure 4.4 for the procedure to change from the Quick-start to Basic access level.

Use the following procedure to change the display from the output voltage to the output power.

Step Key Sequence Digital Operator Display Remarks

Press twice.

DATA

ENTER

Press twice.

DATA

ENTER

G5:Main Menu

Operation

G5:Main Menu

Programming

Function b1

Sequence

Function o1

Monitor Select

User Monitor Sel

Output Voltage

Factory

Setting

V/f

Control

V/f with

B B B B

Changed to constant reading (function) level.

Changed to constant setting level.

Valid Access Levels

Open

Loop

Vector

Flux

Vector

DATA

ENTER

o1−01 = 6

Output Voltage

o1−01 = 8

:::

Output kWatts

Press twice.

DATA

ENTER

Entry Accepted

User Monitor Sel

Output kWatts

Writes-in the new setting.

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

Output power has been set in place of output voltage.

4-18

4.2 Modes

EXAMPLE

Changing Monitor Display to Output Current at Startup in Basic Access Level

Use the following procedure to change user constant o1-02 so that the output current is displayed at startup. (The procedure continues from the end of the previous example.)

Step Key Sequence Digital Operator Display Remarks

1 

DATA

ENTER

Press twice.

DATA

ENTER

ESC

User Monitor Sel

Output kWatts

Power-On Monitor

Frequency Ref

o1−02 = 1

:::

Frequency Ref

o1−02 = 3

Output Current

Entry Accepted

Power-On Monitor

Output Current

Function o1

Monitor Select

G5:Main Menu

Programming

Check the display.

Writes-in the new setting.

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

Output current has been set in monitor selection after power ON.

4.2.5 Initialize Mode

The initialize mode is used to select the language displayed by the Unit, the access level, and the control method; it is also used to initialize the Unit’s user constants. The structure of the initialize mode is shown in Figure 4.7.

Operation mode

Initialize mode

Programming mode

Language

Access level

Control mode

Initialize

Password

Function Selection A2

A2-01 User Pram 1

A2-02 User Pram 2

Accessible/settable only in Advanced setting level.

Fig 4.7 Structure of Initialize Mode User Constants

4-19

A2-32 User Pram 32

Setting User Constants

User

4.2.5 Initialize Mode

Selecting the Display Language: A1-00

Use constant A1-00 to select the language displayed by the Inverter. A value of 0 sets English and a

value of 1 sets Japanese.

This user constant is not returned to the factory setting when constants are initialized. It must be manu-

ally reset to the factory setting.

User

Constant

Number

A1-00

Name

Language selection for Digital Operator display

Change

during

Opera-

tion

Setting

Range

0 (English) 1 (Japanese)

2 (German)

3 (French)

4 (Italian)

5 (Spanish)

6 (Portuguese)

Unit

−

Factory

Setting

(Japanese)

Valid Access Levels

Open

Loop

Vector

V/f

Control

V/f with

Q Q Q Q

Flux

Vector

EXAMPLE

Changing the Language to English

Use the following procedure to change the display language from Japanese to English.

Step Key Sequence Digital Operator Display Remarks

The display language has been set to English.

Setting the Access Level: A1-01

Use constant A1-01 to select the user constant access level. This level determines which user constants

can be changed and displayed.

The user constants that can be displayed and changed also depend upon the control method being used.

User

Constant

Number

A1-01

DATA

ENTER

DATA

ENTER

DATA

ENTER

Name

Constant access level

Change

during

Opera-

tion

Setting

Range

0to4 −

Changed to constant setting level.

Writes-in the new setting.

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

Valid Access Levels

Factory

Unit

Setting

V/f

Control

V/f with

2 (Q) Q Q Q Q

Open

Loop

Vector

Flux

Vector

4-20

Access Level Settings

User

Setting Function

Operation Only

User Program

Quick-start

Basic

Advanced This setting allows all user constants to be changed or displayed.

Setting the Control Method: A1-02

Use constant A1-02 to select one of the four control methods.

This user constant is not returned to the factory setting when constants are initialized. It must be manu-

ally reset to the factory setting.

User

Constant

Number

A1-02

Name

Control method selection

4.2 Modes

This setting allows the operation mode and initialize mode to be changed or displayed.

Use this setting to prevent user constant settings from being changed.

This setting allows only the user-selected constants (up to 32) to be changed or displayed.

Select the desired user constants in A2-01 through A2-32.

This setting allows the user constants required to start the Inverter (about 25) to be changed or displayed.

This setting allows the commonly used user constants to be changed or displayed.

Change

during

Opera-

tion

Setting

Range

Unit

Factory

Setting

Valid Access Levels

V/f

V/f with

Control

Open

Loop

Vector

Flux

Vector

0to3 −

(Open Loop

Vector)

Q Q Q Q

EXAMPLE

Control Method Settings

Setting Function

V/f control without pulse generator (normal V/f control).

V/f control with PG feedback (V/f control using a PG Speed Control Card).

Open-loop vector control (Vector control using the Inverter internal speed information).

Flux vector control (Vector control using a PG Speed Control Card).

Changing the Control Method to Flux Vector

Use the following procedure to change the control method to select flux vector.

Step Key Sequence Digital Operator Display Remarks

DATA

ENTER

Press twice.

DATA

ENTER

DATA

ENTER

G5:Main Menu

Operation

G5:Main Menu

Initialize

Select language

English

Control Method

Open Loop

A1−02 = 2

:::

Open Loop

A1−02 = 3

Flux Vector

Entry Accepted

Control Method

Flux Vector

Changed to constant setting level.

Writes-in the new setting.

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

The control method has been changed to flux vector.

4-21

Setting User Constants

User

4.2.5 Initialize Mode

Table 4.5 Control Method Characteristics

Characteristic V/f Control without PG V/f Control with PG Open Loop Vector Control Flux Vector Control

Basic Control

Method

Speed Detector

Optional Speed

Detectors

Speed Control

Range

Starting Torque

Speed Control

Accuracy

Torque Limit

Torque Control

Example Applica-

tions

Voltage/frequency control

(open loop)

Not required Required (pulse generator) Not required Required (pulse generator)

Not required PG-A2 or PG-D2 Not required PG-B2 or PG-X2

1:40 1:40 1:100 1:1000

150%/3 Hz 150%/3 Hz 150%/1 Hz 150 %/0 r/min

± 2to3% ± 0.03% ± 0.2% ± 0.02%

Not possible Not possible Possible Possible

Not possible Not possible Not possible Possible

S Multiple motor drives. S Replacing existing motor

for which motor constants are not known.

S When autotuning is not

possible.

Initializing User Constants: A1-03

Voltage/frequency control

with speed compensation

S Simple speed feedback

control.

S When a pulse generator is

attached to the machine axis.

Current vector control

without PG

S Variable speed drive ap-

plications.

Current vector control with

S Simple servo drives. S Precision speed control. S Torque control.

Use constant A1-03 to initialize the user constants.

When initialized, the user constants will return to their factory-preset values. You should normally re-

cord the setting of any constants that are changed from the factory presets.

User

Constant

Number

A1-03

Initialize

Name

Change

during

Opera-

tion

Setting

Range

0, 1110,2220 3330

Unit

− 0

Factory

Setting

Valid Access Levels

Open

Loop

Vector

V/f

V/f with

Control

Q Q Q Q

Settings to Initialize User Constants

Setting Function

1110

2220

3330

Returns to the Initialize Display without initializing any user constants.

Initializes the user constants to the user settings.

2-wire sequential initialization (Initializes the user constants to the factory settings.)

3-wire sequential initialization

Initializing to User Settings

This function initializes the user constants to values that have been recorded as user settings.

Torecord the user settings, change the user constants to the desired values and then set user constant o2-03 (User constant initial value) to 1. Once user settings are recorded, the o2-03 value will be automatically reset to 0. (The 1110 function will be disabled when user constant o2-03 is set to 0.)

Example of Wiring for 2-wire Sequential Operation

Forward Run/Stop

Flux

Vector

Reverse Run/Stop

Sequential input common

Fig 4.8 Example of Wiring for 2-wire Sequential Operation

Example of Wiring for 3-wire Sequential Operation

The default settings of the multi-function inputs are different from the default settings of the 2-wire sequence.

4-22

4.2 Modes

When setting a 3-wire sequence, the operation can be started and stopped with an automatically resetting pushbutton switch.

Stop switch (NC) Run switch (NO)

Run command (Operates when the run switch is closed.)

Stop command (Stops when the stop switch is open.)

Forward/Reverse run command (Multi-function input 3)

Sequential input common

Fig 4.9 Example of Wiring for 3-wire Sequential Operation

EXAMPLE

Initializing for 2-wire Sequential Operation

Use the following procedure to initialize user constants to the factory settings.

Step Key Sequence Digital Operator Display Remarks

DATA

ENTER

Press 3 times.

DATA

ENTER

DATA

ENTER

The initialization has been completed for a 2-wire sequence.

G5:Main Menu

Operation

G5:Main Menu

Initialize

Select Language

English

Init Parameters

No Initialize

A1−03 = 0

:::

No Initialize

A1−03 = 2220

2-wire Initial

Entry Accepted

Init Parameters

No Initialize

Writes-in the new setting.

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

4-23

Setting User Constants

User

4.2.5 Initialize Mode

Passwords: A1-04, A1-05

Use constants A1-04 and A1-05 to write-protect the initialize-mode user constants.

User constants A1-01 through A1-03 and A2-01 through A2-32 can be displayed but not changed if

the contents of A1-04 and A1-05 are not the same. To write-protect the initialize-mode user constants, set the password in A1-05 after inputting the de-

sired values in A1-01 through A1-03 and A2-01 through A2-32. User constant A1-05 can be displayed by displaying A1-04 and pressing the Menu Key while pressing the Reset Key. (A1-05 can’t be displayed with the usual Key sequences.)

It will be possible to change the initialize-mode user constants again when the same password is writ-

ten to A1-04 and A1-05.

User

Constant

Number

A1-04

A1-05

Name

Password 1

Password 2

Change

during

Opera-

tion

Setting

Range

Unit

Factory

Setting

0 to 9999 − 0

Valid Access Levels

Open

Loop

Vector

V/f

Control

V/f with

Q Q Q Q

Flux

Vector

EXAMPLE

Setting the Password to 1000

Use the following procedure to set the password to 1000.

Step Key Sequence Digital Operator Display Remarks

The password has been set to 1000.

To enable changing user constants, set the same password in A1-05 = 0.

DATA

ENTER

Press 4 times.

RESET

Hold RESET.

And press MENU.

DATA

ENTER

DATA

ENTER

ESC

G5:Main Menu

Operation

G5:Main Menu

Initialize

Select Language

English

Enter Password

A1−04 = 0

Select Password

A1−05 = 0

Select Password

0000

Select Password

1000

Entry Accepted

Select Password

A1−05 = 1000

Enter Password

A1−04 = 0

The first digit will blink. The blinking digit can be changed.

The value of the digit will increment each time the Increment Key is pressed and then stop at 9. Press the Decrement Key to decrease the value.

Writes-in the new setting.

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

J Setting User Constants: A2-01 to A2-32

User constants A2-01 through A2-32 specify the constants that can be displayed and changed when

the access level (A1-01) is set to 1 (user programs). User constants A2-01 through A2-32 can be changed only in the Advanced access level and cannot

be changed during operation. The following restrictions apply to setting/displaying user constants when the access level is set to the

user program access level.

Operation

Initialize

The Quick-start level user constants can be displayed.

The Quick-start level user constants can be displayed or set.

4-24

4.2 Modes

EXAMPLE

Programming

Only the user constants specified in A2-01 through A2-32 can be displayed or set.

Autotuning

Modified constants

Setting C1-08 (Deceleration Time 4) in A2-01 to Define it as a User Constant

The user constants cannot be displayed.

Step Key Sequence Digital Operator Display Remarks

G5:Main Menu

Operation

G5:Main Menu

Initialize

DATA

ENTER

Select Language

English

Function A2

User Constants

DATA

ENTER

DATA

ENTER

User Param 1

A2−01 = −−−−−

User Param 1

−−−−−−−

User Param 1

C1−01

Press twice.

RESET

User Param 1

C1−01

Press twice.

User Param 1

C1−08

Press 7 times.

DATA

ENTER

Entry Accepted

The first digit blinks.

Writes-in set value 0000.

Writes-in the new setting.

ESC

Press twice.

DATA

ENTER

Press twice.

DATA

ENTER

User Param 1

A2−01 = C1−08

Function A2

User Constants

Access Level

Advanced

A1−01 = 4

:::

Advanced

A1−01 = 1

User Program

Entry Accepted

A1−01 = 4

:::

Advanced

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

The user program access level can be set only after one or more constants are set as user constants in A2-01 to A2-32. If no constants are set, the user program access level will not be displayed for A1-01.

Writes-in the new setting.

If the DATA/ENTER Key is not pressed within one minute, the Operator display will return as shown on the left. In this case, repeat from step

14.

4-25

Setting User Constants

4.2.6 Programming Mode

Step RemarksDigital Operator DisplayKey Sequence

Access Level

User Program

ESC

G5:Main Menu

Initialize

The access level has been set to the user program access level.

Figure 4.10 shows the structure of the user constants.

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

Operation mode

Initialize mode

Programming mode

Language

Access Level

Control Method

Initialize

Password

Function Selection A2

These user constants can be changed and displayed only in the Advanced access level.

A2-01 User Param 1

A2-02 User Param 2

A2-32 User Param 32

Fig 4.10 Structure of User Constants

4.2.6 Programming Mode

The Inverter user constants can be set in programming mode. The user constants which can be changed and displayed depend on the access level and control method that are being used. Refer to the following table to determine if a user constant can be changed.

The groups of constants in programming mode and their functions are shown in Table 4.6 .

4-26

Table 4.6 Programming Mode Constant Groups

Group Function Display Comments

4.2 Modes

Control Meth-

V/f

V/f w/PG

Open-loop Vector

Flux Vector

b Application

C Tuning

d Reference

E Motor

b1 Operating modes Sequence

b2 DC braking DC Braking

b3 Speed searching Speed Search

b4 Timer functions Delay Timers

b5 PID control PID Control

b6 Dwell functions Reference Dwell

b7 Droop control Droop Control

b8 Energy-saving control Energy Saving

b9 Zero servo Zero Servo

Acceleration/deceleration

times

S-curve acceleration/de-

celeration

C3 Slip compensation Motor-Slip Comp

C4 Torque compensation Torque Comp

C5 Speed control ASR Tuning

C6 Carrier frequencies Carrier Freq

Hunting prevention func-

tions

C8 Factory tuning constants Factory Tuning

d1 Frequency references Preset Reference

Frequency upper/lower

limits

d3 Jump frequencies Jump Frequencies

Reference frequency hold

function

d5 Torque control Torque Control

E1 V/f characteristics V/f Pattern

E2 Motor constants Motor Setup

E3 Motor 2 control method Motor 2 Ctl Meth

E4 V/f Characteristics 2 V/F pattern 2

E5 Motor 2 constants Motor 2 Setup

Accel/Decel

S-Curve Acc/Dec

Hunting Prev

Reference Limits

Sequence

Settings such as the reference input method

DC braking function settings

Speed search function settings

Timer function settings

PID control settings

Accel/decel time dwell function settings

Droop control (speed drop) settings

Terminal input energy-saving control settings

Stop in the position loop

Acceleration/deceleration time settings

S-curve characteristics for accel/decel times

Slip compensation function settings

Torque compensation function settings

Speed control loop user constant settings

Carrier frequency settings

Hunting prevention function for V/f control

Adjustment for open-loop vector control

Operator frequency reference settings

Frequency upper and lower limit settings

Prohibited frequency settings

Hold for analog frequency reference

User constant settings for torque control

Sets the motor V/f characteristics.

Sets the motor constants.

Sets the control methods for motor 2.

Sets the V/f characteristics for motor 2.

Sets the motor constants for motor 2.

f f f f

× × ×

f f

× ×

× × ×

f f f f

f f f

f f f f

f f

× ×

f f f f

× × ×

f f f f

4-27

Setting User Constants

4.2.6 Programming Mode

Group Function Display Comments

Control Meth-

V/f

V/f w/PG

Open-loop Vector

Flux Vector

F Options

H Terminal

L Protection

o Operator

PG speed control card

settings

Analog Reference Card

F3 Digital Reference Card DI DI-08, 16 Setup

F4 Analog Monitor Card AO AO-08, 12 Setup

F5 Digital Output Card DO DO-02C

F6 Digital Output Card DO DO-08

F7 Pulse Monitor Card PO PO-36F Setup

SI-F/SI-G Transmission

Card

Transmission cards other

than SI-K2, SI-F/G

H1 Multi-function inputs Digital Inputs

H2 Multi-function outputs Digital Outputs

H3 Analog inputs Analog Inputs

Multi-function analog out-

puts

MEMOBUS communica-

tions

L1 Motor protection functions Motor Overload

Momentary power loss

ride-through

L3 Stall prevention Stall Prevention

L4 Frequency detection Ref Detection

L5 Fault restart Fault Restart

L6 Overtorque detection Torque Detection

L7 Torque limits Torque Limit

L8 Hardware protection Hdwe Protection

o1 Display/Monitor settings Monitor Select

o2 Function settings Key Selections

PG Option Setup

AI-14 Setup

SI-F/G

DDS/SI-B

Analog Outputs

Serial Com Setup

PwrLoss Ridethru

User constant settings for a PG Card

User constant settings for an Analog Reference Card

User constant settings for a Digital Reference Card

User constant settings for an Analog Monitor Card

User constant settings for a Digital Output Card

User constant settings for a Pulse Monitor Card

User constant settings for a Transmission Card

Function selection for multi-function inputs

Function selection for multi-function outputs

Function selection for analog inputs

Function selection for analog outputs

MEMOBUS communications settings

Overload protection settings and selection

Selects the power-loss processing method.

Stall prevention settings and selection

Frequency detection settings and selection

Fault restart function settings

Overtorque detection settings and selection

Torque limit settings (vector control only)

Overheating and phase loss protection settings

Selects the display and setting methods.

Key function selection and other user constants

f f f f

f f

× ×

f f f f

4-28

Figure 4.11 shows the difference in the display structure for the various access levels.

4.2 Modes

[Mode]

Operation mode

Initialize mode

Programming mode

Autotuning mode

Modified constants mode

DATA

ENTER

Advanced Level

[Group]

b Application

C Tuning

d Reference

DATA

ENTER

Basic Level

[Function]

b1 Sequence

DATA

ENTER

Quick-start Level

[Constant]

b1-01 Reference selection

b1-02 Operation method selection

b1-03 Stopping method selection

b2 DC braking b2-01 Zero speed level

b2-02 DC injection braking current

b3 Speed search

b3-01 Speed search selection at start

b3-02 Speed search operating current

C1 Accel/Decel C1-01 Acceleration time 1

C1-02 Deceleration time 1

C2 S-curve characteristic setting

C3 Motor-slip compensation

d1 Frequency refer-

C2-01 S-curve characteristic time at acceleration start

C2-02 S-curve characteristic time at deceleration start

C3-01 Slip compensation gain

d1-01 Frequency reference 1

ence presetting

d1-02 Frequency reference 2

E Motor

F Option

H Terminal

L Protection

o Operator

d2 Frequency up-

d2-01 Frequency reference upper limit

per/lower limit

d2-02 Frequency reference lower limit

d3 Jump frequency d3-01 Jump frequency 1

E1 V/f pattern setting E1-01 Input voltage setting

E1-02 Motor selection

E2 Motor setup E2-01 Motor rated current

F1 PG Speed Control Card

F1-01 PG constant

H1 Sequence input H1-01 Digital input

H2 Sequence output H2-01 Digital output

L1 Motor protection L1-01 Motor protection selection

L2 Momentary power

L1-02 Motor protection time constant

loss ride-through

o1 Display/setting

o1-01 Monitor selection

selection

o1-02 Monitor selection after power up

o2 Function selection

o2-01 LOCAL/REMOTE Key enable/disable

o2-02 STOP Key during control circuit terminal operation

Fig 4.11 Display Structures for Different Access Levels

4-29

Setting User Constants

4.2.7 Autotuning Mode

EXAMPLE

Autotuning Procedure

CAUTION

D Disconnect the load (machine, device) from the motor before autotuning.

The motor may turn, possibly resulting in injury or damage to equipment. Also, motor constants cannot be correctly set with the motor attached to a load.

Autotuning automatically tunes and sets the required motor constants when operating in the open-loop or flux vector control modes. Always perform autotuning before starting operation.

When the rated voltage, rated current, rated frequency, and number of poles listed on the motor nameplate have been input and the RUN Key is pressed, the motor constants calculated from these values will be written to E1-04 through E2-09 automatically.

When the motor cannot be disconnected from the load, motor constants can be set by calculation. Contact your Yaskawa representatives for details.

The autotuning mode won’t be displayed if V/f control has been selected. Refer to Setting the Control Method: A1-02 under 4.2.5 Initialize Mode.

The Inverter’s autotuning function automatically determines the motor constants, while a servo system’s autotuning function determines the size of a load, so these autotuning functions are fundamentally different.

Step Key Sequence Digital Operator Display Remarks

G5:Main Menu

Operation

G5:Main Menu

Autotuning

press 3 times.

DATA

ENTER

DATA

EN-

TER

Rated Voltage

200.0 VAC

Rated Voltage

200.0 VAC

∗

The leading digit blinks.

When Increment Key is pressed, blinking value increases. When Decrement Key is pressed, blinking value decreases.

RESET

DATA ENTER

Rated Voltage

200.0 VAC

Entry Accepted

The digit to be set moves to the right and blinks. Follow the above procedures as outlined in step 4.

After selecting values for steps 4 and 5, press DATA/ENTER Key.

The Operator display is as shown on the left. The value is written-in.

Rated Voltage

200.0 VAC

Rated Current

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

1.90 A

DATA

ENTER

RESET

DATA

ENTER

Press the keys as in steps 4, 5, 6 of rated voltage setting.

Rated Frequency

60.0 HZ

DATA

ENTER

RESET

DATA

ENTER

Press the keys as in steps 4, 5, 6 of rated voltage setting.

Rated Speed

1750 RPM

DATA

ENTER

RESET

DATA

ENTER

Press the keys as in steps 4, 5, 6 of rated voltage setting.

4-30

4.2 Modes

Step

Key Sequence Digital Operator Display Remarks

Number of Poles

DATA

ENTER

RESET

DATA

ENTER

Press the keys as in steps 4, 5, 6 of rated voltage setting.

Select Motor 1/2

DATA ENTER

RESET

DATA

ENTER

Press the keys as in steps 4, 5, 6 of rated voltage setting.

Leave the setting at 1 to set the value for motor 1 (the motor contacts normally used.)

Select “2” to store the autotuning results for motor 2.

Tuning Ready?

Press RUN Key

RUN

Tune Processing

jHzjjjjA

Tune Successful

G5:Main Menu

Operation

Autotuning starts and the motor rotates for approx. one minute.

Then the motor stops automatically.

IMPORTANT

Returns to the operation mode display.

∗

The rated voltage for vector control motors may be 10% to 20% lower than that for general-purpose motors. Check the voltage on the nameplate or in the test reports.

If a fault occurs during autotuning, refer to Table 5.1 Troubleshooting Autotuning Fault s.

4-31

Yaskawa VARISPEED-616G5 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Safety Information

Visual Aids

General Precautions

Safety Precautions

Warning Label Contents and Position

How to Change the Digital Operator Display from Japanese to English

Warranty Information

Before Reading This Manual

CONTENTS

Table of Contents

Introduction

1.1.1 VS-616G5 Inverter Models

1.1 Outline and Functions

1.1.2 Outline of Control Methods

1.1.3 Functions

1.2 Nomenclature

1.2.1 VS-616G5 Components

1.2.2 Digital Operator Components

Handling Inverters

2.1.1 Nameplate Information

2.1 Confirmations upon Delivery

2.2 Exterior and Mounting Dimensions

2.3.1 Installation Site

2.3 Checking and Controlling the Installation Site

2.3.2 Controlling the Ambient Temperature

2.3.3 Protecting the Inverter from Foreign Matter

2.4 Installation Orientation and Space

2.5.1 Inverters of 15 kW or Less

2.5 Removing/Attaching the Digital Operator and Front Cover

2.5.2 Inverters of 18.5 kW or Higher

Wiring

3.1 Connections to Peripheral Devices

3.2 Connection Diagram

3.3 Terminal Block Configuration

3.4.1 Applicable Wire Sizes and Closed-loop Connectors

3.4 Wiring Main Circuit Terminals

3.4.2 Main Circuit Terminal Functions

3.4.3 Main Circuit Configurations

3.4.4 Standard Connection Diagrams

3.4.5 Wiring the Main Circuits

3.5.1 Wire Sizes and Closed-loop Connectors

3.5 Wiring Control Circuit Terminals

3.5.2 Control Circuit Terminal Functions

3.5.3 Control Circuit Terminal Connections (All Models)

3.5.4 Control Circuit Wiring Precautions

3.6 Wiring Check

3.7.1 Installing a PG Speed Control Card

3.7 Installing and Wiring PG Speed Control Cards

3.7.2 PG Speed Control Card Terminal Blocks

3.7.3 Wiring a PG Speed Control Card

3.7.4 Wiring PG Speed Control Card Terminal Blocks

3.7.5 Selecting the Number of PG (Encoder) Pulses PG-A2/PG-B2

Setting User Constants

4.1 Using the Digital Operator

4.2 Modes

4.2.1 Inverter Modes

4.2.2 Switching Modes

4.2.3 User Constant Access Levels

4.2.4 Operation Mode

4.2.5 Initialize Mode

4.2.6 Programming Mode

4.2.7 Autotuning Mode