YASKAWA VARISPEED-656RC5 Instruction Manual

VARISPEED-656RC5
Instruction Manual

POWER REGENERATIVE UNIT (VS-656RC5)
MODEL: CIMR-R5U

200V CLASS 3.7 to 37kW
400V CLASS 3.7 to 75kW

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

WARNING

YASKAWA manufactures component parts that can be used in a wide variety of indu strial applications.
The selection and application of YASKAWA products remain the responsibility of the equipment
designer or end user. YASKAWA accepts no responsibility for the way its products are incorporated
into the final system d e sign.

Under no circumstances should any YASKAW A pro duct be incorporat ed into any pro duct or design as
the exclusive or sole safety control. W itho ut exception, all control s shou ld be designed to detect faults
dynamically and fail safely under all circumstances. All products designed to inc orporate a compo­nent part manufactured by YASKA WA must be supplied to the end user with appropria te warnings and
instructions as to that part’s safe use and operation. Any warnings provided by YASKAWA must be
promptly provided to the end user.

YASKAWA offers an express warranty only as to the quality of its products in conforming to standards
and specifications published in YASKAWA’s manual. NO OTHER WARRANTY, EXPRESS OR
IMPLIED, IS OFFERED. YASKAWA assumes no liability for any perso n a l injury, property damage,
losses, or claims arising from misapplication of its products.

PREFACE

YASKAWA’s VS-656RC5 is a power regenerative unit
which has both braking and regenerative functions.
This instruction manual describes installation,
maintenance, inspection, troubleshooting, and
specifications of the VS -656RC5. Read this instruction
manual thoroughly before operation.

YASKAWA ELECTRIC CORP ORATION

General Precautions

• Some drawings in this manual are shown with the protective covers and shields
removed, in order to illustrate detail with more clarity. Make sure all covers and
shields are replaced before operating this product.

• This manual may be modified when necessary to reflect improvements to the
product, or changes in specifications.
Such modifications are denoted by a revised manual No.

• To order a copy of this manual, contact your YASKAWA representative.

• YASKAWA is not responsible for any modification of the product made by the
user . Any modifications will void the warranty.

1

CONTENTS

NOTES FOR SAFE OPERATION . . . . . . . . . . . . . . . . . . . . 4

1. RECEIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1.1 Checking the Name Plate. . . . . . . . . . . . . . . . . . . . . . . . . . .11

2. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2.1 S tandard Specifications (200V Class). . . . . . . . . . . . . . . . .13

2.2 S tandard Specifications (400V Class). . . . . . . . . . . . . . . . .15

2.3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

3. MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.1 Choosing a Location to Mount the Inverter . . . . . . . . . . . . .19

3.2 Mounting Dimensions . . . . . . . . . . . . . . . . . . . . . . . 21

3.3 Mounting/Removing Components . . . . . . . . . . . . . . . . . . . 22

4. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.1 Connection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

4.2 Wire and Terminal Screw Sizes. . . . . . . . . . . . . . . . . . . . . .27

4.3 Connecting Main and Control Circuit. . . . . . . . . . . . . . . . . .29

4.4 External Terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

5. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5.1 Checkpoints Before Turning On Power Supply. . . . . . . . . .36

5.2 Setting the Power Supply Voltage Jumper . . . . . . . . . . . . .36

5.3 Confirming Display Status . . . . . . . . . . . . . . . . . . . . . . . . . .37

5.4 Power ON/OFF Sequence. . . . . . . . . . . . . . . . . . . . . . . . . .39

5.5 Run Command Selection. . . . . . . . . . . . . . . . . . . . . . . . . . .40

2

6. MAINTENANCE AN D INSPECTION . . . . . . . . . . . . . . .42

6.1 Daily Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

6.2 Periodical Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

6.3 Part Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

7. FAULT DIAGNOSIS AND CORRECTIV E ACTIONS . . .45

3

NOTES FOR SAFE OPERATION

Read this instruction manual thoroughly before installation, operation, maintenance or
inspection of the RC5. In this manual, NOTES FOR SAFE OPERA TION are classified
as “WARNING” or “CAUTION”.

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury to personnel.

CAUTION

Indicates a potentially hazardous situation which, may result in minor or moderate
injury to personnel, and possible damage to equipment if not avoided. It may also be
used to alert against unsafe practices.

Items described in may also result in a vital accident in some situations. In

CAUTION

either case, follow these important notes.

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 these symbols appear on the warning
labels on Yaskawa products. Please abide by these warning labels regardless of which
symbol is used.

NOTE

These are steps to be taken to ensure proper operation.

4

RECEIVING

CAUTION

(Ref. page)

• Do not install or operate any power regenerative unit
which is damaged or has missing parts.

Failure to observe this caution may result in personal injury or

equipment damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5

INSTALLATION

CAUTION

(Ref. page)

• Lift the cabinet by the base. When moving the unit,
never lift by the front cover or the front panel.

Otherwise, the main unit may be dropped causing damage to the unit. . . . . . 19

• Mount the power regenerative unit on nonflammable
material (i.e., metal).

Failure to observe this caution can result in a fire. . . . . . . . . . . . . . . . . . . . . . . 19

• When mounting units in an enclosure, install a fan or other
cooling device to keep the intake air temperature
below 113°F (45°C).

Overheating may cause a fire or damage to the unit. . . . . . . . . . . . . . . . . . . . . 20

WIRING

WARNING

(Ref. page)

• Start wiring only after verifying that the power supply
is turned OFF for at least on e minute.

Failure to observe this warning can result in electric shock or fire.. . . . . . . . . 25

• Wiring should be performed only by qualified personnel.

Failure to observe this warning can result in electric shock or fire.. . . . . . . . . 25

• Make sure to ground the ground terminal before
connecting the other termin als.

Failure to observe this warning can result in an electric shock or a fire. . . . . . 25

• Make sure to ground the ground terminal according
to the local ground code.

Failure to observe this warning can result in electric shock or fire.. . . . . . . . . 25

6

CAUTION

(Ref. page)

• Verify that the power regenerative unit rated v oltage coincides
with the AC power supply voltage.

Failure to observe this caution can result in personal injury

or fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

• Do not perform a withstand voltage test of the power
regenerative unit.

It may cause semi-conductor elements to be damaged. . . . . . . . . . . . . . . . . . . 25

• Connect the power coordination reactor and the power
suppression reactor as described in this instruction manual.

Improper connection may cause a fire.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

• Verify that the rated voltage of the power regene rative
unit coincides with the rated voltage of the power
regenerative unit to be connected.

Failure to observe this caution can resul t in a fire.. . . . . . . . . . . . . . . . . . . . . . 25

• Tighten terminal screws.

Failure to observe this caution can resul t in a fire.. . . . . . . . . . . . . . . . . . . . . . 25

7

OPERATION

WARNING

• Only turn ON the input power sup p ly af te r repl aci n g th e
front cover or the terminal cover.
Do not remove the cover while the power is ON.

Failure to observe this warning can result in electr ic shock. . . . . . . . . . . . . . . 35

• Never operate the digital operator or other switches when
your hand is wet.

Failure to observe this warning can result in electr ic shock. . . . . . . . . . . . . . . 35

• Never touch the terminals while power is ON, even
if the power regenerativ e unit is at stop.

Failure to observe this warning can result in electr ic shock. . . . . . . . . . . . . . . 35

CAUTION

(Ref. page)

(Ref. page)

• Never touch the heatsink or input reactor since the
temperature is very high.

Failure to observe this caution can result in harmful burns

to the body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

• All the parameters of the power regenerative have been preset at
the factory. Do not change the sett ings unnecessarily.

The power regenerative unit may be damaged. . . . . . . . . . . . . . . . . . . . . . . . ..35

8

MAINTENANCE AND INSPECTION

WARNING

• Never touch high-voltage terminals in the power
regenerative unit

Failure to observe this warning can resul t in an electrical shock. . . . . . . . . . . 42

Perform maintenance or insp ection only after verifying
that the CHARGE LED goes OFF, after the main circuit
power supply is turned OFF.

The capacitors are still charged and can be dangerous. . . . . . . . . . . . . . . . . . . 42

• Only authorized personnel should be permitted to perform
maintenance, inspections or parts replacement.

[Remove all metal objects (watches, bracelets, etc.) before operation.]
(Use tools which are insulated against electrical shock.)

Failure to observe this warning can resul t in an electrical shock. . . . . . . . . . . 42

• Never modify the product.

Failure to observe this warning can result in an electric shock or personal injury

and will void the warranty.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

(Ref. page)

CAUTION

(Ref. page)

• The power regenerative unit employs semi-conductor.
elements. Do no t touch the CMOS elements.

They are easily damaged by static electrici ty. . . . . . . . . . . . . . . . . . . . . . . . . . 42

• Do not connect or disconnect wires or connectors while
power is applied to the circuit.

Failure to observe this caution can result in personal in jury. . . . . . . . . . . . . . . 42

9

WARNING LABEL

A warning label is displayed on the front cover of the power regenerative unit, as
shown below. Follow these instructions when handling the power regenerative unit.

Warning Label

Model CIMR-RU23P7

10

1. RECEIVING

CAUTION

• Do not install or operate any power regenerative unit which is
damaged or has missing parts.

Failure to observe this caution may result in personal injury or
equipment damage.

1.1 Inspection Checkpoints

After unpacking the RC5, check the following:

• Verify that the part numbers match your purchase order or packing slip.

• Check the unit for physical damage that may have occurred during shipping.
If any part of RC5 is missing or damaged, call for service immediately.

• Checking the Nameplate

Example of standard domestic model CIMR-R5U23P7

Nameplate Data

U

R5U23P7

11

Model Designation

Standard domestic mod el

U

American model

U

Protective Structure

• Open Chassis Type (IEC IP00)
Protected so that parts of the human body cannot reach electrically charged parts

from the front when the Power regenerative unit is mounted in a control panel.

• Enclosed Wall-mounted Type (IEC IP20, NEMA 1)
The power regenerative unit is structured so that the power regenerative unit 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.

12

2. SPECIFICATIONS

NOTE

1. Use 1 to 1 with an inverter. Do not connect more than one inverter to one
power regenerative unit.

2. Use the power regenerative unit whose capacity is equal to or exceeding

the inverter capacity to be combined.

3. Do not use this unit with single-phase power. Use three-phase power.

2.1 Standard Specifications (200V Class)

Voltage Class 200V

Model CIMR-R5U 23P7 25P5 27P5 2011 2015 2018 2022 2030 2037
Rated Capacity (kW) 3.7 5.5 7.5 11 15 18.5 22 30 37
Rated DC Current (A) 13192637516477102126
Rated Current on

Rating

Power Side (A)
Regenerative Torque 100% for 1 minute, 25% ED, 80% continuous
Voltage Frequency 200 to 220 VAC 50 Hz, 200 to 230 VAC 60 Hz
Allowable Voltage Fluctuation +10 to -15% (Imbalance rat e betw ee n ph ase s: wit hin 2%

Allowable Frequen cy
Fluctuation

Input Power

Supply

Control Method

10 15 20 30 40 50 60 80 100

±3Hz (No phase rotation)

120º current conduction

Input Power Factor

Overload Capacity

Control

Characteristics

Operation Input External terminals

Fault I C contact output
Running, READY

Signal

Status

Output

Analog Output Analog output: 1 point can be selected (current monitor)
Instantaneous Overcurrent Stops at approx. 200% of the current on power side
Blown fuse Stops by blown fuse
Overload Stops after 30 seconds at 150% of rated current
Under voltage

(DC Voltage)
Under voltage

(Power Side Voltage)
Overload Stops at approx. 400 VDC or more.
Fin Overheat Protected by thermistor

Protective Functions

Power Supply Open Phase Stops at power supply open phase detection.
Power Frequency Error Stops by fluctuation more than ±3Hz of rated input frequency.
Power Charge Indication Indicated until main output voltage is approx. 50V or less.

30 seconds at approx. 150% of rated current

0.9 or more (Rated current)

Photocoupler output

Stops at approx. 190 VDC or less.
Stops at approx. 150 VAC or less.

13

Voltage Class 200V

Model CIMR-R5U 23P7 25P5 27P5 2011 2015 2018 2022 2030 2037

Location Indoor (Protected from corrosive gases and dust)
Ambient Temperature
Humidity 90% RH or less (non-condensing)

Vibration

Environmental

Conditions

14°F (-10° C) to 104° F (40° C) (Enclosed wall-mounted type)

14° F (-10° C ) to 113° F (45° C) (Open chassis type)

2

9.8 m/s

(1G) at le ss t h an 20 H z, up t o 1. 96 m/s2 (0.2G) at 20 to 50 Hz

* Use a power regenerative unit with larger output capacity if the imbalance rate

between phases exceeds 2%.

Imbalance rate between phases can be calculated using the following formula (Con-

forming to IEC1800-3).

Imbalance rate between phases [%] =

Max voltage - Min. voltage

Three-phase average voltage

X67

14

2.2 Standard Specifications (400V Class)

Voltage Class 400V

Model CIMR-R5U 43P7 45P5 47P5 4011 4015 4018 4022 4030 4037 4045 4055 4075

Rated Capacity (kW) 3.7 5.5 7.5 11 15 18.5 22 30 37 45 55 75
Rated DC Current (A) 6 9 13 19 26 32 37 51 64 77 96 128
Rated Current on

Rating

Power Side (A)
Regenerative Torque 100% for 1 minute, 25% ED, 80% continuous
Voltage Frequency 380 to460 VAC, 50/60 Hz
Allowable Voltage

Fluctuation
Allowable Frequency

Fluctuation

Input Power

Supply

Control Method

5 7.5 10 15 20 25 30 40 50 60 75 100

+10 to -15% (Imbalance rate between phases: within 2%

±3Hz (No phase rotation)

120º current conduction

Input Power Factor

Overload Capacity

Control

Characteristics

Operation Input External terminals

Fault I C contact output
Running, READY

Signal

Status

Output

Analog Output Analog output: 1 point ca n be sele ct ed (cu rre nt mo nit or)
Instantaneous

Overcurrent
Blown fuse Stops by blown fuse
Overload Stops after 30 seconds at 150% of rated current
Under voltage

(DC Voltage)
Under voltage

(Power Side Voltage)
Overload Stops at approx. 400 VDC or more.
Fin Overheat Protected by thermistor
Power Supply Open

Protective Functions

Phase
Power Frequency Error Stops by fluctuation more than ±3Hz of rated input frequency.
Power Charge

Indication

30 seconds at approx. 150% of rated current

Stops at approx. 200% of the current on power side

Stops at power supply open phase detection.

Indicated until main output voltage is approx. 50V or less.

0.9 or more (Rated current)

Photocoupler output

Stops at approx. 190 VDC or less.
Stops at approx. 150 VAC or less.

15

Voltage Class 400V

Model CIMR-R5U 43P7 45P5 47P5 4011 4015 4018 4022 4030 4037 4045 4055 4075

Location Indoor (Protected from corrosive gases and dust)
Ambient Temperature
Humidity 90% RH or less (non-condensing)

Vibration

Environmental

Conditions

14° F (-10°C) to 104° F (40° C) (Enclosed wall-mounted type)

14° F (-10° C) to 113° F (45° C) (Open chassis type)

2

9.8 m/s

(1G) at less than 20 Hz, up to 1.96 m/s2 (0.2G) at 20 to 50 Hz

Use a power regenerative unit with larger output capacity if the imbalance rate betwe e n p hases

exceeds 2%.

Imbalance rate between phases can be calculated using the following formula (Conforming to

IEC1800-3).

Imbalance rate between phases [%] =

Max voltage - Min. voltage
Three-phase average voltage

X67

16

2.3 Dimensions

Models of 200V/400V 30 kW and Lower

The following figure shows a 200V 3.7kW model. Use open chassis type 200V/400V
30kW and lower with the top and bottom covers removed.

RUNDS1DS2POWER

H

H1

W1

W1

Dimensions in inches (mm)/m

W

H2

d

D

Models of 200V/400V 37 kW and Higher

The following figure shows a 200V/400V 3.7kW model.

H

RUN

W1

W

H1

H2

d

D

17

Voltage VS-

656RC5U

23P7

27P5

2011

200V
Class

2015 6 6
2018
2022

2030 11
2037

43P7

47P5

4011

4015

400V

4018

Class

4030
4037
4045 26 29

4055
4075 36

Dimensions in inches (mm)/mass (kg)

Open Chassis Type (IPOO) Enclosed Wall-Mounted (IP20)

7.08

(180)

8.07

8.85

(225)

(285)

7.08

(180)

8.07
(81)

8.85

(225)

(285)

(285)

Mounting

Dimensions

in/mm

4.96

10.47

(126)

(266)

7.32

11.22

(186)

(285)

9.29

14.37

(236)

(365)

10.82

17.12

(275)

(435)

4.96

10.47

(126)

(266)

7.32

11.22

(96)

(118)

9.29

14.37

(236)

(365)

10.82

17.12

(275)

(435)

10.82

24.01

(275)

(610)

0.275
(7.0)

0.314
(8.0)

0.295
(7.5)

0.295
(7.5)

0.275
(7.0)

0.314
(8.0)

0.295
(7.5)

0.295
(7.5)

0.295
(7.5)

Approx.

Mass

(kg)

4.5

5.5

10

23

3.5

10.5

25

34

Dimensions

in/mm

WHDW1H1H2 WHDW1H1H2

5.51

11.02

(140)

(280)

7.87

11.81

(200)

(300)

(205)

9.84

14.96

(250)

(380)

12.79

17.71
(450)

11.02
(280)

11.81
(128)

14.96
(380)

17.71
(450)

24.60
(625)

11.22

11.22

11.22

(325)

5.51

(140)

7.87

(200)

9.84

(250)

12.79
(325)

12.79
(325)

Dimensions

in/mm

5.51

11.02

(140)

(280)

(180)

7.87

11.81

(200)

(300)

(205)

14.96
(380)

9.84

(250)

12.99
(330)

5.51

(140)

44

7.87

6

(200)

9.84

(250)

12.99
(330)

12.99
(330)

15.74
(400)

24.01
(610)

11.02
(280)

11.81
(300)

14.96
(380)

24.01
(610)

12.99
(330)

33.46
(850)

(225)

11.22
(285)

(180)

(205)

(225)

11.22
(285)

11.22
(285)

7.08

8.07

8.85

7.08

8.07

8.85

Mounting

Dimensions

in/mm

4.96

10.47

(126)

(266)

7.32

11.22

(186)

(285)

9.29

14.37

(236)

(365)

10.82

17.12

(275)

(435)

4.96

10.47

(126)

(266)

7.32

11.22

(186)

(285)

9.29

14.37

(236)

(365)

10.82

17.12

(275)

(435)

10.82

24.01

(275)

(610)

0.275
(7.0)

0.314
(8.0)

0.295
(7.5)

1.08

(27.5)

3.44

(87.5)

0.275
(7.0)

0.314
(8.0)

0.295
(7.5)

3.44

(87.5)

3.44

(87.5)

6.00

(152.5)

Mount-

Approx.

Mass

ing

Hole

(kg)

4.5 M525P5

5.5
M6

10

M6

11
27 M6

3.5
M545P5

6M6

10.5 M64022

28

M6

38

M6

40

18

3. MOUNTING

CAUTION

• Lift the cabinet by the base. When moving the unit,
never lift by the front cover or t he f r ont panel.

Otherwise, the main unit may be dropped causing damage to the unit.

• Mount the power regenerative unit on nonflammable
material (i.e., metal).

Failure to observe this caution can result in a fire.

• When mounting units in an enclosure, install a fan or other
cooling device to keep the intake air temperat ure
below 113°F (45°C).

Overheating may cause a fire or damage to the unit.

This chapter describes the configuration location and space when mounting
the VS-656RC5.

3.1 Choosing a Location to Mount the Inverter

Install the power regenerative unit under the following conditions.

Type Ambient Operatin g Temperature Humidity

Enclosed

wall-mounted
Open chassis 14 to 113° F

14 to 104° F

-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 power regenerative unit. Be
sure to remove the protection covers before installing a 200 or 400V Class power
regenerative unit with an output of 30 kW or less in a panel.

Be sure the power regenerative unit is protected from the following conditions:

• Extreme cold and heat. Use only within the ambient temperature range (for open

chassis type): 14 to 131°F (-10 to +50°C)

• Rain, moisture.

19

• Oil sprays, splashes.

• Salt spray.

• Direct sunlight. (Avoid using outdoors).

• Corrosive gases (e.g. sulfurized gas) or liquids.

• Dust or metallic particles in the air.

• Physical shock, vibration.

• Electromagnetic noise. (Example: welding machines, power devices, etc.)

• High humidity.

• Radioactive materials.

• Combustibles: thinner, solvents, etc.

• Controlling the Ambient Temperature

To enhance the reliability of operation, the power regenerative unit should be installed
in an environment free from extreme temperature increases. If the power regenerative
unit is installed in an enclosed environment, such as a box, us a cooling fan to or air
conditioner to maintain the internal air temperature below 113ºF (45ºC).

• Protecting the Power Regenerative Unit from

Foreign Matter

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

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

20

3.2 Mounting Dimensions

r

Install the VS-656RC5 vertically and allow sufficient clearances for effective cooling
as shown in the figure below.

1.96” (50mm) or more

1.18” (30mm) or more

1.18” (30mm) or more

1.96” (50mm) or more

Front View Side View

Air

4.72” (120mm)
or more

4.72” (120mm)
or more

Air

NOTE

(1) The clearances required at top/bottom and both sides are common in

open chassis type (IPOO) and enclosed wall-mounted type (NEMA 1).

(2) Remove the top and bottom covers to use the open chassis type of

200V/400V 30 kW or less.

(3) When installing the models of 200V/400V 37kW or more, equipped

with eyebolts, extra spacing will be required on either side. For
detailed dimensions, contact your YASKAWA representative.

21

with * in order to permit the flow of i ntake/exhaust air to/f

3.3 Mounting/Removing Components

Removing and Replacing the Front Cover

• Removing front cover

To remove the front cover, first move the LED monitor in the direction shown by
arrow 1 . Then press the right and left sides in the direction shown by arrows 2 ,
and lift cover to direction 3 .

1

2

3

2

NOTE

22

Do not replace the front cover with the LED monitor connected. The LED
monitor will not be connected to the power regenerative unit. Replace the
front cover first and then install the LED monitor on the cover.

• Removing the LED monitor

Push the LED monitor lever in the direction shown by arrow 1 and lift the LED
monitor in the direction shown by arrow 2 to remove the LED monitor from the
front cover.

Front Cover

LED Monitor

2

1

• Replacing the LED Monitor

Engage the LED monitor on claws A in the direction shown by arrow 1 and then
on claws B in the direction shown by arrow 2 to lock the LED monitor.

LED Monitor

Front Cover

2

1

Claws A

Claws B

23

NOTE

Never fit the LED monitor in any other direction or by any other method.
The LED monitor will not be connected to the inverter.

24

4. WIRING

WARNING

• Start wiring only aft er verifying that the power supply is turned OFF.

Failure to observe this warning can result in an electric shock or fire.

• Wiring should be performed only by qualified personnel.

Failure to observe this warning can result in an electric shock or fire.

• Make sure to ground the ground terminal before connecting any other
terminals.

Failure to observe this warning can result in an electric shock or fire.

CAUTION

• Verify that the power regenerative unit rated voltage coincides with the AC
power supply voltage.

Failure to observe this caution can result in personal injury or a fire.

• Do not perform a withstand voltage test of the power reg enerative unit.

It may cause semi-conductor elements to be damaged.

• Connect the power coordination reactor and the pow er suppre ssion react or
as described in this instruction manual.

Improper connection may cause a fire.

• Verify that the rated voltage of the power regenerative unit coincides with
the rated voltage of the power regenerative unit to be connected.

Improper connection may cause a fire.

• Tighten terminal screws.

Failure to observe this caution can result in a fire.

25

4.1 Connection Diagram

The Figure below shows a typical connection diagram of VS-656RC5 with a VS-616G5.

*4

*6

*4

*2

*3

*5

VS-616G5U

*8

*7

*2

*3

*1

*1 Connect to the terminal 1 for 200Vclass 0.4 to22 kW, and 400 V class 0.4 to 45 kW VS-616G5 inverters. Use

terminal 3 for 200V class 30 to 37 kW, and 400V class 55 to 75 kW VS-616G5 inverters.

*2 Connect VS-616G5 AC power supply terminals R/L1, S/L2, and T/L3 to the secondary side of the power coordination

reactor. Connect VS-616RC5 AC power supply terminals R/L1, S/L2, and T/L3 to the secondary side of the power
suppression reactor.

*3 Connect terminals r/l 1, s/l 2 of VS-616G5, and terminals r1/l 11, s1/l 21, and t1/l 31 of VS-656RC5 to the primary side

of the power coordination reactor.
*4 Make sure to use the specified reactor, fuse and fuse holder.
*5 The circuit for the sequence input terminal of VS656RC5 is the same as terminal S1.
*6 The wiring distance between the power coordination reactor and VS-616G5/VS-656RC5 should be 10 m or less.
*7 DC bus wiring ( 1- , - ) between VS-616G5 and VS-656RC5 should be 5 m or less.
*8 Remove the wiring of terminals r/l 1 and s/l 2 (they were connected at the factory.)

26

4.2 Wire and Terminal Screw Sizes

1. Wiring Main Circuit Terminals

Select wires to be used for wiring from the following tables.

200V Class Wire Size

Circuit

Main

Control

VS-656RC5

CIMR-R5U

R/L1,S/L2,T/L3,

23P7

25P5

27P5

2011

2015

2018

2022

2030

2037

Common to al l

models

r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

S1, S2, S3, S4, SS, SP, SC, M1, M2, M3,
M4,
MA, MB, MC, AM, AC

E(G)

Terminal Symbol

_

Wire Size*

mm

3.5 to 5.5
2 to 5.5

3.5 to 5.5

5.5

2 to 5.5

3.5 to 5.5

2 to 5.

5.5 to 8

2 to 5.5

5.5 to 8

twisted wire

0.5 to 1.25
single

0.5 to 1.25

Terminal

Screw

M4 2 to 5.5

M4

M4

M5

M5

M8 22
M4 2 to 5.5
M6 8
M8 22
M4 2 to 5.5
M6 8
M8 30 to 38
M4 2 to 5.5
M6 14
M8 50 to 60
M4 2 to 5.5
M6 14

M3.5 0.5 to 2

2

8

8

Wire Type

Power Cable

600V vinyl-sheathed wire or

equivalent

Shielded twisted-pair wires

* Cable size is selected assuming external wiring of single 3-core cables at an ambient temperature of 86º F (30º C).

27

400V Class Wire Size

_

Wire Size*

2

mm

3.5 to 5.5
2 to 5.5

5.5

2 to 5.5

5.5

twisted wire

0.5 to 1.25
single

0.5 to 1.25

Wire Type

Power Cable

600V vinyl-sheathed wire or

equivalent

Shielded twisted-pair wires

Circuit

Main

Control

Control

VS-656RC5

CIMR-R5U

R/L1,S/L2,T/L3,

43P7

45P5

47P5

4011

4015

4018

4022

4030

4037

4045

4055

4075

Common to all

models

r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

R/L1,S/L2,T/L3,
r 1 / l 11, s1 / l 21, t1 / l 31

S1, S2, S3, S4, SS, SP, SC, M1, M2, M3,
M4,
MA, MB, MC, AM, AC

E(G)

Terminal Symbol

Terminal

Screw

M4 2 to 5.5

M4 2 to 5.5

M4 2 to 5.5

M5

M5

M8 8 to 14
M4 2 to 5.5
M6 8
M8 8 to 14
M4 2 to 5.5
M6 8
M8 14
M4 2 to 5.5
M6 8
M8 14 to 22
M4 2 to 5.5
M6 8
M8 22 to 38
M4 2 to 5.5
M6 8
M8 38 to 60
M4 2 to 5.5
M6 14
M8 50 to 60
M4 2 to 5.5
M6 14

M3.5 0.5 to 2

* Cable size is selected assuming external wiring of single 3-core cables at an ambient temperature of 86º F (30º C).

28

4.3 Connecting Main and Control Circuits

Main Circuit Input Fuse

Connect a fuse at the primary side of the power suppression reactor. Recommended
fuses are shown in the following table.

200V and 400V Class Input Fuses and Fuse Holders - Manufactured by Fuji Electric
Co. Inc.

Input AC Fuse and Fuse Holders

VS-656RC5 Input Fuse Fuse Holder

Rated

Model

CIMR-R5U

23P7 10 250V ac, 20A CR2LS-20/UL FU000799 3 CM-1A FU002014 1
25P5 15 250V ac, 30A CR2LS-30/UL FU000791 3 CM-1A FU002014 1
27P5 20 250V ac, 30A CR2LS-30/UL FU000791 3 CM-1A FU002014 1
2011 30 250V ac, 50A CR2LS-50/UL FU000797 3 CM-1A FU002014 1
2015 40 250V ac, 75A CR2LS-50/UL FU000792 3 CM-1A FU002014 1
2018 50 250V ac, 100A CR2LS-100/UL FU002085 3 CM-1A FU002014 1
2022 60 250V ac, 100A CR2LS-100/UL FU002085 3 CM-1A FU002014 1
2030 80 250V ac, 150A CR2LS-150/UL FU002086 3 CM-2A FU002090 1
2037 100 250V ac, 150A CR2LS-150/UL FU002086 3 CM-2A FU002090 1
43P7 5 600V ac, 20A CR6L-20/UL FU002087 3 CMS-4 FU002091 3
45P5 7.5 600V ac, 20A CR6L-20/UL FU002087 3 CMS-4 FU002091 3
47P5 10 600V ac, 20A CR6L-20/UL FU002087 3 CMS-4 FU002091 3
4011 15 600V ac, 30A CR6L-30/UL FU002088 3 CMS-4 FU002091 3
4015 20 600V ac, 30A CR6L-30/UL FU002088 3 CMS-4 FU002091 3
4018 25 500V ac, 50A CR6L-50/UL FU000935 3 CMS-4 FU002091 3
4022 30 500V ac, 50A CR6L-50/UL FU000935 3 CMS-4 FU002091 3
4030 40 500V ac, 75A CR6L-75/UL FU002089 3 CMS-5 FU002092 3
4037 50 500V ac, 75A CR6L-75/UL FU002089 3 CMS-5 FU002092 3
4045 60 500V ac, 100A CR6L-100/UL FU000927 3 CMS-5 FU002092 3
4055 75 500V ac, 150A CR6L-150/UL FU000928 3 CMS-5 FU002092 3
4075 100 500V ac, 150A CR6L-150/UL FU000928 3 CMS-5 FU002092 3

Input

Current

(Amps)

25%ED

Rating FUJI P/N YEA P/N Qty. FUJI

P/N

YEA P/N Qty.

An input 3-phase reactor corresponding to each model is necessary when operating
VS-656RC5. This input AC reactor is effective against saturated current and excessive
heat.

The table below shows the code numbers of the AC reactor for each model. Check the
table and use a specified AC reactor.

29

AC Reactor

VS-656RC5 Power Coordination Reactor Power Suppression Reactor

Model CIMR-R5U Rated

23P7 20 0.53 X002491 15 0.31 X010121
25P5 30 0.35 X002492 15 0.31 X010121
27P5 40 0.265 X002493 20 0.15 X010122

200V
Class

400V
Class

2011 60 0.18 X002495 40 0.1 X010123
2015 80 0.13 X002497 40 0.1 X010123
2018 90 0.12 X002498 50 0.06 X010124
2022 120 0.09 X002555 60 0.05 X010125
2030 160 0.07 X002556 80 0.04 X010126
2037 200 0.05 X002557 100 0.03 X010127
43P7 10 2.2 X002500 7.5 1.2 X010128
45P5 15 1.42 X002501 7.5 1.2 X010128
47P5 20 1.06 X002502 10 0.6 X010129

4011 30 0.7 X002503 15 0.4 X010130
4015 40 0.53 X002504 25 0.3 X010131
4018 50 0.42 X002505 25 0.3 X010131
4022 60 0.36 X002506 30 0.2 X010132
4030 80 0.26 X002508 40 0.15 X010133
4037 90 0.24 X002509 50 0.12 X010134
4045 120 0.18 X002566 60 0.1 X010135
4055 150 0.15 X002567 75 0.08 X010136
4075 200 0.11 X002568 100 0.06 X010137

Current

(Arms)

Inductance.

(mH)

Code No. Rated

Current

(Arms)

Inductance.

(mH)

Code No.

Voltage Suppression MOV Installation

The following voltage surge supression MOV is required for compliance with UL rec­ognition.

VS-656RC5 *Model Number Code

Number

230V Class RAV-781BYZ-2 XX-000221 2500A Peak,

460V Class RAV-781BYZ-2A XX-000222 2500A Peak,

*Manufactured by OKAYA Electric

30

Specification

75pF

35pF

Coordination
Reactor

AC Fuse

Current
Suppression
Reactor

Surge Protector

R/L1
S/L2
T/L3

r/

1

200/2200
400/ 400

R/L1
S/L2
T/L3

r1/

11

1/

t1/

31

2

1

+

+

21

G5 Inverter

VS­656RC5

U/T1
V/T2
W/T3

-

-

IM

Wiring Precautions

The external interconnection wiring must be performed with the following procedures.
After completing VS-656RC5 interconnections, be sure to check that the connections
are correct. Never use control circuit buzzer check.

Precautions on Control Circui t Wiring

1.Separate control circuit wires from main circuit wires and other power cables to
prevent erroneous operation caused by noise interference.

2. Separate the wiring of control circuit terminals from other control terminals or main
circuit wirings.

3. Wiring distance should be less than 50 m.

4. Insert the wire into the lower part of the terminal block and connect it tightly with a
screwdriver. Wire sheath strip length must be 7 mm.

Screwdriver Blade Width

5. Use twisted shielded or twisted-pair shielded wire for the control circuit line and
connect the shielded sheath to inverter terminal E.

31

Ground Wiring

1. Always ground the ground terminal .

2. Do not share the ground wire with other devices, such as welding machines or power
tools. Separate the grounding cables from the wirings for power tools.

3. Always use a ground wire that complies with technical standards on electrical
equipment and minimize the length on the ground wire.

Leakage current flows through the power regenerative unit. Therefore, if the

distance between the ground electrode and the ground terminal is too long, potential
on the ground terminal of the power regenerative unit will become unstable.

4. When using more than one power regenerative unit, be careful not to loop the ground
wire.

32

Closed-Loop Connector Size

Closed Loop Connectors sizes (JIS C 2805) (For 200V/400 classes)

Wire Size mm

0.5

0.75

1.25

3.5

5.5

14 M6 14 to 6

22 M8 22 to 8
30/38 M8 38 to 8
30/38
50/60 60 to 10

80 80 to 10

100 100 to 10
100
150 150 to 12
200 200 to 12

2

2

8

Terminal Screw Closed Loop Connectors

M3.5

M4

M4 2 to 4
M5 2 to 5
M4 3.5 to 4
M5 3.5 to 5
M4 5.5 to 4
M5 5.5 to 5
M5 8 to 5
M6 8 to 6

M10

M12

1.25 to 3.5

1.25 to 4

38 to 10

100 to 12

NOTE

Determine the wire size for the main circuit so that the line voltage drop is
within 2% of the rated voltage. Line voltage drop is calculated as follows:

(If there is a possibility of excessive voltage drop, use a larger wire suitable

to the required length.)
Line voltage drop (V) = √ 3 × wire resistance (Ω/km) × wire length (m) ×
current (A) × 10

-3

33

4.4 External Terminals

Main Circuit Terminal Functions

Terminal Sym b ol Description

R/L1
S/L2
T/L3

,

r1/

l 11

s 1/l 21

t1/l 31

Power

Regenerative

Unit

Main Circuit Input

Power Supply

Voltage Detection

Power input for

FAN and MC

Control Circuit Terminal Functions

Type No.* Signal Input Function Signal Level

Sequence Input S1 MANUAL RUN Run when Closed, stops when

S2 AUTO RUN Auto run (regenerative operation)

S3 EXFLT Ext ern al fau lt wh en CL OS ED

S4 RESET Fault reset wh en CLOS ED
SC Sequence Common
SS Photo coupler

SP Sequence +24V

M1-M2 CONV READY Closed when power regenerative

M3-M4 RUN CLOSE during run

MA-MC
MB-MC

AM Input Curren t 5V: 100% of rated input current - 10V to +10 VDC
AC Analog ground

Main circuit AC power supply terminal for the power regenerative unit.
Connect to the Inverter’s DC power supply voltage input terminals.

• Two terminals are provided for both and .

Detects the phase sequence and the voltage level.

• Connect to the power side of the power coordination reactor.
Supplies power for the cooling fan and inrush prevention MC of the

power regenerative unit.

OPEN

when CLOSED

internal common

Power Supply

unit is READY

FAULT Output
(Transfer Contact)

Outputs when a fault is detected.
Terminal MA-MC: Closed during

fault detection

Terminal MB-M C: Open durin g

fault detection

24 VDC 8 mA
Photo coupler
isolation

48 VDC 80 mA
or less

250 VAC 1 A or
less
30 VDC 1 A or less

2 mA or less

* Indicates the terminal number of the control card.

34

5. OPERATION

WARNING

• Replace the front cover and the terminal cover before turning on the powe r
supply. Do not remove the cover while power is on.

Failure to observe this warning can result in an electric shock.

• Never operate the digital operator or other switch es when your hand is wet.

Failure to observe this warning can result in an electric shock.

• Never touch the terminals while the power is on, even if the power
regenerative unit is stoppe d.

Failure to observe this warning can result in an electric shock.

CAUTION

• Never touch the heatsink or input reactor since the temperature is very
high.

Failure to observe this caution can result in harmful burns to the body.

• All the parameters of the power regenerative unit have been preset at the
factory. Do not change the settings unnecessaril y.

The power regenerative unit may be damaged.

35

5.1 Checkpoints Before Turning on Power Supply

Check the following before turning ON the power supply.

1. Check that the power supply is in the correct voltage.
200V class: 200 to 230 VAC, 50/60 Hz
400V class: 380 to 460 VAC, 50/60 Hz

2. Make sure that the power regenerative unit and the Inverter are connected correctly.

Check that the phase sequence is correct.

3. Make sure that the phase sequence of the main circuit terminals (R/L1, S/L2, T/L3)

and the power supply voltage detection terminals (rl/l 11, s1/l 21, t1/l 31) are correct.

4. Make sure that the power regenerative unit and the control device are wired

correctly.

5. Set the run command of the power regenerative unit and the inverter to OFF.

5.2 Setting the Power Supply Volt age Jumper

(400V Class Inverters of 18.5 kW or Higher)

Set the power supply voltage jumper for 400V class power regenerative unit of 37 kW
or higher. Insert the jumper into the voltage connector nearest to the actua l power
supply voltage.

The jumper is factory-set to 460V when shipped. If the power supply voltage is not
460V, use the following procedure to change the setting.

1. Turn OFF the power supply switch and wait for at least five minutes before
removing the front panel and setting the jumper.

2. Remove the front cover.

3. Insert the jumper at the position for the voltage supplied to the power regenerative
unit (see figure below).

4. Replace the front cover.

36

h

5.3 Confirming Display Status

LED Monitor Display

The figure below shows the LED monitor display of the VS656RC5.

Operation m od e display

Lit when the power is ON
RUN Indicates the operation
DS1 by the comb ination of t
DS2 displays (Lit, B link, snd
RUN, DS1, DS2.

Ds

Display Status

37

LED Display when power is ON

The following shows the LED display pattern during normal operation.

Indicates READY[At normal operation]

The LED display pattern is different when an alarm (minor fault) occurs. below shows
an example of LED display when a minor fault occurs. Refer to Chapter 6 and take
appropriate countermeasures.

Alarm (monitor fault)

Indicates a minor
fault

38

5.4 Power ON/OFF Sequence

Refer to figure below when building a power ON/OFF sequence for the VS-656RC5.

Check the following when using the power regenerative unit.

1. Run commands of the inverter and the power regenerative unit should be turned ON
after confirming that they are READY.

2. Run commands of the inverter and the power regenerative unit should be turned ON
at the same time.

3. Never turn the run command of the power regenerative unit OFF while the inverter
output during run is ON.

4. Run output of the power regenerative unit turns OFF one second after the run
command is turned OFF.

5. Turn the power OFF after the run output of the power regenerative unit is OFF.

39

5.5 Run Command Selection

This section explains the two run command modes of the power regenerative unit.
Select the mode according to the application.

Auto Run

Auto run is the mode in which the power regenerative unit detects any increase/
decrease of the bus voltage and performs an auto run/stop if the terminal S2-SC is
“closed.”

If the motor vibrates excessively when in AUTO RUN mode, change the mode to
MANUAL RUN.

40

Manual Run

Manual run is the mode in which the power regenerative unit starts running when the

terminal S1-SC is “closed,” and stops one second after S1-SC is “open”.

Build a sequence so that the run commands of the power regenerative unit and the

inverter are turned ON at the same time.

41

6. MAINTENANCE AND INSPECTION

WARNING

• Never touch high-voltage terminals in the power regenerative unit.

Failure to observe this warning can result in an electric shock.

• Perform maintenance or inspecti on only after verifying that the CHARGE
LED goes OFF, after the main circuit power supply is turned OFF.

The capacitors are still charged and can be dangerous.

• Only authorized personnel shou ld be permitted to perform maintenance,
inspections or parts replacement.

[Remove all metal objects (watches, bracelets, etc.) before operation.]
(Use tools which are insulated against electric shock.)
Failure to observe this warning can result in an electric shock.

• Never modify the product.

Failure to observe this warning can result in an electric shock or personal injury
and will invalidate the warranty.

CAUTION

• The power regenerative unit employs semi-conductor elements. Do not
touch the CMOS elements.

They are easily damaged by static electricity.

• Do not connect or disconnect wires o r connecto rs whi le powe r is app lied t o
the circuit.

Failure to observe this caution can result in personal injury.

42

6.1 Daily Inspection

Check the following items with the system in operation.

1. There should be no abnormal heat generation.

2. The ambient temperature should not be too high.

3. The cooling fan on the power regenerative unit should be operating normally.

6.2 Periodical Inspection

Check the following items during periodic maintenance.

Always turn OFF the power supply before beginning inspection. Confirm that the
LED indicators on the front cover have all turned OFF, and then wait at least five
minutes have elapsed before beginning the inspection. Be sure not to touch terminals
right after the power has been turned OFF. Doing so can result in an electric shock.

Location to Check Check For Solution

External terminal, unit
mounting screws, etc.

Cooling fins Built up dust, dirt, and debris.

Printed circuit board

Power elements and
smoothing capacitor

Cooling fan

Power elements

Smoothing capacito r

Connection hardware is properly
seated and securely tightened.

Accumulation of conductive
material or oil mist.

Abnormal odor or discoloration. Replace the inverter unit.
Abnormal noise or vibration.

Cumulative operation time
exceeding 20,000 hours.

Accumulation of conductive
material or oil mist.

Irregularities such as discoloration
or odor.

Properly seat and tighten hardware.
Blow with dry compressed air:

39.2 X 10
to 6kg / cm
Blow with dry compressed air:

39.2 X 10
to 6kg / cm

If dust or oil cannot be removed, replace the
inverter unit.

Replace the cooling fan.

Blow with dry compressed air:

39.2 X 10
to 6kg / cm

If dust or oil cannot be removed, replace the
inverter unit.

Replace the capacitor or power
regenerative unit.

4

to 58.8 X 104 Pa, 57 to 85 psi (4

2

) pressure.

4

to 58.8 X 104 Pa, 57 to 85 psi (4

2

) pressure.

4

to 58.8 X 104 Pa, 57 to 85 psi (4

2

) pressure.

43

6.3 Part Replacement

The power regenerative unit consists of many parts, and they must be operating
properly in order to make full use of the Inverter functions.

Among the electronic components, there are some that require maintenance depending
on their usage conditions. In order to keep the power regenerative unit operating
normally over a long period of time, it is necessary to perform period inspections and
replace parts according to their service life.

Periodic inspection standards vary depending on the installation environment and
usage conditions. The power regenerative unit’s maintenance periods are noted below.
Keep them as a reference.

Part Replacement Guidelines

Part Standard Replacement Period Replacement Method

Cooling fan 2 to 3 years Replace with new part.

Smoothing capacitor 5 years

Breaker relays — Determine need by inspection.

Fuses 10 years Replace with new part.

Electrolytic capacitors on

PCBs

Note: Usage conditions are as follows:

• Ambient temperature: Yearly average of 30°C.

• Load factor: 80% max.

• Operating rate: 12 hours max. per day.

5 years

Replace with new board. (Determine need

Replace with new part.

(Determine need by inspection).

by inspection).

44

7. FAULT DIAGNOSIS AND CORRECTIVE ACTION

When the power regenerative unit detects a fault, the fault code is displayed on the
LED monitor, the fault contact output operates.

1. When a fault has occurred, refer to the following table to identify and correct the
cause of the fault.

2. Before restarting the power regenerative unit, reset the fault by either turning the run

signal OFF then turn the fault reset signal ON, or turn the main circuit power supply
OFF .

: ON : Blinking : OFF

Fault Display and Contents

LED

RUN DS1 DS2 Meaning

EF External Fault

OL

OH

Meaning Trouble Causes

Power Regenerative
Unit Input Overload

Power regenerative unit
input exceeded the
overload capacity.

Heatsink Overheating

The temperature of the
power regenerative unit’s
cooling fins exceeded the
factory setting.

An external fault was input
from the contact input
terminal.

The load is too heavy. Check the size of the load.

The ambient temperature
is too high.

There is a heat source
nearby.

The power regenerative
unit’s cooling fan has
stopped.

Causes and

Corrective Actions

Check the following:

• Reset the fault from the
contact input terminal.

• Correct the cause of the
external fault.

Install a cooling unit.

Remove the heat source.

Replace the cooling fan.
(Contact our sales
representative.)

45

LED

RUN DS1 DS2 Meaning

UV

Meaning Trouble Causes

Main Circuit Under
voltage

The main circuit DC
voltage is below the under
voltage detection level.
200V class: Approx. 190
VDC or less
400V class: Approx. 380
VDC or less

Control Power Fault

The control power supply
voltage dropped.

Inrush Preventi on
Circuit Fault

A fault occurred in the
inrush prevention circuit.

• An open-phase
occurred with the input
power supply.

• A momentary power
loss occurred.

• The wiring terminals for
the input power supply
are loose.

• The voltage fluctuations
in the input power
supply are too large.

_

_

Causes and

Corrective Actions

Reset the fault after
correcting its cause.

• Try turning the power
supply off and on.

• Replace the power
regenerative unit if the
fault continues to occur.

• Try turning the power
supply off and on.

• Replace the power
regenerative unit if the
fault continues to occur.

46

LED

RUN DS1 DS2 Meaning

UV

OV

Meaning Trouble Caus es

Input Under voltage

Input under voltage was
detected during operation.
200V class:
Approx. 150 VDC or less
400V class:
Approx. 300 VDC or less

Power Supply
Frequency Fault

Power supply freque ncy
exceeded the power
supply frequency limit
(factory setting).

Power Supply Phase
Rotation Fault

Phase rot ati on o f th e in put
side changed after the
control power supply was
turned ON.

Main Circuit Over
voltage

The main circuit DC
voltage exceeded under
voltage detection level.
200V class:
Approx. 400VDC or above
400V class:
Approx. 800VDC or above

• There is a fault to the
equipment at the power
side.

• There is a fault to the
power supply.

• The voltage detec tion
circuit at t h e p ow er s id e
is faulty.

The regenerative energy
from the motor is too
large.

The power supply voltage
is too high.

• The wiring between the
voltage detection circuit

at the power side (r1,

s

1,tl) and the main
circuit (R,S,T) is not
correct.

• The wiring distanc e
between the power
regenerative unit and
the AC reactor is too
long.

Causes and

Corrective Actions

• Check the wiring of the
equipment at the power
side.

• Adjust the power supply
voltage.

• Replace the cont rol
card.

• Replace the power
board.

Adjust the regenerative
load.

Decrease the voltage so it
is within specifications.

Check the wiring.

47

LED

RUN DS1 DS2 Meaning

OC

CPF

Meaning Trouble Causes

Overcurrent

The input current of the
power regenerative unit
exceeded the overcurrent
detection level.
(200% of rated current)

Baseblock Circuit Erro r
EEPROM Error
CPU Internal A/D Coverter
error

• A short-circuit occurred
at the power
regenerative output.

• Power supply drop.

• The wiring between the
voltage detection circuit
at the power side (r1,

s

1,tl) and the main
circuit (R,S,T) is not
correct.

• Imbalance of pow er
supply voltage phases.

_ Try turning the power

The control circuit is
damaged.

Causes and

Corrective Actions

• Improve the power
supply

• Check the wiring

• Reset the fault after
correcting its cause.

supply off and on.
Replace the control card.

48

7.1 Minor Fault Detection

An alarm is displayed on the LED monitor when the power regenerative unit
detects a minor fault. The power regenerative unit automatically returns to the
original status once the cause of the minor fault has been removed.

Take appropriate countermeasures according to the table below.

: ON : Blinking : OFF

LED

RUN DS1 DS2 Meaning

ALARM

LED Display Trouble Causes

Main Circuit Under
voltage

The following conditions
occurred during stop.

• The main circuit DC
voltage was below the
under voltage detection

UV

level.

• The surge current limiting
contactor opened.

• The control power supply
is below the under voltage
detection level.

• Frequency detection
exceeded the allowable
level.

• Voltage phase rotation at
the input side changed.

Main Circuit Over voltage

The main circuit DC voltage
exceeded the over voltage
detection level during stop.

OV

200V class:
Approx. 400 VDC or above
400V class:
Approx. 800VDC or above

Heatsink Overheating

The temperature of the

OH

power regenerative unit
heatsink exceeded 90% of
the allowable level.

Power Regenerative Unit
Input Overload

OL

The amount of the load
exceeded 80% of the
overload capacity.

Refer to the UV
section of the Fault
Detection.

The power supply
voltage is too high.

The ambient
temperature is too
high.

There is a heat source
nearby.

The power
regenerative unit
cooling fan has
stopped.

The load is too heavy. Reduce the load

Causes and

Corrective Actions

Refer to the UV section
of the Fault Detection.

Decrease th e voltage so
it is within
specifications.

Install a cooling unit.

Remove the heat
source.

Replace the cooling fan.
(Contact your Yaskawa
representative.)

External Fault

(Operation continue s by the

EF

setting of the digital
operator.)

An external fault was
input from the contact
input terminal

• Reset the external
fault from the contact
input terminal.

• Correct the cause of
the external fault.

49

Y A SKAWA ELECTRIC AME RICA, I NC.
Chicago-Corporate Headquarters 2121 No rman Driv e So uth , Waukegan, IL 60085, U.S.A .

Phone: [phone] Fax : [phone] Inte rne t: ht tp: //www.yaskawa.com

MOTOMAN INC.

805 Liberty Lane, West Carrollto n, OH 45449 , U.S.A .
Phone: [phone] Fa x: (9 37) 847 -62 77 Int erne t: http: // www.motoman.com

Y A SKAWA ELECTRIC COR POR ATION

New Pier T a keshi ba Sout h Tower, 1-16-1 , Kaigan, Minatok u, Tokyo, 105-0022, Japan
Phone: [phone] Fax: [phone] Internet: http://www.yaskawa.co.jp

Y A SKAWA ELETRICO DO B RASIL COME RCI O LTDA.

Avenida Fagun des Filh o, 620 Bai rro Saude S ao Pa olo-S P, Brasil CEP: 04304-000
Phone: [phone] Fax: [phone] Internet: htt p: //w ww.yaskawa.com.br

Y ASKAWA ELECTRIC EUROP E GmbH

Am Kronberger Hang 2, 65824 Schwa lbach , Germany
Phon e: 49 - 61 9 6- 5 69 - 3 00 Fax : 49 -6 1 96 - 88 8 -3 01 Internet: http://www.yaskawa.de

MOTOMAN ROBOTICS A B

Box 504 S38525, Torsas, Sweden
Phone: [phone] Fax : [phone]

MOTOMAN ROBOTEC Gm bH

Kammerfeldstraβe 1, 85391 Allershausen, G erm any
Phone: [phone] Fa x : 49-8 166 -903 9

Y A SKAWA ELECTRIC UK LTD.

1 Hunt Hill Orchardton Wood s Cumbern auld, G6 8 9LF, Scotland, United Ki ngdom
Phone: [phone] Fax: [phone]

Y ASKAWA ELECTRIC KOREA CORPORATION

Paik Nam Bldg. 9 01 18 8-3, 1- Ga E ulj iro, J oon g-Gu, Se oul, K orea
Phone: [phone] Fax: [phone]

Y A SKAWA ELECTRIC (SI NGA PO RE ) P TE. LTD.
Head Office: 151 Loron g Chua n, #0 4-01, New Tech Park Sing apo re 5 567 41, S INGA POR E

Phone: [phone] Fa x : 65-2 89-3 003

TAIP EI OFFICE (A ND YATE C ENG INEERI NG CO RPOR ATION)

10F 146 Sung Chiang Road, Taipei, Taiwan
Phone: [phone] Fax: [phone]

Y A SKAWA JASON (HK) COM PANY LIMITED

Rm. 2909-10, Hong K ong Pl aza, 18 6-19 1 C onn aug ht Roa d W es t , H ong Kong
Phone: [phone] Fax: [phone]

BEIJING OFFICE
Room No. 301 Office Bu ilding of Be ijin g Internati onal Clu b,
21 Jianguomanwai Av enue, Beijing 100 020, China
Phone: [phone] Fax: [phone]

SHANGHAI OFFICE
27 Hui He Road Sh ang hai 200 437 Ch ina
Phone: [phone] Fax: [phone]

SHANGHAI YASKAW A-T ON JI M & E CO ., LTD.

27 Hui He Road Sh ang hai 200 437 Ch ina
Phone: [phone] Fax: [phone]

BEIJING YASKAW A BEIKE AUTOMATIO N EN GINE ER ING CO . , LTD.

30 Xue Yuan Road, Haidian, Beijing 100083 China
Phone: [phone] Fax: [phone]

SHOUGANG MOTOMAN ROBO T CO., LTD.

7, Yongchang-North Street, Beijing Economic & Technological Development Area,
Beijing 100076 China

Phone: [phone] Fax: [phone]

Yaskawa Electric America, Inc., January 2001 YEA-TOA-S656-3 Printed In U.S.A.