Yaskawa Z1000U User Manual

Z1000U HVAC MATRIX Bypass

Low Harmonic Drive Bypass for HVAC Applications

Technical Manual

Type: Z1D1 Models:

To properly use the product, read this manual thoroughly and retain for easy reference, inspection, and maintenance. Ensure the end user receives this manual.

208 V: 7.5 to 75 HP 480 V: 7.5 to 350 HP

Receiving

Mechanical Installation

Electrical Installation

Start-Up Programming &

Operation

Programming

Diagnostics &

Troubleshooting

Periodic Inspection &

Maintenance

Specifications

Parameter List

BACnet Communications

MEMOBUS/Modbus

Communications

MANUAL NO. SIEP YAIZ1D 01A

Apogee FLN Network

Protocol

Metasys N2 Network

Protocol

Standards Compliance

Quick Reference Sheet

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

Quick Start Procedure

This procedure is a supplement to other documentation supplied with this equipment and guides the user in properly wiring the Z1000U Bypass and motor.

WARNING! Read and adhere to all safety messages contained in this manual prior to performing this procedure. When installing the system be sure to follow good wiring practices and all applicable codes. Ensure that the mounting of the various components are secure and that the environment, such as extreme dampness, poor ventilation etc. will not cause system degradation. Please read this cheat sheet and other documentation provided with the bypass thoroughly before attempting any installation.

The setup procedure begins on the next page.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

operation mode.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

desired

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

Table of Contents

QUICK START PROCEDURE.......................................................................... 3

i. PREFACE & GENERAL SAFETY.................................................................. 45

i.1 Preface ....................................................................................................................... 46

Product Description ................................................................................................................. 46

Applicable Documentation....................................................................................................... 46

Symbols................................................................................................................................... 46

Terms and Abbreviations ........................................................................................................ 47

Trademarks ............................................................................................................................. 47

i.2 General Safety ........................................................................................................... 48

Supplemental Safety Information ............................................................................................ 48

Safety Messages..................................................................................................................... 49

General Application Precautions ............................................................................................. 50

Motor Application Precautions................................................................................................. 51

Drive Label Warning Example................................................................................................. 52

Bypass Label Warning Example ............................................................................................. 53

Warranty Information............................................................................................................... 54

1. RECEIVING .................................................................................................... 55

1.1 Section Safety............................................................................................................ 56

1.2 General Description .................................................................................................. 57

Control Mode Details............................................................................................................... 57

1.3 Model Numbers and Nameplate Checks ................................................................. 58

Drive Nameplate...................................................................................................................... 58

Bypass Nameplate .................................................................................................................. 59

Bypass Enclosures.................................................................................................................. 61

Bypass Product Options.......................................................................................................... 61

1.4 Bypass Component Names...................................................................................... 62

1.5 Bypass Component Descriptions............................................................................ 63

Bypass Front Control Panel .................................................................................................... 63

Bypass Internal Components .................................................................................................. 63

Front Views of Drive ................................................................................................................ 66

2. MECHANICAL INSTALLATION..................................................................... 67

2.1 Section Safety............................................................................................................ 68

2.2 Mechanical Installation ............................................................................................. 70

Installation Environment .......................................................................................................... 70

YASKAWA

SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

Table of Contents

Installation Orientation and Spacing.................................................................................................. 71

Exterior and Mounting Dimensions ................................................................................................... 71

3. ELECTRICAL INSTALLATION .............................................................................. 73

3.1 Section Safety......................................................................................................................74

3.2 Standard Connection Diagram...........................................................................................76

3.3 Main Circuit Wiring..............................................................................................................80

Opening the Bypass Enclosure ......................................................................................................... 80

Bypass Main Circuit Terminal Block Configuration ........................................................................... 84

3.4 Input and Output Power Wiring Connections...................................................................85

Factory Recommended Branch Circuit Protection ............................................................................ 85

Main Circuit Terminal Functions........................................................................................................ 86

Wire Gauge and Tightening Torque Specifications........................................................................... 86

Main Input Circuit and Motor Wiring .................................................................................................. 88

Wiring the Main Input Circuit ............................................................................................................. 93

3.5 Control Circuit Wiring .........................................................................................................96

Control Circuit Connection Diagram.................................................................................................. 96

Control Circuit Terminal Block Functions .......................................................................................... 96

Bypass Analog Outputs..................................................................................................................... 97

Serial Communications ..................................................................................................................... 98

Drive Cover Removal ........................................................................................................................ 99

Drives in Bypass Models D024 to D114 and B011 and B124 ........................................................... 99

Drives in Bypass Models D143 to D211 and B156 to B414 ............................................................ 100

Removing/Reattaching the Front Cover .......................................................................................... 100

Wiring the Drive Control Circuit Terminal ........................................................................................ 102

Switches and Jumpers on the Terminal Board................................................................................ 104

3.6 Bypass and Drive Control I/O Connections....................................................................105

Terminals A1, A2, and A3 Input Signal Selection............................................................................ 105

Terminal AM/FM Signal Selection ................................................................................................... 105

MEMOBUS/Modbus Termination .................................................................................................... 106

3.7 External Interlock ..............................................................................................................107

Annunciation Contact Outputs......................................................................................................... 107

Building Automation System Run/Stop Circuit ................................................................................ 107

Safety Interlock Circuit .................................................................................................................... 107

Building Automation System Interlock Circuit (Drive and Bypass Enable Input)............................. 107

Remote Transfer to Bypass............................................................................................................. 108

Smoke Purge Operation.................................................................................................................. 108

Spare Multi-Function Digital Inputs ................................................................................................. 108

4. START-UP PROGRAMMING & OPERATION..................................................... 109

4.1 Section Safety....................................................................................................................110

4.2 Using the HOA Keypad .....................................................................................................111

HOA Keypad Keys and Displays..................................................................................................... 111

LCD Display .................................................................................................................................... 112

Bypass Control Board LEDs............................................................................................................ 113

ALARM (ALM) LED Displays........................................................................................................... 114

AUTO LED and HAND LED Indications .......................................................................................... 114

HOA Keypad Menu Structure.......................................................................................................... 116

HOA Keypad Parameter Display (Drive Off) ................................................................................... 116

4.3 The Drive and Programming Modes................................................................................118

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Changing Parameter Settings or Values ......................................................................................... 118

Verifying Parameter Changes: Modified Constants ........................................................................ 119

Simplified Setup Using the Quick Setting Group............................................................................. 120

4.4 Powering Up the Drive ......................................................................................................122

Powering Up the Drive and Operation Status Display..................................................................... 122

4.5 Application Selection........................................................................................................123

Setting 1: Fan Application ............................................................................................................... 123

Setting 2: Fan with PID Control Application .................................................................................... 123

Setting 3: Return Fan with PID Control Application......................................................................... 123

Setting 4: Cooling Tower Fan Application ....................................................................................... 124

Setting 5: Cooling Tower Fan with PID Control Application ............................................................ 124

Setting 6: Pump (Secondary) Application........................................................................................ 125

Setting 7: Pump with PID Control Application ................................................................................. 125

4.6 Auto-Tuning .......................................................................................................................126

Types of Auto-Tuning ...................................................................................................................... 126

Before Auto-Tuning the Drive.......................................................................................................... 126

Auto-Tuning Interruption and Fault Codes ...................................................................................... 127

Auto-Tuning Operation Example ..................................................................................................... 127

T1: Parameter Settings during Induction Motor Auto-Tuning .......................................................... 129

5. PROGRAMMING .................................................................................................. 131

5.1 A: Initialization...................................................................................................................132

A1: Initialization ............................................................................................................................... 132

5.2 b: Application.....................................................................................................................133

b1: Operation Mode Selection......................................................................................................... 133

b2: DC Injection Braking and Short Circuit Braking......................................................................... 135

b3: Speed Search............................................................................................................................ 136

b5: PID Control................................................................................................................................ 142

5.3 C: Tuning............................................................................................................................153

C1: Acceleration and Deceleration Times ....................................................................................... 153

C2: S-Curve Characteristics............................................................................................................ 153

C4: Torque Compensation .............................................................................................................. 154

C6: Carrier Frequency..................................................................................................................... 154

C7: Voltage Adjustment................................................................................................................... 155

5.4 d: Reference Settings .......................................................................................................156

d1: Frequency Reference................................................................................................................ 156

d2: Frequency Upper/Lower Limits ................................................................................................. 157

d3: Jump Frequency........................................................................................................................ 158

5.5 E: Motor Parameters .........................................................................................................159

E1: V/f Pattern for Motor 1............................................................................................................... 159

E2: Motor 1 Parameters .................................................................................................................. 163

5.6 F: Options...........................................................................................................................164

F6: Drive/Bypass Communications ................................................................................................. 164

5.7 H: Terminal Functions.......................................................................................................165

H1: Multi-Function Digital Inputs ..................................................................................................... 165

H2: Multi-Function Digital Outputs................................................................................................... 167

H3: Multi-Function Analog Inputs .................................................................................................... 174

H4: Multi-Function Analog Outputs ................................................................................................. 180

5.8 L: Protection Functions ....................................................................................................182

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

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L1: Motor Protection ........................................................................................................................ 182

L2: Momentary Power Loss Ride-Thru............................................................................................ 183

L3: Stall Prevention ......................................................................................................................... 184

L4: Reference Detection.................................................................................................................. 186

L5: Fault Restart.............................................................................................................................. 187

L6: Torque Detection....................................................................................................................... 190

L8: Drive Protection......................................................................................................................... 192

5.9 n: Special Adjustments.....................................................................................................194

n1: Hunting Prevention.................................................................................................................... 194

n3: Overexcitation Braking .............................................................................................................. 194

5.10 o: Operator-Related Settings ...........................................................................................195

o1: HOA Keypad Display Selection................................................................................................. 195

o2: HOA Keypad Functions............................................................................................................. 196

o4: Maintenance Monitor Settings................................................................................................... 196

5.11 S: Special Parameters.......................................................................................................198

S1: Dynamic Audible Noise Control Function ................................................................................. 198

S2: Sequence Timers...................................................................................................................... 199

Examples of Sequence Timers ....................................................................................................... 201

5.12 T: Motor Tuning .................................................................................................................205

5.13 U: Monitor Parameters......................................................................................................206

UB: Bypass Monitors....................................................................................................................... 206

U1: Operation Status Monitors ........................................................................................................ 206

U2: Fault Trace................................................................................................................................ 206

U3: Fault History.............................................................................................................................. 206

U4: Maintenance Monitors .............................................................................................................. 206

U5: PID Monitors ............................................................................................................................. 206

U9: Power Monitors......................................................................................................................... 206

5.14 Z: Bypass Parameters.......................................................................................................207

Z1: Bypass Control System............................................................................................................. 207

Z2: Bypass Control Input/Output ..................................................................................................... 216

Z3: Bypass Control Communication................................................................................................ 220

Z4: Ethernet Option Bypass Control................................................................................................ 223

6. DIAGNOSTICS & TROUBLESHOOTING ............................................................ 227

6.1 Section Safety....................................................................................................................228

6.2 Motor Performance Fine-Tuning......................................................................................230

Fine-Tuning V/f Control ................................................................................................................... 230

Parameters to Minimize Motor Hunting and Oscillation .................................................................. 230

6.3 Drive Alarms, Faults, and Errors .....................................................................................231

Types of Alarms, Faults, and Errors................................................................................................ 231

Alarm and Error Displays ................................................................................................................ 232

6.4 Fault Detection ..................................................................................................................235

Fault Displays, Causes, and Possible Solutions ............................................................................. 235

6.5 Alarm Detection.................................................................................................................251

Alarm Codes, Causes, and Possible Solutions ............................................................................... 251

6.6 Operator Programming Errors .........................................................................................259

Operator Programming Error Codes, Causes, and Possible Solutions........................................... 259

6.7 Auto-Tuning Fault Detection ............................................................................................262

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

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Auto-Tuning Codes, Causes, and Possible Solutions..................................................................... 262

6.8 Diagnosing and Resetting Faults.....................................................................................264

Fault Occurs Simultaneously with Power Loss ............................................................................... 264

If the Drive Still has Power After a Fault Occurs ............................................................................. 264

Viewing Fault Trace Data After Fault .............................................................................................. 264

Fault Reset Methods ....................................................................................................................... 264

6.9 Troubleshooting without Fault Display...........................................................................266

Common Problems.......................................................................................................................... 266

Cannot Change Parameter Settings ............................................................................................... 266

Motor Does Not Rotate Properly after Pressing AUTO Button or after Entering External Run

Command ...................................................................................................................................... 267

Motor is Too Hot.............................................................................................................................. 269

oPE02 Error Occurs When Lowering the Motor Rated Current Setting .......................................... 270

Motor Stalls during Acceleration or Acceleration Time is Too Long................................................ 270

Drive Frequency Reference Differs from the Controller Frequency Reference Command ............. 270

Excessive Motor Oscillation and Erratic Rotation............................................................................ 271

Deceleration Takes Longer than Expected ..................................................................................... 271

Noise From Drive or Motor Cables When the Drive is Powered On ............................................... 271

Ground Fault Circuit Interrupter (GFCI) Trips During Run .............................................................. 271

Connected Machinery Vibrates When Motor Rotates ..................................................................... 271

PID Output Fault.............................................................................................................................. 272

Motor Rotates after the Drive Output is Shut Off (Motor Rotates During DC Injection Braking) ..... 272

Output Frequency is Not as High as Frequency Reference............................................................ 272

Sound from Motor............................................................................................................................ 273

Motor Does Not Restart after Power Loss....................................................................................... 273

The Safety Controller Does Not Recognize Safe Disable Monitor Output Signals (Terminals DM

+ and DM-) ..................................................................................................................................... 273

7. PERIODIC INSPECTION & MAINTENANCE....................................................... 275

7.1 Section Safety....................................................................................................................276

7.2 Inspection ..........................................................................................................................278

Recommended Daily Inspection...................................................................................................... 278

Recommended Periodic Inspection................................................................................................. 279

7.3 Periodic Maintenance .......................................................................................................281

Replacement Parts.......................................................................................................................... 281

7.4 HOA Keypad Battery Replacement..................................................................................283

Real-Time Clock Adjustment........................................................................................................... 283

7.5 Drive Cooling Fans............................................................................................................285

Number of Cooling Fans ................................................................................................................. 285

Drive Cooling Fan Component Names............................................................................................ 285

Cooling Fan Replacement: 2o0028 to 2o0130 and 4o0011 to 4o0124 ...................................... 287

Cooling Fan Replacement: 2o0154, 2o0192, 4o0156, and 4o0180 ........................................... 289

Cooling Fan Replacement: 2o0248 and 4o0240 to 4o0414 ........................................................ 293

Installing the Cooling Fan................................................................................................................ 295

A. SPECIFICATIONS ................................................................................................ 299

A.1 Power Ratings ...................................................................................................................300

Three-Phase 208 Vac Models D024 to D211.................................................................................. 300

Three-Phase 480 Vac Models B011 to B077 .................................................................................. 301

Three-Phase 480 Vac Models B096 to B414 .................................................................................. 302

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

Table of Contents

A.2 Drive Specifications ..........................................................................................................303

A.3 Drive Derating Data ...........................................................................................................304

Carrier Frequency Derating............................................................................................................. 304

A.4 Bypass Options .................................................................................................................305

Option B .......................................................................................................................................... 305

Option D .......................................................................................................................................... 305

Option G .......................................................................................................................................... 305

Option K (Control) ........................................................................................................................... 305

Option K (Power)............................................................................................................................. 305

Option L........................................................................................................................................... 305

Option N .......................................................................................................................................... 305

Option W (Control) .......................................................................................................................... 305

Option W (Power)............................................................................................................................ 305

Option Z........................................................................................................................................... 305

B. PARAMETER LIST............................................................................................... 307

B.1 Parameter Groups .............................................................................................................308

Parameters Listed in Dark Gray Rows ............................................................................................ 309

B.2 A: Initialization Parameters ..............................................................................................310

A1: Initialization ............................................................................................................................... 310

B.3 b: Application.....................................................................................................................311

b1: Operation Mode Selection......................................................................................................... 311

b2: DC Injection Braking.................................................................................................................. 311

b3: Speed Search............................................................................................................................ 312

b5: PID Control................................................................................................................................ 313

b8: Energy Saving ........................................................................................................................... 315

B.4 C: Tuning............................................................................................................................316

C1: Acceleration and Deceleration Times ....................................................................................... 316

C2: S-Curve Characteristics............................................................................................................ 316

C4: Torque Compensation .............................................................................................................. 316

C6: Carrier Frequency..................................................................................................................... 317

C7: Voltage Adjustment................................................................................................................... 317

B.5 d: References.....................................................................................................................318

d1: Frequency Reference................................................................................................................ 318

d2: Frequency Upper/Lower Limits ................................................................................................. 318

d3: Jump Frequency........................................................................................................................ 318

d4: Frequency Reference Hold Function......................................................................................... 319

d7: Offset Frequency....................................................................................................................... 319

B.6 E: Motor Parameters .........................................................................................................320

E1: V/f Pattern for Motor 1............................................................................................................... 320

E2: Motor 1 Parameters .................................................................................................................. 321

B.7 F: Options...........................................................................................................................322

F6: Drive/Bypass Communications ................................................................................................. 322

B.8 H Parameters: Multi-Function Terminals ........................................................................323

H1: Multi-Function Digital Inputs ..................................................................................................... 323

H2: Multi-Function Digital Outputs................................................................................................... 325

H3: Multi-Function Analog Inputs .................................................................................................... 326

H4: Analog Outputs ......................................................................................................................... 328

H5: MEMOBUS/Modbus Serial Communication ............................................................................. 329

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

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B.9 L: Protection Function ......................................................................................................330

L1: Motor Protection ........................................................................................................................ 330

L2: Momentary Power Loss Ride-Thru............................................................................................ 330

L3: Stall Prevention ......................................................................................................................... 331

L4: Speed Detection........................................................................................................................ 331

L5: Fault Restart.............................................................................................................................. 332

L6: Torque Detection....................................................................................................................... 332

L8: Drive Protection......................................................................................................................... 333

B.10 n: Special Adjustment.......................................................................................................334

n1: Hunting Prevention.................................................................................................................... 334

n3: Overexcitation Braking .............................................................................................................. 334

B.11 o: Operator-Related Settings ...........................................................................................335

o1: HOA Keypad Display Selection................................................................................................. 335

o2: HOA Keypad Functions............................................................................................................. 335

o4: Maintenance Monitor Settings................................................................................................... 336

B.12 S: HVAC Function..............................................................................................................337

S1: Dynamic Noise Control Function .............................................................................................. 337

S2: Sequence Timers...................................................................................................................... 337

B.13 T: Motor Tuning .................................................................................................................340

T1: Induction Motor Auto-Tuning..................................................................................................... 340

B.14 U: Monitors.........................................................................................................................341

UB: Bypass Control Monitors .......................................................................................................... 341

U1: Operation Status Monitors ........................................................................................................ 342

U2: Fault Trace................................................................................................................................ 344

U3: Fault History.............................................................................................................................. 345

U4: Maintenance Monitors .............................................................................................................. 347

U5: PID Monitors ............................................................................................................................. 348

U9: Power Monitors......................................................................................................................... 349

B.15 Z: Bypass Parameters.......................................................................................................350

Z1: Bypass Control System............................................................................................................. 350

Z2: Bypass Control Input/Output ..................................................................................................... 353

Z3: Bypass Control Communication................................................................................................ 354

Z4: Bypass Control Option Boards.................................................................................................. 355

B.16 Defaults by Drive Model....................................................................................................358

C. BACNET COMMUNICATIONS ............................................................................ 361

C.1 BACnet Configuration.......................................................................................................362

C.2 Communication Specifications........................................................................................363

C.3 Connecting to a Network ..................................................................................................364

Network Cable Connection.............................................................................................................. 364

Wiring Diagram for Multiple Connections ........................................................................................ 365

Network Termination ....................................................................................................................... 365

C.4 BACnet Setup Parameters................................................................................................366

BACnet Serial Communication........................................................................................................ 366

C.5 Bypass Operations by BACnet ........................................................................................368

Observing the Bypass Operation .................................................................................................... 368

Controlling the Bypass .................................................................................................................... 368

C.6 BACnet Objects Supported ..............................................................................................369

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

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Present Value Access ..................................................................................................................... 369

Supported Properties of Objects ..................................................................................................... 369

Analog Input Objects ....................................................................................................................... 370

Analog Output Objects .................................................................................................................... 370

Analog Value Objects...................................................................................................................... 370

Binary Input Objects ........................................................................................................................ 371

Binary Output Objects ..................................................................................................................... 372

Binary Value Objects....................................................................................................................... 372

Device Object .................................................................................................................................. 374

C.7 Accessing Bypass Parameters and the Enter Command .............................................376

Reading Bypass Parameters........................................................................................................... 376

Writing Bypass Parameters............................................................................................................. 376

Enter Command .............................................................................................................................. 376

C.8 Communication Errors .....................................................................................................377

C.9 BACnet Protocol Implementation Conformance Statement..........................................378

D. MEMOBUS/MODBUS COMMUNICATIONS........................................................ 381

D.1 MEMOBUS/Modbus Configuration ..................................................................................382

D.2 Communication Specifications........................................................................................383

D.3 Connecting to a Network ..................................................................................................384

Network Cable Connection.............................................................................................................. 384

Wiring Diagram for Multiple Connections ........................................................................................ 385

Network Termination ....................................................................................................................... 385

D.4 MEMOBUS/Modbus Setup Parameters ...........................................................................386

MEMOBUS/Modbus Serial Communication.................................................................................... 386

D.5 Bypass Operations by MEMOBUS/Modbus....................................................................388

Observing the Bypass Operation .................................................................................................... 388

D.6 Communications Timing...................................................................................................389

Command Messages from Master to Bypass ................................................................................. 389

Response Messages from Bypass to Master.................................................................................. 389

D.7 Message Format ................................................................................................................390

Message Content ............................................................................................................................ 390

Slave Address ................................................................................................................................. 390

Function Code ................................................................................................................................. 390

Data................................................................................................................................................. 390

Error Check ..................................................................................................................................... 390

D.8 Message Examples ...........................................................................................................392

Reading Drive MEMOBUS/Modbus Register Contents .................................................................. 392

Loopback Test................................................................................................................................. 392

Writing to Multiple Registers............................................................................................................ 393

D.9 MEMOBUS/Modbus Data Table........................................................................................394

Command Data ............................................................................................................................... 394

Monitor Data.................................................................................................................................... 395

Broadcast Messages....................................................................................................................... 407

Fault Trace Contents....................................................................................................................... 408

Bypass Fault Codes ........................................................................................................................ 410

Alarm Register Contents ................................................................................................................. 410

D.10 Enter Command.................................................................................................................412

Enter Command Behavior ............................................................................................................... 412

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D.11 Communication Errors .....................................................................................................413

MEMOBUS/Modbus Error Codes.................................................................................................... 413

Slave Not Responding..................................................................................................................... 413

E. APOGEE FLN NETWORK PROTOCOL.............................................................. 415

E.1 APOGEE FLN Set-Up.........................................................................................................416

Bypass Parameter Settings for APOGEE FLN Communications.................................................... 416

E.2 Connecting to a Network ..................................................................................................417

Network Cable Connection.............................................................................................................. 417

Wiring Diagram for Multiple Connections ........................................................................................ 418

Network Termination ....................................................................................................................... 418

Recommended Cable...................................................................................................................... 418

E.3 Slope and Intercept Conversion ......................................................................................419

Drive Controlled Feedback.............................................................................................................. 419

Field Panel Controlled Feedback .................................................................................................... 419

Other Functionality .......................................................................................................................... 420

E.4 APOGEE FLN Point List Summary ..................................................................................421

E.5 Cable Loss Configuration and Behavior.........................................................................425

Drive Behavior at Loss of Communication ...................................................................................... 425

Apogee FLN Points ......................................................................................................................... 425

E.6 Mailbox Function...............................................................................................................427

Mailbox Function Points .................................................................................................................. 427

E.7 Fault Codes........................................................................................................................428

Communications Fault..................................................................................................................... 428

Bypass Faults–Apogee FLN Configuration ..................................................................................... 428

F. METASYS N2 NETWORK PROTOCOL .............................................................. 431

F.1 N2 Specifications and Configuration...............................................................................432

F.2 Connecting to a Network..................................................................................................433

Network Cable Connection.............................................................................................................. 433

Wiring Diagram for Multiple Connections ........................................................................................ 434

Network Termination ....................................................................................................................... 434

F.3 N2 Setup Parameters ........................................................................................................435

N2 Serial Communication................................................................................................................ 435

F.4 Bypass Operations by N2.................................................................................................437

Observing the Bypass Operation .................................................................................................... 437

Controlling the Bypass .................................................................................................................... 437

F.5 Communications Timing...................................................................................................441

Command Messages from Master to Bypass ................................................................................. 441

Response Messages from Bypass to Master.................................................................................. 441

F.6 Metasys N2 Point Database..............................................................................................442

Metasys N2 Analog Input (AI) Summary ......................................................................................... 442

Metasys N2 Analog Output (AO) Summary .................................................................................... 443

Metasys N2 Binary Input (BI) Summary .......................................................................................... 443

Metasys N2 Binary Output (BO) Summary ..................................................................................... 444

F.7 Mailbox Function...............................................................................................................445

Reading Drive Parameters .............................................................................................................. 445

Writing Drive Parameters ................................................................................................................ 445

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G. STANDARDS COMPLIANCE .............................................................................. 447

G.1 Section Safety....................................................................................................................448

G.2 UL/cUL Standards .............................................................................................................450

UL Standards Compliance .............................................................................................................. 450

H. QUICK REFERENCE SHEET .............................................................................. 451

H.1 Z1000U Bypass and Motor Specifications ......................................................................452

Z1000U Bypass Specifications........................................................................................................ 452

Motor Specifications ........................................................................................................................ 452

H.2 Basic Parameter Settings .................................................................................................453

Quick Setting Parameters ............................................................................................................... 453

Motor Setup..................................................................................................................................... 453

Multi-Function Digital Inputs ............................................................................................................ 453

Analog Inputs .................................................................................................................................. 453

Multi-Function Digital Outputs ......................................................................................................... 454

Monitor Outputs............................................................................................................................... 454

H.3 User Setting Table.............................................................................................................455

INDEX ................................................................................................................... 461

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

Preface & General Safety

This section provides safety messages pertinent to this product that, if not heeded, may result in fatality, personal injury, or equipment damage. Yaskawa is not responsible for the consequences of ignoring these instructions.

i.1 PREFACE...............................................................................................................46

i.2 GENERAL SAFETY...............................................................................................48

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

TERMSTERMS

i.1 Preface

Yaskawa manufactures products used as components in a wide variety of industrial systems and equipment. The selection and application of Yaskawa products remain the responsibility of the equipment manufacturer or end user. Yaskawa accepts no responsibility for the way its products are incorporated into the final system design. Under no circumstances should any Yaskawa product be incorporated into any product or design as the exclusive or sole safety control. Without exception, all controls should be designed to detect faults dynamically and fail safely under all circumstances. All systems or equipment designed to incorporate a product manufactured by Yaskawa must be supplied to the end user with appropriate warnings and instructions as to the safe use and operation of that part. Any warnings provided by Yaskawa must be promptly provided to the end user. Yaskawa offers an express warranty only as to the quality of its products in conforming to standards and specifications published in the Yaskawa manual. NO OTHER WARRANTY, EXPRESS OR IMPLIED, IS OFFERED. Yaskawa assumes no liability for any personal injury, property damage, losses, or claims arising from misapplication of its products.

This manual is designed to ensure correct and suitable application of the Z1000U Bypass. Read this manual before attempting to install, operate, maintain, or inspect the bypass unit and keep it in a safe, convenient location for future reference. Be sure you understand all precautions and safety information before attempting application.

Product Description

The Z1000U MATRIX HVAC Bypass combines excellent harmonic mitigation, input power factor control, and energy saving capabilities in a design specifically suited for use in HVAC building automation applications that require reliable motor control.

The bypass package provides a Z1000U MATRIX drive in a NEMA rated enclosure with a 2-contactor style bypass to allow motor operation from the drive or across the line. The Z1000U MATRIX drive incorporates MATRIX technology to directly convert input AC voltage to output AC voltage. The Z1000U MATRIX drive offers real choices and benefits for green HVAC applications.

The Z1000U features HVAC application-specific software macros, a Hand/Off/Auto LCD keypad, and a real time clock for system accuracy. Popular building automation communication protocols BACnet, Siemens APOGEE, Johnson Controls Metasys, and MEMOBUS/ Modbus are embedded in the drive.

Applicable Documentation

The following manuals are available for the Z1000U MATRIX Bypass:

Z1000U HVAC MATRIX Bypass Technical Manual

Read this manual first. This manual is packaged together with the product and contains basic information required to install and wire the bypass. It also gives detailed information on fault diagnostics, parameter settings, and serial communication specifications. The purpose of this manual is to prepare the Z1000U Bypass for a trial run with an application and for basic operation. This manual is also available for download on the Yaskawa documentation website, www.yaskawa.com.

Z1000U HVAC MATRIX Drive User Manual

This manual contains detailed information on fault diagnostics, parameter settings, and BACnet specifications. The most recent version of this manual is available for download on our documentation website, www.yaskawa.com.

Z1000U HVAC MATRIX Drive Programming Manual

This manual provides detailed information on parameter settings, drive functions, and MEMOBUS/ Modbus specifications. Use this manual to expand drive functionality and to take advantage of higher performance features. The most recent version of this manual is available for download on our documentation website, www.yaskawa.com.

Symbols

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

Indicates a term or definition used in this manual.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

TERMSTERMS

i.1 Preface

Terms and Abbreviations

• Bypass: Yaskawa Z1000U MATRIX Bypass

• Drive: Yaskawa Z1000U-Series Drive

• H: Hexadecimal Number Format

• IGBT: Insulated Gate Bipolar Transistor

• kbps: Kilobits per Second

• MAC: Media Access Control

• r/min: Revolutions per Minute

• V/f: V/f Control

Trademarks

This manual may describe trademarked equipment, which is the property of other companies. These trademarks are the property of the registered owner companies and may include the following:

• BACnet is a trademark of the American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE).

•

APOGEE™ FLN, trademark of Siemens Building Technologies, Inc.

• Metasys®, trademark of Johnson Controls Inc.

• Modbus®, trademark of Schneider Automation, Inc.

• LONWORKS®, trademark of Echelon Corporation

• Other companies and product names mentioned in this manual are trademarks of those companies.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

i.2 General Safety

Supplemental Safety Information

General Precautions

• The diagrams in this manual may be indicated without covers or safety shields to show details. Replace the covers or shields before operating the drive and run the drive according to the instructions described in this manual.

• Any illustrations, photographs, or examples used in this manual are provided as examples only and may not apply to all products to which this manual is applicable.

• The products and specifications described in this manual or the content and presentation of the manual may be changed without notice to improve the product and/or the manual.

• When ordering a new copy of the manual due to damage or loss, contact your Yaskawa representative or the nearest Yaskawa sales office and provide the manual number shown on the front cover.

• If nameplate becomes worn or damaged, order a replacement from your Yaskawa representative or the nearest Yaskawa sales office.

WARNING

Read and understand this manual before installing, operating or servicing this drive. The drive must be installed according to this manual and local codes.

The following conventions are used to indicate safety messages in this manual. Failure to heed these messages could result in serious or fatal injury or damage to the products or to related equipment and systems.

DANGER

Indicates a hazardous situation, which, if not avoided, will result in death or serious injury.

WARNING

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

WARNING! may also be indicated by a bold key word embedded in the text followed by an italicized safety message.

CAUTION

Indicates a hazardous situation, which, if not avoided, could result in minor or moderate injury.

CAUTION! may also be indicated by a bold key word embedded in the text followed by an italicized safety message.

NOTICE

Indicates a property damage message.

NOTICE: may also be indicated by a bold key word embedded in the text followed by an italicized safety message.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

i.2 General Safety

Safety Messages

WARNING

Heed the safety messages in this manual.

Failure to comply could result in death or serious injury. The operating company is responsible for any injuries or equipment damage resulting from failure to heed the warnings in

this manual.

Sudden Movement Hazard

System may start unexpectedly upon application of power, resulting in death or serious injury.

Clear all personnel from the drive, motor and machine area before applying power. Secure covers, couplings, shaft keys and machine loads before applying power to the drive.

Electrical Shock Hazard

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

Failure to comply could result in death or serious injury. Before servicing, disconnect all power to the equipment. The internal capacitor remains charged even after the power supply

is turned off. The charge indicator LED will extinguish when the DC bus voltage is below 50 Vdc. To prevent electric shock, wait for at least the time specified on the warning label, once all indicators are OFF, measure for unsafe voltages to confirm the drive is safe prior to servicing.

Do not attempt to modify or alter the drive in any way not explained in this manual.

Failure to comply could result in death or serious injury. Yaskawa is not responsible for any modification of the product made by the user. This product must not be modified.

Do not allow unqualified personnel to use equipment.

Failure to comply could result in death or serious injury. Maintenance, inspection, and replacement of parts must be performed only by authorized personnel familiar with installation,

adjustment and maintenance of AC drives.

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

Failure to comply could result in death or serious injury.

Make sure the protective earthing conductor complies with technical standards and local safety regulations.

Because the leakage current exceeds 3.5 mA, IEC/EN 61800-5-1 states that either the power supply must be automatically disconnected in case of discontinuity of the protective earthing conductor or a protective earthing conductor with a crosssection of at least 10 mm2 (Cu) or 16 mm2 (Al) must be used. Failure to comply may result in death or serious injury.

Always use appropriate equipment for Ground Fault Circuit Interrupters (GFCIs).

The drive can cause a residual current with a DC component in the protective earthing conductor. Where a residual current operated protective or monitoring device is used for protection in case of direct or indirect contact, always use a type B GFCI according to IEC/EN 60755.

Fire Hazard

Branch Circuit protection is required to be installed according to applicable local codes and the requirements listed on the bypass nameplate. Failure to comply could result in fire and damage to the bypass and drive or injury to personnel. Bypass models without soft-starter option PW are suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes, 208 Vac and 480 Vac. Bypass models D169 to D211 and B180 to B414 with option PW are also suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes, 208 Vac and 480 Vac. Bypass models D024 to D143 and B011 to B156 with option PW are suitable for use on a circuit capable of delivering not more than 65,000 RMS symmetrical amperes, 208 Vac and 480 Vac.

Do not use an improper voltage source.

Failure to comply could result in death or serious injury by fire. Verify that the rated voltage of the drive matches the voltage of the incoming power supply before applying power.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

i.2 General Safety

NOTICE

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

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

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

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

Do not operate damaged equipment.

Failure to comply could result in further damage to the equipment. Do not connect or operate any equipment with visible damage or missing parts.

Do not expose the drive to halogen group disinfectants.

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

General Application Precautions

Selection

Installing a Reactor

Use an AC reactor in the following situations:

• to suppress harmonic current.

• when the drive is running from a power supply system with thyristor converters.

Drive Capacity

For specialized motors, make sure that the motor rated current is less than the rated output current for the drive.

When running more than one motor in parallel from a single drive, the capacity of the drive should be larger than [total motor rated current × 1.1].

Starting Torque

The startup and acceleration characteristics of the motor are restricted to the drive overload current rating.

The overload rating for the drive determines the starting and accelerating characteristics of the motor. Expect lower torque than when running from line power. To achieve a higher starting torque, use a larger drive or a drive and motor with larger capacity.

Emergency Stop

During a drive fault condition, the output shuts off but the motor does not stop immediately. A mechanical brake may be required when it is necessary to stop the motor faster than the ability of the Fast Stop function of the drive.

Installation

Enclosure Panels

Keep the drive in a clean environment. Be sure to leave the required space between drives to provide for cooling, and take proper measures so the ambient temperature remains within allowable limits and keep flammable materials away from the drive.

Installation Direction

NOTICE: Install the drive upright as specified in the manual. Refer to Mechanical Installation on page 70 for more information on

installation. Failure to comply may damage the drive due to improper cooling.

Settings

Upper Limits

NOTICE: The drive is capable of running the motor up to 240 Hz. Be sure to set the upper limit for the frequency of the drive to prevent the

possible danger of accidentally operating equipment at higher than rated speed. The default setting for the maximum output frequency is 60 Hz.

DC Injection Braking

NOTICE: Excessive current during DC Injection Braking and excessive duration of DC Injection Braking can cause motor overheat.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

i.2 General Safety

Acceleration/Deceleration Times

Acceleration and deceleration times are affected by the amount of torque generated by the motor, the load torque, and the inertia moment. Set a longer accel/decel time when Stall Prevention is enabled. The accel/decel times are lengthened for as long as the Stall Prevention function is in operation. Install one of the available braking options or increase the capacity of the drive for faster acceleration and deceleration.

General Handling

Wiring Check

NOTICE: Do not connect power supply lines to output terminals U/T1, V/T2, or W/T3. Failure to comply will destroy the drive. Be sure to

perform a final check of all sequence wiring and other connections before turning on the power and also check for short circuits on the control terminals, which may damage the drive.

Inspection and Maintenance

WARNING! Electrical Shock Hazard. Capacitors in the drive do not immediately discharge after shutting off the power. Wait for at least the

amount of time specified on the drive before touching any components after shutting off the power. Failure to comply may cause injury to personnel from electrical shock.

Transporting the Drive

NOTICE: Never steam clean the drive. During transport, keep the drive from coming into contact with salts, fluorine, bromine, phthalate

ester, and other such harmful chemicals.

Motor Application Precautions

Insulation Tolerance

NOTICE: Consider motor voltage tolerance levels and motor insulation in applications with an input voltage of over 480 V or particularly

long wiring distances.

High-Speed Operation

NOTICE: Problems may occur with the motor bearings and dynamic balance of the machine when operating a motor beyond its rated speed.

Contact the motor or machine manufacturer.

Torque Characteristics

Torque characteristics differ compared to operating the motor directly from line power. The user should have a full understanding of the load torque characteristics for the application.

Vibration and Shock

The drive allows selection of high carrier PWM control and low carrier PWM. Selecting high carrier PWM can help reduce motor oscillation.

Take particular caution when adding a variable speed drive to an application running a motor from line power at a constant speed. If resonance occurs, install shock-absorbing isolation mounts around the base of the motor and enable the Jump frequency selection to prevent continuous operation in the resonant frequency range.

Audible Noise

The audible noise of the motor varies based on the carrier frequency setting. However, drive current derating may be required. When using a high carrier frequency, audible noise from the motor is comparable to the motor noise generated when running from line power.

Specialized Motors

Multi-Pole Motor

The rated current of a multi-pole motor differs from that of a standard motor, so be sure to check the maximum current when selecting a drive. Always stop the motor before switching between the number of motor poles. The motor will coast to stop if a regen overvoltage (ov) fault occurs or if overcurrent (oC) protection is triggered.

Submersible Motor

The rated current of a submersible motor is greater than that of a standard motor, so select the drive accordingly. Use a motor cable large enough to avoid decreasing the maximum torque level from voltage drop caused by a long motor cable.

Explosion-Proof Motor

The motor and the drive must be tested together to be certified as explosion-proof. The drive is not designed for explosionproof areas.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

WARNING

Read manual before installing. Wait 5 minutes for capacitor discharge after disconnecting power supply. To conform to requirements, make sure to ground the supply neutral for 400V class. After disconnecting from power supply,please wait 5 minutes before inspecting, performing maintenance or wiring the converter.

Risk of electric shock.

Hot Surfaces

Wait 5 minutes or longer until the unit has cooled.

●

i.2 General Safety

Geared Motor

Make sure that the gear and the lubricant are rated for the desired speed range to avoid gear damage when operating at low speeds or very high speeds. Consult with the manufacturer for applications that require operation outside the rated speed range of the motor or gear box.

Single-Phase Motor

Variable speed drives are not designed to operate with single phase motors. Using capacitors to start the motor causes excessive current to flow and can damage drive components. A split-phase start or a repulsion start can burn out the starter coils because the internal centrifugal switch is not activated. The drive is for use with three-phase motors only.

Motor with Brake

Take caution when using the drive to operate a motor with a built-in holding brake. If the brake is connected to the output side of the drive, it may not release at start due to low voltage levels, so be sure to install a separate power supply for the motor brake. Note that motors with built-in brakes tend to generate a fair amount of noise when running at low speeds.

Drive Label Warning Example

Always heed the warning information listed in Figure i.1.

Figure i.1 Warning Information Example and Position

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

Warning Label B

Warning Label A (inside enclosure)

i.2 General Safety

Bypass Label Warning Example

Always heed the warning information listed in Figure i.2 and Figure i.3 in the positions shown in Figure i.4.

Figure i.2 Warning Information Example A

Figure i.3 Warning Information Example B

Figure i.4 Bypass Warning Label Locations

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

i.2 General Safety

Warranty Information

Scope of Warranty

Inspections

Customers are responsible for periodic inspections of the drive. Upon request, a Yaskawa representative will inspect the drive for a fee. If the Yaskawa representative finds the drive to be defective due to Yaskawa workmanship or materials and the defect occurs during the warranty period, this inspection fee will be waived and the problem remedied free of charge.

Repairs

If a Yaskawa product is found to be defective due to Yaskawa workmanship or materials and the defect 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 the drive is not due to defective workmanship or materials, the customer will be responsible for the cost of any necessary repairs. Some problems that are outside the scope of this warranty are:

Problems due to improper maintenance or handling, carelessness, or other reasons where the customer is determined to be responsible.

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

Problems due to the use of a Yaskawa product under conditions that do not meet the recommended specifications.

Problems caused by natural disaster or fire.

After the free warranty period elapses.

Replenishment or replacement of consumables or expendables.

Defective products due to packaging or fumigation.

Other problems not due to defects in Yaskawa workmanship or materials.

Warranty service is only applicable within the country where the product was purchased. However, after-sales service is available for customers outside of the country where the product was purchased for a reasonable fee.

Contact your local Yaskawa representative for more information.

Exceptions

Any inconvenience to the customer or damage to non-Yaskawa products due to Yaskawa’s defective products whether within or outside of the warranty period are NOT covered by warranty.

Restrictions

The drive is not designed or manufactured for use in devices or systems that may directly affect or threaten human lives or health.

Customers who intend to use the product described in this manual for devices or systems relating to transportation, health care, space aviation, atomic power, electric power, or in underwater applications must first contact their Yaskawa representatives or the nearest Yaskawa sales office.

WARNING! Injury to Personnel. This product has been manufactured under strict quality-control guidelines. However, if this product is to be installed in any location where failure of this product could involve or result in a life-and-death situation or loss of human life or in a facility where failure may cause a serious accident or physical injury, safety devices must be installed to minimize the likelihood of any accident.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

Receiving

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

1.1 SECTION SAFETY.................................................................................................56

1.2 GENERAL DESCRIPTION.....................................................................................57

1.3 MODEL NUMBERS AND NAMEPLATE CHECKS................................................58

1.4 BYPASS COMPONENT NAMES...........................................................................62

1.5 BYPASS COMPONENT DESCRIPTIONS.............................................................63

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

1.1 Section Safety

NOTICE

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

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

A motor connected to a PWM drive may operate at a higher temperature than a utility-fed motor and the operating speed range may reduce motor cooling capacity.

Ensure that the motor is suitable for drive duty and/or the motor service factor is adequate to accommodate the additional heating with the intended operating conditions.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

1.2 General Description

Control Mode Details

Table 1.1 gives an overview of the various features associated with the bypass.

Table 1.1 Control Mode Features

Motor Type Induction Motors Comments

Control Mode V/f –

Basic Description V/f control –

Motor Type IM –

Type of Applications

Control

Characteristics

Application-Specific

Commercial Power Switching

Multi Motor YES –

Motor data unknown YES –

High Speed Accuracy – –

Speed Control Range 1:40

Speed Accuracy ±2 to 3%

Speed Response 3 Hz (approx.)

Starting Torque 150% at 3 Hz

Auto-Tuning

Speed Search YES

Energy-Saving Control YES

Overexcitation

Deceleration

Selection

• Energy Saving Tuning

• Line to line resistance

YES

1.2 General Description

May fluctuate with characteristics and motor temperature.

Speed deviation when operating at constant speed may fluctuate with characteristics and motor temperature.

Max. frequency of a speed reference signal that the drive can follow may fluctuate with characteristics and motor temperature.

Starting torque may fluctuate with characteristics and motor temperature.

Automatically adjusts parameter settings that concern electrical characteristics of the motor.

Bi-directional speed detection of a coasting motor to restart it without stopping.

Saves energy by always operating the motor at its maximum efficiency.

Provides fast deceleration without using a braking resistor.

When the output frequency matches the power supply frequency (60 Hz), the PWM switching operation stops and switches to operation with a direct commercial power supply connection.

Receiving

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

MADE IN JAPAN

PRG : 6110

IND.CONT.EQ.

7J48

CIMR-ZU4U0011AAA

: AC3PH 380-500V 50/60Hz 10A : AC3PH 0-475V 0-400Hz 11A : 20 kg : 6W3050-2-100 : J0065F575310100

: E131457

PASS

MODEL REV : A INPUT OUTPUT MASS O / N S / N

FILE NO

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

G F

E D

1.3 Model Numbers and Nameplate Checks

Please perform the following tasks after receiving the bypass

• Inspect the bypass for damage.

If the bypass appears damaged upon receipt, contact the shipper immediately.

• Verify receipt of the correct model by checking the information on the nameplate.

• If you have received the wrong model or the bypass does not function properly, contact your supplier. If you find any irregularities in the above items, contact the shipping company, the distributor or representative you purchased

the bypass from or your Yaskawa office immediately. The bypass is thoroughly tested at the factory. Any damages or shortages evident when the equipment is received must be reported immediately to the commercial carrier that transported the material. Shipping damage is not covered by the Yaskawa warranty. After unpacking and inspecting for damage, verify that internal wire connections have not come loose during shipment by spot checking wire terminations with a screwdriver or the appropriate tool. Bypass storage must be in a clean and dry location. Maintain the factory packaging and provide covering as needed to protect the bypass from construction site dirt, water, debris and traffic prior to and during construction.

Drive Nameplate

A – Rated Output Current B – Software version C –

Address

D – Serial number

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

E – Lot number F – Output specifications

<1>

G – Input specifications H – AC drive model

Refer to Figure 1.2 for details.

Figure 1.1 Drive Nameplate Information Example

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

CIMR

Z U 4 E A

0096

U A

Z1000U

Series

No.

Enclosure

Type

Design Revision Order

No.

Region Code

U USA

IP00

No. Voltage Class

No.

Environmental Specification

3-phase, 380-480 Vac

3-phase, 200-240 Vac

<1>

Humidity and dust resistant

No.

Customized Specifications

Without EMC Noise Filter

Built-in EMC Noise Filter

Drive Model Amp Rating

A.C. INPUT

A.C. OUTPUT

Designator Rating

Serial No.:4W14Z5747540001 Model No. :Z1D1D002PM

Type: Z1000U BYPASS W.D.: DS.Z1D1.01

Inst. Manual:SIEPYAIZ1D01,

TOEPC71063611

F1,F2 FNQ-R1.5A,600V

Type

Volts: 480

Volts: 0-460

Hz: 50/60

Hz: 0-60

Phase: 3

SCCR: 65kA rms sym.,480V max.

Amps:114.0

Amps:124.0

1.3 Model Numbers and Nameplate Checks

Figure 1.2 Drive Model Number Definition

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

Bypass Nameplate

The nameplate is located on the inside of the enclosure door.

The nameplate shown below is an example for a standard Z1000U Bypass.

Receiving

A – Input specifications B – Output specifications C – Control transformer fuse

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

specifications

Figure 1.3 Bypass Nameplate Information Example

D – Serial number E – Bypass model number F – Schematic document number

Z1D 1 B

Z1000U Bypass

No. Voltage

Refer to the following table

D 208 Vac B 480 Vac

No. Enclosure Type

1 IP20/NEMA Type 1

040 P T

No. Control Options

L LonWorks

D Ethernet/IP

W Custom Nameplate

200 VA Transformer (CPT)

Z Speed Pot

No. Power Options

K Output Reactor 5%

B 3-Contactor Bypass

G Drive Service Switch

N EMC Filter

D/L

W Soft Start Bypass

B/G

1.3 Model Numbers and Nameplate Checks

Bypass Models, Drive Models, and Capacities

Bypass Unit Model Z1D1

D024 7.5 23.3 24.2

D030 10 29.5 30.8

D046 15 43.6 16.2

D059 20 55.8 59.4

D074 25 70 74.8

D088 30 82.1 88.0

D114 40 105.2 114.0

D143 50 132.4 143.0

D169 60 156.4 169.0

D211 75 194.7 211.0

B011 7.5 10.7 11.0

B014 10 13.7 14.0

B021 15 19.7 21.0

B027 20 25.7 27.0

B034 25 31.7 34.0

B040 30 36.7 40.0

B052 40 47.7 52.0

B065 50 60 65.0

B077 60 71 77.0

B096 75 88 96.0

B124 100 114 124

B156 125 143 156

B180 150 165 180

B240 200 219 240

B302 250 276 302

B361 300 330 361

B414 350 378 414

HP Input (A) Output (A)

Capacity

Drive Model Electrical Schematic Weight (lb)

208 Vac

2o0028 2o0042 2o0054 2o0068 2o0081 2o0104 2o0130 2o0154 2o0192 2o0248

480 Vac

4o0011 4o0014 4o0021 4o0027 4o0034 4o0040 4o0052 4o0065 4o0077 4o0096 4o0124 4o0156 4o0180 4o0240 4o0302 4o0361 4o0414

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

DS.Z1D1.01 230

DS.Z1D1.01 325

DS.Z1D1.01 340

DS.Z1D1.01 350

DS.Z1D1.01 465

DS.Z1D1.01 475

DS.Z1D1.01 825

DS.Z1D1.01 1050

DS.Z1D1.01 220

DS.Z1D1.01 230

DS.Z1D1.01 300

DS.Z1D1.01 315

DS.Z1D1.01 350

DS.Z1D1.01 360

DS.Z1D1.01 375

DS.Z1D1.01 475

DS.Z1D1.01 490

DS.Z1D1.01 850

DS.Z1D1.01 900

DS.Z1D1.01 1100

DS.Z1D1.01 1600

DS.Z1D1.01 1750

DS.Z1D1.01 1800

1.3 Model Numbers and Nameplate Checks

Bypass Enclosures

All bypass units are intended for non-hazardous locations. All NEMA Type 1 Enclosure bypass units are constructed for indoor use to provide a degree of protection against incidental contact with enclosed electrical equipment and falling dust or dirt.

Bypass Product Options

Refer to Bypass Options on page 305 for details on available bypass product configuration options.

Receiving

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

1.4 Bypass Component Names

This section gives an overview of the bypass components described in this manual.

Note: Arrangement of components differs on models B302 to B414.

A – Bypass bracket mounting hole B – Disconnect shaft C – Bypass enclosure fan D – Bypass front door E – Bypass control board

Figure 1.4 View of Bypass Components

F – Circuit breaker handle G – Z1000U drive H – Bypass enclosure I – HOA keypad J – Floor mount door handle

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

HOA keypad

Circuit breaker

F2F1

ESC

M M

AUTO OFF

ENTERRESET

ALM

DIGITAL OPERATOR JVOP-183

HAND

1.5 Bypass Component Descriptions

Bypass Front Control Panel

The external appearance and component names of the bypass are shown in Figure 1.5.

Figure 1.5 Bypass Control Panel with Keypad Operator Controls

Refer to Using the HOA Keypad on page 111 for details on the HOA keypad.

Bypass Internal Components

The appearance and internal component names of the bypass are shown in Figure 1.6.

Note: Arrangement of components differs on models B302 to B414.

Receiving

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

1.5 Bypass Component Descriptions

A – Main input disconnect B – Motor overload C – Bypass contactor D – Soft starter option PW E – Air filter F – Enclosure cooling fan G – 120 V control transformer

Circuit Breaker (100 kAIC)

Electrically located on the input power side of the bypass, the door mounted circuit breaker provides a means of disconnecting

Figure 1.6 Interior View of Bypass Unit

H – Terminal TB1 I – Terminal TB2 J – Terminal TB3 K – Communications port CN2 L – Option card connector CN5 M – Ground terminal

the bypass from line power for equipment maintenance. The circuit breaker must be in the OFF position to open the bypass enclosure door. When opened, the handle can be locked in the OFF position using a padlock.

Branch short circuit protection for the bypass must be supplied by the customer.

Contactors

The bypass is a 2-contactor or 3-contactor bypass circuit employing IEC rated contactors in an electrically interlocked arrangement to allow mutually exclusive operation in Drive or Bypass modes.

The control logic and “soft start” characteristic of the drive limit the drive input and output contactors to motor FLA current or less. For this reason, the drive output contactor has a lower current rating than the bypass contactor. The bypass contactor is exposed to motor inrush current (LRA) when starting the motor across-the-line and therefore requires a higher current rating.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

1.5 Bypass Component Descriptions

Use an optional soft starter on the line side of the bypass contactor to limit the current on the bypass circuit to motor FLA or less. In this case, the bypass contactor is tested for a short-circuit combination rating of 65 kA or greater with the soft starter and large enough to handle the motor FLA current.

Overload Relay

The adjustable thermal overload relay (OLR) provides overload protection for the motor in Drive and Bypass operating modes. The bypass three-phase output power connection to the motor is made to the output terminals of the OLR. The OLR is set up in the factory to be a manual reset device, requiring operator attention if an overload trip-out is experienced.

Control Power Transformer

A Control Power Transformer (CPT) is provided to power the bypass 120 Vac control circuit. The VA capacity is determined by the control circuit and optional functions specified for the unit. The CPT primary is fused in both legs, the secondary is fused when required by NEC (transformer VA and wire size dependent). One side of the transformer secondary is grounded to the bypass enclosure.

Electronic Bypass Control Logic

Operating elements such as indicating LEDs, selector buttons, and control logic are incorporated into a PCB assembly to eliminate the potential for loose wires after shipment.

The operating elements are located on PCB A3 and the control logic PCB A2 contains the control circuit field wiring terminal blocks TB1 through TB5.

Drive/Bypass Logic Interlocks

The bypass 120 Vac logic circuit is interconnected with the drive multi-function digital input terminals and multi-function digital output terminals to allow a single customer interface to control both drive and bypass circuits. These drive terminals are not available for field connections. All field control connections are landed at terminal blocks TB1 through TB5 on control logic PCB A2 and drive PCB A1.

Receiving

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

E(G)

IG R+ R- S+ S-

S1 S2 S3 S4 S5 S6 S7 S8 SN SC SP

V+ AC A1 A2 A3 FM AMAC 24VRP AC

M1 M2 M3 M4

MD ME MF

MA MB MC

E(G)

IG R+ R- S+ S-

S1 S2 S3 S4 S5 S6 S7S8 SN SC SP

V+AC A1 A2 A3 FM AM AC 24VRPAC

M1 M2 M3 M4

MD ME MF

MA MB MC

1.5 Bypass Component Descriptions

Front Views of Drive

A – Terminal board (Refer to Control

Circuit Wiring on page 96)

B – Main circuit terminal (Refer to

Wiring the Main Input Circuit on page 93)

C – EMC filter switch (Drive Models

ZUoEoooo and ZUoWoooo)

Figure 1.7 Front Views of Drives

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

Mechanical Installation

This chapter explains how to properly mount and install the bypass.

2.1 SECTION SAFETY.................................................................................................68

2.2 MECHANICAL INSTALLATION.............................................................................70

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

2.1 Section Safety

WARNING

Crush Hazard

Use a dedicated lifting device when moving or positioning the drive.

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

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

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

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

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

Do not attempt to flip the drive over or leave the drive unattended while it is suspended by the wires.

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

CAUTION

Crush Hazard

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

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

NOTICE

Equipment Hazard

Prevent foreign matter such as metal shavings or wire clippings from falling into the drive during drive installation and project construction.

Failure to comply could result in damage to the drive. Place a temporary cover over the top during installation. Be sure to remove the temporary cover before start-up, as the cover will reduce ventilation and cause the unit to overheat.

Observe proper electrostatic discharge (ESD) procedures when handling the drive.

Failure to comply could result in ESD damage to the drive circuitry.

Operating the motor in the low-speed range diminishes the cooling effects, increases motor temperature, and may lead to motor damage by overheating.

Reduce the motor torque in the low-speed range whenever using a standard blower cooled motor. If 100% torque is required continuously at low speed, consider using a special drive or vector-control motor. Select a motor that is compatible with the required load torque and operating speed range.

The speed range for continuous operation differs according to the lubrication method and motor manufacturer.

If the motor is to be operated at a speed higher than the rated speed, consult with the manufacturer. Continuously operating an oil-lubricated motor in the low-speed range may result in burning.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

2.1 Section Safety

NOTICE

When the input voltage is 480 V or higher or the wiring distance is greater than 100 meters, pay special attention to the motor insulation voltage or use a drive-rated motor with reinforced insulation.

Failure to comply could lead to motor winding failure.

Motor vibration may increase when operating a machine in variable-speed mode, if that machine previously operated at a constant speed.

Install vibration-proof rubber on the motor base or use the frequency jump function to skip a frequency resonating the machine.

The motor may require more acceleration torque with drive operation than with a commercial power supply.

Set a proper V/f pattern by checking the load torque characteristics of the machine to be used with the motor.

The rated input current of submersible motors is higher than the rated input current of standard motors.

Select an appropriate drive according to its rated output current. When the distance between the motor and drive is long, use a cable thick enough to connect the motor to the drive to prevent motor torque reduction.

The current rating for a motor with variable pole pitches differs from a standard motor.

Check the maximum current of the motor before selecting the drive capacity. Only switch motor poles when the motor is stopped. Switching between motor during run will trigger overcurrent protection circuitry or result in overvoltage from regeneration, and the motor will simply coast to stop.

Never lift or move the drive while the cover is removed.

This can damage the terminal board and other components.

Mechanical Installation

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

2.2 Mechanical Installation

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

Installation Environment

Install the bypass in an environment matching the conditions below to prolong its optimum performance life.

Table 2.1 Installation Environment

Environment Conditions

Installation Area Indoors

Ambient Temperature

Humidity 95% RH or less and free of condensation

Storage Temperature

Surrounding Area

Altitude Up to 1000 meters without derating. Up to 3000 meters with output current and voltage derating

Orientation Install the bypass vertically to maintain maximum cooling effects.

-10 to + 40 °C (+14 to +104 °F) NEMA Type 1 Enclosure

-20 °C to +60 °C (-4 °F to +104 °F)

Install the drive in an area free from:

• oil mist and dust

• metal shavings, oil, water, or other foreign materials

• radioactive materials

• combustible materials (e.g., wood)

• harmful gases and liquids

• excessive vibration

• chlorides

• direct sunlight.

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

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

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

2.2 Mechanical Installation

Installation Orientation and Spacing

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

Figure 2.1 Correct Installation Orientation

Exterior and Mounting Dimensions

Refer to bypass dimension drawing DD.Z1U.1.oo.01 packaged with the bypass for bypass enclosure dimensions and proper installation clearances necessary to maintain sufficient space for airflow and wiring.

Mechanical Installation

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

2.2 Mechanical Installation

This Page Intentionally Blank

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

Electrical Installation

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

3.1 SECTION SAFETY.................................................................................................74

3.2 STANDARD CONNECTION DIAGRAM.................................................................76

3.3 MAIN CIRCUIT WIRING.........................................................................................80

3.4 INPUT AND OUTPUT POWER WIRING CONNECTIONS....................................85

3.5 CONTROL CIRCUIT WIRING................................................................................96

3.6 BYPASS AND DRIVE CONTROL I/O CONNECTIONS......................................105

3.7 EXTERNAL INTERLOCK.....................................................................................107

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

3.1 Section Safety

WARNING

Electrical Shock Hazard

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

Failure to comply may result in death or serious injury. Before servicing, disconnect all power to the equipment. The internal capacitor remains charged even after the power supply

Do not operate equipment with covers removed.

Failure to comply could result in death or serious injury. The diagrams in this section may show drives without covers or safety shields to show details. Be sure to reinstall covers or

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

Make sure the protective earthing conductor complies with technical standards and local safety regulations.

Always use appropriate equipment for Ground Fault Circuit Interrupters (GFCIs).

Always ground the motor-side grounding terminal.

Improper equipment grounding could result in death or serious injury by contacting the motor case.

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

Failure to comply could result in death or serious injury. Remove all metal objects such as watches and rings, secure loose clothing, and wear eye protection before beginning work

on the drive.

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

Failure to comply could result in death or serious injury.

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

Failure to comply could result in death or serious injury. Installation, maintenance, inspection, and servicing must be performed only by authorized personnel familiar with

installation, adjustment, and maintenance of AC drives.

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

Failure to comply could result in death or serious injury. Before servicing, disconnect all power to the equipment. The internal capacitor remains charged even after the power supply

Fire Hazard

Tighten all terminal screws to the specified tightening torque.

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

Do not use improper combustible materials.

Failure to comply could result in death or serious injury by fire. Do not install the drive to a combustible surface. Never place combustible materials on the drive.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

3.1 Section Safety

WARNING

Do not use an improper voltage source.

Failure to comply could result in death or serious injury by fire. Verify that the rated voltage of the drive matches the voltage of the incoming power supply before applying power.

Properly handle the HOA keypad battery.

Improper use of the battery may cause fire by explosion and personal injury. Correctly install the battery, paying attention to polarity (+/-). Do not attempt to charge the battery or improperly disassemble the HOA keypad.

CAUTION

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

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

NOTICE

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

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

Never connect or disconnect the motor from the drive while the drive is outputting voltage.

Improper equipment sequencing could result in damage to the drive.

Do not use unshielded cable for control wiring.

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

Do not allow unqualified personnel to use the product.

Failure to comply could result in damage to the drive.

Do not modify the drive circuitry.

Failure to comply could result in damage to the drive and will void warranty. Yaskawa is not responsible for any modification of the product made by the user. This product must not be modified.

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

Failure to comply could result in damage to the drive.

Do not heat or throw the battery into fire.

The battery remains in use even when power to the drive has been shut off. Be sure to also remove the battery in the HOA keypad when the drive will be shut off for long periods of time.

A dead battery left inside the HOA keypad may leak and damage the keypad and drive. Be sure to replace the battery with a new one immediately after the expected lifespan has passed or when the “bAT” error is displayed on the HOA keypad.

Be sure to observe the Perchlorate Best Management Practices (BMPs).

BMPs apply to primary lithium (manganese dioxide) coin batteries sold or distributed in California. Perchlorate Materialspecial handling may apply, please refer to: www.dtsc.ca.gov/hazardouswaste/perchlorate.

Electrical Installation

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

3.2 Standard Connection Diagram

Connect the bypass and peripheral devices as shown in Figure 3.1. It is possible to set and run the bypass via the HOA keypad without connecting digital I/O wiring. This section does not discuss drive operation; Refer to Start-Up Programming &

Operation on page 109 for instructions on operating the drive.

WARNING! Fire Hazard. Branch Circuit protection is required to be installed according to applicable local codes and the requirements listed on the bypass nameplate. Failure to comply could result in fire and damage to the bypass and drive or injury to personnel. Bypass models without soft-starter option PW are suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes, 208 Vac and 480 Vac. Bypass models D169 to D211 and B180 to B414 with option PW are also suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes, 208 Vac and 480 Vac. Bypass models D024 to D143 and B011 to B156 with option PW are suitable for use on a circuit capable of delivering not more than 65,000 RMS symmetrical amperes, 208 Vac and 480 Vac.

NOTICE: When the input voltage is 440 V or higher or the wiring distance is greater than 100 meters, pay special attention to the motor insulation voltage or use a drive duty motor. Failure to comply could lead to motor insulation breakdown.

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

Note: The minimum load for relay outputs DO-7, DO-8, DO-9, DO-10, M1-M2, M3-M4, M5-M6, and MA-MB-MC is 10 mA.

WARNING! Sudden Movement Hazard. Do not close the wiring for the control circuit unless the multifunction input terminal parameters are properly set. Improper sequencing of run/stop circuitry could result in death or serious injury from moving equipment.

WARNING! Sudden Movement Hazard. Ensure start/stop circuits are wired properly and in the correct state before energizing the drive. Failure to comply could result in death or serious injury from moving equipment. When programmed for 3-Wire control, a momentary closure on terminal S1 may cause the drive to start.

WARNING! Sudden Movement Hazard. When using a 3-Wire sequence, set the drive to 3-Wire sequence prior to wiring the control terminals and set parameter b1-17 to 0 so the drive will not accept a Run command at power up (default). If the drive is wired for a 3-Wire sequence but set up for a 2-Wire sequence (default), and parameter b1-17 is set to 1 so the drive accepts a Run command at power up, the motor will rotate in reverse direction at drive power up and may cause injury.

WARNING! Sudden Movement Hazard. Confirm the drive I/O signals and external sequence before executing the application preset function. Executing the application preset function or setting A1-06 ≠ 0 will change the drive I/O terminal functions and may cause unexpected equipment operation. Failure to comply may cause death or serious injury.

NOTICE: When using the automatic fault restart function with wiring designed to shut off the power supply upon drive fault, make sure the drive does not trigger a fault output during fault restart (L5-02 = 0, default). Failure to comply will prevent the automatic fault restart function from working properly.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

<4>

3.2 Standard Connection Diagram

<3>

<1>

<6>

<7>

<9>

<2>

<1>

<5>

<10>

Electrical Installation

<1>

<2>

<8>

Figure 3.1 Z1000U Bypass Standard Connection Diagram

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

3.2 Standard Connection Diagram

This Page Intentionally Blank

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

3.2 Standard Connection Diagram

<1> Connect the cabinet ground lug to earth ground and utility ground.

<2> Insulated twisted shielded wire is required. Connect the shield only at one end to avoid ground loops. Do not run these wires in the same conduit as AC power or AC control wires.

<3> Secondary fuse F6 is added with control transformer T1 or a power rating 350 VA or greater.

<4> Set E1-05 to 208 for 208 Vac applications.

<5> The motor overload relay is factory set for manual reset. Adjust the motor overload relay trip setting for the actual AC motor full load amps.

<6> Bypasses with option PW should set Z1-42 to 1, and Z2-07 to 36 and Z2-15 to 1 to trigger an “EFb” fault with the motor coasting to stop when the soft starter faults.

<7> R1 is a fail-safe contact. It is shown de-energized.

<8> Set DIP switch S1 to the ON position to enable the termination resistor only in the last drive in a MEMOBUS/Modbus network.

<9> The maximum output current capacity for the +V terminal on the control circuit is 20 mA. Never short terminals +V and AC, as it can cause erroneous operation or damage the drive.

<10> Use jumper S5 to select between voltage or current output signals at terminals FM and AM. Set parameters H4-07 and H4-08 accordingly.

Electrical Installation

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

OFF

3.3 Main Circuit Wiring

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

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

NOTICE: Do not switch the bypass input to start or stop the motor. Frequently switching the bypass on and off shortens the life of the DC bus charge circuit and the DC bus capacitors, and can cause premature bypass failures. For the full performance life, refrain from switching the bypass on and off more than once every 30 minutes.

Opening the Bypass Enclosure

WARNING! Electrical Shock Hazard. Do not open the bypass enclosure while the power is on. Failure to comply may result in death or

serious injury. Make sure that the circuit breaker is in the “OFF” position before attempting to open the doors.

Models D024 to D114 and B011 to B124

Turn the circuit breaker to the “OFF” position.

Figure 3.2 Disconnect Power

Turn the flat head screw fasteners on the cover 1/2 turn counter-clockwise.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

OFF

Figure 3.3 Turn Fasteners

3.3 Main Circuit Wiring

Door will now swing open on hinges located on left side of the bypass.

Electrical Installation

Figure 3.4 Swing Open Door

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

3.3 Main Circuit Wiring

Models D143 to D211, B156 to B240, and B302 to B414

Move the circuit breaker handle to the “OFF” position.

Figure 3.5 Disconnect Power

Turn the door handle 1/4 towards the door hinges and open the door.

Note: Models B302 to B414 have two doors.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

3.3 Main Circuit Wiring

Figure 3.6 Turn Door Handle

Electrical Installation

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

D024 to D114 B011 to B124

D143 to D211 B156 to B414

L1 L2 L3

T1 T2 T3

L1 L2 L3

3.3 Main Circuit Wiring

Bypass Main Circuit Terminal Block Configuration

Figure 3.7 shows the different main circuit terminal arrangements by model.

Figure 3.7 Main Circuit Terminal Block Configuration

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

3.4 Input and Output Power Wiring Connections

The input disconnect switch is located in the upper right hand side of the bypass. The three-phase input power connection is made to the input terminals of the disconnect. Refer to Figure 3.8 for a representative example.

The Overload Relay (OLR) is mounted to the contactor assembly or back panel (depending on rating), just above the bypass contactor. The bypass three-phase output power connection to the motor is made to the output terminals of the Overload Relay.

A – Ground screw B – Input power terminals C – Motor overload relay D – Motor connections E – Drive output contactor K2

Factory Recommended Branch Circuit Protection

WARNING! Fire Hazard. Branch Circuit protection is required to be installed according to applicable local codes and the requirements listed

on the bypass nameplate. Failure to comply could result in fire and damage to the bypass and drive or injury to personnel. Bypass models without soft-starter option PW are suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes, 208 Vac and 480 Vac. Bypass models D169 to D211 and B180 to B414 with option PW are also suitable for use on a circuit capable of delivering not more than 100,000 RMS symmetrical amperes, 208 Vac and 480 Vac. Bypass models D024 to D143 and B011 to B156 with option PW are suitable for use on a circuit capable of delivering not more than 65,000 RMS symmetrical amperes, 208 Vac and 480 Vac.

Figure 3.8 Bypass Circuit Components

F – Bypass contactor K3 G – 120 V control transformer H – A2 bypass control board I – 5 V bypass power supply board

Yaskawa recommends installing branch circuit protection according to maintain compliance with UL508C. Semiconductor protective type fuses are preferred. Alternate branch circuit protection devices are also listed in this manual.

Electrical Installation

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

3.4 Input and Output Power Wiring Connections

Main Circuit Terminal Functions

Table 3.1 Main Circuit Terminal Functions

Terminal Description Function Page

1/L1

Main circuit power supply input Connects line power to the bypass 762/L2

3/L3

1/T1

Drive output Connects to the motor 762/T2

3/T3

For 208 Vac: 100 Ω or less

For 480 Vac: 10 Ω or less

Wire Gauge and Tightening Torque Specifications

Note: 1. For 0 to 100 A, use a minimum of 60 °C - 75 °C copper wire.

2. For above 100 A, use a minimum of 75 °C copper wire.

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

temperature within 40 °C and wiring distance less than 100 m.

Grounding terminal 88

• Consider the amount of voltage drop when selecting wire gauges. Increase the wire gauge when the voltage drop is greater than 2% of motor rated voltage. Ensure the wire gauge is suitable for the terminal block. Use the following formula to calculate the amount of voltage drop:

Line drop voltage (V) = 3 × wire resistance (Ω/km) × wire length (m) × current (A) × 10

-3

• Refer to UL Standards Compliance on page 450 for information on UL compliance.

Table 3.2 Main Input Circuit Wiring Tightening Torques and Wire Gauges With Option PW

Bypass Model Z1D1 Standard Circuit Breaker With Option PW

208 Vac 480 Vac Current Rating (A) Wire Size Range (AWG) Tightening Torque (lb. in.)

– B011 25

– B014 30

– B021 45

D024 B027 60

D030 B034 70

– B040 80

D046 B052 110

D059 B065 125

D074 B077

150D088 B096

D114 –

– B124

D143 B156

D169 B180

D211 – 400

– B032

– B361

– B414

250

600

(1-2) x (2/0-500 kcmil) (1-2) x 442– B240

(1-3) x (3/0-500 kcmil) (1-3) x 450

14-10

8-3/0

4-4/0 225

3/0-350 kcmil 225

120

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

3.4 Input and Output Power Wiring Connections

Table 3.3 Main Input Circuit Wiring Tightening Torques and Wire Gauges Without Option PW

Bypass Model Z1D1 Standard Circuit Breaker Without Option PW

208 Vac 480 Vac Current Rating (A) Wire Size Range (AWG) Tightening Torque (lb. in.)

– B011

– B014

– B021 40

D024 – 45

– B027 50

D030 B034 60

– B040 80

D046 B052

D074 B077

D088 B096 125

D114 – 175

– B156 225

D169 B180

D211 –

– B240

– B032

– B361

– B414

110D059 B065

400

600

14-10

8-3/0

4-4/0 225D143 B124 200

(1-2) x (2/0-500 kcmil) (1-2) x 442

(1-3) x (3/0-500 kcmil) (1-3) x 450

120

Table 3.4 Motor and Ground Wire Gauges and Tightening Torques

Bypass Model Z1D1

208 Vac 480 Vac Wire Size Range (AWG)

– B011

– B014

D024 B021

D030 B027

– B034

– B040

D046 –

D059 B052

– B065

D074 B077

D088 B096

D143 –

D169 B156

– B180

D211 B240

(1-2) x (2-600 kcmil) (1-2) x 500– B302

– B361

– B414 (1-3) x (2-600 kcmil) (1-3) x 500

Output Circuit Motor Wiring Earth Ground Wiring

Motor Overload Relay Ground Lug

Tightening Torque

18-8 15

16-2 70

10-1/0 100

6-3/0 200D114 B124

6–300 kcmil 275

(lb. in.)

Wire Size Range (AWG)

14-10 or 8

6-4 or 2

14-2/0 120

Tightening Torque

(lb. in.)

35 or 40

45 or 50

Electrical Installation

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

3.4 Input and Output Power Wiring Connections

Main Input Circuit and Motor Wiring

This section outlines the various steps, precautions, and checkpoints for wiring the main circuit terminals and motor terminals.

WARNING! Electrical Shock Hazard. Do not connect the AC power line to the bypass output terminals. Failure to comply could result in death or serious injury by fire as a result of bypass damage from line voltage application to output terminals.

NOTICE: Route motor leads U/T1, V/T2, and W/T3 separate from all other leads to reduce possible interference related issues. Failure to comply may result in abnormal operation of drive and nearby equipment.

NOTICE: When connecting the motor to the output terminals T1, T2, and T3, the phase order for the drive and motor should match. Failure to comply with proper wiring practices may cause the motor to run in reverse if the phase order is backward.

NOTICE: Do not connect phase-advancing capacitors or LC/RC noise filters to the output circuits. Failure to comply could result in damage to the drive, phase-advancing capacitors, LC/RC noise filters or ground fault circuit interrupters.

Cable Length Between Bypass and Motor

Voltage drop along the motor cable may cause reduced motor torque when the wiring between the bypass and the motor is too long, especially at low frequency output. This can also be a problem when motors are connected in parallel with a fairly long motor cable. Bypass output current will increase as the leakage current from the cable increases. An increase in leakage current may trigger an overcurrent situation and weaken the accuracy of the current detection.

Adjust the carrier frequency according to Table 3.5. If the motor wiring distance exceeds 100 m because of the system configuration, reduce the ground currents. Refer to C6-02: Carrier Frequency Selection on page 154.

Table 3.5 Cable Length Between Bypass and Motor

Cable Length 50 m or less 100 m or less Greater than 100 m

Carrier Frequency 12.5 kHz or less 5 kHz or less 2 kHz or less

Note: 1. When setting carrier frequency for bypasses running multiple motors, calculate cable length as the total wiring distance to all connected

Ground Wiring

motors.

2. Do not use a long distance shielded line if there is an overvoltage problem at start. Either lower the carrier frequency or switch on the internal EMC filter if the power supply has a neutral ground.

Follow the precautions below when wiring the ground for one bypass or a series of bypasses.

WARNING! Electrical Shock Hazard. Do not touch SW screw while power is applied to the drive. Failure to comply could result in death or serious injury. Before servicing, disconnect all power to the equipment. The internal capacitor remains charged even after the power supply is turned off. The charge indicator LED will extinguish when the DC bus voltage is below 50 Vdc. To prevent electric shock, wait for at least the time specified on the warning label, once all indicators are OFF, measure for unsafe voltages to confirm the drive is safe prior to servicing.

WARNING! Electrical Shock Hazard. Make sure the protective earthing conductor complies with technical standards and local safety regulations. Because the leakage current exceeds 3.5 mA, IEC/EN 61800-5-1 states that either the power supply must be automatically disconnected in case of discontinuity of the protective earthing conductor or a protective earthing conductor with a cross-section of at least 10 mm2 (Cu) or 16 mm2 (Al) must be used. Failure to comply may result in death or serious injury.

WARNING! Electrical Shock Hazard. Always use a ground wire that complies with technical standards on electrical equipment and minimize the length of the ground wire. Improper equipment grounding may cause dangerous electrical potentials on equipment chassis, which could result in death or serious injury.

WARNING! Electrical Shock Hazard. Be sure to ground the drive ground terminal (208 Vac: ground to 100 Ω or less and 480 Vac: ground to 10 Ω or less). Improper equipment grounding could result in death or serious injury by contacting ungrounded electrical equipment.

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

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

Refer to Figure 3.9 when using multiple drives. Do not loop the ground wire.

The drive ground lug (terminal

) is connected to the enclosure. The enclosure ground lug must be connected to earth ground.

See Figure 3.8.

The drive has a second ground lug to accept the motor ground lead.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

3.4 Input and Output Power Wiring Connections

Figure 3.9 Ground Wiring for Multiple Bypass Units

Enable the Internal EMC Filter

If EMC is a concern and the network is grounded symmetrically, install the SW screw to the ON position. Installing the SW screw enables the internal EMC filter (Drives are shipped with the SW screw installed at the OFF position).

DANGER! Electrical Shock Hazard. Do not touch SW screw while power is applied to the drive. Failure to comply will result in death or serious injury.

WARNING! Electrical Shock Hazard. Connect the ground cable correctly. Failure to comply may result in death or serious injury.

NOTICE: When disabling the internal EMC filter, move the screws from ON to OFF and then tighten to the specified torque. Completely

removing the screws or tightening the screws to an incorrect torque may cause drive failure.

Note: For floating, impedance grounded, or asymmetrically grounded networks, disconnect the internal EMC filter by moving the SW screw to

the OFF position.

Table 3.6 shows asymmetrical grounded networks. Asymmetrical networks require first moving the SW screw to disconnect

the internal ground connection. (Drives are shipped with the SW screw installed at the OFF position.)

Table 3.6 Asymmetrical Grounded Network

Electrical Installation

Grounded at the corner of the delta

Grounded at the middle of the side

Single-phase, grounded at the end point

L2L3

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

OFF

E(G)

IG R+ R- S+ S-

S1 S2 S3 S4 S5 S6 S7 S8 SN SC SP

V+ AC A1 A2 A3 FM AM AC 24VRP AC

M1 M2 M3 M4

MD ME MF

MA MB MC

3.4 Input and Output Power Wiring Connections

Three-phase variable transformer without solidly grounded neutral

Figure 3.10 Symmetrical Grounded Network

A – SW (ON) B – Screw (OFF)

Figure 3.11 EMC Filter Switch Location

(Models 2E0028, 2W0028, 4E0011 to 4E0034, and 4W0011 to 4W0034)

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

OFF

S1 S2 S3 S4 S5 S6 S7 S8 SN SC SP

V+ AC A1 A2 A3 FM AM AC 24VRP AC

MD ME MF

MA MB MC

OFF

3.4 Input and Output Power Wiring Connections

A – SW (ON) B – Screw (OFF)

Figure 3.12 EMC Filter Switch Location

(Models 2E0042, 2W0042, 2E0054, 2W0054, 4E0040 to 4E0077, and 4W0040 to 4W0077)

Electrical Installation

A – SW (ON)

Figure 3.13 EMC Filter Switch Location

(Models 2E0104, 2W0104, 2E0130, 2W0130, 4E0096, 4W0096, 4E0124, and 4W0124)

B – Screw (OFF)

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

3.4 Input and Output Power Wiring Connections

A – SW (ON) B – Screw (OFF)

Figure 3.14 EMC Filter Switch Location

(Models 2E0154, 2W0154, 2E0192, 2W0192, 4E0156, 4W0156, 4E0180, and 4W0180)

A – SW (ON)

B – Screw (OFF)

Figure 3.15 EMC Filter Switch Location

(Models 2E0248, 2W0248, 4EU0216, 4W0216, 4E0240, and 4W0240)

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

B A

n1 p1

3.4 Input and Output Power Wiring Connections

A – SW (ON) B – Screw (OFF)

Figure 3.16 EMC Filter Switch Location

(Models 4E0302 to 4E0414 and 4W0302 to 4W0414)

Wiring the Main Input Circuit

WARNING! Electrical Shock Hazard. Shut off the power supply to the drive before wiring the main circuit terminals. Failure to comply may

result in death or serious injury.

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

Electrical Installation

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

3.4 Input and Output Power Wiring Connections

Main Input Circuit Wire Routing

Figure 3.17 shows suggested wire entry and bending areas for representative enclosures.

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

E(G)

IG R+ R- S+ S-

S1 S2 S3 S4 S5 S6S7 S8SN SCSP

V+AC A1 A2 A3FM AM AC 24VRPAC

M1 M2 M3 M4

MD ME MF

MA MB MC

E(G)

IG R+ R- S+ S-

S1S2 S3 S4S5 S6 S7 S8 SN SC SP

V+AC A1 A2 A3 FM AM AC 24VRPAC

M1 M2 M3 M4

MD ME MF

MA MB MC

Models D024 to D114 and B011 to B124

Models D143 to D211 and B156 to B414

3.4 Input and Output Power Wiring Connections

A – Control, frequency reference, and

communications wiring

B – Motor output circuit

Figure 3.17 Bypass Wire Routing Example

C – Main input circuit

Electrical Installation

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

12. SHIELD

11. SHIELD

10. IG24

9. IG24

8. DI-8

7. DI-7

6. DI-6

5. DI-5

4. DI-4

3. DI-3

2. DI-2

1. DI-1

TB2

TB3

4. SHIELD

3. TXRX-

2. TXRX+

1. IG5

TB1

12. DO-10 NO

11. DO-10 C

10. DO-10 NC

9. DO-9 NO

8. DO-9 C

7. DO-9 NC

6. DO-8 NO

5. DO-8 C

4. DO-8 NC

3. DO-7 NO

2. DO-7 C

1. DO-7 NC

3.5 Control Circuit Wiring

Control Circuit Connection Diagram

Refer to Figure 3.1 on page 77 when wiring terminals on the bypass and drive control circuits.

Control Circuit Terminal Block Functions

WARNING! Sudden Movement Hazard. Always check the operation and wiring of control circuits after being wired. Operating a bypass with

untested control circuits could result in death or serious injury.

WARNING! Sudden Movement Hazard. Confirm the drive I/O signals and external sequence before starting test run. Setting parameter Z1-01 may change the I/O terminal function automatically from the default setting. Refer to Application Selection on page 123. Failure to comply may result in death or serious injury.

The functions of the control circuit terminals are shown in Table 3.7.

The control circuit terminals on Terminal Board A2 are arranged as shown in Figure 3.18.

Type Signal Name Description Specification

Digital Inputs

DI-1 Digital Input 1

DI-2 Digital Input 2

DI-3 Digital Input 3

DI-4 Digital Input 4

DI-5 Digital Input 5

DI-6 Digital Input 6

DI-7 Digital Input 7

DI-8 Digital Input 8

IG24 Isolated Ground Digital Input Common

Figure 3.18 Control Circuit Terminal Board A2 Arrangement

Table 3.7 Bypass Control Circuit Terminal Board A2

Dry contact rated, photocoupler sinking input to IG, 24 Vdc 8 mA,

ground fault protected

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

E(G)

IG R+ R- S+ S-

S1 S2 S3 S4 S5 S6 S7 S8 SN SC SP

V+ AC A1 A2 A3 FM AM AC 24VRP AC

M1 M2 M3 M4

MD ME MF

MA MB MC

E(G)

IG R+ R- S+ S-

S1 S2 S3 S4 S5 S6 S7 S8 SN SC SP

V+ AC A1 A2 A3 FM AM AC 24VRP AC

M1 M2 M3 M4

MD ME MF

MA MB MC

TB5

3.5 Control Circuit Wiring

Type Signal Name Description Specification

DO-1 Digital Output 1

DO-2 Digital Output 2

Digital Outputs

120 Vac

DO-3 Digital Output 3

(Factory use only) 120 Vac, 66 VA sealed, 1650 inrush

DO-4 Digital Output 4

DO-5 Digital Output 5

DO-6 Digital Output 6

Digital Outputs

DO-7 Digital Output 7

DO-8 Digital Output 8

DO-9 Digital Output 9

Relay, dry contact form C, 30 Vdc or 120 Vac,

DO-6 (factory use only), 3.7 Amp 360 VA,

DO-7 to DO-10 for customer use, 2 Amp

DO-10 Digital Output 10

Table 3.8 lists the available control circuit input terminals on the drive. Text in parenthesis indicates the default setting for

each multi-function input.

The drive control circuit terminals on Terminal Board A1 are arranged as shown in Figure 3.19.

Figure 3.19 Control Circuit Terminal Arrangement

Table 3.8 Control Circuit Input Terminals

Type No. Terminal Name (Function) Function (Signal Level) Default Setting Page

+V Power supply for analog inputs 10.5 Vdc (max allowable current 20 mA) 208

+24 Vdc transducer power supply for customer

Analog Inputs

24 V

use

Multi-function analog input 1

(Frequency reference bias)

Multi-function analog input 2

(Frequency reference bias)

Multi-function analog input 3

(Aux reference 1)

150 mA maximum capacity –

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

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

• Voltage or current input must be selected by jumper S1 and H3-01.

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

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

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

208 174

208 208 176

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

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

208

• Voltage or current input must be selected by jumper S1 and H3-05.

AC Frequency reference common 0 V 208

E (G) Ground for shielded lines – –

Bypass Analog Outputs

There are two analog outputs that can be configured for a signal level of 0 to 10 Vdc or 4 to 20 mA. The signal level is controlled by the position of jumpers J2 and J3 on Control PCB A2 and by the values set to drive parameters H4-07 and H4-08.

Electrical Installation

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

3.5 Control Circuit Wiring

Serial Communications

Refer to BACnet Communications on page 361 or Refer to MEMOBUS/Modbus Communications on page 381 for details

depending on the applicable serial communications protocol.

Serial Communication Terminals

Table 3.9 Control Circuit Terminals: Serial Communications

Type Name Description Notes

Ground reference for RS-485 signals. This is an isolated ground

MEMOBUS/Modbus, BACnet, Metasys N2, or Apogee P1 Communication

Bypass and Drive Control Circuit Wire Size and Torque Specifications

IG5 Isolated ground

TXRX+ (+) Differential communication signal

TXRX- (-) Differential communication signal

SHIELD Shield tie point Connected to chassis ground

used only for communications and may be used in certain circumstances to connect to other communication devices floating ground references.

RS-485 signal levels

Select appropriate wire type and gauges from Table 3.10. For simpler and more reliable wiring, use crimp ferrules on the wire ends. Refer to Table 3.11 for ferrule terminal types and sizes.

Table 3.10 Bypass and Drive Control Circuit Gauge and Torque Values

Bare Wire Terminal Ferrule-Type Terminal

Applicable

wire size

mm2 (AWG)

Stranded wire:

0.2 to 1.0

(24 to 16)

Solid wire:

0.2 to 1.5

(24 to 16)

Stranded wire:

0.2 to 1.0

(24 to 16)

Solid wire:

0.2 to 1.5

(24 to 16)

Recomm.

wire size

mm2 (AWG)

0.75 (18)

Applicable

wire size

mm2 (AWG)

0.25 to 0.5 (24 to 20)

Recomm.

wire size

mm2 (AWG)

0.5 (20)

Wire Type

Shielded wire, etc.

Terminal

DO-7, DO-8, DO-9, DO-10 DI-1, DI-2, DI-3, DI-4, DI-5, DI-6, DI-7, DI-8, IG24 IG5, TXRX+, TXRX-, SHIELD

+V, A1, A2, AC FM, AM, AC R+, R-, S+, S-, IG

Screw

Size

Tightening

Torque

N•m

(lb. in)

0.5 to 0.6

(4.4 to 5.3)

0.5 to 0.6

(4.4 to 5.3)

Ferrule-Type Wire Terminals

Yaskawa recommends using CRIMPFOX 6, a crimping tool manufactured by PHOENIX CONTACT, to prepare wire ends with insulated sleeves before connecting to the drive. See Table 3.11 for dimensions.

8 mm

Figure 3.20 Ferrule Dimensions

Table 3.11 Ferrule Terminal Types and Sizes

Size mm

(AWG)

0.25 (24) AI 0.25-8YE 12.5 0.8 1.8

0.34 (22) AI 0.34-8TQ 10.5 0.8 1.8

0.5 (20)

Type L (mm) d1 (mm) d2 (mm) Manufacturer

AI 0.5-8WH or

AI 0.5-8OG

14 1.1 2.5

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

PHOENIX CONTACT

<1>

Drive Cover Removal

Follow the procedures below to remove and reattach the drive covers for wiring.

Drives in Bypass Models D024 to D114 and B011 and B124

Removing the Terminal Cover

Loosen the terminal cover screw.

3.5 Control Circuit Wiring

Figure 3.21 Removing the Terminal Cover

Push in on the tab located on the bottom of the terminal cover and gently pull forward to remove the terminal cover.

Figure 3.22 Removing the Terminal Cover

Reattaching the Terminal Cover

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

93 and Wiring the Drive Control Circuit Terminal on page 102 for details on wiring.

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

Electrical Installation

Figure 3.23 Reattaching the Terminal Cover

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

<1>

3.5 Control Circuit Wiring

<1> Connect the ground wiring first, then the main circuit wiring, and finally the control circuit wiring.

Drives in Bypass Models D143 to D211 and B156 to B414

Removing the Terminal Cover

Loosen the screws on the terminal cover, then pull down on the cover.

CAUTION! Do not completely remove the cover screws, just loosen them. If the cover screws are removed completely, the terminal

cover may fall off causing an injury.

Figure 3.24 Removing the Terminal Cover

Pull forward on the terminal cover to free it from the drive.

Figure 3.25 Removing the Terminal Cover

Reattaching the Terminal Cover

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

the Main Input Circuit on page 93 and Wiring the Drive Control Circuit Terminal on page 102 for details on wiring.

Figure 3.26 Reattaching the Terminal Cover

<1> Connect the ground wiring first, then the main circuit wiring, and finally the control circuit wiring.

Removing/Reattaching the Front Cover

Removing the Front Cover

Models 2o0028 to 2o0130 and 4o0011 to 4o0124

100

YASKAWA SIEP YAIZ1D 01A Z1000U HVAC MATRIX Drive Bypass Technical Manual

Yaskawa Z1000U User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Quick Start Procedure

Preface & General Safety

i.1 Preface

Product Description

Applicable Documentation

Symbols

Terms and Abbreviations

Trademarks

i.2 General Safety

Supplemental Safety Information

Safety Messages

General Application Precautions

Motor Application Precautions

Drive Label Warning Example

Bypass Label Warning Example

Receiving

1.1 Section Safety

1.2 General Description

Control Mode Details

1.3 Model Numbers and Nameplate Checks

Drive Nameplate

Bypass Nameplate

Bypass Enclosures

Bypass Product Options

1.4 Bypass Component Names

1.5 Bypass Component Descriptions

Bypass Front Control Panel

Bypass Internal Components

Front Views of Drive

Mechanical Installation

2.1 Section Safety

2.2 Mechanical Installation

Installation Environment

Installation Orientation and Spacing

Exterior and Mounting Dimensions

Electrical Installation

3.1 Section Safety

3.2 Standard Connection Diagram

3.3 Main Circuit Wiring

Opening the Bypass Enclosure

Bypass Main Circuit Terminal Block Configuration

3.4 Input and Output Power Wiring Connections

Factory Recommended Branch Circuit Protection

Main Circuit Terminal Functions

Wire Gauge and Tightening Torque Specifications

Main Input Circuit and Motor Wiring

Wiring the Main Input Circuit

3.5 Control Circuit Wiring

Control Circuit Connection Diagram

Control Circuit Terminal Block Functions

Bypass Analog Outputs

Serial Communications

Drive Cover Removal

Drives in Bypass Models D024 to D114 and B011 and B124

Drives in Bypass Models D143 to D211 and B156 to B414

Removing/Reattaching the Front Cover