YASKAWA V1000 Series Installation and operation manual

Upon receipt of the product and prior to initial operation, read these

instructions thoroughly, and retain for future reference.

V1000 Series AC Drive

Yaskawa Electric America

Document Number: TM.V1000.01

Mechanical

Electrical

Start-Up Programming

Troubleshooting

Periodic Inspection

Options and

Specifications

Parameter List

and Operation

Receiving

Installation

and Maintenance

Peripheral Devices

Network

Communications

Standards

Compliance

Installation & Start-Up Manual

(PRELIMINARY)

Date: 01.19.2007

YASKAWA TM.V1000.01 V1000 Drive Installation & Start-Up Manual (Preliminary 01-19-07) 3

Table of

Contents

i. PREFACE & GENERAL SAFETY........................ 11

i.1 Preface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

i.2 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Supplemental Safety Information . . . . . . . . . . . . . . . . . . . . 14

Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1. RECEIVING........................................................... 21

1.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.2 Model Number and Nameplate Check . . . . . . . . . 23

1.3 Drive Models and Enclosure Types . . . . . . . . . . . 25

1.4 Component Names . . . . . . . . . . . . . . . . . . . . . . . . 27

IP20/Open-Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

IP20/NEMA Type 1 Enclosure . . . . . . . . . . . . . . . . . . . . . . 31

2. MECHANICAL INSTALLATION........................... 33

2.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2.2 Mechanical Installation . . . . . . . . . . . . . . . . . . . . . 38

Installation Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Installation Orientation and Spacing . . . . . . . . . . . . . . . . . . 39

Installing Multiple Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

4 YASKAWA TM.V1000.01 V1000 Drive Installation & Start-Up Manual (Preliminary 01-19-07)

Removing and Attaching the Protective Covers . . . . . . . . . 41

Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

3. ELECTRICAL INSTALLATION ............................ 51

3.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.2 Standard Connection Diagram . . . . . . . . . . . . . . . 56

3.3 Main Circuit Connection Diagram . . . . . . . . . . . . 59

Single-Phase 200 V Class (CIMR-VBA0001 to 0020) . . 59

Three-Phase 200 V Class (CIMR-V2A0001 to 0020)

Three-Phase 400 V Class (CIMR-V4A0001 to 0011) . . . 60

3.4 Terminal Block Configuration. . . . . . . . . . . . . . . . 61

3.5 Protective Covers . . . . . . . . . . . . . . . . . . . . . . . . . 64

Open-Chassis Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

NEMA Type 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3.6 Main Circuit Wiring . . . . . . . . . . . . . . . . . . . . . . . . 68

Main Circuit Terminal Functions . . . . . . . . . . . . . . . . . . . . . 68

Wire Gauges and Tightening Torque . . . . . . . . . . . . . . . . . 69

Main Circuit Terminal Power Supply and Motor Wiring . . . 71

Main Circuit Design (Internal Block Diagram) . . . . . . . . . . . 74

3.7 Control Circuit Wiring . . . . . . . . . . . . . . . . . . . . . . 75

Control Circuit Terminal Block Functions . . . . . . . . . . . . . . 76

Wire Size and Torque Specifications . . . . . . . . . . . . . . . . . 80

Wiring Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

3.8 I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Sinking/Sourcing Mode Switch . . . . . . . . . . . . . . . . . . . . . . 84

Using Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

3.9 Main Frequency Reference . . . . . . . . . . . . . . . . . . 88

Terminal A2 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

3.10 MEMOBUS/Modbus Termination . . . . . . . . . . . . 90

3.11 Braking Resistor . . . . . . . . . . . . . . . . . . . . . . . . . 91

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

3.12 Wiring Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . 94

YASKAWA TM.V1000.01 V1000 Drive Installation & Start-Up Manual (Preliminary 01-19-07) 5

4. START-UP PROGRAMMING & OPERATION .... 97

4.1 Safety Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

4.2 Using the Digital LED Operator . . . . . . . . . . . . . .102

Keys, Displays, and LEDs . . . . . . . . . . . . . . . . . . . . . . . . 102

Digital Text Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

LED Screen Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

LO/RE LED and RUN LED Indications . . . . . . . . . . . . . . 105

Menu Structure for Digital LED Operator . . . . . . . . . . . . 107

The Drive and Programming Modes . . . . . . . . . . . . . . . . 108

Navigating the Drive and Programming Modes . . . . . . . 109

Changing Parameter Settings or Values . . . . . . . . . . . . . 113

Verifying Parameter Changes: Verify Menu . . . . . . . . . . 114

Switching Between LOCAL and REMOTE . . . . . . . . . . . 115

Parameters Available in the Setup Group . . . . . . . . . . . . 117

4.3 Start-up Flowcharts . . . . . . . . . . . . . . . . . . . . . . .118

Flowchart A: Basic Start-Up Sequence . . . . . . . . . . . . . . 119

Flowchart B: V/F Motor Control Set-Up . . . . . . . . . . . . . 120

Flowchart C: Open Loop Vector Motor Control Set-Up . . 121

Flowchart D: Permanent Magnet Motor Control (PM) . . . 122

Flowchart E: Using Application-Specific Presets . . . . . . 123

4.4 Basic Parameter Adjustments . . . . . . . . . . . . . . . 124

Control Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Initialize Parameter Values: A1-03 . . . . . . . . . . . . . . . . . 124

Drive Duty Mode and Carrier Frequency Selection . . . . 125

Drive Input Voltage Setting E1-01 . . . . . . . . . . . . . . . . . . 129

Frequency Reference Source: b1-01 . . . . . . . . . . . . . . . 130

Run Command Input Selection: b1-02 . . . . . . . . . . . . . . 133

Stopping Method Selection: b1-03 . . . . . . . . . . . . . . . . . 136

Acceleration/Deceleration C1-01 to C1-11 . . . . . . . . . . . 141

V/f Pattern Selection: E1-03 . . . . . . . . . . . . . . . . . . . . . . 143

Motor Parameters: E2-01 through E2-12

(Manually Entering Parameter Settings) . . . . . . . . . . . . 147

Drive Status Monitors: U1-01 to U6-19 . . . . . . . . . . . . . . 150

Analog Outputs: H4-01 to H4-03 . . . . . . . . . . . . . . . . . . . 153

Digital Outputs H2-01 to H2-03 . . . . . . . . . . . . . . . . . . . . 155

6 YASKAWA TM.V1000.01 V1000 Drive Installation & Start-Up Manual (Preliminary 01-19-07)

Motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

4.5 Test Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Powering Up the Drive and Operation Status Display . . . 160

Auto-Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Operating with the Load Connected . . . . . . . . . . . . . . . . . 172

Verifying Parameter Settings and Backing Up Changes . 172

Jog Operation: FJOG/RJOG . . . . . . . . . . . . . . . . . . . . . . 174

Multi-Step Speed Operation (4-Step Speed) . . . . . . . . . . 177

4.6 Test Run Checklist. . . . . . . . . . . . . . . . . . . . . . . . 181

5. TROUBLESHOOTING........................................ 183

5.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

5.2 Motor Performance Fine Tuning. . . . . . . . . . . . . 188

V/f Motor Control Method Tuning . . . . . . . . . . . . . . . . . . . 188

Open Loop Vector (OLV) Motor Control Method Tuning . 189

Motor Hunting and Oscillation Control Parameters . . . . . 191

5.3 Main Circuit Test Procedure . . . . . . . . . . . . . . . . 192

5.4 Drive Alarms, Faults, and Errors . . . . . . . . . . . . 195

Types of Alarms, Faults, and Errors . . . . . . . . . . . . . . . . . 195

Alarm and Error Displays . . . . . . . . . . . . . . . . . . . . . . . . . 196

5.5 Fault Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

Fault Displays, Causes, and Possible Solutions . . . . . . . 202

5.6 Alarm Detection . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Alarm Codes, Causes, and Possible Solutions . . . . . . . . 224

5.7 Operator Programming Errors . . . . . . . . . . . . . . 236

oPE Codes, Causes, and Possible Solutions . . . . . . . . . . 236

5.8 Auto-Tuning Fault Detection. . . . . . . . . . . . . . . . 241

Auto-Tuning Codes, Causes, and Possible Solutions . . . 241

5.9 Using Fault Trace Monitors. . . . . . . . . . . . . . . . . 245

If Fault is not Displayed on the Digital Operator . . . . . . . . 245

If Fault is Displayed on the Digital Operator . . . . . . . . . . . 245

Fault Trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

YASKAWA TM.V1000.01 V1000 Drive Installation & Start-Up Manual (Preliminary 01-19-07) 7

Fault Reset Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247

5.10 Detailed Troubleshooting. . . . . . . . . . . . . . . . . . 248

Cannot Change Parameter Settings . . . . . . . . . . . . . . . . 248

No Text on Digital Operator Display . . . . . . . . . . . . . . . . 248

Motor Does Not Rotate Properly After the RUN Button is Pressed or

After an External Run Command is Entered . . . . . . . . . . 248

5.11 Main Circuit Design . . . . . . . . . . . . . . . . . . . . . . 263

Main Circuit Design (Internal Block Diagram) . . . . . . . . . 263

5.12 Drive Date Stamp Information . . . . . . . . . . . . . .265

6. PERIODIC INSPECTION

& MAINTENANCE 267

6.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

6.2 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Recommended Daily Inspection . . . . . . . . . . . . . . . . . . . 273

Recommended Periodic Inspection . . . . . . . . . . . . . . . . 273

6.3 Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . 276

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

6.4 Drive Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . 278

Cooling Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . 278

6.5 Drive Replacement . . . . . . . . . . . . . . . . . . . . . . . . 282

Serviceable Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

Terminal Board Overview . . . . . . . . . . . . . . . . . . . . . . . . 282

Replacing the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Details on Terminal Board (TB) or Control Board (CNT)

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

7. PERIPHERAL DEVICES & OPTIONS ............... 289

7.1 Section Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

7.2 Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . .293

7.3 Connecting Peripheral Devices . . . . . . . . . . . . . .294

7.4 Installing Peripheral Devices . . . . . . . . . . . . . . . . 295

8 YASKAWA TM.V1000.01 V1000 Drive Installation & Start-Up Manual (Preliminary 01-19-07)

Installing a Molded Case Circuit Breaker . . . . . . . . . . . . . 295

Installing a Leakage Breaker . . . . . . . . . . . . . . . . . . . . . . 295

Installing a Magnetic Contactor . . . . . . . . . . . . . . . . . . . . 296

Connecting an AC or DC Reactor . . . . . . . . . . . . . . . . . . 296

Connecting a Surge Protector . . . . . . . . . . . . . . . . . . . . . 298

Connecting a Noise Filter . . . . . . . . . . . . . . . . . . . . . . . . . 298

EMC Filter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 302

Installing a Thermal Overload Relay (Drive Output) . . . . . 306

7.5 Communication Options . . . . . . . . . . . . . . . . . . . 308

7.6 Connecting an Option Card . . . . . . . . . . . . . . . . 309

Verifying Option Card and Product Type . . . . . . . . . . . . . 309

Connecting the Option Card . . . . . . . . . . . . . . . . . . . . . . . 310

A. SPECIFICATIONS .............................................. 313

A.1 Heavy Duty and Normal Duty Ratings. . . . . . . . 314

A.2 Power Specifications . . . . . . . . . . . . . . . . . . . . . 315

A.3 Common Drive Specifications . . . . . . . . . . . . . . 317

A.4 Drive Watts Loss Data . . . . . . . . . . . . . . . . . . . . 325

A.5 Drive Derating Data . . . . . . . . . . . . . . . . . . . . . . . 328

Carrier Frequency Derating . . . . . . . . . . . . . . . . . . . . . . . 328

Temperature Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

Altitude Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

B. PARAMETER LIST............................................. 331

B.1 Parameter Groups . . . . . . . . . . . . . . . . . . . . . . . . 332

B.2 Parameter Table . . . . . . . . . . . . . . . . . . . . . . . . . 333

A: Initialization Parameters . . . . . . . . . . . . . . . . . . . . . . . . 333

b: Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

C: Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

d: References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350

E: Motor Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355

F: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

H Parameters: Multi-Function Terminals . . . . . . . . . . . . . 368

L: Protection Function . . . . . . . . . . . . . . . . . . . . . . . . . . . 382

YASKAWA TM.V1000.01 V1000 Drive Installation & Start-Up Manual (Preliminary 01-19-07) 9

n: Advanced Performance Set Up . . . . . . . . . . . . . . . . . 396

o: Operator Related Parameters . . . . . . . . . . . . . . . . . . . 400

r: DWEZ Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

T: Motor Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407

U: Monitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

Factory Default Settings

V/f patterns when in V/f Control Mode . . . . . . . . . . . . . . 420

Default Settings Determined by Drive Capacity (o2-04) . 421

C. NETWORK COMMUNICATIONS ....................... 427

C.1 MEMOBUS/Modbus Basic Set-Up. . . . . . . . . . . .428

MEMOBUS/Modbus Communication Configuration . . . . 428

Communication Specifications . . . . . . . . . . . . . . . . . . . . 429

Communication Connection Terminal . . . . . . . . . . . . . . . 429

Communication Set-Up Procedure . . . . . . . . . . . . . . . . . 432

D. STANDARDS COMPLIANCE............................. 435

D.1 Section Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . 436

D.2 European Standards . . . . . . . . . . . . . . . . . . . . . . 440

CE Low Voltage Directive Compliance . . . . . . . . . . . . . . 440

EMC Guidelines Compliance . . . . . . . . . . . . . . . . . . . . . 442

D.3 UL Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . .443

UL Standards Compliance . . . . . . . . . . . . . . . . . . . . . . . 443

Drive Motor Overload Protection . . . . . . . . . . . . . . . . . . . 446

INDEX.................................................................. 449

10 YASKAWA TM.V1000.01 V1000 Drive Installation & Start-Up Manual (Preliminary 01-19-07)

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