YASKAWA AC Drive A1000 IP23/54 Floor Standing Panel Quick Start Guide Type: A14 Models: 400 V Class: 90 to 315 kW To properly use the product, read this manual thoroughly and retain for easy reference, inspection, and maintenance. Ensure the end user receives this manual. MANUAL NO.
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Table of Contents 1 SAFETY INSTRUCTIONS AND GENERAL WARNINGS . . . . . . . . . . . . . . . . . . . . . . . 4 2 MECHANICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3 ELECTRICAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 4 KEYPAD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 5 START UP . . . . . . . . . . . . . . . . . . . . . .
1 Safety Instructions and General Warnings 1 Safety Instructions and General Warnings YASKAWA Europe supplies component parts for use in a wide variety of industrial applications. The selection and application of YASKAWA products remain the responsibility of the equipment designer or end user. YASKAWA accepts no responsibility for the way its products are incorporated into the final system design.
1 Safety Instructions and General Warnings Nameplate A1000 Floor Standing drives have a full name plate inside and a type code label outside (underneath the digital operator).
1 Safety Instructions and General Warnings Safety Warnings WARNING Electrical Shock Hazard Do not attempt to modify or alter the drive in any way not explained in this manual. YASKAWA is not responsible for the damage caused by modification of the product made by the user. Failure to comply could result in death or serious injury from operation of damaged equipment. Do not touch any terminals before the capacitors have fully discharged. Failure to comply could result in death or serious injury.
1 Safety Instructions and General Warnings WARNING Do not use improper combustible materials in drive installation, repair or maintenance. Failure to comply could result in death or serious injury by fire. Attach the drive or braking resistors to metal or other noncombustible material. Do not connect the AC power line to the output terminals of the drive. Failure to comply could result in death or serious injury by fire as a result of drive damage from line voltage application to output terminals.
1 Safety Instructions and General Warnings NOTICE 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 carelessly connect parts or devices to the drives braking transistor terminals. Failure to comply could result in damage to the drive or braking circuit.
2 Mechanical Installation 2 Mechanical Installation Upon Receipt Perform the following tasks after receiving the drive: • Inspect the drive for damage. If the drive appears damaged upon receipt, contact your supplier. • Verify receipt of the correct model by checking the information on the nameplate. If you have received the wrong model, contact your supplier.
2 Mechanical Installation Dimensions Drive Dimensions without Option Extension Bay W Model CIMR-A14 0208 0250 0296 0362 0414 0515 0675 W H H W H D W Device Dimensions (mm) H D A 620 2350 600 B 800 2350 600 C 1200 2350 600 Drive size Weight (kg)* IP54 IP23 217 212 234 229 238 233 243 238 271 266 362 357 365 360 * Depending on the options built in, weight might be higher.
2 Mechanical Installation Unpacking the Unit 1. Remove screws from the front of the crate, then remove the front door. 2. Remove screws from the rear of the crate, then slide the crate off the bottom pallet. 3. Remove the cardboard edging strips. 4. Use scissors carefully to remove the cellophane. Make sure not to damage the paintwork. Depending on local conditions either follow the crane lifting instructions or the forklift lifting instructions. Crane Lifting Instructions 1.
2 Mechanical Installation Forklift Lifting Instructions 1. Remove screws on both sides of the unit and remove the side panels. The screws will be needed in step 4. 2. Remove M10 bolts on both sides of the unit and remove all washers. 3. Remove screws on both sides of the unit and remove the front and rear panel. 4. Attach both side panels back to the unit with the screws. 5. Place forks carefully under the unit and lift slowly off the pallet. 6. Attach the front and the rear panel.
3 Electrical Installation 3 Electrical Installation Main Circuit Notes KTS-011 N/O Thermostat TS1 L 1 Without the circuit breaker (Option A, B or C), or disconnect switch option B, C, E, F, L or M the disconnect means must be installed externally. 2 Without the input fuses option (Option K, L or M), the proper branch circuit protection must be installed externally.
3 Electrical Installation Control Circuit Drive Control Circuit Multi-function digtial inputs (default setting) Forward Run / Stop S1 Reverse Run / Stop S2 External Fault S3 Fault reset S4 Multi-speed step 1 S5 Multi-speed step 2 S6 Jog speed S7 External Baseblock S8 Option card connectors CN5-C CN5-B CN5-A Terminal board jumpers and switches V I Off On DIP Switch S4 A3 Analog/PTC Input Sel AI SN V <1> DIP Switch S2 Term. Res. On/Off Jumper S3 H1, H2 Sink/Source Sel.
3 Electrical Installation Wiring Specification Main Circuit Power Cable, Ground Wire and Motor Shield Connection Connect power supply and motor cables as shown below. Use a saddle clamp for fixing the motor cable to make sure the cable shield is properly connected to ground. The power supply ground wire shall be connected to the earth bar at the bottom of the panel. The motor cable ground wire shall be connected to the drive or alternatively to the earth bar at the panel bottom.
3 Electrical Installation Power Supply Side Cable Connections The way the drive is connected to the mains depends on the optional components installed on the input side. Refer to the table below for terminal labelling, screw sizes and torque values.
3 Electrical Installation Motor side cable connections The way the motor cable is connected to the drive depends on the optional components installed on the output side. Refer to the table below for terminal labelling, screw sizes and torque values.
3 Electrical Installation Main and Control Circuit Wiring Wiring the Main Circuit Input Consider the following precautions for the main circuit input. • • • • If not built in the cabinet, use fuses recommended in Power Supply Side Cable Connections on page 16 only. If using a ground fault circuit breaker, make sure that it can detect both DC and high frequency current. If using an input switch, make sure that this switch is not operated more than once every 30 minutes.
3 Electrical Installation Control Circuit Terminals The figure below shows the control circuit terminal arrangement. The drive is equipped with screwless terminals. S1 S3 S5 S2 E(G) HC H1 H2 DM+ DM- IG R+ R- S+ S- S4 M3 M6 M4 V+ AC V- A1 A2 A3 FM AM AC MP RP AC S1 S2 S3 S4 S5 S6 S7 S8 SN SC SP M1 M2 M5 Use a straight-edge screwdriver with a blade width of max 2.5 mm and a thickness of max 0.
3 Electrical Installation Control Circuit Terminal Functions Type No. S1 S2 Multi-Function Digital Inputs Safe Disable Inputs Analog Inputs / Pulse Train Input EN 20 Photocoupler 24 Vdc, 8 mA Use the wire link between terminals SC and SN or SC and SP to select between sinking, sourcing mode, and the power supply. Multi-function input 3 (External fault, N.O.
3 Electrical Installation Type Monitor Output No. Terminal Name (Function) Function (Signal Level) Default Setting MP Pulse train output (Output frequency) 32 kHz (max) FM Analog monitor output 1 (Output frequency) AM Analog monitor output 2 (Output current) -10 to +10 V DC, 0 to +10 V DC, or 4 to 20 mA Use jumper S5 on the control terminal board to select between voltage or current output at terminals AM and FM. Set parameters H4-07 and H4-08 accordingly when changing the jumper setting.
4 Keypad Operation 4 Keypad Operation Digital Operator and Keys The digital operator is used to program the drive, to start/stop it, and to display fault information. The LEDs indicate the drive status. ALM DIGITAL OPERATOR JVOP-180 F1 F2 ESC LO RE RESET ENTER RUN STOP Keys and Functions Key Name Function F1 Function Key (F1, F2) The functions assigned to F1 and F2 vary depending on the menu that is currently displayed.
4 Keypad Operation Menu Structure and Modes The following illustration explains the operator keypad menu structure. Figure 1.1 Programming Mode <2> Drive Mode <1> - MODE - DRV Rdy FREF (OPR) U1-01= 0.00Hz -MONITR- DRV Rdy FREF (d1-01) U1-02= 0.00Hz LSEQ U1-03= 0.00A LREF JOG FWD FWD/REV U1-01= 000.00Hz 㧔0.00㨪50.00㧕 ̌0.00Hz̍ FWD - MODE - DRV Rdy Monitor Menu U1-01= 0.00Hz -MONITR- DRV Rdy Monitor U1 -01= 0.00Hz -MONITR- DRV Rdy Frequency Ref U1- 01 = 0.00Hz U1-02= 0.00Hz LSEQ U1-03= 0.
5 Start Up 5 Start Up Drive Setup Procedure The illustration below shows the basic setup procedure. Each step is explained more detailed on the following pages. START Install and wire the drive as explained. Turn the power on. Initialize the drive if necessary using parameter A1-03. Set the control mode. Select Normal / Heavy Duty Perform Auto-Tuning or set the motor data manually.
5 Start Up Control Mode Selection (A1-02) There are three control modes available. Select the control mode that best suits the application the drive will control.
5 Start Up Type Setting Stationary AutoTuning 1 T1-01 = 1 Stationary AutoTuning 2 T1-01 = 4 Stationary AutoTuning for Line-toLine Resistance T1-01 = 2 Rotational AutoTuning for V/f Control T1-01 = 3 Control Mode (A1-02) V/f w/PG OLV (2) CLV (3) V/f (0) (1) Application Conditions and Benefits • Motor and load can not be decoupled and the load is higher than 30%. • A motor test report listing motor data is not available. • Automatically calculates motor parameters needed for vector control.
5 Start Up External Reference Selection and Acceleration/ Deceleration Times Frequency Reference Selection (b1-01) Set parameter b1-01 according to the frequency reference used. b1-01 Reference source 0 Operator keypad 1 2 3 4 Analog input Serial Comm. Option Card Pulse input Frequency reference input Set the frequency references in the d1- parameters and use digital inputs to switch over between different reference values. Apply the frequency reference signal to terminal A1, A2, or A3.
5 Start Up I/O Setup Note: The default setting functions can be seen in the connection diagram on page 13. Multi-Function Digital Inputs (H1-) The function of each digital input can be assigned in the H1- parameters. Multi-Function Digital Outputs (H2-) The function of each digital output can be assigned in the H2- parameters.
6 Parameter Table 6 Parameter Table This parameter table shows the most important parameters. Default settings are bold type. Refer to the Technical Manual for a complete list of parameters. No. A1-00 A1-01 A1-02 A1-03 b1-01 b1-02 b1-03 b1-04 b1-14 Name Description Initialization Parameters 0: English 1: Japanese 2: German 3: French 4: Italian 5: Spanish Language 6: Portuguese Selection 7: Chinese 8: Czech 9: Russian 10: Turkish 11: Polish 12: Greek 0: View and set A1-01 and A1-04.
6 Parameter Table No. Name Description 1: 2.0 kHz 2: 5.0 kHz 3: 8.0 kHz 4: 10.0 kHz 5: 12.5 kHz Carrier 6: 15.0 kHz C6-02 Frequency 7: Swing PWM1 (Audible sound 1) Selection 8: Swing PWM2 (Audible sound 2) 9: Swing PWM3 (Audible sound 3) A: Swing PWM4 (Audible sound 4) B to E: No setting possible F: User defined (determined by C6-03 through C6-05) Frequency Reference Frequency Sets the frequency reference for the drive. d1-01 to Reference Setting units are determined by parameter d1-16 1 to 16 o1-03.
6 Parameter Table No. Name Description H3-09 Terminal A2 Signal Level Selection 0: 0 to 10 V 1: –10 to 10 V 2: 4 to 20 mA 3: 0 to 20 mA Note: Use DIP switch S1 to set input terminal A2 for a current or a voltage input signal. H3-10 Terminal A2 Function Selection Sets the function of terminal A2. H3-11 H3-12 H3-13 H3-14 H4-01 H4-02 H4-03 H4-04 H4-05 H4-06 H4-07 Sets the level of the input value selected in H3-10 when 10 V (20 mA) is input at terminal A2.
6 Parameter Table No. L3-04 L3-05 L3-06 T1-01 T1-02 T1-03 T1-04 T1-05 T1-06 T1-07 T1-08 EN 32 Name Stall Prevention Selection during Deceleration Stall Prevention Selection during Run Description 0: Disabled. Deceleration at the active deceleration rate. An ov fault may occur. 1: General purpose. Deceleration is paused when the DC bus voltage exceeds the Stall Prevention level. 2: Intelligent. Decelerate as fast as possible while avoiding ov faults. 3: Stall Prevention with braking resistor.
6 Parameter Table Monitor U1-01 U1-02 U1-03 U1-05 U1-06 U1-07 U1-08 U1-09 Description Frequency Reference (Hz) Output Frequency (Hz) Output Current (A) Motor Speed (Hz) Output Voltage Reference (Vac) DC Bus Voltage (Vdc) Output Power (kW) Torque Reference (% of motor rated torque) Displays the input terminal status.
7 Troubleshooting 7 Troubleshooting General Fault and Alarms Faults and alarms indicate problems in the drive or in the machine. An alarm is indicated by a code on the data display and the flashing ALM LED. The drive output is not necessarily switched off. A fault is indicated by a code on the data display and the ALM LED is on. The drive output is always switched off immediately and the motor coast to stop.
7 Troubleshooting Digital Operator AL Safe Disable Fault HbbF Output Phase Loss PF Overcurrent oC Heatsink Overheat oH or oH1 Motor Overload oL1 Drive Overload oL2 DC Overvoltage ov FLT Input Phase Loss LF Braking Transistor Fault Cause Drive output is disabled while only one of the Safe Disable inputs is open. (normally both input signals H1 and H2 should be open) • One channel is internally broken and does not switch off, even if the external signal is removed.
7 Troubleshooting Operator Programing Errors An Operator Programming Error (oPE) occurs when an inapplicable parameter is set or an individual parameter setting is inappropriate. When an oPE error is displayed, press the ENTER button to display U1-18 (oPE fault constant). This monitor will display the parameter that is causing the oPE error. Digital Operator Cause Corrective Action oPE01 Drive capacity and value set to o2-04 do not match. Correct the value set to o2-04.
7 Troubleshooting Digital Operator Er-09 Er-11 Er-12 Er-13 Cause Acceleration error The motor did not accelerate for the specified acceleration time. Motor speed fault. The torque reference was too high. Current detection error • One or all output phases are lost. • Current is either too low or exceeds the drives rating. • The current sensors are faulty. Corrective Action • Increase the acceleration time C1-01. • Check the torque limits L7-01 and L7-02.
8 Maintenance 8 Maintenance Replacing Filter Mats WARNING Power off the unit before replacing or removing the filter mats. Replacing or removing filter mats while the unit is powered on may result in electric shock or malfunction of the unit. Base of the Unit Perform as follows to remove the filter mats from the base of the unit: 1. Remove the screws that hold the aire intake grill. 2. Remove the front panel from the base and remove the filter mat from inside the panel for replacement. 3.
8 Maintenance Air Inlets and Outlets Perform as follows to remove the filter mats from the air inlets: 1. Remove the screws that hold the air inlet and outlet grills. 2. Remove the air inlets and outlets from the closure and remove the filter mat from inside the inlets and outlets for replacement. 3. Refit the filter mat inside the inlets and replace the inlet. 4. Torque the screws to 4.5 Nm.
9 Safe Disable Input Function 9 Safe Disable Input Function Specifications Inputs / Outputs Two Safe Disable inputs and one EDM output according to ISO13849-1 Cat. 3 PLd, IEC/ EN61508 SIL2. Time from input open to drive output stop is less than 1 ms. PFD = 5.15E-5 Operation Time Demand Rate Low Failure Probability Demand Rate High or PFH = 1.
9 Safe Disable Input Function Main Power 24V Safety Relay or PLC with safety functionality Control Circuit HC Feedback Safety Outputs H1 Jumper S3 Setting: SOURCE Gate Block 1 N Power Module P H2 Gate Block 2 DM+ >=1 DMDrive M Disabling and Enabling the Drive Output (“Safe Torque Off”) The diagram below illustrates the Safe Disable input operation.
9 Safe Disable Input Function Safe Disable Monitor Output Function and Digital Operator Display The table below explains the drive output and Safe Disable monitor state depending on the Safe Disable inputs. Safe Disable Input Status Safe Disable Status Monitor, DM+ - DM- <1> S6 Selected N.C. S6 Selected N.O.
Revision History The revision dates and the numbers of the revised manuals appear on the bottom of the back cover. MANUAL NO.ޓTOEP C710616 88A Published in Germany May 2013 Date of publication Date of Publication May 2013 YASKAWA Europe Rev. No.
YASKAWA AC Drive A1000 IP23/54 Floor Standing Quick Start Guide EUROPEAN HEADQUARTERS YASKAWA EUROPE GmbH Hauptstrasse 185, 65760 Eschborn, Germany Phone: +49 (0)6196 569 300 Fax: +49 (0)6196 569 398 E-mail: info@yaskawa.eu.com Internet: http://www.yaskawa.eu.com YASKAWA ENGINEERING EUROPE GmbH Hauptstrasse 185, 65760 Eschborn, Germany Phone: +49 (0)6196 569 520 Fax: +49 (0)6196 888 598 E-mail: support@yaskawa.de Internet: http://www.yaskawa-eng.eu.com MANUFACTURING FACILITY YASKAWA ELECTRIC UK LTD.
