YASKAWA DO-A3 User manual

MANUAL NO. TOBP C730600 41C
形式 DO-A3
取扱説明書
ディジタル出力
安川インバータ1000シリーズオプション
製品を安全にお使い頂くために，この取扱説明書を必ずお読みください。
また，本書をお手元に保管していただくとともに，最終的に本製品をご使用になる
ユーザー様のお手元に確実に届けられるよう，お取り計らい願います。
To properly use the product, read this manual thoroughly and retain
for easy reference, inspection, and maintenance. Ensure the end user
receives this manual.
Installation Manual
Digital Output
YASKAWA AC Drive 1000-Series Option
Type DO-A3

2YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual
Copyright © 2008 YASKAWA ELECTRIC CORPORATION
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted, in any form or by any means, mechanical, electronic, photocopying, recording, or otherwise,
without the prior written permission of Yaskawa. No patent liability is assumed with respect to the use of the
information contained herein. Moreover, because Yaskawa is constantly striving to improve its high-quality
products, the information contained in this manual is subject to change without notice. Every precaution has
been taken in the preparation of this manual. 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.

YASKAWA E LE CT RIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual 3
Table of Contents
1 PREFACE AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 PRODUCT OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 RECEIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 OPTION COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 INSTALLATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . 10
6 RELATED PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
8 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4 YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual
1 Preface and Safety
1 Preface and Safety
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.
◆Applicable Documentation
The following manuals are available for the option:
Digital Output DO-A3 Option
Yaskawa AC Drive
1000-Series Option
Digital Output DO-A3
Installation Manual
Manual No: TOBPC73060041
Read this manual first.
The installation manual is packaged with the
option and contains information required to install
the option and set up related drive parameters.
Yaskawa Drive
Yaskawa AC Drive
1000-Series
Quick Start Guide
The drive manuals cover basic installation,
wiring, operation procedures, functions,
troubleshooting, and maintenance information.
The manuals also include important information
about parameter settings and drive tuning.
Access these sites to obtain Yaskawa instruction
manuals:
U.S.: http://www.yaskawa.com
Europe: http://www.yaskawa.eu.com
Japan: http://www.e-mechatronics.com
For questions, contact your local Yaskawa sales
office or the nearest Yaskawa representative.
Yaskawa AC Drive
1000-Series
Technical Manual

1 Preface and Safety
YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual 5
◆Terms
◆Registered Trademarks
Trademarks are the property of their respective owners.
◆Supplemental Safety Information
Read and understand this manual before installing, operating, or servicing this option. Install
the option according to this manual and local codes.
The following conventions indicate safety messages in this manual. Failure to heed these
messages could cause fatal injury or damage products and related equipment and systems.
Note: Indicates supplemental information that is not related to safety messages
Drive: Yaskawa AC Drive 1000-Series
Option: Yaskawa AC Drive 1000-Series Option Digital Output DO-A3
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.
CAUTION
Indicates a hazardous situation, which, if not avoided, could result in minor or
moderate injury.
NOTICE
Indicates an equipment damage message.

1 Preface and Safety
6YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual
■General Safety
General Precautions
• The diagrams in this book may include options and drives without covers or safety shields to
illustrate details. Be sure to reinstall covers or shields before operating any devices. Use the option
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 new copies of the manual, contact a Yaskawa representative or the nearest Yaskawa
sales office and provide the manual number shown on the front cover.
DANGER
Heed the safety messages in this manual.
Failure to comply will 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.
NOTICE
Do not modify the drive or option circuitry.
Failure to comply could result in damage to the drive or option and will void warranty.
Yaskawa is not responsible for any modification of the product made by the user. This
product must not be modified.
Do not expose the drive or option to halogen group disinfectants.
Failure to comply may cause damage to the electrical components in the drive or option.
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.

YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual 7
2 Product Overview
2 Product Overview
◆About This Product
The Digital Output Option DO-A3 allows the user to expand the number of available digital
outputs to monitor drive run status.
The option has the following features:
• Six photocoupler outputs (48 V, 50 mA or less)
• Two relay outputs (250 Vac, 1 A or less; 30 Vdc, 1 A or less)
◆Applicable Models
The option can be used with the drive models in Table 1.
Table 1 Applicable Models
Drive Series Drive Model Number
A1000 All models
L1000A All models

8 YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual
3 Receiving
3 Receiving
Please perform the following tasks upon receiving the option:
• Inspect the option for damage. Contact the shipper immediately if the option appears
damaged upon receipt.
• Verify receipt of the correct model by checking the model number printed on the option
nameplate. (Refer to Figure 1 on page 9for more information)
• Contact your supplier if you have received the wrong model or the option does not
function properly.
◆Option Package Contents
◆Tools Required for Installation
• A Phillips screwdriver (M3 metric / #1, #2 U.S. standard size) is required to install the
option.
• A straight-edge screwdriver (blade depth: 0.4 mm, width: 2.5 mm) is required to wire the
option terminal block.
• A pair of diagonal cutting pliers.
• A small file or medium-grit sandpaper.
Note: Tools required to prepare option cables for wiring are not listed in this manual.
Description: Option Ground Wires Screws (M3) Installation Manual
–
Quantity: 1331
MANUAL

YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual 9
4 Option Components
4 Option Components
◆Digital Output DO-A3 Option
Figure 1
Figure 1 Digital Output DO-A3 Option Components
◆Terminal Blocks TB1 and TB2
Refer to Table 4 on page 21 for details on TB1 and TB2 terminal functions and signal levels.
A – Terminal block TB1 D – Terminal block TB2
B – Connector (CN5) E – Model number
C – Installation hole F – Ground terminal and installation
hole <1>
<1> The ground wires provided in the option shipping package must be connected during installation.
DO-A3
Underside
F
B
C
D
A
E
P1 P2 P3 P4 P5 P6 PC
M1 M2 M3 M4
TB2
TB1

10 YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual
5 Installation Procedure
5 Installation Procedure
◆Section Safety
DANGER
Electric Shock Hazard
Do not connect or disconnect wiring while the power is on.
Failure to comply will result in death or serious injury.
Disconnect all power to the drive and wait at least the amount of time specified on the
drive front cover safety label. After all indicators are off, measure the DC bus voltage to
confirm safe level, and check for unsafe voltages. The internal capacitor remains charged
after the power supply is turned off.
WARNING
Electrical Shock Hazard
Do not remove the front covers of the drive while the power is on.
Failure to comply could result in death or serious injury.
The diagrams in this section may include options and drives without covers or safety
shields to show details. Be sure to reinstall covers or shields before operating any devices.
Use the option according to the instructions described in this manual.
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 this product.
Do not touch circuit boards while the power to the drive is on.
Failure to comply could result in death or serious injury.

5 Installation Procedure
YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual 11
Do not use damaged wires, stress the wiring, or damage the wire insulation.
Failure to comply could result in death or serious injury.
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.
NOTICE
Damage to Equipment
Observe proper electrostatic discharge (ESD) procedures when handling the option,
drive, and circuit boards.
Failure to comply may result in ESD damage to circuitry.
Never shut the power off while the drive is running or outputting voltage.
Failure to comply may cause the application to operate incorrectly or damage the drive.
Do not operate damaged equipment.
Failure to comply may cause further damage to the equipment.
Do not connect or operate any equipment with visible damage or missing parts.
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.
Properly connect all pins and connectors.
Failure to comply may prevent proper operation and possibly damage equipment.
Check wiring to ensure that all connections are correct after installing the option
and connecting any other devices.
Failure to comply may result in damage to the option.
WARNING

5 Installation Procedure
12 YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual
◆Prior to Installing the Option
Prior to installing the option, wire the drive, make the necessary connections to the drive
terminals, and verify that the drive functions normally. Refer to the Quick Start Guide
packaged with the drive for information on wiring and connecting the drive.
Figure 2 shows an exploded view of the drive with the option and related components for
reference.
Figure 2
Figure 2 Drive Components with Option
A – Insertion point for CN5 G – Included screws
B – Option card H – Ground wire
C – Front cover I – Drive grounding terminal (FE)
D – Digital operator J – Connector CN5-A
E – Terminal cover K – Connector CN5-B
F – Removable tabs for wire
routing
L – Connector CN5-C
E
G
L
K
J
I
H
BC
D
A
F

5 Installation Procedure
YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual 13
◆Installing the Option
Refer to the instructions below to install the option.
1. Shut off power to the drive, wait the appropriate amount of time for voltage to
dissipate, then remove the digital operator (D) and front covers (C, E). Refer to the
Quick Start Guide packaged with the drive for directions on removing the front
covers. Cover removal varies depending on drive size.
DANGER! Electrical Shock Hazard. Disconnect all power to the drive and wait at least the amount of time
specified on the drive front cover safety label. After all indicators are off, measure the DC bus voltage to
confirm safe level, and check for unsafe voltages before servicing to prevent electric shock. The internal
capacitor remains charged even after the power supply is turned off.
NOTICE: Damage to Equipment. Observe proper electrostatic discharge procedures (ESD) when handling
the option, drive, and circuit boards. Failure to comply may result in ESD damage to circuitry.
Figure 3
Figure 3 Remove the Front Covers and Digital Operator
C
D
E

5 Installation Procedure
14 YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual
2. Insert the option card (B) into the CN5-A (J), CN5-B (K), or CN5-C (L) connector
located on the drive and fasten it into place using one of the included screws (G).
Figure 4
Figure 4 Insert the Option Card
J
G
B
K
L

5 Installation Procedure
YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual 15
3. Connect one end of the ground wire (H) to the ground terminal (I) using one of the
remaining screws (G). Connect the other end of the ground wire (H) to the
remaining ground terminal and installation hole on the option (B) using the last
remaining provided screw (G).
Figure 5
Figure 5 Connect the Ground Wire
Note: 1. The option package includes three ground wires. Use the longest wire when plugging the option into
connector CN5-C on the drive side. Use the next longest wire when plugging the option into connector
CN5-B. Use the shortest wire when plugging the option into connector CN5-A. Refer to Option
Package Contents on page 8 for more information.
2. There are two screw holes on the drive for use as ground terminals (I). When connecting three options,
two ground wires will need to share the same drive ground terminal.
I
G
H
B

5 Installation Procedure
16 YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual
4. Prepare and connect the wire ends as shown in Figure 6 and Figure 7. Refer to
Wire Gauges, Tightening Torques, and Crimp Terminals on page 20 to confirm
that the proper tightening torque is applied to each terminal. Take particular
precaution to ensure that each wire is properly connected and wire insulation is not
accidentally pinched into electrical terminals.
WARNING! Fire Hazard. Tighten terminal screws to the specified tightening torque. Loose electrical
connections could result in death or serious injury by fire due to overheating. Tightening screws beyond the
specified tightening torque may cause erroneous operation, damage the terminal block, or cause a fire.
NOTICE: Heat shrink tubing or electrical tape may be required to ensure that cable shielding does not
contact other wiring. Insufficient insulation may cause a short circuit and damage the option or drive.
Figure 6
Figure 6 Preparing Ends of Shielded Cable
Figure 7
Figure 7 Preparing and Connecting Cable Wiring
Insulation
Shield sheath
Option terminal To customer
circuit
Shield
Shield
(Insulate with electrical tape
or shrink tubing)
Option Terminal block
Preparing wire ends: Screwdriver blade size
about 5.5 mm (7/32”)
When not using
crimped insulated
sleeves
Pull back the shielding and lightly
twist the end with fingers, keeping
the ends from fraying.
To customer circuit
(do not solder ends)
Loosen the screws and
insert the wire into the
opening on the terminal block.
Blade depth of
0.4 mm or less
Blade width of
2.5 mm or less

5 Installation Procedure
YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual 17
5. Wire the customer-supplied circuit to the terminal blocks on the option. Refer to
Figure 8 for wiring instructions.
Connection Diagram
Refer to Table 4 on page 21 for a detailed description of the option board terminal
functions. To ensure accurate control, use stable power supply for the voltage
reference source
Figure 8
Figure 8 Option Connection Diagram
<1> Double-check the polarity on the diode when connecting a DC relay.
<2> Install a surge absorber (SA) when using an AC relay.
Ground wire
CN5-A/
CN5-B/
CN5-C
Drive
DO-A3 TB2
TB1
RLY1
RLY2
RLY3
RLY4
RLY5
RLY6
P1
P2
P4
P3
P5
P6
PC
M1
M2
M4
M3
RLY7
SA RLY8
SA
DC power supply
(48 V,50 mA or less)
Photocoupler
output
Relay output
AC power supply
(AC250 V,1 A or less)
or
DC power supply
(30 V,1 A or less)
R/L1
T/L2
S/L3
<1>
<2>
FE
Main circuit terminal Control circuit terminal

5 Installation Procedure
18 YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual
6. Route the option wiring.
Depending on the drive model, some drives may require routing the wiring through
the side of the front cover to the outside. In these cases, cut out the perforated
openings on the left side of the drive front cover as shown in Figure 9-A and leave
no sharp edges to damage wiring.
Route the wiring inside the enclosure as shown in Figure 9-B for drives that do not
require routing through the front cover.
Refer to the Peripheral Devices & Options section of the Yaskawa AC Drive
Technical Manual for more information.
Figure 9
Figure 9 Wire Routing Examples
A – Route wires through the openings
provided on the left side of the
front cover. <1>
<1> The drive will not meet NEMA Type 1 requirements if wiring is exposed outside the enclosure.
B – Use the open space provided
inside the drive to route option
wiring.
B
A

5 Installation Procedure
YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual 19
7. Replace and secure the front covers of the drive (C, E) and replace the digital
operator (D).
Figure 10
Figure 10 Replace the Front Covers and Digital Operator
Note: Take proper precautions when wiring the option so that the front covers will easily fit back onto
the drive. Make sure cables are not pinched between the front covers and the drive when
replacing the covers.
8. Set drive parameters in Table 7 for proper option performance.
E
C
D

5 Installation Procedure
20 YASKAWA ELECTRIC TOBP 730600 41C 1000-Series Option DO-A3 Installation Manual
◆Wire Gauges, Tightening Torques, and Crimp Terminals
■Wire Gauges and Tightening Torques
Wire gauge and torque specifications are listed in Table 2 .
Table 2 Wire Gauges and Tightening Torques
■Crimp Terminals
Yaskawa recommends using CRIMPFOX 6 by Phoenix Contact or equivalent crimp
terminals with the specifications listed in Table 3 for wiring to ensure proper connections.
Note: Properly trim wire ends so loose wire ends do not extend from the crimp terminals.
Table 3 Crimp Terminal Sizes
Terminal
signal
Screw
Size
Tightening
Torque
Nxm (inxlb)
Bare Cable Crimp Terminals Wire
Type
Applicable
Gauges mm2Recomm. Gauge mm2Applicable Gauges mm2Recomm. Gauge mm2
P1 to P6,
PC M2 0.22 to 0.25
(1.95 to 2.21)
Stranded wire:
0.25 to 1.0
(24 to 17 AWG)
Solid wire:
0.25 to 1.5
(24 to 16 AWG) 0.75
(18 AWG)
0.25 to 0.5
(24 to 20 AWG)
0.5
(20 AWG)
Shielded
twisted
pair, etc.
M1 to
M4 M3 0.5 to 0.6
(4.43 to 5.31)
Stranded wire:
0.25 to 1.5
(24 to 16 AWG)
Solid wire:
0.25 to 2.5
(24 to 13 AWG)
0.25 to 1.0
(24 to 17 AWG)
Wire Gauge mm2Phoenix Contact
Model
L
mm (in)
d1
mm (in)
d2
mm (in)
0.25 (24 AWG) AI 0.25 - 6YE 10.5 (13/32) 0.8 (1/32) 2 (5/64)
0.34 (22 AWG) AI 0.34 - 6TQ 10.5 (13/32) 0.8 (1/32) 2 (5/64)
0.5 (20 AWG) AI 0.5 - 6WH 14 (9/16) 1.1 (3/64) 2.5 (3/32)
1.0 (16 AWG) AI 1-6RD 12 (15/32) 1.5 (1/16) 3.0 (1/8)
d1 d2
6 mm
L