YASKAWA CIMR-JA Series Installation and operation manual

Installation & Start-Up Manual
YASKAWA AC Drive J1000
Compact V/f Control Drive
Models: 200 V Class, Three-Phase Input: 0.1 to 5.5 kW
200 V Class, Single-Phase Input: 0.1 to 2.2 kW
400 V Class, Three-Phase Input: 0.2 to 5.5 kW
MANUAL NO. TOEP C710606 25B
Type: CIMR-JA , CIMR-JT
To properly use the product, read this manual thoroughly
and retain for easy reference, inspection, and maintenance.
Ensure the end user receives this manual.
Peripheral Devices &
Options
Specifications
Parameter List
Standards Compliance
7
Mechanical Installation
Electrical Installation
Start-Up Programming &
Operation
Troubleshooting
Periodic Inspection &
Maintenance
Receiving 1
2
3
4
5
6
A
B
C

This Page Intentionally Blank
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Copyright © 2008 YASKAWA ELECTRIC CORPORATION. All rights reserved.
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.

Table of Contents
i. PREFACE & GENERAL SAFETY ........................9
i.1 Preface .................................................................. 10
Applicable Documentation ..........................................10
Symbols..................................................................10
Terms and Abbreviations............................................11
i.2 General Safety ....................................................... 12
Supplemental Safety Information..................................12
Safety Messages ......................................................13
Drive Label Warnings ................................................15
Warranty Information .................................................16
Quick Reference.......................................................18
1. RECEIVING .........................................................19
1.1 Section Safety........................................................ 20
1.2 Model Number and Nameplate Check.................... 21
Nameplate...............................................................21
1.3 Drive Models.......................................................... 24
1.4 Component Names ................................................ 25
IP20/Open-Chassis ...................................................25
Front Views .............................................................27
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2. MECHANICAL INSTALLATION .................................. 29
2.1 Section Safety.................................................................. 30
2.2 Mechanical Installation .................................................... 33
Installation Environment .......................................................33
Installation Orientation and Spacing........................................34
Removing and Attaching the Protective Covers .........................35
Exterior and Mounting Dimensions .........................................35
3. ELECTRICAL INSTALLATION.................................... 39
3.1 Section Safety.................................................................. 40
3.2 Standard Connection Diagram......................................... 43
3.3 Main Circuit Connection Diagram .................................... 46
Single-Phase 200 V Class (CIMR-JoBA0001 ~ 0010)................46
Three-Phase 200 V Class (CIMR-Jo2A0001 ~
0020);
Three-Phase 400 V Class (CIMR-Jo4A0001 ~ 0011) ...............46
3.4 Terminal Block Configuration.......................................... 47
3.5 Protective Covers ............................................................ 48
IP20/Open-Chassis Cover Removal and Installation...................48
3.6 Main Circuit Wiring .......................................................... 50
Main Circuit Terminal Functions .............................................50
Wire Gauges and Tightening Torque.......................................50
Main Circuit Terminal Power Supply and Motor Wiring................52
3.7 Control Circuit Wiring...................................................... 54
Control Circuit Terminal Block Functions..................................55
Terminal Configuration.........................................................56
Wiring Procedure ................................................................57
3.8 I/O Connections ............................................................... 60
Sinking/Sourcing Mode Switch...............................................60
3.9 Main Frequency Reference .............................................. 63
DIP Switch S1 Analog Input Signal Selection............................63
3.10 Braking Resistor.............................................................. 65
Installation.........................................................................65
3.11 Interlocking with Connected Machinery .......................... 67
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Drive Ready Signal .............................................................67
4. START-UP PROGRAMMING & OPERATION ............ 69
4.1 Section Safety.................................................................. 70
4.2 Using the Digital LED Operator........................................ 73
Keys, Displays, and LEDs.....................................................73
Digital Text Display .............................................................74
LED Screen Displays...........................................................75
LO/RE LED and RUN LED Indications ....................................75
Menu Structure for Digital LED Operator..................................77
4.3 The Drive and Programming Modes ................................ 78
Navigating the Drive and Programming Modes..........................78
Changing Parameter Settings or Values ..................................82
Verifying Parameter Changes: Verify Menu ..............................83
Switching Between LOCAL and REMOTE................................84
Parameters Available in the Setup Group.................................85
4.4 Start-up Flowcharts ......................................................... 86
Flowchart: Basic Start-up and Motor Tuning .............................86
4.5 Basic Operation ............................................................... 87
Initialize Parameter Values: A1-03..........................................87
Frequency Reference Source: b1-01.......................................87
Run Command Input Selection: b1-02 .....................................89
Stopping Method Selection: b1-03 ..........................................91
Acceleration/Deceleration: C1-01 to C1-04...............................92
Drive Duty Mode and Carrier Frequency Selection: C6-01 and
C6-02..............................................................................93
Multi-Step Speed Operation (4-Step Speed).............................96
Drive Input Voltage Setting: E1-01..........................................99
V/f Pattern Settings: E1-04 to E1-10 ..................................... 100
Motor Parameters: E2-01 to E2-03 ....................................... 103
Digital Output: H2-01 ......................................................... 103
Analog Outputs: H4-01 to H4-03 .......................................... 104
Motor Protection: L1-01 and L1-02 ....................................... 105
Notes on Controlling the Brake for the Hoist Application............ 108
Drive Status Monitors: U1-01 to U4-13 .................................. 109
4.6 Powering Up the Drive ....................................................111
Powering Up the Drive and Operation Status Display ............... 111
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V/f Pattern Setting............................................................. 111
4.7 No-Load Operation Test Run ..........................................113
No-Load Operation Test Run............................................... 113
4.8 Test Run with Load Connected.......................................115
Test Run with the Load Connected ....................................... 115
4.9 Verifying and Backing Up Parameter Settings................116
Parameter Access Level: A1-01 ........................................... 116
Password Settings: A1-04, A1-05 ......................................... 116
5. TROUBLESHOOTING ............................................... 117
5.1 Section Safety.................................................................118
5.2 Motor Performance Fine Tuning .....................................121
Parameters for Tuning the Drive .......................................... 121
Motor Hunting and Oscillation Control Parameters ................... 121
5.3 Drive Alarms, Faults, and Errors.....................................123
Types of Alarms, Faults, and Errors ...................................... 123
Alarm and Error Displays.................................................... 124
5.4 Fault Detection ...............................................................126
Fault Displays, Causes, and Possible Solutions ...................... 126
5.5 Alarm Detection ..............................................................134
Alarm Codes, Causes, and Possible Solutions ........................ 134
5.6 Operator Programming Errors........................................139
oPE Codes, Causes, and Possible Solutions .......................... 139
5.7 Diagnosing and Resetting Faults....................................141
Fault Occurs Simultaneously with Power Loss ........................ 141
If the Drive Still has Power After a Fault Occurs ...................... 141
Viewing Fault Trace Data After Fault..................................... 141
Fault Reset Methods ......................................................... 142
5.8 Troubleshooting without Fault Display...........................143
Cannot Change Parameter Settings...................................... 143
Motor Does Not Rotate Properly after Pressing RUN Button or
after Entering External Run Command ................................. 143
6. PERIODIC INSPECTION & MAINTENANCE ........... 151
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6.1 Section Safety.................................................................152
6.2 Inspection.......................................................................155
Recommended Daily Inspection........................................... 155
Recommended Periodic Inspection....................................... 156
6.3 Periodic Maintenance .....................................................159
Replacement Parts............................................................ 159
6.4 Drive Cooling Fans .........................................................161
Cooling Fan Replacement .................................................. 161
7. PERIPHERAL DEVICES & OPTIONS ...................... 165
7.1 Section Safety.................................................................166
7.2 Peripheral Devices..........................................................168
7.3 Connecting Peripheral Devices ......................................170
7.4 Installing Peripheral Devices ..........................................171
Installing a Molded Case Circuit Breaker (MCCB) .................... 171
Installing a Leakage Breaker ............................................... 172
Installing a Magnetic Contactor ............................................ 172
Connecting an AC or DC Reactor......................................... 173
Connecting a Surge Absorber.............................................. 174
Connecting a Noise Filter ................................................... 174
Zero-Phase Reactor .......................................................... 177
Installing Fuses on the Input Side......................................... 178
Installing a Motor Thermal Overload (oL) Relay on the Drive
Output........................................................................... 178
NEMA Type 1 Kit .............................................................. 180
7.5 Communication Options.................................................185
A. SPECIFICATIONS...................................................... 187
A.1 Heavy Duty and Normal Duty Ratings.............................188
A.2 Single/Three-Phase 200 V Class Drive............................189
A.3 Three-Phase 400 V Class Drives .....................................190
A.4 Drive Specifications........................................................191
A.5 Drive Watt Loss Data ......................................................194
A.6 Drive Derating Data.........................................................195
Temperature Derating........................................................ 195
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B. PARAMETER LIST .................................................... 197
B.1 Parameter Groups ..........................................................198
B.2 Parameter Table..............................................................199
A: Initialization Parameters ................................................. 199
b: Application ................................................................... 199
C: Tuning ........................................................................ 201
d: References .................................................................. 203
E: Motor Parameters ......................................................... 204
H Parameters: Multi-Function Terminals ................................ 206
L: Protection Function ........................................................ 210
n: Advanced Performance Set-Up ........................................ 214
o: Operator Related Parameters .......................................... 214
U: Monitors...................................................................... 216
B.3 Defaults Determined by Drive Capacity (o2-04) and ND/
HD (C6-01) ......................................................................219
B.4 Defaults Determined by Carrier Frequency Selection
(C6-02) ............................................................................222
B.5 Defaults Determined by Carrier Frequency Reduction
(L8-38).............................................................................223
C. STANDARDS COMPLIANCE .................................... 225
C.1 Section Safety.................................................................226
C.2 European Standards .......................................................229
CE Low Voltage Directive Compliance .................................. 229
EMC Guidelines Compliance............................................... 230
C.3 UL Standards..................................................................236
UL Standards Compliance .................................................. 236
Drive Motor Overload Protection .......................................... 238
Table of Contents
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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.........................................................10
I.2 GENERAL SAFETY...........................................12
i
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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, EXPRESSED 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 Variable J1000-Series
Inverters. Read this manual before attempting to install, operate, maintain, or inspect an
Inverter and keep it in a safe, convenient location for future reference. Be sure you understand
all precautions and safety information before attempting application.
uApplicable Documentation
The following manuals are available for J1000 series drives:
J1000 Series Compact V/f Control Drive Installation and Start-Up Manual
Read this manual first. This guide is packaged together with the product. It
contains basic information required to install and wire the drive. This guide
provides basic programming and simple setup and adjustment. Refer to the
J1000 Technical Manual for complete descriptions of drive features and
functions.
J1000 Series Compact V/f Control Drive Technical Manual
This manual describes installation, wiring, operation procedures, functions,
troubleshooting, maintenance, and inspections to perform before operation.
uSymbols
Note: Indicates a supplement or precaution that does not cause drive damage.
TERMSTERMS
Indicates a term or definition used in this manual.
i.1 Preface
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uTerms and Abbreviations
•Drive: Yaskawa J1000 Series Drive
i.1 Preface
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i.2 General Safety
uSupplemental Safety Information
General Precautions
• The diagrams in this manual may be indicated without covers or safety shields to show details. Restore
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 possibly even 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! will also be indicated by a bold key word embedded in the text followed by an italicized safety
message.
i.2 General Safety
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CAUTION
Indicates a hazardous situation, which, if not avoided, could result in minor or
moderate injury.
CAUTION! will 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: will also be indicated by a bold key word embedded in the text followed by an italicized safety
message.
uSafety Messages
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.
Electrical Shock Hazard
Do not connect or disconnect wiring while the power is on.
Failure to comply will 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 at least one minute
after all indicators are OFF and measure the DC bus voltage level to confirm safe level.
i.2 General Safety
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WARNING
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 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.
Fire Hazard
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.
CAUTION
Crush Hazard
Do not carry the drive by the front cover.
Failure to comply may result in minor or moderate injury from the main body of the drive
falling.
i.2 General Safety
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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 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.
Install adequate branch circuit short circuit protection per applicable codes.
Failure to comply could result in damage to the drive.
The drive is suitable for circuits capable of delivering not more than 30,000 RMS
symmetrical Amperes, 240 Vac maximum (200 V Class) and 480 Vac maximum (400 V
Class).
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.
uDrive Label Warnings
Always heed the warning information listed in Figure i.1 in the position shown in Figure i.
2.
i.2 General Safety
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Risk of electric shock.
WARNING
Read manual before installing.
Wait 1 minute for capacitor discharge after
disconnecting power supply.
To conform to requirements, make sure
to ground the supply neutral for 400V class.
Figure i.1 Warning Information
Warning
Label
Figure i.2 Warning Information Position
uWarranty Information
nWarranty Period
This drive is warranted for 12 months from the date of delivery to the customer or 18 months
from the date of shipment from the Yaskawa factory, whichever comes first.
i.2 General Safety
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nScope 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 Japan. However, after-sales service is available for
customers outside of Japan 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.
nRestrictions
The J1000 was not designed or manufactured for use in devices or systems that may directly
affect or threaten human lives or health.
i.2 General Safety
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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.
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.
uQuick Reference
Run a Motor of One-Frame Larger Capacity
When using this drive for variable torque loads such as fans and pumps, a motor one frame size larger can be used.
Know the Details of Safety Measures
The functions listed below affect the safe operation of the drive. Ensure that the settings fit the application requirements
prior to operation.
Safe operations. Run by power on. Parameter setting b1-17.
LOCAL/REMOTE key effective during stop in drive mode. Parameter o2-01.
LED operator stop key priority selection. Parameter o2-02.
Enter press required after changing the keypad frequency reference. Parameter o2-05.
Operation interlock when program mode is selected. Parameter b1-08.
Check the Maintenance Period Using Drive Monitors
The maintenance period of fans and capacitors can be checked with drive monitors.
Drive or Motor Faults are Displayed on a Digital Operator
Refer to Fault Displays, Causes, and Possible Solutions on page 126 and Refer to Alarm Codes, Causes, and Possible
Solutions on page 134.
Standards Compliance
Refer to European Standards on page 229 and Refer to UL Standards on page
236.
UL
C
R
US
LISTED
i.2 General Safety
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Receiving
This chapter describes the proper inspections to perform after
receiving the drive and illustrates the different enclosure types
and components.
1.1 SECTION SAFETY.............................................20
1.2 MODEL NUMBER AND NAMEPLATE CHECK
.........................................................................21
1.3 DRIVE MODELS................................................24
1.4 COMPONENT NAMES.......................................25
1
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1.1 Section Safety
CAUTION
Do not carry the drive by the front 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.
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 inverter duty and/or the motor service factor is adequate
to accommodate the additional heating with the intended operating conditions.
1.1 Section Safety
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