YASKAWA GPD515C User manual

GPD 515/G5 Drive
Technical Manual
Models: GPD515C- and CIMR-G5M Document Number: TM 4515

The GPD 515/G5, hereafter referred to as the drive, is a general purpose sine-coded pulse
width modulated AC motor drive which generates an adjustable voltage/frequency three
phase output for complete speed control of most conventional squirrel cage induction
motors. Automatic stall prevention and voltage boost prevents nuisance tripping during load
or line side transient conditions. The drive will not induce any voltage line notching distortion
back to the utility line and maintains a displacement power factor of not less than 0.98
throughout its speed range.
When properly installed, operated and maintained, the drive will provide a lifetime of
service. It is mandatory that the person who operates, inspects, or maintains this
equipment thoroughly read and understand this manual before proceeding.
This manual primarily describes the GPD 515/G5, but contains basic information for the
operator control station as well. This manual is equally applicable to drives labelled
GPD 515 or G5.
The drive is thoroughly tested at the factory. After unpacking, verify the part numbers
with the purchase order (invoice). Any damages or shortages evident when the equipment
is received must be reported immediately to the commercial carrier who transported the
equipment. Assistance, if required, is available from your sales representative.
If the drive will be stored after receiving, keep it in its original packaging and store
according to storage temperature specifications in Appendix 2.
Location of the drive is important to achieve proper performance and normal operating life.
The unit should be installed in an area where it will be protected from:
• Direct sunlight, rain or moisture.
• Corrosive gases or liquids.
• Vibration, airborne dust or metallic particles.
When preparing to mount the drive, lift it by its base, never by the front cover. For
effective cooling as well as proper maintenance, the drive must be installed on a flat, non-
flammable vertical surface (wall or panel) using four mounting screws. There MUST be a
MINIMUM 4.7 in. clearance above and below the drive to allow air flow over the heat sink
fins. A minimum 1.2 in. clearance is required on each side on the drive.
A GPD 515/G5 in a free-standing floor-mount cabinet must be positioned with enough
clear-ance for opening the door of the cabinet; this will ensure sufficient air space for
cooling. Make sure air entering the drive is below 113°F (45°C) (for protected chassis
drives), or below 104°F (40°C) (for NEMA 1 drives), by adding a fan or other cooling
device, if needed. See environmental specifications in Appendix 2.
1-1
Section 1. RECEIVING AND INSTALLATION
1.1 GENERAL
1.2 RECEIVING
1. 3 PH YS ICAL INSTALLATION

All basic interconnections (using the Digital Operator) are shown in Figures 1-3 and 1-4.
1 . 4 . 1 M a i n C i r c u i t I n p u t / O u t p u t
Complete wire interconnections according to Table 1-2, Figure 1-3 and Figure 1-4. Be sure to
observe the following:
• Use 600V vinyl-sheathed wire or equivalent. Wire size and type should be determined by local
electrical codes.
• Avoid routing power wiring near equipment sensitive to electrical noise.
• Avoid running input and output wiring in the same conduit.
• NEVER connect AC main power to output terminals T1(U), T2(V), and T3(W).
• NEVER allow wire leads to contact metal surfaces. Short-circuit may result.
• NEVER connect power factor correction capacitors to the drive output. Consult
Yaskawa when connecting noise filters to the drive output.
• WIRE SIZING MUST BE SUITABLE FOR CLASS I CIRCUITS.
• When connecting motor to drive’s output terminals, include a separate ground wire. Attach ground
wire solidly to motor frame and to drive’s ground terminal.
• When using armored or shielded cable for connection between drive and motor, solidly connect
armor or shield to motor frame, and to drive’s ground terminal.
• Motor lead length should NOT EXCEED 164 feet (50 meters), and motor wiring should be run in
a separate conduit from other power wiring. If lead length must exceed this distance, reduce
carrier frequency (see paragraph 5.8) and consult factory for proper installation procedures.
• Use UL listed closed loop connectors or CSA certified ring connectors sized for the selected wire
gauge. Install connectors using the correct crimp tool recommended by the connector
manufacturer.
1-2
1.4 ELECTRICAL INSTALLATION
WIRE SIZE TERMINAL CLOSED-LOOP CLAMPING TORQUE
AWG mm2SCREW CONNECTOR STEEL COPPER
lb-in N-m lb-in N-m
20 0.5 M3.5 1.25 - 3.5 7.8 0.9 7.0 0.8
18 0.75 M4 1.25 - 4 13.0 1.5 10.4 1.2
16 1.25 M4 1.25 - 4 13.0 1.5 10.4 1.2
M4 2 - 4 13.0 1.5 10.4 1.2
14 2 M5 2 - 5 26.1 20.9 3.1 2.4
M4 3.5 - 4 13.0 1.5 10.4 1.2
12 3.5 M5 3.5 - 5 26.1 20.9 3.1 2.4
M4 5.5 - 4 13.0 1.5 10.4 1.2
10 5.5 M5 5.5 - 5 26.1 20.9 3.1 2.4
M5 8 - 5 26.1 20.9 3.1 2.4
8 8 M6 8 - 6 40.9 34.8 4.8 4.1
6 14 M6 14 - 6 40.9 34.8 4.8 4.1
4 22 M8 22 - 8 100.0 82.6 11.7 10.7
M8 38 - 8 100.0 82.6 11.7 10.7
2 38 M10 38 - 10 182.6 156.5 21.4 18.4
1/0 60 M10 60 - 10 182.6 156.5 21.4 18.4
3/0 80 M10 80 - 10 182.6 156.5 21.4 18.4
M10 100 - 10 182.6 156.5 21.4 18.4
4/0 100 M12 100 - 12 313.0 191.3 36.7 23.1
MCM300 150 M12 150 - 12 313.0 191.3 36.7 23.1
MCM400 200 M12 200 - 12 313.0 191.3 36.7 23.1
M12 325 - 12 313.0 191.3 36.7 23.1
MCM650 325 M16 325 - 16 313.0 191.3 36.7 23.1

1-3
HP TERMINAL WIRE SIZE
RATING TERMINAL SYMBOL SCREW AWG MM2
20P41F A003, L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, M4 14 - 10 2 - 5.5
20P71F A006 T1 (U), T2 (V), T3 (W),
21P51F A008 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, T1 (U), M4 14 - 10 2 - 5.5
T2 (V), T3 (W)
M4 12 - 10 3.5 - 5.5
22P21F A011 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, T1 (U), M4 12 - 10 3.5 - 5.5
T2 (V), T3 (W),
23P71F A017 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, T1 (U), M4 10 5.5
T2 (V), T3 (W),
25P51F A025, L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, T1 (U), M5 8 8
27P51F A033 T2 (V), T3 (W)
M5 10 - 8 5.5 - 8
20111F A049 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, ⊕3, T1 (U), M6 4 22
T2 (V), T3 (W)
M6 8 8
20151F A064 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, ⊕3, T1 (U), M8 3 30
T2 (V), T3 (W)
M6 8 8
20181F A080, L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, ⊕3, T1 (U), M8 3 30
20221F A096 T2 (V), T3 (W)
M8 6 14
l 1 (r), l 2 ( s ) M4 20 - 10 0.5 - 5.5
20300F A130 L1 (R), L2 (S), L3 (T), T1 (U), T2 (V), T3 (W) M10 4/0 100
, ⊕3, M8 4 22
l 1 (r), l 2 ( s ) M4 20 - 10 0.5 - 5.5
20370F A160 L1 (R), L2 (S), L3 (T), T1 (U), T2 (V), T3 (W) M10 1/0 x 2P 60 x 2P
, ⊕3, M8 4 22
l 1 (r), l 2 ( s ) M4 20 - 10 0.5 - 5.5
20550F A224 L1 (R), L2 (S), L3 (T), T1 (U), T2 (V), T3 (W) M10 1/0 x 2P 60 x 2P
, ⊕3, M8 3 30
l 1 (r), l 2 ( s ) M4 20 - 10 0.5 - 5.5
20750F A300 L1 (R), L2 (S), L3 (T), T1 (U), T2 (V), T3 (W) M12 4/0 x 2P 100 x 2P
, ⊕3, M8 1 50
l 1 (r), l 2 ( s ) M4 20 - 10 0.5 - 5.5
SECTION A. 230V
NEW DRIVE OLD DRIVE
TERMINAL
WIRE SIZE
MODEL NO. MODEL NO. TERMINAL SYMBOL
CIMR-G5M GPD515C– SCREW AWG mm2
Table 1-1. Typical Wire Sizing For Main Circuit*
* Consult local electrical codes for wire sizing requirements.

1-4
DRIVE TERMINAL WIRE SIZE
MODEL NO. TERMINAL SYMBOL SCREW AWG mm2
40P41F B001 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, T1 (U), M4 14 - 10 2 - 5.5
T2 (V), T3 (W),
40P71F B003, L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, T1 (U), M4 14 - 10 2 - 5.5
41P51F B004, T2 (V), T3 (W)
43P71F B008 M4 12 - 10 3.5 - 5.5
44P01F B011, L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, T1 (U), M4 12 - 10 3.5 - 5.5
45P51F B014 T2 (V), T3 (W),
47P51F B021 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, T1 (U), M4 8 - 6 8 - 14
T2 (V), T3 (W),
40111F B027, L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, T1 (U), M5 8 - 6 8 - 14
40151F B034 T2 (V), T3 (W)
M6 8 8
40181F B041 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, ⊕3, T1 (U), M6 6 14
T2 (V), T3 (W)
M8 8 8
l 1 (r), l 2 ( s ) M4 20 - 10 0.5 - 5.5
40221F B052 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, ⊕3, T1 (U), M6 4 22
T2 (V), T3 (W)
M8 8 8
l 1 (r), l 2 ( s ) M4 20 - 10 0.5 - 5.5
40301F B065 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, ⊕3, T1 (U), M8 4 22
T2 (V), T3 (W)
M8 8 8
l 1 (r), l 2 ( s ) M4 20 - 10 0.5 - 5.5
40371F B080 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, ⊕3, T1 (U), M8 3 30
T2 (V), T3 (W)
M8 6 14
l 1 (r), l 2 ( s ) M4 20 - 10 0.5 - 5.5
40451F B096 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, ⊕3, T1 (U), M8 1 50
T2 (V), T3 (W)
M8 6 14
l 1 (r), l 2 ( s ) M4 20 - 10 0.5 - 5.5
40551F B128 L1 (R), L2 (S), L3 (T), T1 (U), T2 (V), T3 (W) M10 4/0 100
, ⊕3, M8 4 22
l 1 (r), l 2 200 ( s 200), l 2 400 ( s 400) M4 20 - 10 0.5 - 5.5
40750F B165 L1 (R), L2 (S), L3 (T), T1 (U), T2 (V), T3 (W) M10 1/0 x 2P 60 x 2P
, ⊕3, M8 4 22
l 1 (r), l 2 200 ( s 200), l 2 400 ( s 400) M4 20 - 10 0.5 - 5.5
41100F B224 L1 (R), L2 (S), L3 (T), T1 (U), T2 (V), T3 (W) M10 1/0 x 2P 60 x 2P
, ⊕3, M8 3 30
l 1 (r), l 2 200 ( s 200), l 2 400 ( s 400) M4 20 - 10 0.5 - 5.5
41600F B302 L1 (R), L2 (S), L3 (T), T1 (U), T2 (V), T3 (W) M12 4/0 x 2P 100 x 2P
, ⊕3, M8 1 50
l 1 (r), l 2 200 ( s 200), l 2 400 ( s 400) M4 20 - 10 0.5 - 5.5
41850F B340, L1 (R), L2 (S), L3 (T), , ⊕1, ⊕3, T1 (U), T2 (V), M16
MCM650 x 2P 325 x 2P
42200F B450, T3 (W)
43000F B605 M8 1/0 60
l 1 (r), l 2 200 ( s 200), l 2 400 ( s 400) M4 20 - 10 0.5 - 5.5
Section B. 460V
NEW DRIVE OLD DRIVE
TERMINAL
WIRE SIZE
MODEL NO. MODEL NO. TERMINAL SYMBOL
CIMR-G5M GPD515C– SCREW AWG mm2
Table 1-1. Typical Wire Sizing For Main Circuit - Continued*
* Consult local electrical codes for wire sizing requirements.

1-5
DRIVE TERMINAL WIRE SIZE
MODEL NO.TERMINAL SYMBOL SCREW AWG mm2
51P51F C003, L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, T1 (U), M4 14-10 2 - 5.5
52P21F C004 T2 (V), T3 (W)
53P71F C006 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, T1 (U), M4 14-10 2 - 5.5
T2 (V), T3 (W)
12-10 3.5-5.5
55P51F C010 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, T1 (U), M4 12-10 3.5-5.5
T2 (V), T3 (W)
57P51F C012 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, T1 (U), M4 10 5.5
T2 (V), T3 (W)
12-10 3.5-5.5
50111F C017 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, T1 (U), M5 10-6 5.5-14
T2 (V), T3 (W)
M6
50151F C022 L1 (R), L2 (S), L3 (T), , ⊕1, ⊕2, B1, B2, T1 (U), M5 8-6 8-14
T2 (V), T3 (W)
M6 10-6 5.5-14
50181F C027 L1 (R), L2 (S), L3 (T),
,
⊕1, B1, B2, T1 (U), M6 8-6 8-14
50221F C032 T2 (V), T3 (W)
◆10-6 5.5-14
l 1 (r), l 2( s ) M4 14 - 10 2 - 5.5
50301F C041 L1 (R), L2 (S), L3 (T),
,
⊕1, T1 (U), T2 (V), T3 (W) M8 6-1/0 14-50
◆8-2 8-30
l 1 (r), l 2( s ) M4 14 - 10 2 - 5.5
50371F C052 L1 (R), L2 (S), L3 (T),
,
⊕1, T1 (U), T2 (V), T3 (W) M8 4-1/0 22-50
◆8-2 8-30
l 1 (r), l 2( s ) M4 14 - 10 2 - 5.5
50451F C062 L1 (R), L2 (S), L3 (T),
,
⊕1, T1 (U), T2 (V), T3 (W) M8 3-1/0 30-50
◆8-2 8-30
l 1 (r), l 2( s ) M4 14 - 10 2 - 5.5
50551F C077 L1 (R), L2 (S), L3 (T),
,
⊕1, T1 (U), T2 (V), T3 (W) M8 2-1/0 30-50
◆6-2 22-30
l 1 (r), l 2( s ) M4 14 - 10 2 - 5.5
50751F C099 L1 (R), L2 (S), L3 (T),
,
⊕1, T1 (U), T2 (V), T3 (W) M8 2/0-1/0 50-60
◆4-2 22-30
l 1 (r), l 2( s ) M4 14 - 10 2 - 5.5
50900F C130 L1 (R), L2 (S), L3 (T),
,
⊕1, T1 (U), T2 (V), T3 (W) M10 3/0-300 80-150
◆4-2/0 22-60
l 1 (r), l 2( s ) M4 14 - 10 2 - 5.5
51100F C172 L1 (R), L2 (S), L3 (T),
,
⊕1, T1 (U), T2 (V), T3 (W) M12 300-400 150-200
◆4-2/0 22-60
l 1 (r), l 2( s ) M4 14 - 10 2 - 5.5
51600F C200 L1 (R), L2 (S), L3 (T),
,
⊕1, T1 (U), T2 (V), T3 (W) M12 350-400 180-200
◆3-2/0 30-60
l 1 (r), l 2( s ) M4 14 - 10 2 - 5.5
Section C. 600V
NEW DRIVE OLD DRIVE
TERMINAL
WIRE SIZE
MODEL NO. MODEL NO. TERMINAL SYMBOL
CIMR-G5M GPD515C– SCREW AWG mm2
◆Indicates terminal uses a pressure lug.
* Consult local electrical codes for wire sizing requirements.
Table 1-1. Typical Wire Sizing For Main Circuit - Continued*

SECTION A. 230V
TERMINAL FUNCTION
1 HP 3 TO 40 HP
L1 (R) Three phase Main circuit input power supply
L2 (S) 200 / 208 / 220V at 50 Hz; 200 / 208 / 220 / 230V at 60 Hz
L3 (T)
T1 (U) Three phase AC output to motor
T2 (V) 0V to max. input voltage level
T3 (W)
B1
B2 DB Resistor terminals (B1 & B2) – – – – – –
⊕1 DC Reactor terminals (⊕1 & ⊕2)
⊕2 DC Bus terminals (⊕1 & ) – – – – – –
⊕3 – – – – – – DB Unit terminals (⊕3 & )
l 1(r) Power for heat sink fan:
l 2( s ) – – – – – – l 1to l 2: 230 VAC
Ground terminal (100 ohms or less)
SECTION B. 460V
TERMINAL FUNCTION 1 TO 60 HP
L1 (R) Three phase Main circuit input power supply
L2 (S) 380 / 400 / 415 / 460V at 50/60 Hz
L3 (T)
T1 (U) Three phase AC output to motor
T2 (V) 0V to max. input voltage level
T3 (W)
B1
B2 DB Resistor terminals (B1 & B2) – – – – – –
⊕1 DC Reactor terminals (⊕1 & ⊕2)
⊕2 DC Bus terminals (⊕1 & ) – – – – – –
⊕3 – – – – – – DB Unit terminals (⊕3 & )
l 1(r) Power for heat sink fan: Power for heat sink fan:
l 2( s ) l 1to l 2: 230 VAC l 1to l 2200: 230 Vac
l 2200 ( s 200) – – – – – – l 1to l 2400: 460 Vac
l 2400 ( s 400) – – – – – –
Ground terminal
SECTION A. 230V
FUNCTION
New Model No. 20P41F - 20111F - 20151F 20181F 20300F - 20750F
TERMINAL CIMR-G5M 27P51F 20221F
Old Model No. A003 - A033 A049 - A064 A080, - A130 - A300
GPD515C- A096
1-6
Table 1-2. Terminal Functions and Voltages of Main Circuit
– – – – – indicates that terminals are not present.
SECTION B. 460V
FUNCTION
New Model No. 40P41F - 40151F 40181F - 40451F 40551F - 43000F
TERMINAL CIMR-G5M
Old Model No. B001 - B034 B041 - B096 B128 - B605
GPD515C-

L1 (R) Three phase Main circuit input power supply
L2 (S) 500 / 575 / 600V at 50 Hz / 60HZ
L3 (T)
T1 (U) Three phase AC output to motor
T2 (V) 0V to max. input voltage level
T3 (W)
B1
B2 DB Resistor terminals (B1 & B2)
⊕1
⊕2
l 1(r) Power for heat sink fan:
l 2( s ) l 1to l 2: 600 VAC
DB Units terminals (⊕1 & ) (C041 to C200 only)
DC Bus terminals (⊕1 & )
DC Reactor terminals (⊕1 & ⊕2)
DC Bus terminals (⊕1 & )
Ground terminal (100 ohms or less)
SECTION C. 600V
FUNCTION
New Model No. 51P51F - 50151F 50181F - 50221F 50301F - 51600F
TERMINAL CIMR-G5M
Old Model No. C003 - C022 C027 - C032 C041 - C200
GPD515C-
1-7
Table 1-2. Terminal Functions and Voltages of Main Circuit

Main Circuit Configuration Block Diagrams 230V
CIMR-G5M20P41F to 27P51F
GPD515C-A003 to -A033
CIMR-G5M20111F to 20151F
GPD515C-A049 to -A064
CIMR-G5M20181F, 20221F
GPD515C-A080, -A096
CIMR-G5M20300F to 20750F
GPD515C-A130 to -A300
1-8
+
1
+
2
_
L1 (R)
L2 (S)
L3 (T)
+
Power
Supply
Control
Circuit
Cooling Fan
(A011 to A033 only)
(RCC)
U (T1)
V (T2)
W (T3)
B1
B2
(DCL
Option)
+1
+2
_
L1 (R)
L2 (S)
L3 (T)
+
Power
Supply
Control
Circuit
Cooling Fan
(RCC)
U (T1)
V (T2)
W (T3)
(DCL
Option)
+3
_
L1 (R)
L2 (S)
L3 (T)
+
Power
Supply
Control
Circuit
Internal
Cooling Fan
(RCC)
U (T1)
V (T2)
W (T3)
+3
Cooling Fan
+2
+1
_
L1 (R)
L2 (S)
L3 (T)
+
Power
Supply
Control
Circuit
Internal
Cooling Fan
(RCC)
U (T1)
V (T2)
W (T3)
+3
Cooling Fan
When using DC input as main circuit
power, connect 230Vac to control power
transformer terminals l(r) and l(s).
When using DC input as main circuit
power, connect 230Vac to control power
transformer terminals l(r) and l(s).

1-9
Main Circuit Configuration Block Diagrams 460V
CIMR-G5M40P41F to 40151F
GPD515C- B001 to - B034
CIMR-G5M40181F to 40451F
GPD515C- B041 to - B096
CIMR-G5M40551F to 41600F
GPD515C- B128 to - B302
CIMR-G5M41850F to 43000F
GPD515C- B340 to - B605
_
L1 (R)
L2 (S)
L3 (T)
+
Power
Supply
Control
Circuit
Internal
Cooling Fan
(RCC)
U (T1)
V (T2)
W (T3)
+3
Cooling Fan
+2
+1
+
1
+
2
_
L1 (R)
L2 (S)
L3 (T)
+
Power
Supply
Control
Circuit
Cooling Fan
(B008 to B034 only)
(RCC)
U (T1)
V (T2)
W (T3)
B1
B2
(DCL
Option)
_
L1 (R)
L2 (S)
L3 (T)
+
Power
Supply
Control
Circuit
Internal
Cooling Fan
(RCC)
U (T1)
V (T2)
W (T3)
+3
Cooling Fan
_
L1 (R)
L2 (S)
L3 (T)
+
Power
Supply
Control
Circuit
(RCC)
U (T1)
V (T2)
W (T3)
+3
Cooling Fan
+1
When using DC input as main circuit
power, connect 460Vac to control power
transformer terminals l1(r) and l2(s).
When using DC input as main circuit
power, connect 460Vac to control
power transformer terminals l1(r) and
l2400 (s400).
When using DC input as main
circuit power, connect 460Vac to
control power transformer
terminals l1(r) and l2400 (s400).