Yaskawa Di-a3 User manual

MANUAL NO. TOBP C730600 39A

形式 DI-A3

取扱説明書

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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 Input

YASKAWA AC Drive-Option Card

Type DI-A3

This Page Intentionally Blank

YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual 3

Table of Contents

1 PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2 PRODUCT OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 OPTION CARD COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 8

4 ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 9

5 RELATED PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

7 SPECIFICATIONS & WARRANTY INFORMATION . . . . . . . 22

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.

4 YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual

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, 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

This instruction manual has been written for the items listed below. Use this option card for

its intended purpose only.

Option Card

YASKAWA AC Drive-Option Card

Digital Input DI-A3 Installation Manual (this book)

Document No. TOBP C730600 39

Read this manual first.

It contains information required to install the option card and set up related drive

parameters.

Drive

Refer to the manual of the drive this option card is being used with.

The manual for the drive covers basic installation, wiring, operation procedures,

functions, troubleshooting, and maintenance information.

It also includes important information on parameter settings and how to tune the drive.

To obtain instruction manuals for Yaskawa products access these sites:

Europe: http://www.yaskawa.eu.com

Japan: http://www.e-mechatronics.com

Other areas: contact a Yaskawa representative.

1 Preface

YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual 5

◆Registered Trademarks

• Company names and product names listed in this manual are the registered trademarks of

those companies.

◆Supplemental Safety Information

Read and understand this manual before installing, operating or servicing this option unit.

The option unit 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.

CAUTION

Indicates a hazardous situation, which, if not avoided, could result in minor or moderate

injury.

NOTICE

Indicates an equipment damage message.

1 Preface

6YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual

■General Safety

General Precautions

• The diagrams in this section may include option units and drives without covers or safety shields to

illustrate details. Be sure to reinstall covers or shields before operating any devices. The option

board should be used 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.

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 expose the drive to halogen group disinfectants.

Failure to comply may cause damage to the electrical components in the option unit

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 C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual 7

2 Product Overview

◆Regarding this Product

Using this option card the drive's frequency reference can be set using binary coded digital

inputs.

◆Checking Package Contents

Table 1 Items Included with this Option Card

• Inspect the Option Card for damage. If the Option Card appears damaged upon receipt,

contact the shipper immediately.

• Verify receipt of the correct model by checking the model number printed on the Name

plate of the Option Card. (see Figure 1)

• If you have received the wrong model or the Option Card does not function properly,

contact your supplier.

◆Tools Required for Installation

A Phillips screwdriver PH1 (#1) is needed to install this option card.

Additionally a straight-edge screwdriver (blade depth: 0.4 mm, width: 2.5 mm) will be

needed to wire the terminal block.

Note: Other tools are required for preparing cables.

Package

Contents Option Card Lead Lines

(for grounding) Screws (M3) Manual (this book)

–

Number of

Items 1331

MANUAL

8 YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual

3 Option Card Components

◆Option Card

Figure 1

Figure 1 Option Card

◆Terminal Block

Figure 2

Figure 2 Terminal Block

A – Terminal block TB1 E – Model number

B – Ground terminal (installation hole) F – Installation hole

C – Terminal block TB2 G – Connector (CN-5)

D – Terminal block TB3

DI-A3

Underside

FESDSNSCSPSESI

D7D6D5D4D3D2D1D0

DFDEDDDCDBDAD9D8

TB3

TB2

TB1

YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual 9

4 Electrical Installation

◆Safety Messages

DANGER

Electric Shock Hazard

Power to the drive must be shut off when installing this option card.

Even though the power has been shut off, voltage still remains in the drive’s DC bus. Wait

before removing the front cover once the drive has been turned off.

The CHARGE light on the drive will go out after voltage in the DC bus drops below 50 V,

at which point it is safe to remove the front cover.

Due to the risk of electric shock, be sure that all LEDs have gone out and that the DC bus

voltage has reached a safe level prior to performing any work on the drive.

WARNING

Electrical Shock Hazard

Do not allow unqualified personnel to perform work on the drive.

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 and Option

Cards.

4 Electrical Installation

10 YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual

NOTICE

Damage to Equipment

Observe proper electrostatic discharge procedures (ESD) when handling the option

unit, drive, and circuit boards.

Failure to comply may result in ESD damage to circuitry.

Never shut the power off while the drive is 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.

Properly connect all pins and connectors.

Failure to comply may prevent proper operation and possibly damage equipment.

4 Electrical Installation

YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual 11

◆Installing the Option Card

Insert the option card in the CN5-A connectors located on the drive’s control board.

See the drive manual for directions on removing the front cover.

1. Shut off power to the drive, wait the appropriate amount of time for voltage to

dissipate, then remove the operator and front cover.

2. Insert the CN5 connector on the option card into the matching CN5 connector on

the drive, then fasten it into place using one of the screws included with the option

card.

Connect one of the lead lines using one of the screws to the ground terminal.

Note: There are only two screw holes on the drive for ground terminals. If three option cards are

connected, two of the lead lines will need to share the same ground terminal.

Figure 3

Figure 3 Installing the Option Card

A – Connector CN5-C G – Mounting screw

B – Connector CN5-B H – Lead line

C – Connector CN5-A I – Use wire cutters to create an

opening for cable lines

D – Drive grounding terminal (FE) J – Front cover

E – Insert connector CN5 here K – Digital operator

F – Option card L – Terminal cover

EFG

4 Electrical Installation

12 YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual

3. Wire the option card to the terminal block on the option card.

For wiring instructions, see Connection Diagram on page 13.

In the drives CIMR-A2A0004 to 0040, 4A0002 to 0023 the cable might need to be

routed through the top cover to the outside. In this case cut out the perforated

openings at the left side of the drive top cover. Make sure no sharp edges that can

damage the cable remain.

In the drives CIMR-A2A0056 to 0211, 4A0031 to 0165 the cable can be routed

inside the drive.

Figure 4

Figure 4 Wiring space

4. Place the front cover back onto the drive.

Note: 1. Take care when wiring the option card so that the front cover easily fits back onto the drive. Make sure

a cable is not caught between the front cover and the drive when putting the cover back on.

2. The drive will not be used as NEMA Type1 if there is any exposed wiring outside the enclosure.

A – Wires should pass through the

access hold provided on the left

side of the front cover.

(CIMR-A2A0004 to 0040, 4A0002

to 0023)

B – Use the open space provided

inside the drive to route option

card wiring.

(CIMR-A2A0056 to 0211, 4A0031

to 0165)

4 Electrical Installation

YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual 13

◆Connection Diagram

Wire terminals on the option card as illustrated in Figure 5.

Refer to Terminal Functions on page 15 for the different functions that can be assigned to

the terminals.

Figure 5

Figure 5 Wiring the Option Card and Drive

Take the following steps to prevent erroneous operation caused by noise interference:

• Use shielded wire for the signal lines.

• Keep wiring under 50 m.

• Make sure that control lines to the option card, main circuit wiring, and power lines are

separated from one another.

Internal power

Supply wiring

SINK mode

TB2

TB3

TB1

Drive

R/L1

T/L2

S/L3

Lead line

CN5

DI-A3

shielded line

main circuit terminal control circuit terminal

4 Electrical Installation

14 YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual

SINK Mode

• To use the drive’s internal powers supply, short circuit terminals SP and SC.

• To use an external power supply, connect the positive lead from the power supply to

terminal SC on the option card. Do not connect the negative lead to terminal SN on the

option card.

SOURCE Mode

• To use the drive’s internal powers supply, short circuit terminals SN and SC.

• To use an external power supply, connect the negative lead from the power supply to

terminal SC on the option card. Do not connect the positive lead to terminal SP.

䋫

Internal power supply wiring

Photocoupler

Signal

processor

External power supply wiring

External

power supply

24 Vdc

Signal

processor

360㩷Ω

3.3㫂Ω

0 V

24 V

360 Ω

㪊㪅㪊㫂Ω

0 V

24 V

D0〜DF,SI,SE

䋫

Photocoupler

External

24 Vdc

Internal power supply wiring

External power supply wiring

Signal

processor

D0〜DF,SI,SE

360 Ω

3.3㫂Ω

0 V

24㩷㪭

360 Ω

3.3㫂Ω

0 V

24 V

Signal

processor

4 Electrical Installation

YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual 15

◆Terminal Functions

Table 2 Terminal Function Selection

Termin

Block

Termin

BCD, Signed BCD,

Unsigned Binary, Signed

F3-01 = 0 to 5 F3-01 = 6 <1> F3-01 = 7

8 bit 12 bit 16 bit 16 bit 8 bit 12 bit 16 bit

F3-03 = 0 F3-03 = 1 F3-03 = 2 F3-03

= 0

F3-03

= 1

F3-03

= 2

TB2

<1> The setting F3-01 = 6 is enabled only when F3-03 = 2. Once enabled, the frequency reference can be set from 0.00

to 399.8 Hz with a BCD signal. Because the signed bit SI is also used, a negative reference cannot be input. The

smallest bit of the first digit starts with 2, so that 0.02 Hz is the smallest unit that can be used for the frequency

reference setting.

1 digit

(0 to 9)

1 digit

(0 to 9)

1 digits

(0 to 9)

1 digit

(0 to 9)

2 bit 0 bit 0 bit 0

D1 2 2 2 4 bit 1 bit 1 bit 1

D2 4 4 4 8 bit 2 bit 2 bit 2

D3 8 8 8

2 digits

(0 to 9)

1 bit 3 bit 3 bit 3

2 digits

(0 to

15)

2 digits

(0 to

15)

2 digits

(0 to 9)

1 2 bit 4 bit 4 bit 4

D5 2 2 2 4 bit 5 bit 5 bit 5

D6 4 4 4 8 bit 6 bit 6 bit 6

D7 8 8 8

3 digits

(0 to 9)

1 bit 7 bit 7 bit 7

TB3

–

3 digits

(0 to

15)

3 digits

(0 to 9)

1 2 – bit 8 bit 8

D9–224–bit9bit9

DA – 4 4 8 – bit 10 bit 10

DB – 8 8

4 digits

(0 to 9)

1 – bit 11 bit 11

–

4 digits

(0 to

15)

1 2 – – bit 12

DD – – 2 4 – – bit 13

DE – – 4 8 – – bit 14

DF – – 8 5 digits

(0 to 3)

1 – – bit 15

TB1

SI Signed

0: Forward 1: Reverse 2Signed

0: Forward 1: Reverse

SE Set (Read) signal

1: Reads values set to D0 to DF, SI

SP 24 V ±5% internal power supply

SC Input signal common

SN Internal power supply common: 0 V

SD Cable shield 2 (open)

FE Shield ground

4 Electrical Installation

16 YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual

◆Input Timing

In order to activate the reference value set by the digital input as frequency reference the

controller has to activate the SET input using the timing illustrated in Figure 6. The

controller should switch off the SET signal and wait at least 1 ms before the changing digital

inputs. After changing the inputs it should wait at least 1 ms before enabling the SET signal.

The SET signal should be activated for at least 3 ms.

Figure 6

Figure 6 SET Input Timing

D0㨪DF

SIGN data

SET input timing

1 ms min. 3 ms min.

(SET is switched on)

Setting value change Setting value change

1 ms min.

Reads setting

4 Electrical Installation

YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual 17

◆Wire Gauges and Tightening Torque

Wire gauge specifications are listed below in Table 3.

Yaskawa recommends using crimp terminals for easy of wiring and to ensure proper

connection. Crimp terminal specifications can be found in Table 4.

Table 3 Wire Gauges and Tightening Torque

■Crimp Terminals

Yaskawa recommends using CRIMPFOX ZA-3 by Phoenix Contact to crimp the terminal

ends.

Note: Wire ends should be properly trimmed so no wire extends out from the crimp terminals.

Table 4 Crimp Terminal Sizes

Terminal

Signal

Screw

Size

Tightening

Torque

(Nxm)

Bare Cable Wiring Gauges with

Crimp Terminals

Wire Type

Possible

Gauges

mm2

(AWG)

Recom

mended

Gauges

mm2

(AWG)

Possible

Gauges

mm2

(AWG)

Recom

mended

Gauges

mm2

(AWG)

D0 to DF,

SI,SE,SP,

SC,SN,FE

M2 0.22 to 0.25

Stranded wire:

0.25 to 1.0

(24 to 17)

Single line:

0.25 to 1.5

(24 to 16)

0.75

(18)

0.25 to 0.5

(24 to 20)

0.5

(20)

Shielded

twisted pair,

etc.

Wire Gauge

mm2

(AWG)

Model L

(mm)

(mm) Manufacturer

0.25 (24) AI 0.25 - 6YE 10.5 0.8 2

Phoenix Contact0.34 (22) AI 0.34 - 6TQ 10.5 0.8 2

0.5 (20) AI 0.5 - 6WH 14 1.1 2.5

d1 d2

6 mm

4 Electrical Installation

18 YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual

◆Wiring Procedure

When wiring the option card, wire ends should be prepared as shown in Figure 7. See Wire

Gauges and Tightening Torque on page 17 to make sure the proper tightening torque is

applied to each terminal end.

Take particular precautions to ensure that each cable is properly connected, and that wire

insulation has not been accidentally inserted into the terminals.

NOTICE: Insulation or tape may be required to ensure that shielded lines do not come into contact with

other wiring. Insufficient insulation may cause a short circuit that can damage the option card and the drive.

NOTICE: Follow the tightening torque specifications in this manual for all terminal screws. Failing to do so

may keep the drive from functioning properly and could damage the terminal block.

Figure 7

Figure 7 Treating Terminal Ends for Shielded Line

Figure 8

Figure 8 Terminal Block Wiring

Insulation

Shield shearth (Insulate with tape)

Shield

Option Card PG

FE/SD

Insulation

Shield sheath (Insulate with tape)

Shield

Option Card External device

FE/SD

Blade depth of

0.4 mm or less

Avoid fraying wire stands

when stripping insulation

from wire.

Blade width of

2.5 mm or less

Strip length 5.5 mm

Terminal

block

Loosen screw to

insert wire.

Single wire or

stranded wire

YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual 19

5 Related Parameters

The following parameters are used to set up the drive for operation with an option card.

Set parameters as needed. Instructions on how to set parameters can be found in the

instruction manual for the drive the option card is connected to.

Table 5 Related Parameters

No.

<1> Binary input is not possible if o1-03 is set to 2 or 3. The setting of F3-01 will be disregarded and setting units

will be determined by o1-03.

<1>

Parameter Name Description Setting

Range Default

F3-01

<1>

Option Card Input

Selection

Selects the method to input the option card data.

0: BCD 1% unit

1: BCD 0.1% unit

2: BCD 0.01% unit

3: BCD 1 Hz unit

4: BCD 0.1Hz unit

5: BCD 0.01Hz unit

6: BCD custom setting (5 digit input), 0.02 Hz units

7: Binary input

0 to 7 0

F3-03 Data Length

Selection

0: 8 bit

1: 12 bit

2: 16 bit

0 to 2 2

20 YASKAWA ELECTRIC TOBP C730600 39A YASKAWA AC Drive-Option Card DI-A3 Installation Manual

6 Troubleshooting

◆Error Codes Displayed on the Drive Operator

The table below lists the various fault codes related to this option card.

Further detail on various faults can be found in the instruction manual for the drive.

• Check all cables connected to the option card.

• Make sure the option card is properly installed to the drive.

Table 6 Fault Display