YASKAWA VS-616G5 Series User manual

2
PREFACE
YASKAWA’s VS−616G5 is a user−friendly inverter provided with vector control for
standard models in addition to V/f control. This instruction manual describes
installation, maintenance and inspection, troubleshooting, and specifications of the
VS−616G5. Read this instruction manual thoroughly before operation.
YASKAWA ELECTRIC CORPORATION
General Precautions
SSome drawings in this manual are shown with the protective cover or shields removed, in order to
describe detail with more clarity. Make sure all covers and shields are replaced before operating
this product.
SThis manual may be modified when necessary because of improvement of the product, modifica-
tion, or changes in specifications.
Such modifications are denoted by a revised manual No.
STo order a copy of this manual, if your copy has been damaged or lost, contact your YASKAWA
representative.
SYASKAWA is not responsible for any modification of the product made by the user, since that will
void your guarantee.

NOTE
NOTES FOR SAFE OPERATION
Read this instruction manual thoroughly before installation, operation, maintenance or inspection of
the VS−616G5. In this manual, NOTES FOR SAFE OPERATION are classified as ”WARNING” or
”CAUTION”.
WARNING
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury
to personnel.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate inju-
ry to personnel and damage to equipment.
It may also be used to alert against unsafe practices.
Even items described in CAUTION may result in a vital accident in some situations. In either
case, follow these important notes.
: These are steps to be taken to insure proper operation.
RECEIVING
CAUTION
(Ref. page)
SDo not install or operate any inverter which is damaged or has missing
parts.
Failure to observe this caution may result in personal injury or equipment damage. 10
NOTES FOR SAFE OPERATION
3

4
INSTALLATION
CAUTION
(Ref. page)
SLift the cabinet by the base. When moving the unit, never lift by the front
cover.
Otherwise, the main unit may be dropped causing damage to the unit. 12..........
SMount the inverter on nonflammable material (i.e. metal).
Failure to observe this caution can result in a fire. 12............................
SWhen mounting units in an enclosure, install a fan or other cooling device
to keep the intake air temperature below 45_C.
Overheating may cause a fire or damage to the unit. 12........................
WIRING
WARNING
(Ref. page)
SOnlycommencewiringafterverifyingthatthepowersupplyisturnedOFF.
Failure to observe this warning can result in an electrical shock or a fire. 17........
SWiring should be performed only by qualified personnel.
Failure to observe this warning can result in an electrical shock or a fire. 17........
SWhen wiring the emergency stop circuit, check the wiring thoroughly
before operation.
Failure to observe this warning can result in personal injury. 17.................
SMake sure to ground the ground terminal before connecting the other
terminals.
Failure to observe this warning can result in an electrical shock. 21..............

NOTES FOR SAFE OPERATION
5
CAUTION
(Ref. page)
SVerify that the inverter rated voltage coincides with the AC power supply
voltage.
Failure to observe this caution can result in personal injury or a fire. 17...........
SDo not perform a withstand voltage test of the inverter.
It may cause semi−conductor elements to be damaged. 17......................
STo connect a braking resistor, braking resistor unit or braking unit, follow
the procedures described in APPENDIX 3.
Improper connection may cause a fire. 17..................................
STighten terminal screws to the specified tightening torque.
Failure to observe this caution can result in a fire. 17..........................
SNever connect the AC main circuit power supply to output terminals U, V
and W.
The inverter will be damaged and invalidate the guarantee. 21.................

6
OPERATION
WARNING
(Ref. page)
SOnlyturn ON theinputpower supply afterreplacing the front cover. Do not
remove the cover while current is flowing.
Failure to observe this warning can result in an electrical shock. 35..............
SWhen the retry function (L5−02) is selected, do not approach the inverter
or the load, since it may restart suddenly after being stopped.
(Construct machine system, so as to assure safety for personnel, even if the
inverter should restart.)
Failure to observe this warning can result in personal injury. 35.................
SSince the stop button can be disabled by a function setting, install a sepa-
rate emergency stop switch.
Failure to observe this warning can result in personal injury. 35.................
SIf an alarm is reset with the operation signal ON, the inverter restarts auto-
matically. Only reset the alarm after verifying that the operation signal is
OFF.
Failure to observe this warning can result in personal injury. 35.................
CAUTION
(Ref. page)
SNever touch the heatsink or discharging resistor since the temperature is
very high.
Failure to observe this caution can result in harmful burns to the body. 35.........
SSince it is easy to change operation speed from low to high speed, verify
the safe working range of the motor and machine before operation.
Failure to observe this caution can result in personal injury and machine damage. 35..
SInstall a holding brake separately if necessary.
Failure to observe this caution can result in personal injury. 35..................
SDo not change signals during operation.
The machine or the inverter may be damaged. 35.............................
SAll the constants of the inverter have been preset at the factory. Do not
change the settings unnecessarily.
The inverter may be damaged. 35........................................

NOTES FOR SAFE OPERATION
7
MAINTENANCE AND INSPECTION
WARNING
(Ref. page)
SNever touch high−voltage terminals in the inverter.
Failure to observe this warning can result in an electrical shock. 60..............
SReplace all protective covers before powering up the inverter. To remove
the cover, make sure to disconnect supply mains.
Failure to observe this warning can result in an electrical shock. 60..............
SPerform maintenance or inspection only after verifying that the CHARGE
LED goes OFF, after the main circuit power supply is turned OFF.
The capacitors are still charged and can be dangerous. 60......................
SOnly authorized personnel should be permitted to perform maintenance,
inspections or parts replacement.
[Remove all metal objects (watches, bracelets, etc.) before operation.]
(Use tools which are insulated against electrical shock.)
Failure to observe this warning can result in an electrical shock. 60..............
CAUTION
(Ref. page)
SThe control PC board employs CMOS ICs. Do not touch the CMOS ele-
ments.
They are easily damaged by static electricity. 60.............................
SDo not connect or disconnect wires or connectors while power is applied
to the circuit.
Failure to observe this caution can result in personal injury. 60..................
SWhen removing the wiring, remove the ground wire last.
60....................................................................
OTHERS
WARNING
SNever modify the product.
Failure to observe this warning can result in an electrical shock or personal injury and will invali-
date the guarantee.

8
WARNING LABEL
A warning label is displayed on the front cover of the inverter, as shown below. Follow these instruc-
tions when handling the inverter.
Warning Label
Model CIMR−G5C51P5
Warning Label
WARNING
May cause injury or electric shock.
SPlease follow the instructions in the manual before
installation or operation.
SDisconnect all power before opening front cover of unit.
Wait 5 minutes until DC Bus capacitors discharge.
SUse proper grounding techniques.
AVERTISSMENT
Risque de blessure ou décharge électrique.
SFaites attention au mode d’emploi avant d’installer et
mettre en marche.
SDébranchez le courant avant d’ouvrir la couverture
d’avant. Attendez 5 minutes jusqu’à les condensateurs de
DC Bus sont déchargés.
SSoyez à la masse Par une bonne technique.

9
CONTENTS
NOTES FOR SAFE OPERATION 3.......................................
1 RECEIVING 10......................................................
1.1 INSPECTION CHECKPOINTS 10.............................................
1.2 IDENTIFYING THE PARTS 11................................................
2 INSTALLATION 12...................................................
2.1 REMOVING AND REPLACING THE DIGITAL OPERATOR 12....................
2.2 REMOVING AND REPLACING THE FRONT COVER 14.........................
2.3 CHOOSING A LOCATION TO MOUNT THE INVERTER 15......................
2.4 CLEARANCES 16...........................................................
3 WIRING 17.........................................................
3.1 CONNECTION DIAGRAM 18.................................................
3.2 WIRING THE MAIN CIRCUIT 21..............................................
3.3 WIRING THE CONTROL CIRCUIT 30.........................................
3.4 CONFORMATION TO EMC STANDARDS 32...................................
3.5 WIRING INSPECTION 34....................................................
4 OPERATION 35.....................................................
4.1 OPERATION MODE SELECTION 36..........................................
4.2 TEST RUN CHECKPOINTS 37...............................................
4.3 TEST RUN 38..............................................................
5 SETTING OPERATION CONDITIONS 44...............................
5.1 DIGITAL OPERATOR KEY DESCRIPTION 44..................................
5.2 DIGITAL OPERATOR MODE SELECTION 45...................................
5.3 OPERATION MODE 47......................................................
5.4 INITIALIZE MODE 51........................................................
5.5 PROGRAMMING MODE 53..................................................
5.6 MODIFIED CONSTANTS MODE 57...........................................
5.7 MEMOBUS CONTROL 58....................................................
6 MAINTENANCE AND INSPECTION 60.................................
6.1 PERIODIC INSPECTION 61..................................................
6.2 PARTS REPLACEMENT SCHEDULE (GUIDELINES) 61.........................
7 TROUBLESHOOTING 62............................................
7.1 FAULT DIAGNOSIS AND CORRECTIVE ACTIONS 62...........................
7.2 MOTOR FAULTS AND CORRECTIVE ACTIONS 67.............................
APPENDIX 1 SPECIFICATIONS 68.....................................
APPENDIX 2 DIMENSIONS (mm) 70....................................
APPENDIX 3 TYPICAL CONNECTION DIAGRAM 71......................
3.1 BRAKING RESISTOR UNIT 71..............................................
3.2 VS OPERATOR MODELS JVOP−95 AND JVOP−96 72.........................
3.3 SEQUENCE INPUT AND OUTPUT CONNECTION WITH NPN
TRANSISTOR (0V COMMON) 73............................................
3.4 SEQUENCE INPUT AND OUTPUT CONNECTION WITH PNP
TRANSISTOR (SUPPLY SIDE COMMON) 74..................................
APPENDIX 4 CONSTANTS LIST 75.....................................

10
1 RECEIVING
CAUTION
SDo not install or operate any inverter which is damaged or has missing parts.
Failure to observe this caution may result in personal injury or equipment damage.
This chapter describes how to verify the inverter after delivery to the user.
1.1 INSPECTION CHECKPOINTS
(1) Receiving Checkpoints
Table 1 Checkpoints
Checkpoints Description
Does the inverter model number correspond with
the purchase order?
Check the model number on the nameplate on the side of the
VS-616G5. (Refer to page 11.)
Are any parts damaged? Visually check the exterior and verify that there was no damage during
transport.
Is hardware properly seated and securely tightened? Remove inverter front cover.
Check all visible hardware with appropriate tools.
Was an instruction manual received? VS-616G5 Instruction manual (No.: TOE-S616-10.13)
VS-616G5 Descriptive manual for constants (No.: TOEZ-S616-10.11)
If any of the above checkpoints are not satisfactory, contact your YASKAWA representative.
(2) Checking the Nameplate Data
(a) Nameplate Data
Example of European model CIMR−G5C51P5
Inverter Model
INPUT :AC 3PH 500−600 V50/60Hz 4.3A
MODEL :CIMR−G5C51P5 SPEC :51P51A
OUTPUT :AC3PH 0−600 V0−400Hz
SER NO :
Input Spec.
Lot No.
Inverter Spec.
Output Spec.
Mass
Serial No.
VARIABLE TORQUE CONT. 3.9 A PRG:
CONSTANT TORQUE CONT.3.5 AMASS: 4.0kg
Prg. No.
YASKAWA ELECTRIC CORPORATION E131457 MS UL File No.
LOT NO :
Fig. 1Nameplate Data

1 RECEIVING
11
(b) Model Designation
Voltage
53−phase 575 V class
CIMR −G5 C 5 1P5
Inverter
VS −616G5 Series
Symbol Max. applicable motor output
1P5 1.5 kW
2P2
to
015
2.2 kW
to
15 kW
Symbol
Symbol
C
Specifications
Europe use
Fig. 2Model Designation
(c) Specification Designation
5 1P5 1 A *
Revision symbol
* For special specifications, a spec. sheet No. appears on the nameplate.
Symbol Enclosure
Enclosed wall−mounted
type (IP20)
0 Open chassis type
1
Voltage
53−phase 575 V class
Symbol
Symbol Max. applicable motor output
1P5 1.5 kW
2P2
to
015
2.2 kW
to
15 kW
Fig. 3Specification Designation
1.2 IDENTIFYING THE PARTS
4−Mounting Holes
Protective Cover (top/bottom)
Digital Operator
JVOP−130
Front Cover
Heatsink
Nameplate
Ventilation Slots
Fig. 4Configuration of VS−616G5 (Model CIMR−G5C51P5)

12
2 INSTALLATION
CAUTION
SLift the cabinet by the base. When moving the unit, never lift by the front cover.
Otherwise, the main unit may be dropped causing damage to the unit.
SMount the inverter on nonflammable material (i.e. metal).
Failure to observe this caution can result in a fire.
SWhen mounting units in an enclosure, install a fan or other cooling device to keep the in-
take air temperature below 45_C.
Overheating may cause a fire or damage to the unit.
This chapter describes the configuration, location and space when mounting the VS−616G5.
2.1 REMOVING AND REPLACING THE DIGITAL OPERATOR
Remove and replace the digital operator as follows.
(1) Removing the Digital Operator
Digital Operator 1
2
Push the digital operator lever in the
direction shown by arrow 1 and lift the
digital operator in the direction
shown by arrow 2 to remove the digi-
tal operator from the front cover.
Front Cover
Fig. 5Removing the Digital Operator

2INSTALLATION
13
(2) Replacing the Digital Operator
Engage the digital operator on claws
A in the direction shown by arrow 1
and then on claws B in the direction
shown by arrow 2 to lock the digital
operator.
Digital Operator
Front Cover
2
1
Claws A
Claws B
Fig. 6Replacing the Digital Operator
Never fit the digital operator in any other direction or by any other method.
The digital operator will not be connected to the inverter.
NOTE

14
2.2 REMOVING AND REPLACING THE FRONT COVER
To remove the front cover, first move the digital operator in the direction shown by arrow 1. (See Par.
2.1.) Then squeeze the cover in the direction shown by arrows 2 on both sides and lift in the direction
shown by arrow 3.
Front Cover
1
2
3
2
Fig. 7Removing and Replacing the Front Cover
Do not replace the front cover with the digital operator connected. The digital operator will not
be connected to the inverter. Replace the front cover first and then install the digital operator
on the cover. See Par. 2.1 for replacing the digital operator.
NOTE

2INSTALLATION
15
2.3 CHOOSING ALOCATION TOMOUNT THE INVERTER
To ensure proper performance and long operating life, follow the recommendations below when
choosing a location for installing the VS−616G5. Make sure the inverter is protected from the
following conditions:
VExtreme cold and heat.
Use only within ambient temperature range: −10_C to +40_C
VRain, moisture.
VOil sprays, splashes
VSalt spray.
VDirect sunlight. (Avoid using outdoors.)
VCorrosive gases or liquids.
VDust or metallic particles in the air. (For enclosed wall−mounted type)
VPhysical shock, vibration.
VMagnetic noise. (Example: welding machines, power devices, etc.)
VHigh humidity.
VRadioactive materials.
VCombustibles: thinners, solvents, etc.
Climatic condition for temperature, humidity and air pressure should be 3K3 (prEN50178).

16
2.4 CLEARANCES
Install the VS−616G5 vertically and allow sufficient clearances for effective cooling as shown in Fig.
8.
(a) Front View
50 mm or more
*
30 mm or more
50 mm or more
*
(b) Side View
120 mm or more
120 mm or more
Air
Air
30 mm or more
Fig. 8Clearances
1. The clearances required at top/bottom and both sides are common in open chassis type
(IP00) and enclosed wall−mounted type (IP20).
2. Remove the top and bottom covers to use the open chassis type of 15 kW or less.
3. For the external dimensions and mounting dimensions, refer to APPENDIX 2 “DIMEN-
SIONS.”
4. Allowable intake air temperature to the inverter:
Open chassis type : −10_C to +45_C
Enclosed wall−mounted type : −10_C to +40_C
5. Ensure sufficient space for the sections at the upper and lower parts marked with ∗in order
to permit the flow of intake/exhaust air to/from the inverter.
NOTE

3 WIRING
17
3 WIRING
WARNING
SOnly commence wiring after verifying that the power supply is turned OFF.
Failure to observe this warning can result in an electrical shock or a fire.
SWiring should be performed only by qualified personnel.
Failure to observe this warning can result in an electrical shock or a fire.
SWhen wiring the emergency stop circuit, check the wiring thoroughly before operation.
Failure to observe this warning can result in personal injury.
CAUTION
SVerify that the inverter rated voltage coincides with the AC power supply voltage.
Failure to observe this caution can result in personal injury or a fire.
SDo not perform a withstand voltage test of the inverter.
It may cause semi−conductor elements to be damaged.
STo connect a braking resistor, braking resistor unit or braking unit, follow the procedures
described in APPENDIX 3.
Improper connection may cause a fire.
STighten terminal screws to the specified tightening torque.
Failure to observe this caution can result in a fire.
This chapter describes the main circuit wiring and the control circuit wiring of the VS−616G5.

18
3.1 CONNECTION DIAGRAM
Below is a connection diagram of the main circuit and control circuit. Using the digital operator, the
motor can be operated by wiring the main circuit only.
13 Master Freq. Ref.
−10 to +10V (20kΩ)
FM
©
VS−616G5
Braking Resistor Unit
(Option)
¨1¨2B1 B2
MCCB
3−Phase
Power Supply
500 to 600V
50/60 Hz
L1(R)
L2(S)
L3(T)
Factory
Setting
Forward
Run/Stop 1 Forward Run
when CLOSED
Reverse
Run/Stop 2 Reverse Run
when CLOSED
External
Fault 3
Fault Reset 4
Multi−step Speed Setting 1
(Master/Aux Change) 5
Multi−step Speed
Setting 2 6
Jog Reference 7
External
Baseblock 8
Multi−function
Contact Input
11 Sequence Common
Terminal (0V)
E Shield Sheath
Connecti
on
Terminal
Master
Frequency
Reference
2kΩ
15 Freq. Setting Power
Supply 15 V 20 mA
2kΩ
0 to +10 V
4to20mA P14 Master Freq. Ref.
4 to 20 mA (250Ω)
0 to +10 V P16 Multi−function Analog
Input −10 to +10V (20kΩ)
0V P
+
AM
17
0V
33
Frequency Setting
Power Supply
−15V 20 mA
U (T1)
V (T2)
W (T3)
Motor
IM
23
+
−
Multi−function Analog Output
−10 to +10 V
(Output Current at Factory
Setting, 5 V / Inverter Rated
Current)
21
22 −
Model CIMR−G5C57P5
Multi−function
Open Collector
Output
48 V 50 mA or
less
27
Opto−coupler Output 2
(Speed Agree Signal at
Factory Setting)
26
Opto−coupler Output 1
(Zero Speed Signal at
Factory Setting)
25
Multi−function Contact Output
250 VAC 1 A or less
30 VDC 1 A or less
(Signal during Running at
Factory Setting)
10
9
20
19 Fault Contact Output
Contact Capacity:
250 VAC 1A or less
30 VDC 1A or less
Analog
Monitor 1
18
Multi−function Analog Output
−10 to +10V
(Output Frequency at Factory
Setting, 0 to 10 V / 100% Fre-
quency)
Analog
Monitor 2
DC Reactor
(Option)
Short−circuit Bar
E
37
35
36 +24V
Serial Communication
RS−422/485
P
P
40
41
42
43
Line Filter
PE
L1
L2
L3
Fuse
2
3
1
Fig. 9Connection Diagram

3 WIRING
19
Circuit Descriptions
Refer to the numbers indicated in the diagram on the left.
1These circuits are hazardous and are separated from accessible surfaces by protective separation.
2These circuits are separated from all other circuits by protective separation consisting of double
and reinforced insulation. These circuits may be interconnected with SELV (or equivalent) or
non−SELV circuits, but not both.
3These circuits are not separated from hazardous circuits by protective separation, but only with
basic insulation. These circuits cannot be accessed and must not be interconnected with any
circuits which are accessible, unless they are isolated from accessible circuits by supplemental
insulation.
Layout of control circuit terminals
21 22 23 910
25 27 26
33 18 19 20
12345678
13 14 15 16 17
11 35 36 42 43
41
40
37 ª
ª
EE
NOTE

20
1. indicates shielded wires and indicates twisted−pair shielded wires.
2. Either control circuit terminal 13 or 14 can be used. (For simultaneous inputs, the two
signals are added internally.)
3. Control circuit terminal 15/33 of +15 V/−15 V has a maximum output current capacity
of 20 mA.
4. Multi−function analog output should be used for monitoring meters (e.g. output
frequency meter) and should not be used for feedback control system. Use analog monitor
cards (Model AO−08 or AO−12) for the control system, for a more accurate signal.
5. When using a braling resistor unit, set the constant L3−04 to “0” (stall prevention level
during decel is “disabled”). If it is not changed, the motor may not stop within the setdecel
time.
6. When using model ERF braking resistor (inverter−mounted type), set the braking resistor
protection selection to “enabled”. If it is not changed, the braking resistor cannot be pro-
tected.
7. When installing a DC reactor (optional for models of 15 kW or below), remove the short−
circuit bar between ¨1 and ¨2 terminals and connect a DC reactor with the terminals.
8. Select RS−422 or RS−485 of serial communication (terminals 40 to 43) by using the dip
switch on the control PC board. The terminal functions differ between RS−422 and
RS−485.
Table 2 Functions of RS−422 and RS−485
Terminal No. RS−422 RS−485
40 R+ Receiver R+/S+ Receiver/
41 R−
Receiver
R−/S−
Receiver/
Driver
42 S+ Driver R+/S+ Receiver/
43 S−
Driver
R−/S−
Receiver/
Driver
NOTE

3 WIRING
21
3.2 WIRING THE MAIN CIRCUIT
WARNING
SMake sure to ground the ground terminal before connecting other terminal.
Failure to observe this warning can result in an electrical shock or a fire.
CAUTION
SNever connect the AC main circuit power supply to output terminals U, V and W.
The inverter will be damaged and invalidate the guarantee.
(1) Wiring Precautions for Main Circuit Input
(a) Installation of Mains Fuses
An input fuse is not provided with VS−616G5. Make sure to connect fuses between the AC
main circuit power supply and VS−616G5 input terminals L1, L2 and L3 to protect the input
diode or cables.
SInput diode protection
A semiconductor protection fuse is recommended to protect the input diode when a
short−circuit occurs in the inverter. Table 3 shows the recommended fuse specifica-
tons. Another fuse can be applied if I2t is smaller than that in the table and rated current
is larger than inverter input current shown in the table.
SCable protection
General fuse can be applied for cable protection. Follow the local safety regulation
for selection. Select the fuse whose rated current is larger than the inverter input cur-
rent shown in Table 3.