YASKAWA VARISPEED-656RC5 Instruction Manual
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YASKAWA VARISPEED-656RC5 Instruction Manual

Power regenerative unit
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VARISPEED-656RC5
INSTRUCTION MANUAL
POWER REGENERATIVE UNIT (VS-656RC5)
MODEL :
CIMR-R5U
200V CLASS 3.7 to 37kW
400V CLASS 3.7 to 75kW
Upon receipt of the product and prior to initial operation, read these instructions
thoroughly, and retain for future reference.
YASKAWA
, CIMR-R5A
YASKAWA
MANUAL NO. TOE-S656-3D

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  • Page 1 YASKAWA VARISPEED-656RC5 INSTRUCTION MANUAL POWER REGENERATIVE UNIT (VS-656RC5) MODEL : CIMR-R5U , CIMR-R5A 200V CLASS 3.7 to 37kW 400V CLASS 3.7 to 75kW Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference.
  • Page 2 Such modifications are denoted by a revised manual No. To order a copy of this manual, if your copy has been damaged or lost, contact your YASKAWA representative. YASKAWA is not responsible for any modification of the product made by the user, since that will void your guarantee.

  • Page 3: Safety Information

    SAFETY INFORMATION Read this instruction manual thoroughly before installation, operation, maintenance or inspection of the VS-656RC5. In this manual, NOTES FOR SAFE OPERATION are classified as “WARNING” or “CAU- TION.” WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to personnel.

  • Page 4: Notes For Safe Operation

    NOTES FOR SAFE OPERATION NOTES FOR SAFE OPERATION RECEIVING CAUTION (Ref. page) Do not install or operate any power regenerative unit which is damaged or has missing parts. Failure to observe this caution may result in personal injury or equipment damage. .
  • Page 5 WIRING WARNING (Ref. page) Only commence wiring after verifying that the power supply is turned OFF. Failure to observe this warning can result in an electric shock or a fire........... Wiring should be performed only by qualified personnel.
  • Page 6 NOTES FOR SAFE OPERATION CAUTION (Ref. page) Verify that the power regenerative unit rated voltage coincides with the AC power supply voltage. Failure to observe this caution can result in personal injury or a fire........... Do not perform a withstand voltage test of the power regenerative unit.
  • Page 7 OPERATION WARNING (Ref. page) Only turn ON the input power supply after replacing the front cover or the terminal cover. Do not remove the cover while current is flowing. Failure to observe this warning can result in an electric shock. .
  • Page 8 NOTES FOR SAFE OPERATION MAINTENANCE AND INSPECTION WARNING (Ref. page) Never touch high-voltage terminals in the power regenerative unit. Failure to observe this warning can result in an electric shock..Perform maintenance or inspection only after verifying that the CHARGE LED goes OFF, after the main circuit power supply is turned OFF.
  • Page 9 WARNING LABEL A warning label is displayed on the front cover of the power regenerative unit, as shown below. Follow these instructions when handling the pow- er regenerative unit. 6 5 6 R C 5 Warning Label Model CIMR-R5A23P7 Warning Label WARNING - Risk of electric shock.

  • Page 10: Table Of Contents

    CONTENTS SAFETY INFORMATION ........NOTES FOR SAFE OPERATION .

  • Page 11: Receiving

    Remove the front cover of the power regenerative unit. Is hardware properly seated and securely tightened? Check all visible hardware with appropriate tools. If any of the above checkpoints are not satisfactory, contact your YASKAWA representative. (2) Checking the Nameplate Data...
  • Page 12 RECEIVING (b) Model Designation CIMR - R5 U 2 3P7 1 A Power Regenerative Version (Enter the specifications Unit form number when special speci- VS - 656RC5 Series fications are required.) Protective Structure Specifications Symbol Open chassis (IEC IP00) Standard domestic model Enclosed wall-mounted Japan standard model (IEC IP20, NEMA1)

  • Page 13: Installation

    INSTALLATION CAUTION Lift the cabinet by the base. When moving the unit, never lift by the front cover or the front panel. Otherwise, the main unit may be dropped causing damage to the unit. Mount the power regenerative unit on nonflammable material (i.e. metal). Failure to observe this caution can result in a fire.
  • Page 14 INSTALLATION To ensure proper performance and long operating life, follow the recommendations below when choosing a location for installing the VS-656RC5. Make sure the power regenerative unit is protected from the following conditions: V Extreme cold and heat. Use only within ambient temperature range: −10°C to +40°C V Rain, moisture.

  • Page 15: Clearances

    3. When installing the models of 200 V/400 V 37 kW or more equipped with eyebolts, extra spacing will be required on either side. For detailed dimensions, contact your YASKAWA representative. 4. Ensure sufficient space for the sections at the upper and lower parts marked...

  • Page 16: Dimensions (Mm)

    INSTALLATION DIMENSIONS (mm) (1) Models of 200 V/400 V 30 kW and Lower The following figure shows a 200 V 3.7 kW model. Use open chassis type 200 V/400 V 30 kW and lower with the top and bottom covers removed. RUN DS1 DS2 POWER LED MONITOR...
  • Page 17 Table 2 VS-656RC5 Dimensions (mm) and Approx. mass (kg) Open Chassis Type (IP00) Enclosed wall-mounted (IP20) Mount- Mount- VS-656RC5 Mounting Mounting Voltage Dimensions (mm) Approx. Dimensions (mm) Approx. CIMR-R5Uj Dimension (mm) Dimension mm) Hole Mass Mass Mass Mass (kg) (kg) 23P7 25P5 27P5...

  • Page 18: Removing And Replacing The

    INSTALLATION REMOVING AND REPLACING THE FRONT COVER To remove the front cover, first move the LED monitor/digital operator in the direction shown by arrow 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 Fig.5 Removing and Replacing the Front Cover NOTE...

  • Page 19: Removing And Replacing The Led Monitor/Digital Operator

    REMOVING AND REPLACING THE LED MONITOR/DIGITAL OPERATOR Remove and replace the LED monitor/digital operator as follows. (1) Removing the LED Monitor/Digital Operator Push the LED monitor/digital operator lever in the direction Front Cover shown by arrow 1 and lift the LED monitor/digital operator in LED Monitor/ Digital Operator...

  • Page 20: Wiring

    WIRING WIRING WARNING Only commence wiring after verifying that the power supply is turned OFF. Failure to observe this warning can result in an electric shock or a fire. Wiring should be performed only by qualified personnel. Failure to observe this warning can result in an electric shock or a fire. Make sure to ground the ground terminal before connecting the other terminals.
  • Page 21 Power Coordinating Reactor VS-616G5A MCCB R/L1 U/T1 S/L2 V/T2 T/L3 W/T3 Current r/ 1 Suppressing VS-656RC5 Reactor *8, *10 R/L1 S/L2 − T/L3 − − Analog Forward Run Multi-function Monitor 1 Analog Output − Reverse Run -10 to +10V Analog IP24 CONV −...
  • Page 22 WIRING (2) Connection Diagram with Servo Fig.9 shows a diagram of a typical connection of the VS-656RC5 with the Σ-series SGDB Servopack. Power Supply Power Supply Servo Unit Power Coordinating Reactor SGDB MCCB R/L1 S/L2 T/L3 Current Suppressing VS-656RC5 Reactor Ground (100Ω...

  • Page 23: Connecting Main And Control Circuits

    CONNECTING MAIN AND CONTROL CIRCUITS (1) Main Circuit Input Fuse Connet a fuse at the primary side of the power suppressing reactor. Recom- mended fuses are shown in Tables 3 and 4. Table 3 200 V Class Input Fuse VS-656RC5 Input fuse Fuse holder Rated re-...
  • Page 24 WIRING (2) Input AC Reactor An input 3-phase reactor corresponding to each model is necessary when operat- ing VS-656RC5. This input AC reactor is effective against saturated current and excessive heat. Table 5 shows the code numbers of AC reactor of each model. Check the table and use a specified AC reactor.
  • Page 25 (3) Main Circuit Surge Protector Fig.10 shows a diagram of a typical connection of the surge protector. Recom- mended protectors are shown in Tables 6 and 7. Power PWM Inverter Coordination Reactor U/T1 R/L1 V/T2 S/L2 W/T3 T/L3 200/ 400/ 1 ⊖...
  • Page 26 WIRING Table 6 200 V Class Surge Protector VS-656RC5 Surge protector Rated Rated Input Model Capacity Manufactured Amount Current Model Code No. (kW) per unit CIMR-R5Uj (Aac) 25%ED 25%ED 23P7 V-781BYZ-2 Okaya Electric XX 000221 25P5 V-781BYZ-2 Okaya Electric XX 000221 27P5 V-781BYZ-2 Okaya Electric XX 000221...
  • Page 27 (4) Wiring Precautions The external interconnection wiring must be performed with following proce- dures. After completing VS-656RC5 interconnections, be sure to check that the connections are correct. Never use control circuit buzzer check. (a) Precautions on Control Circuit Wiring S Separate control circuit wires from main circuit wires and other power cables to prevent erroneous operation caused by noise interference.
  • Page 28 WIRING (b) Ground Wiring S Do not share the ground wire with other devices, such as welding machines or power tools. Separate the grounding cables from the wirings for power tools. S Always use a ground wire that complies with technical standards on electri- cal equipment and minimize the length of the ground wire.

  • Page 29: Wiring Main Circuit Terminals

    WIRING MAIN CIRCUIT TERMINALS (1) Required Wire Size Select wires to be used for wiring from Tables 8 and 9. Table 8 200 V Class Wire Size Wire Size VS-656RC5 VS 656RC5 Terminal Terminal Circuit Circuit Terminal Symbol Terminal Symbol Wire Type Wire Type CIMR-R5Uj...
  • Page 30 WIRING Table 9 400 V Class Wire Size Wire Size* VS-656RC5 VS 656RC5 Terminal Terminal Circuit Circuit Terminal Symbol Terminal Symbol Wire Type Wire Type CIMR-R5Uj Screw R/L1, S/L2, T/L3, ¨ , ¨ , © , © 43P7 r1/ 11, 1/ 21, t1/ 31 2 to 5.5 14 to 10 R/L1, S/L2, T/L3, ¨...
  • Page 31 (2) Closed-Loop Connectors Size Table 10 Closed Loop Connectors Sizes (JIS C 2805) (For 200 V/400 V classes) Wire Size Terminal Screw Terminal Screw Tightening Torque (N•m) Closed Loop Connectors Tightening Torque (N•m) Closed Loop Connectors M3.5 0.8 to 1.0 1.25 to 3.5 0.75 1 2 to 1 4...

  • Page 32: External Terminals

    WIRING EXTERNAL TERMINALS (1) Main Circuit Terminal Functions Table 11 Main Circuit Terminal Functions Terminal Symbol Description R/L1 Main circuit AC power supply terminal for the power regenerative unit. S/L2 Power T/L3 Regenerative U it Unit Connect to the Inverter’s DC power supply voltage input terminals. Main Circuit Input ¨...

  • Page 33: Operation

    OPERATION WARNING Only turn ON the input power supply after replacing the front cover or the terminal cover. Do not remove the cover while current is flowing. Failure to observe this warning can result in an electric shock. Never operate the digital operator or other switches when your hand is wet.

  • Page 34: Setting The Power Supply Voltage Jumper (400 V Class Converters Of 37 Kw Or Higher)

    OPERATION SETTING THE POWER SUPPLY VOLTAGE JUMPER (400 V CLASS CONVERTERS OF 37 KW OR HIGHER) Set the power supply voltage jumper for 400 V class power regenerative unit of 37 kW or higher. Insert the jumper into the voltage connector nearest to the actual power supply voltage.

  • Page 35: Confirming Display Status

    CONFIRMING DISPLAY STATUS (1) LED Monitor Display Fig.15 shows the LED monitor of the VS-656RC5. POWER Operation mode display Lit when the power is ON Indicates the operation status by the combination of the LED displays (Lit, Blink, and Off) at RUN, DS1, and DS2.
  • Page 36 OPERATION (2) LED Display when the Power is ON The following shows the LED display pattern during normal operation. POWER [At normal operation] Indicates READY The LED display pattern is different when a fault (minor fault) occurs. Below shows an example of LED display when a minor fault occurs. Refer to Chapter 6 and take appropriate countermeasures.

  • Page 37: Power On/Off Sequence

    POWER ON/OFF SEQUENCE Refer to Fig. 16 when building a power ON/OFF sequence for the VS-656RC5. AC Power Supply Power Regenerative Unit READY Inverter READY STOP Inverter Run Command STOP Inverter Output during Run STOP Power Regenerative Unit Run Command STOP Power Regenerative Unit Output during Run...

  • Page 38: Run Command Selection

    OPERATION RUN COMMAND SELECTION This section explains the two run command modes of the power regenerative unit. Select the mode according to the application. (1) Auto Run Auto run is the mode in which the power regenerative unit detects any increase/ decrease of the bus voltage and performs an auto run/stop if the terminal S2-SC is “closed.”...
  • Page 39 (2) Manual Run Manual run is the mode in which the power regenerative unit starts running when the terminal S1-SC is “closed,” and stops one second after S1-SC is “open.” Auto Run Inverter Status Regeneration DC Bus Voltage AC Power Supply Voltage × 1.35 MANUAL RUN C8-20: default setting 1 sec Regenerative Unit...

  • Page 40: Maintenance And Inspection

    MAINTENANCE AND INSPECTION MAINTENANCE AND INSPECTION WARNING Never touch high-voltage terminals in the power regenerative unit. Failure to observe this warning can result in an electric shock. Perform 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.

  • Page 41: Maintenance Period

    MAINTENANCE PERIOD The maintenance period of the power regenerative unit is as follows. Maintenance period: Within 18 months of shipping from the factory or within 12 months of being delivered to the final user, whichever comes first. DAILY INSPECTION Check the following items with the system in operation. S There should be no abnormal heat generation.

  • Page 42: Periodic Maintenance Of Parts

    MAINTENANCE AND INSPECTION PERIODIC MAINTENANCE OF PARTS The power regenerative unit is configured of many parts, and these parts must be op- erating properly in order to make full use of the Inverter functions. Among the electronic components, there are some that require maintenance depend- ing on their usage conditions.

  • Page 43: Troubleshooting

    TROUBLESHOOTING FAULT DETECTION When the power regenerative unit detects a fault, the fault code is displayed on the LED monitor, the fault contact output operates. S When a fault has occurred, refer to the following table to identify and cor- rect the cause of the fault.
  • Page 44 TROUBLESHOOTING Meaning Meaning Trouble Causes Trouble Causes Corrective Actions Corrective Actions Meaning Input Undervoltage Input undervoltage was detected during operation. S There is a fault to the equipment S Check the wiring of the equip- 200 V class : Approx. 150 VAC at the power side.

  • Page 45: Minor Fault Detection

    Remove the heat source. ed 90 % of the allowable level ed 90 % of the allowable level. Replace the cooling fan. The power regenerative unit (Contact your Yaskawa repre- cooling fan has stopped. sentative.) Power Regenerative Unit Input Overload The load is too heavy.

  • Page 46: Specifications

    SPECIFICATIONS SPECIFICATIONS NOTE 1. Use 1:1 with an inverter. Do not connect more than one inverter to one power regenerative unit. 2. Use the power regenerative unit whose capacity is equal to one exceeding the inverter capacity to be combined. 3.
  • Page 47 Model CIMR-R5Uj 23P7 25P5 27P5 2011 2015 2018 2022 2030 2037 Location Indoor (Protected from corrosive gases and dust) −10 °C to +40 °C (Enclosed wall-mounted type) Ambient Temperature −10 °C to +45 °C (Open chasis type) Humidity 90 % RH or less (non-condensing) Vibration 9.8 m/s (1G) less than 20 Hz, up to 1.96 m/s...
  • Page 48 SPECIFICATIONS Table 18 400 V Class Specifications Model CIMR-R5Uj 43P7 45P5 47P5 4011 4015 4018 4022 4030 4037 4045 4055 4075 Rated Capacity 18.5 Rated DC Current Rated Current on Power Side Regenerative Torque 100 % for 1 minute, 25 % ED, 80 % continuous Voltage Frequency 380 to 460 VAC 50/60 Hz, Allowable Voltage...

  • Page 49: Appendix 1 Optional Functions

    APPENDIX 1 OPTIONAL FUNCTIONS USING DIGITAL OPERATOR JVOP-130 The following functions are available by using the digital operator JVOP-130. Starts and stops by using the RUN and STOP keys. Monitors the operation status of the power regenerative unit. Check the current fault and the fault history. Sets and changes constants.

  • Page 50: Using The Digital Operator

    APPENDIX 1 OPTIONAL FUNCTIONS USING THE DIGITAL OPERATOR This section describes the component names and functions of the Digital Operator. The component names and functions are shown in Fig. A-2 and Key function are de- scribed in Table A-1. DRIVE FWD REV REMOTE Operation Mode Indicators DRIVE : Lit when in operation mode.
  • Page 51 Table A-1 Key Function Name Function Switches between operation (LOCAL) via the Digital Operator and control circuit terminal (REMOTE) operation. LOCAL LOCAL/REMOTE Key REMOTE This key can be enabled or disabled by setting a user constant (o2-01). MENU Key Displays menus. MENU ESC Key Returns to the status before the DATA/ENTER Key was pressed.

  • Page 52: Modes

    APPENDIX 1 OPTIONAL FUNCTIONS MODES This section describes the VS-656RC5’s monitor modes, switching between modes, and accessing/setting user constants. (1) Modes The VS-656RC5’s user constants and monitoring functions have been organized in groups called modes that make it easier to read and set user constants. The VS-656RC5 is equipped with 4 modes, as shown in the Table A-2.
  • Page 53 All modes/constant Power ON status MENU Operation mode DATA Monitor (DC bus voltage) ENTER Main Menu Dc Bus Voltage Operation U1-02 = 300 VDC Initialize mode DATA Operator display language selection DATA ENTER ENTER Main Menu Select Language A1-00 = 0 Initialize English English...
  • Page 54 APPENDIX 1 OPTIONAL FUNCTIONS Setting a user constant [Example] The group level will be displayed when the DATA/ENTER Key is pressed at the programming mode display. Step Key Sequence Digital Operator Display Remarks Main Menu MENU Operation Main Menu Programming Press twice.
  • Page 55 NOTE When running the power regenerative unit after using digital operator, press the MENU Key to enter the operation mode and then press the DATA/ENTER Key from the operation mode display to bring up the monitor display. Run commands can’t be received from any other dis- play.

  • Page 56: Appendix 2 Protective And Diagnostic Functions Of The Digital Operator

    APPENDIX 2 PROTECTIVE AND DIAGNOSTIC APPENDIX 2 PROTECTIVE AND DIAGNOSTIC FUNCTIONS OF THE DIGITAL OPERATOR FAULT DETECTION When the power regenerative unit detects a fault, the fault code is displayed on the Digital Operator and the fault contact output operates. When a fault has occurred, refer to the following table to identify and correct the cause of the fault.
  • Page 57 Fault Display Meaning Probable Causes Corrective Actions Ovecurrent S A short-circuit occurred at the The output current of the power power regenerative output. Reset the fault after correcting its regenerative unit exceeded the S Power supply drop cause. Over Current overcurrent detection level.

  • Page 58: Minor Fault Detection

    L8-02. Heatsink Overtmp Replace the cooling fan. (Con- (Stopping method can be The cooling fan of the power re- tact your YASKAWA representa- changed by L8-03.) generative unit has stopped. tive.) Power Regenerative Unit In- put Overload The load is too heavy.

  • Page 59: Operation Errors

    Incorrect settings OPE01 Incorrect Power Regenerative The power regenerative unit capacity setting does not match the Unit Capacity Setting Unit. (Contact your YASKAWA representative.) kVA Selection OPE02 Constant Setting Range Error The constant setting is outside of the valid setting range.

  • Page 60: Appendix 3 Constants List

    APPENDIX 3 CONSTANTS LIST APPENDIX 3 CONSTANTS LIST Table A-6 shows the items that can be monitored in operation mode. The output sig- nal levels for multi-function analog outputs shown in the table are for a gain of 100.0 and a bias of 0.00. Table A-6 Constants Monitored in Operation Mode Con- Output Signal Level for...
  • Page 61 Con- Output Signal Level for Func- Min. stant Name Function Multi-function tion Unit Analog Outputs Voltage deviation Monitors the deviation between the AC power supply volt- Monitors the deviation between the AC power supply volt- 200 V class : 400 V/10 V 200 V class : 400 V/10 V U1 21 U1-21...
  • Page 62 APPENDIX 3 CONSTANTS LIST Table A-7 Constant List Name Change Constant Constant Setting Range Factory Setting Range Factory Access Access during during Description Description Setting Level Display Operation Language selection for 0 : English operator display, 1 : Japanese 1 : Japanese A1-00 A1-00 0, 1...
  • Page 63 Change Name Constant Constant Setting Range Factory Setting Range Factory Access Access during during Description Description Setting Level Display Operation 0 : Fault 1 : Operation continues within power loss Momentary power loss ridethrough time detection 2 : Operation continues if control power supply is hold.
  • Page 64 APPENDIX CONSTANTS LIST3 Table A-8 Multi-function Input Functions Function Setting Value Remarks (H1-01, 02) External baseblock (NO contact) [Ext BaseBlk N.O.] External baseblock (NC contact) [Ext BaseBlk N.C.] Not used [Term Not Used] Fault reset [Fault Reset] 24 : NO input, Normally detected, stop External fault External fault [External Fault]...
  • Page 65 Table A-10 Multi-function Analog Output Functions Setting value Function (H4-01) Output signal level Remarks Not used [Not Used] DC bus voltage 200 V class : 400 V/10 V [DC Bus Voltage] 400 V class : 800 V/10 V Power supply voltage 200 V class : 200 V/5 V [AC Voltage] 400 V class : 400 V/5 V...
  • Page 66 No.18 Xizang Zhong Road. Room 1702-1707, Harbour Ring Plaza Shanghai 200001, China Phone 86-21-5385-2200 Fax 86-21-5385-3299 YASKAWA ELECTRIC (SHANGHAI) CO., LTD. BEIJING OFFICE Room 1011A, Tower W3 Oriental Plaza, No.1 East Chang An Ave., Dong Cheng District, Beijing 100738, China...

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