YASKAWA Z1000 CIMR-ZU*A Series User manual

YASKAWA AC Drive Z1000

AC Drive for HVAC Fan and Pump

User Manual

MANUAL NO. TOEP C710616 45F

Models:

200 V Class: 2.2 to 110 kW (3 to 150 HP)

400 V Class: 2.2 to 370 kW (3 to 500 HP)

To properly use the product, read this manual thoroughly and retain

for easy reference, inspection, and maintenance. Ensure the end user

receives this manual.

Type: CIMR-ZUA

Mechanical Installation

2

3

Electrical Installation

1

Receiving

4

5

A

B

A

D

E

6

Peripheral Devices &

Options

C

BACnet Communications

Quick Reference Sheet

SpecificationsSpecifications

Parameter List

Start-Up Programming &

Operation

Troubleshooting

Standards Compliance

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.................................................................. 11

i.1 Preface ....................................................................................................................... 12

Applicable Documentation....................................................................................................... 12

Symbols................................................................................................................................... 12

Terms and Abbreviations ........................................................................................................ 12

Trademarks ............................................................................................................................. 12

i.2 General Safety ........................................................................................................... 14

Supplemental Safety Information ............................................................................................ 14

Safety Messages..................................................................................................................... 15

General Application Precautions ............................................................................................. 17

Motor Application Precautions................................................................................................. 18

Drive Label Warning Example................................................................................................. 20

Warranty Information............................................................................................................... 21

1. RECEIVING .................................................................................................... 23

1.1 Section Safety............................................................................................................ 24

1.2 General Description .................................................................................................. 25

Z1000 Model Selection............................................................................................................ 25

Control Mode Selection ........................................................................................................... 26

1.3 Model Number and Nameplate Check ..................................................................... 27

Drive Nameplate...................................................................................................................... 27

Drive Model Number Definition ............................................................................................... 28

1.4 Drive Models and Enclosure Types......................................................................... 29

1.5 Component Names.................................................................................................... 30

IP20/NEMA 1, UL Type 1 Enclosure ....................................................................................... 30

IP00/Open-Type Enclosure ..................................................................................................... 33

Front Views ............................................................................................................................. 37

2. MECHANICAL INSTALLATION..................................................................... 39

2.1 Section Safety............................................................................................................ 40

2.2 Mechanical Installation ............................................................................................. 42

Installation Environment .......................................................................................................... 42

Transporting the Drive............................................................................................................. 42

Installation Orientation and Spacing........................................................................................ 43

Instructions on Installation Using the Eye Bolts ...................................................................... 43

Panel Cut-Out Dimensions...................................................................................................... 45

HOA Keypad Remote Usage .................................................................................................. 46

Exterior and Mounting Dimensions ......................................................................................... 49

YASKAWA ELECTRIC

TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

3

3. ELECTRICAL INSTALLATION .............................................................................. 59

3.1 Section Safety......................................................................................................................60

3.2 Standard Connection Diagram...........................................................................................62

3.3 Main Circuit Connection Diagram......................................................................................65

Three-Phase 200 V Class (2A0011 to 2A0273)

Three-Phase 400 V Class (4A0005 to 4A0302)............................................................................... 65

Three-Phase 200 V Class (2A0343 and 2A0396)

Three-Phase 400 V Class (4A0361 to 4A0590)............................................................................... 65

12-Pulse/18-Pulse Rectification ........................................................................................................ 65

Wiring to –/+1 Terminals (2A0343 to 2A0396 and 4A0361 to 4A0590) ............................................ 66

3.4 Terminal Block Configuration ............................................................................................68

3.5 Terminal Cover ....................................................................................................................70

Models 2A0143 to 2A0396 and 4A0124 to 4A0590 .......................................................................... 70

3.6 HOA Keypad and Front Cover............................................................................................72

Removing/Reattaching the HOA Keypad .......................................................................................... 72

Removing/Reattaching the Front Cover ............................................................................................ 73

3.7 Top Protective Cover ..........................................................................................................79

Removing the Top Protective Cover ................................................................................................. 79

Reattaching the Top Protective Cover .............................................................................................. 80

3.8 Main Circuit Wiring..............................................................................................................81

Factory Recommended Branch Circuit Protection ............................................................................ 81

Main Circuit Terminal Functions........................................................................................................ 81

Protecting Main Circuit Terminals ..................................................................................................... 82

Wire Gauges and Tightening Torque ................................................................................................ 83

Main Circuit Terminal and Motor Wiring ............................................................................................ 86

3.9 Control Circuit Wiring .........................................................................................................91

Control Circuit Connection Diagram.................................................................................................. 91

Control Circuit Terminal Block Functions .......................................................................................... 91

Terminal Configuration ...................................................................................................................... 93

Wiring the Control Circuit Terminal ................................................................................................... 95

Switches and Jumpers on the Control Board .................................................................................... 99

3.10 Control I/O Connections ...................................................................................................100

Sinking/Sourcing Mode Switch for Digital Inputs............................................................................. 100

Input Signal Selection for Terminals A1 and A2.............................................................................. 100

Terminal FM/AM Signal Selection ................................................................................................... 101

MEMOBUS/Modbus Termination .................................................................................................... 101

3.11 Connect to a PC.................................................................................................................102

3.12 External Interlock ..............................................................................................................103

Drive Ready..................................................................................................................................... 103

3.13 Wiring Checklist ................................................................................................................104

4. START-UP PROGRAMMING & OPERATION..................................................... 105

4.1 Section Safety....................................................................................................................106

4.2 Using the HOA Keypad .....................................................................................................107

HOA Keypad Keys and Displays..................................................................................................... 107

LCD Display .................................................................................................................................... 108

ALARM (ALM) LED Displays........................................................................................................... 109

AUTO LED and HAND LED Indications .......................................................................................... 109

Table of Contents

4

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

Menu Structure for HOA Keypad..................................................................................................... 111

4.3 The Drive, Programming, and Clock Adjustment Modes ..............................................112

Real-Time Clock (RTC) ................................................................................................................... 112

Clock Adjustment ............................................................................................................................ 112

Changing Parameter Settings or Values ......................................................................................... 115

Verifying Parameter Changes: Verify Menu .................................................................................... 116

Simplified Setup Using the Setup Group......................................................................................... 117

4.4 Start-Up Flowcharts ..........................................................................................................119

Flowchart A: Basic Start-Up and Motor Tuning ............................................................................... 120

Subchart A-1: Simple Motor Setup Using V/f Control...................................................................... 121

Subchart A-2: Operation with Permanent Magnet Motors............................................................... 122

4.5 Powering Up the Drive ......................................................................................................123

Powering Up the Drive and Operation Status Display..................................................................... 123

4.6 Application Selection........................................................................................................124

HVAC Application Parameters ........................................................................................................ 124

Setting 1: Fan Application ............................................................................................................... 124

Setting 2: Fan with PI Control Application ....................................................................................... 125

Setting 3: Return Fan with PI Control Application ........................................................................... 125

Setting 4: Cooling Tower Fan Application ....................................................................................... 125

Setting 5: Cooling Tower Fan with PI Control Application............................................................... 126

Setting 6: Pump (Secondary) Application........................................................................................ 126

Setting 7: Pump with PI Control Application.................................................................................... 126

4.7 Basic Drive Setup Adjustments .......................................................................................127

4.8 Auto-Tuning .......................................................................................................................143

Types of Auto-Tuning ...................................................................................................................... 143

Before Auto-Tuning the Drive.......................................................................................................... 144

Auto-Tuning Interruption and Fault Codes ...................................................................................... 145

Auto-Tuning Operation Example ..................................................................................................... 145

T1: Parameter Settings during Induction Motor Auto-Tuning .......................................................... 147

T2: Parameter Settings during PM Motor Auto-Tuning ................................................................... 148

4.9 No-Load Operation Test Run............................................................................................151

No-Load Operation Test Run .......................................................................................................... 151

4.10 Test Run with Load Connected........................................................................................152

Test Run with the Load Connected ................................................................................................. 152

4.11 Verifying Parameter Settings and Backing Up Changes...............................................153

Backing Up Parameter Values: o2-03 ............................................................................................. 153

Parameter Access Level: A1-01...................................................................................................... 153

Password Settings: A1-04, A1-05 ................................................................................................... 153

Copy Function ................................................................................................................................. 154

4.12 Test Run Checklist ............................................................................................................155

4.13 Advanced Drive Setup Adjustments ...............................................................................156

U1: Operation Status Monitors ........................................................................................................ 194

U2: Fault Trace................................................................................................................................ 194

U3: Fault History.............................................................................................................................. 194

U4: Maintenance Monitors .............................................................................................................. 194

U5: PI Monitors................................................................................................................................ 195

U6: Operation Status Monitors ........................................................................................................ 195

5. TROUBLESHOOTING.......................................................................................... 197

Table of Contents

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

5

5.1 Section Safety....................................................................................................................198

5.2 Motor Performance Fine-Tuning......................................................................................200

Fine-Tuning V/f Control ................................................................................................................... 200

Fine-Tuning Open Loop Vector Control for PM Motors................................................................... 201

Parameters to Minimize Motor Hunting and Oscillation .................................................................. 202

5.3 Drive Alarms, Faults, and Errors .....................................................................................203

Types of Alarms, Faults, and Errors................................................................................................ 203

Alarm and Error Displays ................................................................................................................ 204

5.4 Fault Detection ..................................................................................................................207

Fault Displays, Causes, and Possible Solutions ............................................................................. 207

5.5 Alarm Detection.................................................................................................................220

Alarm Codes, Causes, and Possible Solutions ............................................................................... 220

5.6 Programming Errors .........................................................................................................227

Programming Error Codes, Causes, and Possible Solutions.......................................................... 227

5.7 Auto-Tuning Fault Detection ............................................................................................231

Auto-Tuning Codes, Causes, and Possible Solutions..................................................................... 231

5.8 Copy Function Related Displays .....................................................................................233

Tasks, Errors, and Troubleshooting ................................................................................................ 233

5.9 Diagnosing and Resetting Faults.....................................................................................235

Fault Occurs Simultaneously with Power Loss ............................................................................... 235

If the Drive Still has Power After a Fault Occurs ............................................................................. 235

Viewing Fault Trace Data After Fault .............................................................................................. 235

Fault Reset Methods ....................................................................................................................... 236

5.10 Troubleshooting without Fault Display...........................................................................237

Common Problems.......................................................................................................................... 237

Cannot Change Parameter Settings ............................................................................................... 237

Motor Does Not Rotate Properly after Pressing AUTO Button or after Entering External Run

Command ...................................................................................................................................... 238

Motor is Too Hot.............................................................................................................................. 239

oPE02 Error Occurs When Lowering the Motor Rated Current Setting .......................................... 240

Motor Stalls during Acceleration or Acceleration Time is Too Long................................................ 240

Drive Frequency Reference Differs from the Controller Frequency Reference Command ............. 241

Excessive Motor Oscillation and Erratic Rotation............................................................................ 241

Deceleration Takes Longer than Expected ..................................................................................... 241

Noise From Drive or Motor Cables When the Drive is Powered On ............................................... 241

Ground Fault Circuit Interrupter (GFCI) Trips During Run .............................................................. 241

Connected Machinery Vibrates When Motor Rotates ..................................................................... 242

PI Output Fault ................................................................................................................................ 242

Motor Rotates after the Drive Output is Shut Off (Motor Rotates During DC Injection Braking) ..... 242

Output Frequency is Not as High as Frequency Reference............................................................ 243

Sound from Motor............................................................................................................................ 243

Unstable Motor Speed when Using PM .......................................................................................... 243

Motor Does Not Restart after Power Loss....................................................................................... 243

6. PERIPHERAL DEVICES & OPTIONS ................................................................. 245

6.1 Section Safety....................................................................................................................246

6.2 Drive Options and Peripheral Devices ............................................................................248

6.3 Connecting Peripheral Devices .......................................................................................249

Table of Contents

6

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

6.4 Option Installation.............................................................................................................250

Prior to Installing the Option ............................................................................................................ 250

Installing the Option......................................................................................................................... 250

6.5 Installing Peripheral Devices ...........................................................................................254

Installing a Molded Case Circuit Breaker (MCCB) or Ground Fault Circuit Interrupter (GFCI) ....... 254

Installing a Magnetic Contactor at the Power Supply Side.............................................................. 255

Connecting an AC Reactor.............................................................................................................. 255

Connecting a Surge Absorber ......................................................................................................... 255

Attachment for External Heatsink Mounting .................................................................................... 257

Installing a Motor Thermal Overload (oL) Relay on the Drive Output ............................................. 265

A. SPECIFICATIONS ................................................................................................ 267

A.1 Power Ratings ...................................................................................................................268

Three-Phase 200 V Class Drive Models 2A0011 to 2A0088 .......................................................... 268

Three-Phase 200 V Class Drive Models 2A0114 to 2A0396 .......................................................... 269

Three-Phase 400 V Class Drive Models 4A0005 to 4A0027 .......................................................... 270

Three-Phase 400 V Class Drive Models 4A0034 to 4A0096 .......................................................... 271

Three-Phase 400 V Class Drive Models 4A0124 to 4A0302 .......................................................... 272

Three-Phase 400 V Class Drive Models 4A0361 to 4A0590 .......................................................... 273

A.2 Drive Specifications ..........................................................................................................274

A.3 Drive Watt Loss Data ........................................................................................................276

A.4 Drive Derating Data ...........................................................................................................278

Carrier Frequency Derating............................................................................................................. 278

Temperature Derating ..................................................................................................................... 279

Altitude Derating.............................................................................................................................. 280

B. PARAMETER LIST............................................................................................... 281

B.1 A: Initialization Parameters ..............................................................................................282

A1: Initialization ............................................................................................................................... 282

A2: User Parameters....................................................................................................................... 283

B.2 b: Application.....................................................................................................................284

b1: Operation Mode Selection......................................................................................................... 284

b2: DC Injection Braking and Short Circuit Braking......................................................................... 284

b3: Speed Search............................................................................................................................ 285

b4: Timer Function .......................................................................................................................... 286

b5: PI Control .................................................................................................................................. 287

b8: Energy Saving ........................................................................................................................... 290

B.3 C: Tuning............................................................................................................................291

C1: Acceleration and Deceleration Times ....................................................................................... 291

C2: S-Curve Characteristics............................................................................................................ 291

C4: Torque Compensation .............................................................................................................. 291

C6: Carrier Frequency..................................................................................................................... 292

B.4 d: References.....................................................................................................................293

d1: Frequency Reference................................................................................................................ 293

d2: Frequency Upper/Lower Limits ................................................................................................. 293

d3: Jump Frequency........................................................................................................................ 294

d4: Frequency Reference Hold Function......................................................................................... 294

d6: Field Weakening........................................................................................................................ 294

d7: Offset Frequency....................................................................................................................... 295

Table of Contents

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

7

B.5 E: Motor Parameters .........................................................................................................296

E1: V/f Pattern for Motor 1............................................................................................................... 296

E2: Motor Parameters ..................................................................................................................... 297

E5: PM Motor Settings .................................................................................................................... 297

B.6 F: Communication Option Parameters............................................................................299

F6, F7: Communication Option Card............................................................................................... 299

B.7 H Parameters: Multi-Function Terminals ........................................................................302

H1: Multi-Function Digital Inputs ..................................................................................................... 302

H2: Multi-Function Digital Outputs................................................................................................... 306

H3: Multi-Function Analog Inputs .................................................................................................... 308

H4: Analog Outputs ......................................................................................................................... 309

H5: MEMOBUS/Modbus Serial Communication ............................................................................. 310

B.8 L: Protection Function ......................................................................................................312

L1: Motor Protection ........................................................................................................................ 312

L2: Momentary Power Loss Ride-Thru............................................................................................ 313

L3: Stall Prevention ......................................................................................................................... 314

L4: Speed Detection........................................................................................................................ 315

L5: Fault Restart.............................................................................................................................. 315

L6: Torque Detection....................................................................................................................... 316

L8: Drive Protection......................................................................................................................... 316

B.9 n: Special Adjustment.......................................................................................................319

n1: Hunting Prevention.................................................................................................................... 319

n3: High Slip Braking (HSB) and Overexcitation Braking................................................................ 319

n8: PM Motor Control Tuning .......................................................................................................... 320

B.10 o: Operator-Related Settings ...........................................................................................321

o1: HOA Keypad Display Selection................................................................................................. 321

o2: HOA Keypad Functions............................................................................................................. 322

o3: Copy Function ........................................................................................................................... 323

o4: Maintenance Monitor Settings................................................................................................... 323

B.11 S: Special Application.......................................................................................................324

S1: Dynamic Noise Control Function .............................................................................................. 324

S2: Sequence Timers...................................................................................................................... 324

S3: Secondary PI (PI2) Control ....................................................................................................... 326

S4: Bypass Operation ..................................................................................................................... 328

S5: HOA Keypad Parameters ......................................................................................................... 328

S6: Z1000 Protection....................................................................................................................... 329

B.12 T: Motor Tuning .................................................................................................................330

T1: Induction Motor Auto-Tuning..................................................................................................... 330

T2: PM Motor Auto-Tuning .............................................................................................................. 330

B.13 U: Monitors.........................................................................................................................332

U1: Operation Status Monitors ........................................................................................................ 332

U2: Fault Trace................................................................................................................................ 333

U3: Fault History.............................................................................................................................. 334

U4: Maintenance Monitors .............................................................................................................. 336

U5: PI Monitors................................................................................................................................ 337

U6: Operation Status Monitors ........................................................................................................ 338

C. BACNET COMMUNICATIONS ............................................................................ 341

C.1 BACnet Configuration.......................................................................................................342

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8

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

C.2 Communication Specifications........................................................................................343

C.3 Connecting to a Network ..................................................................................................344

Network Cable Connection.............................................................................................................. 344

Wiring Diagram for Multiple Connections ........................................................................................ 345

Network Termination ....................................................................................................................... 345

C.4 BACnet Setup Parameters................................................................................................346

BACnet Serial Communication........................................................................................................ 346

C.5 Drive Operations by BACnet ............................................................................................350

Observing the Drive Operation........................................................................................................ 350

Controlling the Drive........................................................................................................................ 350

C.6 Communications Timing...................................................................................................351

Command Messages from Master to Drive..................................................................................... 351

Response Messages from Drive to Master ..................................................................................... 351

C.7 BACnet Objects Supported ..............................................................................................352

Present Value Access ..................................................................................................................... 352

Supported Properties of Objects ..................................................................................................... 352

Analog Input Objects ....................................................................................................................... 353

Analog Output Objects .................................................................................................................... 353

Analog Value Objects...................................................................................................................... 353

Binary Input Objects ........................................................................................................................ 356

Binary Output Objects ..................................................................................................................... 356

Binary Value Objects....................................................................................................................... 356

Device Object .................................................................................................................................. 357

C.8 Accessing Drive Parameters and the Enter Command .................................................358

Reading Drive Parameters .............................................................................................................. 358

Writing Drive Parameters ................................................................................................................ 358

Enter Command .............................................................................................................................. 358

C.9 Communication Errors .....................................................................................................359

C.10 Self-Diagnostics ................................................................................................................360

C.11 BACnet Protocol Implementation Conformance Statement..........................................361

D. STANDARDS COMPLIANCE .............................................................................. 363

D.1 Section Safety....................................................................................................................364

D.2 European Standards .........................................................................................................366

CE Low Voltage Directive Compliance............................................................................................ 366

EMC Guidelines Compliance .......................................................................................................... 367

D.3 UL/cUL Standards .............................................................................................................372

UL Standards Compliance .............................................................................................................. 372

Drive Motor Overload Protection ..................................................................................................... 375

Precautionary Notes on External Heatsink (IP00/Open-Type Enclosure)....................................... 376

E. QUICK REFERENCE SHEET .............................................................................. 377

E.1 Drive and Motor Specifications........................................................................................378

Drive Specifications......................................................................................................................... 378

Motor Specifications ........................................................................................................................ 378

E.2 Basic Parameter Settings .................................................................................................379

Basic Setup ..................................................................................................................................... 379

Motor Setup..................................................................................................................................... 379

Table of Contents

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

9

Multi-Function Digital Inputs ............................................................................................................ 379

Analog Inputs .................................................................................................................................. 379

Multi-Function Digital Outputs ......................................................................................................... 380

Monitor Outputs............................................................................................................................... 380

E.3 User Setting Table.............................................................................................................381

INDEX ................................................................................................................... 387

Table of Contents

10

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

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...............................................................................................................12

i.2 GENERAL SAFETY...............................................................................................14

i

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

11

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. 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.

This manual is designed to ensure correct and suitable application of Z1000-series drives. Read this manual before attempting

to install, operate, maintain, or inspect a drive and keep it in a safe, convenient location for future reference. Be sure you

understand all precautions and safety information before attempting application.

u

Applicable Documentation

The following manuals are available for Z1000-series drives:

危　険

据え付け、運転の前には必ず取扱説明書を読むこと。

通電中および電源遮断後

5

分以内はフロントカバー

を外さない事。

400V

級インバータの場合は、電源の中性点が接地

されていることを確認すること

。

(

対応）

保守・点検、配線を行う場合は、出力側開閉器を

遮断後

5

分待って実施してください。

けが．感電のおそれがあります。

高温注意

インバータ上部、両側面は高温になります。

触らないでください。

●

AVERTISSMENT

NPJT31470-1

Lire le manuel avant l'installation.

Attendre 5 minutes après la coupure

de l'alimentation, pour permettre

la décharge des condensateurs.

Pour répondre aux exigences , s

assurer que le neutre soit relié

à la terre, pour la série 400V.

Après avoir déconnécte la protection

entre le driver et le moteur, veuillez

patienter 5 minutes avain d’effectuer

une opération de montage ou de

câblage du variateur.

Risque de décharge électrique.

Surfaces Chaudes

Dessus et cotés du boitier Peuvent

devenir chaud. Ne Pas toucher.

WARNING

Read manual before installing.

Wait 5 minutes for capacitor

discharge after disconnecting

power supply.

To conform to requirements,

make sure to ground the supply

neutral for 400V class.

After opening the manual switch

between the drive and motor,

please wait 5 minutes before

inspecting, performing

maintenance or wiring the drive.

Risk of electric shock.

Hot surfaces

Top and Side surfaces may

become hot. Do not touch.

●

F2F1

ESC

M M

AUTO OFF

ENTERRESET

ALM

DIGITAL OPERATOR JVOP-183

HAND

Z1000-Series AC Drive Quick Start Guide (TOEPC71061654)

Read this guide first. This guide is packaged together with the product and contains basic information required to install

and wire the drive. It also gives an overview of fault diagnostics, maintenance safety, and parameter settings. The most

recent version of this manual is available for download on our documentation website, www.yaskawa.com.

Z1000-Series AC Drive User Manual (TOEPC71061645)

This manual contains detailed information on fault diagnostics, parameter settings, and BACnet specifications. The purpose

of this manual is to prepare the drive for a trial run with an application and for basic operation. The most recent version of

this manual is available for download on our documentation website, www.yaskawa.com.

Z1000-Series AC Drive Programming Manual (SIEPC71061645)

This manual provides detailed information on parameter settings, drive functions, maintenance, and MEMOBUS/ Modbus

specifications. Use this manual to expand drive functionality and to take advantage of higher performance features. The

most recent version of this manual is available for download on our documentation website, www.yaskawa.com.

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Symbols

Note: Indicates a supplement or precaution that does not cause drive damage.

TERMSTERMS

Indicates a term or definition used in this manual.

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Terms and Abbreviations

TERMSTERMS

• Drive: Yaskawa Z1000-Series Drive

• Digital Operator: Hand Off Auto (HOA) Keypad JVOP-183

• H: Hexadecimal Number Format

• IGBT: Insulated Gate Bipolar Transistor

• kbps: Kilobits per Second

• MAC: Media Access Control

• r/min: Revolutions per Minute

• V/f: V/f Control

• OLV/PM: Open Loop Vector Control for PM

• PM motor: Permanent Magnet Synchronous motor (an abbreviation for IPM motor or SPM motor)

• IPM motor: Interior Permanent Magnet Motor (e.g., Yaskawa SSR1 Series and SST4 Series motors)

• SPM motor: Surface mounted Permanent Magnet Motor (e.g., Yaskawa SMRA Series motors)

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Trademarks

• APOGEE® FLN is a registered trademark of Siemens Building Technologies, Inc.

• APOGEE® Anywhere™ is a trademark of Siemens Building Technologies, Inc.

• BACnet is a trademark of the American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE).

i.1 Preface

12

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

• GPD is a trademark of Yaskawa, Inc.

• Metasys® N2 is a trademark of Johnson Controls, Inc.

• MODBUS® is a registered trademark of Schneider Automation, Inc.

• Other companies and product names mentioned in this manual are trademarks of those companies.

i.1 Preface

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

13

i.2 General Safety

u

Supplemental Safety Information

General Precautions

• The diagrams in this manual may be indicated without covers or safety shields to show details. Replace the 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 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! may also be indicated by a bold key word embedded in the text followed by an italicized safety message.

CAUTION

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

CAUTION! may 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: may also be indicated by a bold key word embedded in the text followed by an italicized safety message.

i.2 General Safety

14

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

u

Safety 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. After shutting off the power, wait for at least the amount of time specified on the drive before touching any

components.

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.

Make sure the protective earthing conductor complies with technical standards and local safety regulations.

Because the leakage current exceeds 3.5 mA, IEC/EN 61800-5-1 states that either the power supply must be automatically

disconnected in case of discontinuity of the protective earthing conductor or a protective earthing conductor with a cross-

section of at least 10 mm

2

(Cu) or 16 mm

2

(Al) must be used. Failure to comply may result in death or serious injury.

Always use appropriate equipment for Ground Fault Circuit Interrupters (GFCIs).

The drive can cause a residual current with a DC component in the protective earthing conductor. Where a residual current

operated protective or monitoring device is used for protection in case of direct or indirect contact, always use a type B GFCI

according to IEC/EN 60755.

Fire Hazard

Install adequate branch circuit protection according to applicable local codes and this manual.

Failure to comply could result in fire and damage to the drive or injury to personnel. The device is suitable for use on a circuit

capable of delivering not more than 100,000 RMS symmetrical amperes, 240 Vac (200 V class) and 480 Vac (400 V class),

when protected by branch circuit protection devices specified in this manual.

i.2 General Safety

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

15

WARNING

Branch circuit protection shall be provided by any of the following: Non-time delay Class J, T, or CC fuses sized at 300%

of the drive input rating, or Time delay Class J, T, or CC fuses sized at 175% of the drive input rating, or MCCB sized at

200% maximum of the drive input rating.

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.

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.

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.

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.

Do not use screws of different sizes in SW1 and SW2.

Failure to comply may cause overheating and electrical damage.

i.2 General Safety

16

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

u

General Application Precautions

n

Selection

Installing a Reactor

Use an AC reactor in the following situations:

• to suppress harmonic current.

• when the drive is running from a power supply system with thyristor converters.

Drive Capacity

For specialized motors, make sure that the motor rated current is less than the rated output current for the drive.

When running more than one motor in parallel from a single drive, the capacity of the drive should be larger than [total motor

rated current × 1.1].

Starting Torque

The startup and acceleration characteristics of the motor are restricted to the drive overload current rating.

The overload rating for the drive determines the starting and accelerating characteristics of the motor. Expect lower torque

than when running from line power. To achieve a higher starting torque, use a larger drive or a drive and motor with larger

capacity.

Emergency Stop

During a drive fault condition, the output shuts off but the motor does not stop immediately. A mechanical brake may be

required when it is necessary to stop the motor faster than the ability of the Fast Stop function of the drive.

Options

NOTICE: The -M, +M, -, +1, and +3 terminals are used to connect optional Z1000-compatible devices only. Connecting non-Yaskawa-

approved devices to these terminals may damage the drive.

n

Installation

Enclosure Panels

Keep the drive in a clean environment by installing the drive in an enclosure panel. Be sure to leave the required space between

drives to provide for cooling, and take proper measures so the ambient temperature remains within allowable limits and keep

flammable materials away from the drive. Yaskawa offers protective designs for drives that must be used in areas subjected

to oil mist and excessive vibration. Contact Yaskawa or your Yaskawa agent for details.

Installation Direction

NOTICE: Install the drive upright as specified in the manual. Refer to the Mechanical Installation section for more information on installation.

Failure to comply may damage the drive due to improper cooling.

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Settings

Upper Limits

NOTICE: The drive is capable of running the motor up to 240 Hz. Be sure to set the upper limit for the frequency of the drive to prevent the

possible danger of accidentally operating equipment at higher than rated speed. The default setting for the maximum output frequency is

60 Hz.

DC Injection Braking

NOTICE: Excessive current during DC Injection Braking and excessive duration of DC Injection Braking can cause motor overheat.

Acceleration/Deceleration Times

Acceleration and deceleration times are affected by the amount of torque generated by the motor, the load torque, and the

moment of inertia. Set a longer accel/decel time when Stall Prevention is enabled. The accel/decel times are lengthened for

as long as the Stall Prevention function is in operation. Install one of the available braking options or increase the capacity of

the drive for faster acceleration and deceleration.

n

General Handling

Wiring Check

NOTICE: Do not connect power supply lines to output terminals U/T1, V/T2, or W/T3. Failure to comply will destroy the drive. Be sure to

perform a final check of all sequence wiring and other connections before turning on the power and also check for short circuits on the

control terminals, which may damage the drive.

Selecting a Circuit Breaker or Circuit Interrupter

Yaskawa recommends installing a Ground Fault Circuit Interrupter (GFCI) to the power supply side. The GFCI should be

designed for use with AC drives (e.g., Type B according to IEC/EN 60755).

i.2 General Safety

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

17

Select a Molded Case Circuit Breaker (MCCB) or GFCI with a rated current 1.5 to 2 times higher than the drive rated current

to avoid nuisance trips caused by harmonics in the drive input current. Refer to Installing a Molded Case Circuit Breaker

(MCCB) or Ground Fault Circuit Interrupter (GFCI) on page 254 for more information.

Magnetic Contactor Installation

WARNING! Fire Hazard, Sudden Movement Hazard. Shut off the drive with a magnetic contactor (MC) when a fault occurs in external

equipment. Refer to Installing a Magnetic Contactor at the Power Supply Side on page 255. Failure to comply may cause serious

injury or death due to fire or inadvertent equipment movement.

NOTICE: To get the full performance life out of the electrolytic capacitors and circuit relays, refrain from switching the drive power supply

off and on more than once every 30 minutes. Frequent use can damage the drive. Use the drive to stop and start the motor.

Inspection and Maintenance

WARNING! Electrical Shock Hazard. Capacitors in the drive do not immediately discharge after shutting off the power. Wait for at least the

amount of time specified on the drive before touching any components after shutting off the power. Failure to comply may cause injury to

personnel from electrical shock.

WARNING! Electrical Shock Hazard. When a drive is running a PM motor, voltage continues to be generated at the motor terminals after

the drive is shut off while the motor coasts to stop. Take the precautions described below to prevent shock and injury:

∙ In applications where the machine can still rotate after the drive has fully stopped a load, install a switch to the drive output side to disconnect

the motor and the drive.

∙ Do not allow an external force to rotate the motor beyond the maximum allowable speed or to rotate the motor when the drive has been

shut off.

∙ Wait for at least the time specified on the warning label after opening the load switch on the output side before inspecting the drive or

performing any maintenance.

∙ Do not open and close the load switch while the motor is running.

∙ If the motor is coasting, make sure the power to the drive is turned on and the drive output has completely stopped before closing the load

switch.

WARNING! Burn Hazard. Because the heatsink can get very hot during operation, take proper precautions to prevent burns. When replacing

the cooling fan, shut off the power and wait at least 15 minutes to be sure that the heatsink has cooled down. Failure to comply may cause

burn injury to personnel.

Wiring

Yaskawa recommends using ring terminals on all drive models. Drive models 2A0031 to 2A0396 and 4A0034 to 4A0590

require the use of ring terminals for UL/cUL compliance. Use only the tools recommended by the terminal manufacturer for

crimping.

Transporting the Drive

NOTICE: Never steam clean the drive. During transport, keep the drive from coming into contact with salts, fluorine, bromine, phthalate

ester, and other such harmful chemicals.

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Motor Application Precautions

n

Standard Induction Motors

Low-Speed Range

The cooling fan of a standard motor should sufficiently cool the motor at the rated speed. As the self-cooling capability of

such a motor decreases with the speed, applying full torque at low speed will possibly damage the motor. Reduce the load

torque as the motor slows to prevent motor damage from overheat. Figure i.1 shows the allowable load characteristics for a

Yaskawa standard motor. Use a motor designed specifically for operation with a drive when 100% continuous torque is needed

at low speeds.

50

3 6

60

70

80

90

100

25% ED (or 15 min)

40% ED (or 20 min)

60% ED (or 40 min)

Frequency (Hz)

Continuous operation

Torque

(%)

20

Figure i.1 Allowable Load Characteristics for a Yaskawa Motor

i.2 General Safety

18

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

Insulation Tolerance

NOTICE: Consider motor voltage tolerance levels and motor insulation in applications with an input voltage of over 440 V or particularly

long wiring distances.

High-Speed Operation

NOTICE: Problems may occur with the motor bearings and dynamic balance of the machine when operating a motor beyond its rated speed.

Contact the motor or machine manufacturer.

Torque Characteristics

Torque characteristics differ compared to operating the motor directly from line power. The user should have a full

understanding of the load torque characteristics for the application.

Vibration and Shock

The drive allows selection of high carrier PWM control and low carrier PWM. Selecting high carrier PWM can help reduce

motor oscillation.

Take particular caution when adding a variable speed drive to an application running a motor from line power at a constant

speed. If resonance occurs, install shock-absorbing rubber around the base of the motor and enable the Jump frequency selection

to prevent continuous operation in the resonant frequency range.

Audible Noise

The audible noise of the motor varies based on the carrier frequency setting. However, drive current derating may be required.

When using a high carrier frequency, audible noise from the motor is comparable to the motor noise generated when running

from line power.

n

Specialized Motors

Synchronous Motor

• Contact Yaskawa or a Yaskawa agent when planning to use a synchronous motor not endorsed by Yaskawa.

• Use a standard induction motor when running multiple synchronous motors simultaneously. A single drive does not have

this capability.

• A synchronous motor may rotate slightly in the opposite direction of the Run command at start depending on parameter

settings and rotor position.

• The amount of generated starting torque differs depending on the control mode and motor type. Set up the motor with the

drive after verifying the starting torque, allowable load characteristics, impact load tolerance, and speed control range.

Contact Yaskawa or a Yaskawa agent when planning to use a motor that does not fall within these specifications:

• In Open Loop Vector Control for PM motors, braking torque is less than 125% when running between 20% and 100% speed.

Braking torque drops to less than 50% when running at less than 20% speed.

• In Open Loop Vector Control for PM motors, the allowable load moment of inertia is approximately 50 times higher than

the motor moment of inertia.

Contact Yaskawa or a Yaskawa agent for questions concerning applications with a larger moment of inertia.

• To restart a coasting motor rotating below 100 Hz, use the Speed Search function if the motor cable is not too long. If the

motor cable is relatively long, stop the motor using Short Circuit Braking.

Multi-Pole Motor

The rated current of a multi-pole motor differs from that of a standard motor, so be sure to check the maximum current when

selecting a drive. Always stop the motor before switching between the number of motor poles. The motor will coast to stop if

a regenerative overvoltage (ov) fault occurs or if overcurrent (oC) protection is triggered.

Submersible Motor

The rated current of a submersible motor is greater than that of a standard motor, so select the drive accordingly. Use a motor

cable large enough to avoid decreasing the maximum torque level from voltage drop caused by a long motor cable.

Explosion-Proof Motor

The motor and the drive must be tested together to be certified as explosion-proof. The drive is not designed for explosion-

proof areas.

Geared Motor

Make sure that the gear and the lubricant are rated for the desired speed range to avoid gear damage when operating at low

speeds or very high speeds. Consult with the manufacturer for applications that require operation outside the rated speed range

of the motor or gear box.

i.2 General Safety

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

19

Single-Phase Motor

Variable speed drives are not designed to operate with single phase motors. Using capacitors to start the motor causes a high-

frequency current to flow to the capacitors and can damage the capacitors. A split-phase start or a repulsion start can burn out

the starter coils because the internal centrifugal switch is not activated. The drive is for use with three-phase motors only.

Motor with Brake

Take caution when using the drive to operate a motor with a built-in holding brake. If the brake is connected to the output side

of the drive, it may not release at start due to low voltage levels, so be sure to install a separate power supply for the motor

brake. Note that motors with built-in brakes tend to generate a fair amount of noise when running at low speeds.

u

Drive Label Warning Example

Always heed the warning information listed in Figure i.2.

危　険

据え付け、運転の前には必ず取扱説明書を読むこと。

通電中および電源遮断後

5

分以内はフロントカバー

を外さない事。

級インバータの場合は、電源の中性点が接地

されていることを確認すること (

対応）

保守・点検、配線を行う場合は、出力側開閉器を

遮断後

5

分待って実施してください。

けが．感電のおそれがあります。

高温注意

インバータ上部、両側面は高温になります。

触らないでください。

●

AVERTISSMENT

NPJT31470-1

Lire le manuel avant l'installation.

Attendre 5 minutes après la coupure

de l'alimentation, pour permettre

la décharge des condensateurs.

Pour répondre aux exigences , s

assurer que le neutre soit relié

à la terre, pour la série 400V.

Après avoir déconnécte la protection

entre le driver et le moteur, veuillez

patienter 5 minutes avain d’effectuer

une opération de montage ou de

câblage du variateur.

Risque de décharge électrique.

Surfaces Chaudes

Dessus et cotés du boitier Peuvent

devenir chaud. Ne Pas toucher.

WARNING

Read manual before installing.

Wait 5 minutes for capacitor

discharge after disconnecting

power supply.

To conform to requirements,

make sure to ground the supply

neutral for 400V class.

After opening the manual switch

between the drive and motor,

please wait 5 minutes before

inspecting, performing

maintenance or wiring the drive.

Risk of electric shock.

Hot surfaces

Top and Side surfaces may

become hot. Do not touch.

●

F2F1

ESC

M M

AUTO OFF

ENTERRESET

ALM

DIGITAL OPERATOR JVOP-183

HAND

400

。

WARNING

Read manual before installing.

Wait 5 minutes for capacitor

discharge after disconnecting

power supply.

To conform to requirements,

make sure to ground the supply

neutral for 400V class.

After opening the manual switch

between the drive and motor,

please wait 5 minutes before

inspecting, performing

maintenance or wiring the drive.

Risk of electric shock.

Hot surfaces

Top and Side surfaces may

become hot. Do not touch.

●

Figure i.2 Warning Information Example and Position

i.2 General Safety

20

YASKAWA ELECTRIC TOEP C710616 45F YASKAWA AC Drive – Z1000 User Manual

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