Yaskawa Electric America, Inc. Modular Drive
Contents
1. The current software version release is VSG110211 Software release VSG110211 is based on G5 standard software VSG101043 with changes as indicated in section 5 10 Table 5 2 1 Software numbers for current release DEVICE CPU FLASH Master 5280A VSGI110211A Slave 1 5280B VSG110211B Slave 2 Slave 3 5280C VSG110211C 5 3 Start Up After installation and mounting as described in VS 616 G5 Series Instruction Manual publication number TOE S616 10 21 the procedure after initial power on is as follows 1 Set Access Level to Advanced A1 01 4 2 Access the kVA Selection 02 04 and enter proper setting using the following table Table 5 3 1 kVA Selection Inverter Capacity 400 Volt 200 400 600 800 kVA Selection 02 04 81 82 83 84 Inverter Capacity 600 Volt 300 600 900 1200 kVA Selection 02 04 91 92 93 94 95 Access the Initialization Mode Select and set to American Specifications 02 09 1 4 Initialize to factory settings A 1 03 2220 for 2 wire or 3330 for 3 wire initialization Be sure to set parameters 02 04 and 02 09 before initializing Remove power from the inverter allowing the keypad display to fade out completely 6 Reapply power and follow standard trial operation as stated in VS 616 G5 Series Instruction Manual publication number TOE S616 10 21 Nn 17 5 INVERTER SOFTWARE continued 5 4 Parameter Setting Range The following describ2. 765 0 voltage L2 03 Minimum baseblock time 0 1 Sec 0 0 25 5 0 0 25 5 L2 05 Low voltage detection level 1V 300 420 450 750 5 5 Deleted Parameters The following factory level parameters have been deleted from the standard GS software set A C8 13 B L8 10 18 5 INVERTER SOFTWARE continued 5 6 Parameter Defaults The following table shows the factory defaults based on inverter capacity Table 5 6 1 400V class factory defaults based on KVA setting No NAME UNIT Model Type G5X 0 4200 4400 4600 4800 No of inverter modules 1 2 3 4 Inverter Capacity kw 200 400 600 800 02 04 KVA selection 81 82 83 84 B3 04 V F during speed search 80 80 80 80 C6 01 Upper limit Carrier Freq kHz 2 0 2 0 2 0 2 0 C6 02 Lower Limit Carrier Freq kHz 2 0 2 0 2 0 2 0 C6 03 Proportional gain of carrier 0 0 0 0 C7 03 Time constant of hunting msec 30 30 30 30 C8 15 ON delay time usec 15 0 15 0 15 0 15 0 C8 16 ON delay compensation usec 11 0 11 0 11 0 11 0 C8 18 Power factor detect filter 1 msec 4 4 4 4 C8 19 Power factor detect filter 2 msec 4 4 4 4 C8 27 Inverter rated current A 414 800 1200 1600 C8 28 DCCT Gain 1 162 1 122 1 122 1 122 C9 04 CT VT selection 0 CT 0 CT 0 CT 0 CT E2 01 Motor rated current A 370 0 370 0 370 0 370 0 E2 02 Motor rated slip Hz 1 30 1 30 1 30 1 30 E2 03 Motor no load current A 96 0 96 0 96 0 96 0 E2 05 Moto
3. The output reactor acts as a load balancing impedance in conjunction with the active load balancing software in the inverter The reactor itself is about 1 PU impedance to the output circuit so this reactor does not provide any significant help with DV DT issues The reactor is physically designed to mount to the bottom of the inverter module support bracket and attach to the inverter module output terminals via short bus bar links DC LINK REACTOR The DC link reactor is used to filter the DC Bus voltage and to provide load sharing when two converter modules are required The reactor is wired to the converter module via terminals provided at the bottom of the converter module There are three different sizes of reactors rated at 520ADC 780ADC and 1040ADC are used in the four different inverter rating configurations AC INPUT REACTOR REGENERATIVE Input 3 phase reactors are necessary for the pulse width modulation PWM regenerative converters The AC reactor filters the PWM waveform that is present at its load end so that the input AC voltage that is present at its line end is clean and devoid of PWM switching noise The regenerative converter also behaves like a 3 phase boost converter which needs to store energy in the AC inductors and transfer it to the DC bus The reactor also helps in load sharing when multiple regenerative converters are connected in parallel and are being fed from a common AC source AC INPUT HARMONIC FILTER The AC
4. This electronic equipment utilizes power semiconductors and is vulnerable to high voltages Failure to comply will result in non warrantable damage to the equipment Rotating shafts and above ground electrical potentials can be hazardous Therefore it is strongly recommended that all electrical work conform to National Electrical Codes and local regulations Installation alignment and maintenance should be performed only be qualified personnel IMPORTANT NOTICE The information contained within this document is the proprietary of Yaskawa Electric America Inc and may not be copied reproduced or transmitted to other parties without the expressed written authorization of Yaskawa Electric America Inc No patent liability is assumed with respect to the use of the information contained herein Moreover because Yaskawa Electric America Inc is constantly improving 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 Nevertheless Yaskawa Electric America Inc 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 SECTION 1 0 2 0 3 0 4 0 5 0 6 0 TABLE OF CONTENTS DESCRIPTION PAGE INTRODUCTION 4 PURPOSE and SCOPE RECEIVING HANDLING STORAGE DESCRIPTION OF OPERATION 5 SPECIFICATIONS 6 VS 61
5. in the heatpipe s thus eliminating any chance of cylinder pressure build up The interconnect cabling and bus bar arrangement is described below Power Wiring Terminal Terminal Material Terminal Bus Bar Max Torque Symbol Connection Area sq in Ib in Nm mm BUS tin plated copper M12 carriage bolt 294 7 46 350 39 5 BUS tin plated copper M12 carriage bolt 294 7 46 350 39 5 R S T tin plated copper M12 carriage bolt 487 12 38 350 39 5 Ground zinc plated steel M8 hex head screw 90 10 2 11 4 DRIVE SYSTEM COMPONENTS continued Control Wiring Terminal C Terminal Description Wire Size Max Torque onnector Connector mating connector AWG Ib in Nm Symbol Rating mm 7CN 150V 0 5A 26 pin D sub miniature 3M 28 0 08 10126 3000 VE connector 10326 52A0 008 backshell 30CN 250V 7A 3 pin JST 22 18 VHR 3N 0 33 0 83 SVH 21T P1 1 contact 15CN 250V 7A 6 pin JST 22 18 VHR 6N 0 33 0 83 SVH 21T P1 1 contact TB1 250V 20A M4 terminal screw 20 10 12 4 1 4 0 5 5 5 TB2 250V 20A M4 terminal screw 20 10 12 4 1 4 0 5 5 5 G M3 5 terminal screw 20 14 8 9 1 0 0 5 2 0 CAI 600V 30A 10 terminal screw 10 14 20 2 3 5 5 2 0 CA3 250V 7A 3 pin JST 22 18 VHR 3N 0 33 0 83 SVH 21T P1 1 contact 12 4 DRIVE SYSTEM COMPONENTS continued 4 4 4 5 4 6 4 7 OUTPUT REACTOR
6. Nm mm BUS tin plated copper M12 carriage bolt 294 7 46 350 39 5 BUS tin plated copper M12 carriage bolt 294 7 46 350 39 5 TI T2 T3 tin plated copper M12 carriage bolt 294 7 46 350 39 5 Ground zinc plated steel M8 hex head screw 90 10 2 Control Wiring Terminal C Terminal Description Wire Size Max Torque onnector Connector mating connector AWG Ib in N m Symbol Rating mm 7CN 150V 0 5A 26 pin D sub miniature 3M 28 0 08 10126 3000 VE connector 10326 52A0 008 backshell 30CN 250V 7A 3 pin JST 22 18 VHR 3N 0 33 0 83 SVH 21T P1 1 contact 15CN 250V 7A 6 pin JST 22 18 VHR 6N 0 33 0 83 SVH 21T P1 1 contact TB1 250V 20A M4 terminal screw 20 10 12 4 1 4 0 5 5 5 SG M3 5 terminal screw 20 14 8 9 1 0 0 5 2 0 4 DRIVE SYSTEM COMPONENTS continued 4 2 CONVERTER Diode Type Non Regenerative The converter module is a metal chassis equipped with bottom rollers for rack out of the inverter enclosure Enclosed in the chassis are the following main components A Surge suppressors MOVs B Diode modules C Heatsink temperature monitoring device s thermistor D Cooling fan s Refer to G5 High Horsepower Inverter Product CD for drawings and specific details Cooling of the converter module heatsink is accomplished by use of a heatpipe heatsink assembly The diodes are mounted on a large aluminum block in which th
7. Phase 500 575 600V Proportional to input voltage 3 Rated Output Frequency 150 Hz Max Carrier Frequency 2 0kHz Overload Capacity 150 of Rated Output Current for minute a Input Current CT 450 820 1280 1480 B VT A 490 925 1440 1665 7 Voltage V 3 Phase 380 400 415 440 460 VAC 5 Frequency H2 50 60Hz Z Voltage Fluctuation 10 15 z 5 Frequency Fluctuation Model numbers are intended for reference only 2 Hp ratings are based on Nema 4 pole motor data However when sizing a drive to match the motor use the drive output current rating kVA rating is based on 600V 3 SPECIFICATIONS continued 3 2 Common features Control Characteristics Control Method Sine Wave PWM Starting Torque 150 below 1Hz 150 at 0 rpm with PG Speed Control Range 100 1 1000 1 with PG Speed Control 0 2 0 02 with PG Accuracy Speed Response 5 Hz 30Hz with PG Torque Limit Can be set by software 4 steps available Torque Accuracy 5 Torque Response 20Hz 150Hz with PG Frequency Control Range 0 1 to 120 0 Hz Frequency Accuracy Digital command 0 01 Analog command 0 1 Frequency Setting Digital Operator reference 0 01Hz Resolution Analog Reference 0 03Hz 60Hz Output Frequency 0 01Hz Resolution Frequency Setting 10 to 10V 0 to 10V 4 to 20mA Signal Accel De
8. or 600V CLASS application The software features and functions are identical as the standard VS 616 G5 series drives with the exception of a few additional factory parameters required for parallel operation The last essential item to complete the drive system design is the control power transformer assembly A single 1400VA transformer provides all power to the control logic circuits as well as supplying power to the cooling fans for the converter inverter or regeneration module s A voltage tap PCB and power ride thru capacitors completes the assembly Minimal interconnect low power wiring for all drive system components is required but has been optimized and made simple The wiring can be furnished by Yaskawa Electric America Inc in complete cable harness packaged assemblies Main circuit and high power connections have been designed for quick and easy installation of wire conductors cabling and bus bars The design requirements may incorporate the use of a regenerative front end to supply power to the inverter during motoring conditions and send energy back to the power supply side during regeneration conditions The regeneration module used in the drive system will meet IEEE 519 harmonic specifications The regeneration modules can not be used in conjunction with the converter module s A DCCT is used on the output of the regenerative module s for current sensing and bus regulation The input filter required is used for harmonic filtering an
9. warrantable equipment damage See G5 High Horsepower Inverter Product CD for component listings bills of material mechanical drawings and electrical diagrams 1 2 Receiving Carefully and thoroughly unpack and inspect the individual components which make up the modular drive system for any damage which may have been sustained during shipment If any obvious damage is noticed do not accept shipment until you have contacted the freight company or agent Have the agent note the damage on the freight bill before accepting the shipment If you should happen to find any concealed damage during unpacking you should again contact the freight company Yaskawa Electric America Inc is not responsible for any damage which may have resulted during shipment 1 3 Handling The G5 modular drive system components contain Electrostatic Discharge ESD sensitive CMOS ICs Special static control measures must be followed to prevent damage to the equipment Equipment in excess of 20kg 45 pounds should be moved by qualified personnel with a lifting apparatus Failure to observe the preceding may result in personal injury and or equipment damage 1 4 Storage If the drive system components are to be stored for an extended period of time it is recommended to observe the following precautions Store within an ambient temperature range of 4 to 140 F 20 to 60 C Avoid direct sunlight not outdoors Store in an area free from moisture dust vibration
10. 1790 2690 3580 MC 40 80 120 160 50 100 150 200 Fuse 130 260 390 480 160 320 480 640 Discharge Resistor 90 180 270 360 90 180 270 360 PCB s 50 100 150 200 50 100 150 200 CPT 80 80 80 80 80 80 80 80 DC Link Choke 150 370 700 740 190 470 840 890 Output Choke 0 1480 2220 2960 1880 2650 3750 Total 5760 12980 17530 25850 6860 15580 23250 31020 NOTE Cooling fans excluded Efficiency of fans is very high approximately 43watts 27
11. 6G5 MODULAR DRIVE RATINGS COMMON FEATURES DRIVE SYSTEM COMPONENTS 8 INVERTER CONVERTER Diode Type Non Regenerative CONVERTER IGBT Type Regenerative OUTPUT REACTOR DC LINK REACTOR AC INPUT REACTOR Regenerative AC INPUT HARMONIC FILTER CONTROL POWER SUPPLY AND TRANSFORMER CONTROL UNIT ASSEMBLY SOFTWARE 16 CONTROL BOARD CONFIGURATION SOFTWARE VERSION START UP PARAMETER SETTING RANGE DELETED PARAMETERS PARAMETER DEFAULTS DEFAULT VALUES FOR CT VT MAJOR CHANGES FROM THE STANDARD G5 SOFTWARE APPENDIX 23 FLASHWRITE PROCEDURE UNBALANCE CURRENT CONTROL HEAT LOSS DATA 1 INTRODUCTION 1 1 Purpose and Scope This G5 Modular Drive Component Selection Guide is intended to assist in the design assembly and maintenance of the modular inverter G5 series drives models G5U4200 G5U4400 G5U4600 G5U4800 G5U5300 G5U5600 G5U5900 and G5U5C00 This guide is intended to be used in conjunction with the VS 616G5 Series User s Manual publication number TOA S616 10 10 VS 616 G5 Series Instruction Manual publication number TOE S616 10 21 and G5 High Horsepower Inverter Product CD This guide will provide the necessary information to properly design and construct a complete functioning inverter drive system All design and construction should be undertaken only by qualified electrical and mechanical design personnel familiar with the principles of drive system application and design Improper design could result in bodily injury and or non
12. Horsepower Inverter Product CD for drawings and specific details Control Wiring Terminal Terminal Description Wire Size Max Torque Connector Connector mating connector AWG Ib in Nm Symbol Rating mm 13CN 14CN 250V 7A 3 pin JST 22 18 31CN VHR 3N 0 33 0 83 SVH 21T P1 1 contact 30CN 1TRM 250V 7A 4 pin JST 22 18 to VHR 3N 0 33 0 83 30CN 4TRM SVH 21T P1 1 contact 31CN 32CN 250V 7A 6 pin JST 22 18 33CN 34CN VHR 6N 0 33 0 83 35CN SVH 21T P1 1 contact TCN ITRM 150V 0 5A 26 pin D sub miniature 3M 28 0 08 to 10126 3000VE connector 7CN 4TRM 10326 52A0 008 backshell 10CN 9CN 150V 0 5A 20 pin D sub miniature 3M 28 0 08 10120 3000VE connector 10326 52A0 008 backshell TBI 4 Pin Phoenix 24 12 MSTB2 5 4 ST 2 2 5 TB2 5 Pin Phoenix 24 12 MSTB2 5 5 ST 2 2 5 SG E M3 5 terminal screw 20 14 8 9 1 0 0 5 2 0 15 5 INVERTER SOFTWARE 5 1 Control Board Configuration The control board for the modular inverter consists of four microprocessor controllers on one main control board Each microprocessor has it s own flash memory ram memory and interface circuits to an inverter module The processors are configured as a master and 3 slaves The processors communicate with each other through a dual port RAM scheme The tasks for each processor chip are as follows A Master Provides operator keypad serial communication interface to
13. Terminal Description Wire Size Max Torque nnector Connector mating connector AWG Ib in Nm Symbol Rating mm 36CN 37CN 250V 7A 4 pin JST 28 0 08 VHR 4N SVH 21T P1 1 contact 30CN 1TRM 250V 7A 3 pin JST 22 18 to VHR 3N 0 33 0 83 30CN 4TRM SVH 21T P1 1 contact 31CN 32CN 250V 7A 3 pin JST 22 18 33CN 34CN VHR 3N 0 33 0 83 35CN SVH 21T P1 1 contact TBI 250V 20A M4 terminal screw 20 10 12 4 1 4 0 5 5 5 14 4 DRIVE SYSTEM COMPONENTS continued 4 9 CONTROL UNIT ASSEMBLY The Control Unit Assembly is made up of a mounting panel which is to be mounted on the door of the inverter enclosure On the mounting panel are a control power supply main control PCB and the digital operator which is mounted such that the operator is accessible from outside of the inverter controller The control power supply changes the 330VAC to the ISVDC and 5Vdc required for the main control PCB and the isolated portion of the gate drive PCB The main control board is the heart of the inverter It provides all of the control protection and sequencing of the inverter and converter modules The control cables are used to connect the power supply to all converter module s and inverter module s The customer I O terminals are also remotely located as the control PCB itself does not have any terminals A complete description of operation for the main control board can be found in section 5 1 Refer to G5 High
14. Y Yaskawa Electric America Inc Modular Drive Component Selection Guide MODEL G5 MODULAR DRIVE SYSTEM NON REGENERATIVE REGENERATIVE SINGLE TYPES GENERAL PURPOSE INVERTERS W FLUX VECTOR CONTROL 400V CLASS 200 to 800kW 300 to 1400kVA 600V CLASS 300 to 1200kW 400 to 1600kV A P MI 00007 HHP Motor control equipment and electronic controllers are connected to hazardous line potentials When servicing drives and electronic controllers there may be exposed components with their cases and protrusions at or above line potential Extreme care should be taken to prevent against electrical shock Stand on an insulating pad and make it a habit to use only one hand when checking components Always work with another person in case an emergency occurs Disconnect power and wait the proper amount of time for the DC bus capacitors to discharge to a safe level of 5 0VDC or less before servicing the controller Be sure equipment is properly grounded Wear safety glasses whenever working on an electronic controller or electrical rotating equipment Read this manual VS 616G5 Series User s Manual publication number TOA S616 10 10 VS 616 G5 Series Instruction Manual publication number TOE S616 10 21 in its entirety before installation operation maintenance or inspection of this equipment Do not connect or disconnect wiring while the input power supply is ON Do not perform a withstand voltage test or megger test on any part of this equipment
15. and corrosive gases Relative Humidity should not exceed 95 non condensing By observing the above precautions the G5 modular drive system components will be maintained with no degradation in performance Model numbers are intended for reference only 2 DESCRIPTION OF OPERATION The G5 Modular Drive System incorporates a modular design style approach for inverter drive system designers This enables the system designer the capability to provide an economical flexible compact non complex user friendly high performance solution for applications involving drive loads requiring constant torque ampacities of 400 to 1600Aac and variable torque ampacities of 450 to 1800Aac These modular drive systems are offered in two voltage categories 400 and 600V CLASS Each system incorporates at least one inverter module utilizing third generation IGBTs capable of delivering 414A constant torque CT 450A variable torque VT 3 phase continuous output This system has the capability to be expanded by paralleling up to three additional inverter modules quadruplex for a maximum continuous output current rating of 1600A CT 1800A VT 3 phase This is made possible by the use of specially designed output interphase reactors along with the adoption of a newly designed gated array and a 32 bit RISC type MPU incorporating new technologies for parallel processing for synchronization of IGBT gate pulses minimizing the cross current flow between the inverter modu
16. are considered out of tolerance H C9 09 This parameter enables disables voltage limiting after the AVR circuit 25 6 APPENDIX continued 6 4 Heat loss data The following tables 6 4 1 and 6 4 2 shows a detailed list of heat loss through each component in the modular drive system according to their kVA ratings Table 6 4 1 Component 400 Volt Heat Loss Data CT VT watts 200K W 400K W 600K W 800K W Input Diode 1030 2050 3030 4110 1230 2450 3620 4900 IGBT 2510 5020 7530 10040 3000 5990 8980 11980 Main Capacitor 700 1400 2100 2800 840 1670 2510 3340 MC 40 80 120 160 50 100 150 200 Fuse 130 260 390 480 160 320 480 640 Discharge Resistor 50 100 150 200 50 100 150 200 PCB s 50 100 150 200 50 100 150 200 CPT 80 80 80 80 80 80 80 80 DC Link Choke 150 370 700 740 190 470 840 890 Output Choke 0 1480 2220 2960 1880 2650 3750 Total 4740 10950 16470 21770 5650 13160 19610 26180 NOTE Cooling fans excluded Efficiency of fans is very high approximately 43watts 26 6 APPENDIX continued Table 6 4 2 Component 600 Volt Heat Loss Data CT VT watts 300K W 600K W 900K W 1200KW Input Diode 1030 2050 3030 4110 1230 2450 3620 4900 IGBT 3440 6880 10320 13760 4110 8210 12320 16420 Main Capacitor 750 1500 2250 3000 900
17. cally designed for the modular inverter It should be noted that this procedure covers the writing of all four flash memories Most software changes and updates may only require the writing of the master and or slave 1 When required flash memories are finished the remainder of the procedure can be bypassed A read me file covering any software update will instruct the user which flash memories must be re written 1 Make sure power is switched off to the inverter and the DC power supplies are completely discharged Connect the flash write cable to the digital operator port cable part no UWR00100 1 The flash write software must be compatible with the modular inverter 2 Remove the metal rear cover on the control board assembly There are five suitcase jumpers by the connector ICN These jumpers are used to select which flash memory is to be programmed Make sure the jumper is in the M or master position 3 With the switch on the cable in the flash or on position power up the inverter The red LED M will be on Write the master flash file using the flash writing software While the flash memory is being written the green M LED will flash rapidly When the software is finished writing to the flash power down the inverter Note If at any time during a flash write to the control PCB an error occurs power down the inverter and then re apply power and again re write the flash memory 4 Move the jumper to the SLI position Power up t
18. ce regulators for each connected inverter module Each regulator compares the average of all of the inverter module s output currents against its output current The result of this comparison is the module output current difference This difference is then sent to a PI controller The proportional and integral of this controller are set in C9 01 and C9 02 respectively The output of the PI controller passes through a limiter which is set by C9 03 and then goes to the PWM generator of that particular module as a signal called inverter module output voltage trim This signal trims the voltage reference to finely adjust the inverter output voltage This change in voltage results in a change of output current An unbalance detector for each inverter module monitors the level of that module s output current difference If the difference is higher that the level set by parameter C9 05 for a time greater than the time set in C9 06 an unbalance fault will be detected and the inverter will fault Figure 5 0 Unbalanced current controller Phase U of inverter module 1 or A shown Inverter Module A U Phase Output VuA O PWM Limiter C9 03 Current Unbalance K 1 ST K Gain C9 01 T Time constant C9 02 IuB IuC IuD AVERAGE INVERTER U PHASE CURRENT 24 6 APPENDIX continued 6 3 Parameters for unbalance current control The following parameters in the software VSG110211 are used to control current unbalance and circu
19. cel Time 0 0 to 6000 0 sec Braking Torque Approx 20 Motor Overload UL NEC recognized electronic thermal overload protection It Instantaneous Motor coasts to stop at approx 200 rated output current Overcurrent a DC Bus Fuse Motor coasts to stop when at fuse clearing Inverter Overload Motor coasts to stop after 1 min at 150 rated output current 2 Overvoltage Motor coasts to stop if DC bus voltage exceeds 820Vdc 1040Vdc for 600V Class 5 Undervoltage Motor coasts to stop if DC bus voltage drops below user adjustable value S Momentary Power Immediately stop after 15ms of power loss 9setting mode before shipment 9 Loss Continuous system operation during power loss less than 2 sec equipped as S standard A Heatsink Overheat Thermistor OH1 OH2 Stall Prevention Stall prevention during acceleration deceleration and constant speed operation Ground Fault Provided by electronic circuit overcurrent level Input Phase Loss Single phase protection Location Drive System Components to be protected against corrosive gases dust and direct ae sunlight Z Ambient Temperature 14 to 113 F 10 to 45 C 2 2 Storage Temperature 4 to 140 20 to 60C 5 E Humidity 95 RH non condensing S m Vibration 9 8m s 1G less than 20Hz up to 1 96m s 0 2G at 20 to 50 Hz 4 DRIVE SYSTEM MAIN COMPONENTS 4 1 INVERTER The inverter module is a metal chassis equipped with bottom rollers for rack out of the inverter enclosure Enclosed in t
20. comp time sec 1 0 1 0 1 0 1 0 L2 03 Minimum baseblock time sec 4 0 4 0 4 0 4 0 L2 05 Low voltage selection level V 570 570 570 570 Model numbers are intended for reference only 20 5 INVERTER SOFTWARE continued 5 7 Default values for CT VT When the Constant Torque Variable Torque CT VT Selection is changed from the default of Constant Torque C9 04 0 to Variable Torque C9 04 1 the other default values change See table 5 7 1 and 5 7 2 for parameter default values Table 5 7 1 400Volt Class Parameter Name C9 04 0 CT C9 04 1 VT Model Type 4200 4400 4600 4800 4200 4400 4600 4800 G5X sa 02 04 kVA Selection 81 82 83 84 81 82 83 84 C8 28 INV Rated Current A 414 800 1200 1600 450 900 1350 1800 C8 29 KDCCT Gain 1162 1122 1122 1122 1263 1263 1263 1263 L8 02 OH Pre Alarm Level 959C 959C L8 04 OH Level 105 C 105 C OL2 INV Overheat Pre alarm 112 continuous 112 continuous 150 for 1 minute 120 for 1 minute Table 5 7 2 600Volt class Parameter Name C9 04 0 CT C9 04 1 VT Model Type 5300 5600 5900 5C00 5300 5600 5900 5C00 G5X 02 04 kVA Selection 91 92 93 94 91 92 93 94 C8 28 INV Rated Current A 414 800 1200 1600 450 900 1350 1800 C8 29 KDCCT Gain 1162 1122 1122 1122 1263 1263 1263 1263 L8 02 OH Pre Alarm Level 95 C 115 C L8 04 OH Level 105 C 125 C OL2 INV Ove
21. d provides line surge protection Refer to section 4 for further information 3 SPECIFICATIONS 3 1 VS 616G5 Modular drive ratings 400V CLASS Inverter Model VS 616G5 CIMR G5U_ 4200 4400 4600 4800 Nominal Motor Output 350 650 1000 1300 HP 2 2 Capacity CT 330 635 995 1275 VT KVA 360 715 1075 1435 2 Rated Output Current CT 414 800 1200 1600 Ss VT A 450 900 1350 1800 9 Max Voltage 3 Phase 380 400 415 440 460V a Proportional to input voltage 5 Rated Output Frequency 150 Hz Max Carrier Frequency 2 0kHz Overload Capacity 150 of Rated Output Current for minute Input Current CT 450 820 1280 1480 B VT A 490 925 1440 1665 a Voltage V 3 Phase 380 400 415 440 460 VAC 5 Frequency H2 50 60Hz Z Voltage Fluctuation 10 15 5 Frequency Fluctuation Model numbers are intended for reference only 2 Hp ratings are based on Nema 4 pole motor data However when sizing a drive to match the motor use the drive output current rating kVA rating is based on 460V 600V CLASS Inverter Model VS 616G5 CIMR G5U 5300 5600 5900 5C00 Nominal Motor Output 450 800 1200 1600 i HP 3 Capacity CT 430 830 1245 1660 VT kVA 465 935 1400 1870 9 Rated Output Current CT 414 800 1200 1600 E VT A 450 900 1350 1800 O Max Voltage 3
22. e heat is transferred to a finned radiator by an heatpipe assembly The heatpipe s thermal management media is provided in the form of 3M fluorine In addition honeycomb fins are attached to the heatpipe heatsink assembly and cooled by use of front mounted fans The warm air is then exhausted through a ductwork arrangement and out the top of the inverter module It is therefore extremely important to mount the inverter module upright to achieve maximum thermal conductivity CAUTION If disposal of the heatpipe heatsink assembly is required it is recommended to puncture a hole in the heatpipe s thus eliminating any chance of cylinder pressure build up The interconnect cabling and bus bar arrangement is described below Power Wiring Terminal Terminal Terminal Bus Bar Area Max Torque Symbol Material Connection sq in mm Ib in Nm PA PB tin plated copper M12 carriage bolt 783 18 73 350 39 5 L1 L2 L3 tin plated copper M12 carriage bolt 487 12 38 350 39 5 L11 L21 L31 tin plated copper M12 carriage bolt 487 12 38 350 39 5 1 tin plated copper M12 carriage bolt 783 18 73 350 39 5 Ground zinc plated steel M8 hex head screw 90 10 2 Control Wiring Terminal C Terminal Description Wire Size Max Torque lb onnector Connector mating connector AWG mm in Nm Symbol Rating TBI 250V 20A M4 terminal screw 20 10 12 4 1 4 0 5 5 5 TB2 250V 20A M4
23. es the parameter setting ranges which are different from the standard G5 software Table 5 4 1 Parameter Setting Ranges No Name Unit 400V class 600V class C8 27 Inverter rated current 01A 0 1 2000 0 0 1 2000 0 C9 04 CT VT Selection 0 CT or 1 VT 0 CT or 1 VT E1 01 Input voltage 1V 360 460 460 690 E1 04 Maximum frequency 0 1hz 50 0 150 0 50 0 150 0 E1 05 Maximum voltage 0 1V 0 0 510 0 0 0 765 0 E1 06 Maximum voltage frequency 0 1 Hz 0 0 150 0 0 0 150 0 E1 07 Middle output frequency 0 1Hz 0 0 150 0 0 0 150 0 E1 08 Middle output frequency voltage 0 1V 0 0 510 0 0 0 765 0 E1 09 Minimum output frequency 0 1Hz 0 0 150 0 0 0 150 0 E1 10 Minimum output frequency volts 0 1V 0 0 510 0 0 0 765 0 El1 11 Middle output frequency 2 0 1Hz 0 0 150 0 0 0 150 0 E1 12 Middle output frequency 2 volts 0 1V 0 0 510 0 0 0 765 0 E1 13 Base voltage 0 1Hz 0 0 510 0 0 0 765 0 E4 01 Motor 2 maximum frequency 0 1hz 50 0 150 0 50 0 150 0 E4 02 Motor 2 maximum voltage 0 1V 0 0 510 0 0 0 765 0 E4 03 Motor 2 maximum voltage frequency 0 1 Hz 0 0 150 0 0 0 150 0 E4 04 Motor 2 middle output frequency 0 1Hz 0 0 150 0 0 0 150 0 E4 05 Motor 2 middle output frequency 0 1V 0 0 510 0 0 0 765 0 voltage E4 06 Motor 2 minimum output frequency 0 1Hz 0 0 150 0 0 0 150 0 E4 07 Motor 2 minimum output frequency 0 1V 0 0 510 0 0 0
24. harmonic filter comprises of a 3 phase reactor and a 3 phase delta connected capacitor Since the input AC side of a regenerative converter can contain some amount of PWM switching noise that can interfere with other loads connected to the same AC source there could be a need for a small filter One such shunt filter topology is provided as a recommended option for use with regenerative converters The shunt filter topology is as shown below li LA ry Lie A E RA i REGEN Loe n c es CONVERTER L3e AC INPUT AC INPUT REACTOR HARMONIC FILTER 13 4 DRIVE SYSTEM COMPONENTS continued 4 8 CONTROL POWER SUPPLY AND TRANSFORMER The control power supply consists of a control power transformer and power supply assembly which has a tap change printed circuit board attached to a bus capacitor bank assembly The 1 4kVA rated power delivers 230VAC fan power 330VDC power to the inverter gate drive PCB and the G5 Control Assembly The control power supply can accommodate various input power supply ratings ranging from 200 thru 460V AC for the 400 volt series and 500 thru 600VAC for the 600V series Several fuses on the tap change board protect the power supply in the event of an overload or short circuit condition Refer to G5 High Horsepower Inverter Product CD for drawings and specific details Control Wiring Terminal Co
25. he chassis are the following main components DC bus capacitors DC bus capacitor softcharge resistor Softcharge resistor bypass contactor IGBTs with associated snubber circuits DCCT output phase current sensors Gate drive PCB DC bus fuse per phase Heatsink assembly Heatsink temperature monitoring device thermistor Cooling fans TT TOMMONW Refer to G5 High Horsepower Inverter Product CD for drawings and specific details Cooling of the inverter module heatsink is accomplished by use of a heatpipe heatsink assembly The IGBT s are mounted on a large aluminum block in which the heat is transferred to a finned radiator by a heatpipe assembly The heatpipe s thermal management media is provided in the form of 3M fluorine In addition honeycomb fins are attached to the heatpipe heatsink assembly and cooled by use of front mounted fans The warm air is then exhausted through a ductwork arrangement and out the top of the inverter module It is therefore extremely important to mount the inverter module upright to achieve maximum thermal conductivity CAUTION If disposal of the heatpipe heatsink assembly is required it is recommended to puncture a hole in the heatpipe s thus eliminating any chance of cylinder pressure build up The interconnect cabling and bus bar arrangement is described below Power Wiring Terminal Terminal Material Terminal Bus Bar Max Torque Symbol Connection Area sq in Ib in
26. he inverter The red LED M will be on Write the slave 1 flash file using the flash writing software While the flash is being written the green SL1 LED will flash rapidly When finished writing the flash power down the inverter 5 Move the jumper to the SL2 position Power up the inverter The red LED M will be in Write the slave 2 amp 3 flash file using the flash writing software While the flash is being written the green SL2 LED will flash rapidly When finished writing the flash power down the inverter 6 Move the jumper to the SL3 position Power up the inverter The red LED M will be on Write the slave 2 amp 3 flash file using the flash writing software While the flash is being written the green SL3 LED will flash rapidly When finished writing the flash power down the inverter 7 Move the jumper back to the M position Reinstall the metal cover on the rear of the control assembly Disconnect the flash write cable and reinstall the LCD operator in its pocket Power up the inverter and check that the LCD operator comes up to the default monitor display 23 6 APPENDIX continued 6 2 Unbalance Current Control When two or more inverter modules are connected in parallel a means to control current unbalance and circulating current between inverter modules is required This is accomplished in the G5 modular inverter by an active current unbalance regulator in software There are current unbalan
27. lating current between inverter modules during paralleling operation These parameters are in the factory level and should not be adjusted without consulting Yaskawa Electric America Inc Table 5 7 1 Parameter Name Set range Units Default Modbus adr C9 01 Circ current gain 0 0 25 5 0 1 1 0 580 H C9 02 Circ current time 0 3 25 5 0 1 ms 2 0 ms 581 H C9 03 Circ current limit 0 0 25 5 0 1 5 582 H C9 05 UNBC level 0 50 1 10 584 H C9 06 UNBC time 0 01 5 0 01 sec 2 00 sec 585 H C9 07 PWM timer flt 20 50 1 1 clock 20 586 H C9 08 A D fault detect 0 50 1 10 587 H C9 09 V Limit AVR out 0 1 0 579 H Description of parameters A C9 01 This parameter controls the gain of the unbalance regulator PI controller B C9 02 This parameter controls the integral time constant of the unbalance regulator PI controller C C9 03 This parameter controls the error or correction limit of the compensation for unbalanced current D C9 05 This parameter controls the unbalanced current fault trip level E C9 06 This parameter controls the amount of time during an unbalanced condition This unbalanced condition must be above the level set in C9 05 before an unbalance fault trip occurs F C9 07 This parameter sets the level where the timing between processors becomes out of synchronization G C9 08 This parameter sets the level where the A D converters on the control board
28. les In the past it has always been a disadvantage to achieve an efficient and economical design for parallel operation of multiple low voltage IGBTs in very large capacity inverters But with the advent of third generation devices improved gating and cooling techniques and an optimized cross current or current balance control method not only has the overall size of the inverter been decreased but the output current balance factor has increased to over 98 percent Depending on the designer s requirements each drive system may incorporate a converter section supplying the necessary energy required for the inverter module s The converter module provides the necessary DC rectified voltage to meet the performance specification for the inverter module When a maximum of two converter sections are used in parallel it is necessary to combine the correct DC link and or AC input reactor for each converter section to maintain proper load sharing of the individual converter sections The converter design has also taken into consideration the requirements for input current harmonic distortion reduction and can be configured for up to 24 pulse operation Refer to section 4 for additional details A single control unit assembly consisting of a control power supply PCB a control board and a digital operator provide the necessary control functions and I O interface for all drive system configurations whether it be a single duplex triplex quadruplex 400V
29. modules 2 3 amp 4 have a fault the appropriate green LEDs SL1 SL3 will be on as well as the red M LED If an inverter reset keypad or contact has been input and the fault still exists the red LED M will flash and if the fault is in inverter modules 2 4 the appropriate LED will be on I UNBC Fault This checks the differential current between any of the operating inverter modules This fault will occur when the magnitude of circulating current between modules exceeds C9 05 Unbalanced current detect level for the amount of time set in C9 06 unbalanced current detect time This fault is disabled if 02 04 is set for 81 H 200 KW or 91 H 300 KW J OH4 Fault This fault occurs when any of converter heatsinks reaches 105 deg C K CPEO7 Fault This fault occurs when the PWM synchronizing signal between the processors falls out of tolerance L CPFO8 Fault This fault occurs when a BCC check fails during DPRAM communication between processors M CPFO9 Fault This fault occurs when there is a general communication fault in the DPRAM communication between processors N CPF10 Fault This fault occurs when there is an error in writing data to a DPRAM during DPRAM communication between processors 22 6 APPENDIX 6 1 Flash memory writing procedure This procedure is used when it is required to write to the flash memories of the G5 modular control card The only flash data files that will work are ones specifi
30. options interface to I O G5 sequence control master control of inverter and master fault control of inverter Provides fault control PWM and current detection of inverter module 1 B Slave 1 Provides cross current control and dual port RAM control of communication between the 4 microprocessors Provides fault control PWM and current detection of inverter module 2 C Slave 2 Provides fault control PWM and current detection of inverter module 3 D Slave 3 Provides fault control PWM and current detection of inverter module 4 LED Indicators There are five LED indicators on the bottom right hand corner of the control board which are used to indicate status of the individual processors The LED s are A DSI M red LED This LED indicates a fault condition When it is steady on the inverter is in a fault state and the fault relay is energized If no other LED is on then inverter section 1 has a fault When the LED is blinking an alarm or fault condition exists but the fault relay is not energized B DS2 M green LED This LED indicates that the inverter is in the run mode C DS3 SL1 green LED This LED indicates that there is a fault with inverter section 2 D DS4 SL2 green LED This LED indicates that there is a fault with inverter section 3 E DS5 SL3 green LED This LED indicates that there is a fault with inverter section 4 16 5 INVERTER SOFTWARE continued 5 2 Software Version
31. r line resistance Ohm 0 020 0 020 0 020 0 020 E2 06 Motor leakage inductance 20 0 20 0 20 0 20 0 L2 02 Instant stop comp time sec 1 0 1 0 1 0 1 0 L2 03 Minimum baseblock time sec 4 0 4 0 4 0 4 0 Model numbers are intended for reference only 19 5 INVERTER SOFTWARE continued Table 5 6 2 600V class factory defaults based on KVA setting No NAME UNIT Model Type G5X 0 5300 5600 5900 5C00 No of inverter modules 1 2 3 4 Inverter Capacity kw 300 600 900 1200 02 04 KVA selection 91 92 93 94 B3 04 V F during speed search 80 80 80 80 C6 01 Upper limit Carrier Freq KHz 2 0 2 0 2 0 2 0 C6 02 Lower Limit Carrier Freq KHz 2 0 2 0 2 0 2 0 C6 03 Proportional gain of carrier 0 0 0 0 C7 03 Time constant of hunting msec 30 30 30 30 C8 15 ON delay time usec 15 0 15 0 15 0 15 0 C8 16 ON delay compensation usec 11 0 11 0 11 0 11 0 C8 18 Power factor detect filter 1 msec 4 4 4 4 C8 19 Power factor detect filter 2 msec 4 4 4 4 C8 27 Inverter rated current A 414 800 1200 1600 C8 28 DCCT Gain 1 290 1 290 1 290 1 290 C9 04 CT VT selection 0 CT 0 CT 0 CT 0 CT E2 01 Motor rated current A 370 0 370 0 370 0 370 0 E2 02 Motor rated slip Hz 1 30 1 30 1 30 1 30 E2 03 Motor no load current A 96 0 96 0 96 0 96 0 E2 05 Motor line resistance Ohm 0 020 0 020 0 020 0 020 E2 06 Motor leakage inductance 20 0 20 0 20 0 20 0 L2 02 Instant stop
32. rheat Pre alarm 112 continuous 112 continuous 150 for 1 minute 120 for 1 minute Model numbers are intended for reference only 21 5 INVERTER SOFTWARE continued 5 8 Major Changes from the Standard G5 Software 5 8 1 Braking transistor control software has been eliminated 5 8 2 Fault signals added changed A FU Fault Checks all inverter modules for fuse open Signal is logical OR d from each module B UV1 UV2 UV3 Faults Checks all inverter modules for power circuit control circuit and MC answer back for low voltage Signal is logical OR d from each module C SC Fault Checks all inverter modules for short circuit fault Signal is logical OR d from each module D OC Fault Checks all inverter modules for over current fault Signal is logical OR d from each module E OV Fault Checks all inverter modules for power circuit overvoltage Signal is logical OR d from each module F OH OHI Fault Checks all inverter modules for heatsink overheat warning and fault Signal is logical OR d from each module G OL2 Fault Uses current from all operating modules for calculation H UV4 Fault Checks for fault in control assembly power supply NOTE When any of the above faults occur the LEDs DS1 to DS5 on the rear of the main control board will indicate which module had the fault indicated on the operator display If inverter module 1 has a fault only the RED M LED will be on steady If inverter
33. terminal screw 20 10 12 4 1 4 0 5 5 5 10 4 DRIVE SYSTEM COMPONENTS continued 4 3 CONVERTER IGBT Type Regenerative The converter module is a metal chassis equipped with bottom rollers for rack out of the inverter enclosure Enclosed in the chassis are the following main components DC bus capacitors DC bus capacitor softcharge resistor Softcharge resistor bypass contactor IGBTs with associated snubber circuits DC Bus DCCTs and input phase current sensors Gate drive PCB DC bus fuse per phase Heatsink assembly Heatsink temperature monitoring device thermistor Cooling fans TE ROMMOOD gt Refer to G5 High Horsepower Inverter Product CD for drawings and specific details Cooling of the converter module heatsink is accomplished by use of a heatpipe heatsink assembly The IGBT s are mounted on a large aluminum block in which the heat is transferred to a finned radiator by a heatpipe assembly The heatpipe s thermal management media is provided in the form of 3M fluorine In addition honeycomb fins are attached to the heatpipe heatsink assembly and cooled by use of front mounted fans The warm air is then exhausted through a ductwork arrangement and out the top of the inverter module It is therefore extremely important to mount the converter module upright to achieve maximum thermal conductivity CAUTION If disposal of the heatpipe heatsink assembly is required it is recommended to puncture a hole
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