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YASKAWA AI-A3, Installation Manual

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5  Installation Procedure

YASKAWA ELECTRIC

 TOBP C730600 78D YASKAWA AC Drive Option AI-A3 Installation Manual

 29

Install the Option

Refer to the instructions below to install the option. 

DANGER!

Electrical Shock Hazard. Do not inspect, connect, or disconnect any wiring while the drive is 

energized. Failure to comply will cause death or serious injury. Before servicing, disconnect all power to the 

equipment and wait for at least the time specified on the warning label. The internal capacitor remains 

charged even after the drive is de-energized. The charge indicator LED will extinguish when the DC bus 

voltage is below 50 Vdc. When all indicators are OFF, measure for unsafe voltages to confirm the drive is 

safe. 

1.

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

dissipate, then remove the keypad (B) and front covers (A). 

Refer to the manual packaged with the drive for details on keypad and cover 

removal.

NOTICE:

Damage to Equipment. Observe proper electrostatic discharge (ESD) procedures when handling 

the option, drive, and circuit boards. Failure to comply could cause ESD damage to circuitry.

Figure 20  

Figure 20  Remove the Front Cover and Keypad

A – Drive front cover

B – Keypad

B

A

GEM_IO_conditional_E - コピー.fm  29 ページ  ２０２２年１月１９日　水曜日　午前９時５６分

Summary of Contents for AI-A3

Page 1: ...nual thoroughly and retain for easy reference inspection and maintenance Ensure the end user receives this manual 製品を安全にお使いいただくために この取扱説明書を必ずお読みください また 本書をお手元に保管していただくとともに 最終的に本製品をご使用になる ユーザー様のお手元に確実に届けられるよう お取り計らい願います COSMOS 140 182 和英併記 新CI MANUAL NO TOBP C730600 78D YASKAWA AC Drive Option 安川インバータ オプション ...

Page 2: ...n 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...

Page 3: ...on Manual 3 Table of Contents 1 PREFACE AND SAFETY 4 2 OVERVIEW 8 3 RECEIVING 9 4 OPTION COMPONENTS 10 5 INSTALLATION PROCEDURE 11 6 RELATED PARAMETERS 39 7 TROUBLESHOOTING 46 8 EUROPEAN STANDARDS 51 9 SPECIFICATIONS 54 GEM_IO_conditional_E コピー fm 3 ページ ２０２２年１月１９日 水曜日 午前９時５６分 ...

Page 4: ... express warranty only as to the quality of its products in conforming to standards and specifications published in the manual NO OTHER WARRANTY EXPRESS OR IMPLIED IS OFFERED YASKAWA assumes no liability for any personal injury property damage losses or claims arising from misapplication of its products Applicable Documentation The following manuals are available for the option Analog Input AI A3 ...

Page 5: ...Indicates supplemental information that is not related to safety messages Option YASKAWAAC Drive Option Analog Input Drive YASKAWAAC Drive 1000 Series A1000 U1000 YASKAWAAC Drive GA700 YASKAWAAC Drive GA800 YASKAWAAC Drive CR700 YASKAWAAC Drive CH700 YASKAWAAC Drive FP605 Keypad LCD Operator for YASKAWAAC Drive 1000 Series LED Operator for YASKAWAAC Drive 1000 Series LCD Keypad for YASKAWAAC Drive...

Page 6: ...this manual The diagrams in this manual are provided as examples only and may not pertain to all products covered by this manual 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 Contact Yaskawa or a Yaskawa representative and provide the manual number shown on the front cove...

Page 7: ...y the user Do not modify this product NOTICE Do not modify the drive or option circuitry Failure to comply could result in damage to the drive or option and will void warranty Yaskawa is not responsible for any modification of the product made by the user Do not expose the drive or the option to halogen group disinfectants Do not pack the drive or the option in fumigated or sterilized wooden mater...

Page 8: ...combined input where the drive adds the input of all signals to the option to build the frequency reference The option has an input signal of 10 to 10 Vdc 20 kΩ or 4 to 20 mA 250 Ω with three input channels DIP switches to select voltage current input 13 bit signed 1 8192 input voltage resolution and 1 4096 current input resolution Compatible Products The option can be used with the products in Ta...

Page 9: ...ame Refer to Figure 1 on page 10 for details Contact the distributor where the option was purchased or contact Yaskawa or a Yaskawa representative about any problems with the option Option Package Contents Installation Tools A Phillips screwdriver Phillips screw sizes vary by drive capacity A flat blade screwdriver blade depth 0 4 mm 0 02 in width 2 5 mm 0 1 in A pair of diagonal cutting pliers A ...

Page 10: ...l selection voltage current D Installation Hole E Connector CN5 B DIP switch S2 for terminal V2 input signal selection voltage current F Option model number G Ground terminal FE and installation hole 1 1 Connect the provided ground wire during installation Installation on GA700 GA800 CR700 and CH700 drives does not require the ground wire C DIP switch S3 for terminal V3 input signal selection volt...

Page 11: ...es to confirm the drive is safe WARNING Electrical Shock Hazard Do not operate equipment with covers removed Failure to comply could cause death or serious injury The diagrams in this section may include options and drives without covers or safety shields to illustrate details Reinstall covers and shields before operating the drive and run the drive according to the instructions described in this ...

Page 12: ...ry Never connect or disconnect the motor from the drive while the drive is outputting voltage Improper equipment sequencing could damage the drive Do not connect or operate any equipment with visible damage or missing parts Failure to comply could further damage the equipment Do not use unshielded wire for control wiring Failure to comply may cause electrical interference resulting in poor system ...

Page 13: ...on the product Refer to Table 2 to check the procedures for installing and wiring options on a drive Table 2 Option Installation and Wiring Procedures Product Series Option Installation and Wiring Procedures Page A1000 Procedure A 14 U1000 Procedure A 14 GA700 Procedure B 21 GA800 Procedure B 21 CR700 Procedure B 21 CH700 Procedure B 21 FP605 Procedure C 28 GEM_IO_conditional_E コピー fm 13 ページ ２０２２年...

Page 14: ...ure that the drive functions correctly Refer to Figure 2 for an exploded view of the drive with the option and related components for reference in the installation procedure Figure 2 Figure 2 Drive Components with Option A Insertion point for CN5 G Included screws B Option card H Ground wire C Front cover I Drive grounding terminal FE D Keypad J Connector CN5 A E Terminal cover K Connector CN5 B F...

Page 15: ...ve is de energized The charge indicator LED will extinguish when the DC bus voltage is below 50 Vdc When all indicators are OFF measure for unsafe voltages to confirm the drive is safe 1 Shut off power to the drive wait the appropriate amount of time for voltage to dissipate then remove the keypad D and front covers C E Refer to the manual packaged with the drive for details on keypad and cover re...

Page 16: ...ten both screws to 0 5 to 0 6 N m 4 4 to 5 3 in lb Note Install the option to ports CN5 B and CN5 C on the drive for monitoring purposes only and input levels will be displayed in monitors U1 21 to U1 23 The option will not set the frequency reference or replace the drive analog input with higher resolution inputs when connected to ports CN5 B or CN5 C Figure 4 Figure 4 Insert the Option Card J G ...

Page 17: ...ckage includes three ground wires Use the longest wire to connect the option to CN5 C Use the next longest wire to connect the option to CN5 B Use the shortest wire to connect the option to CN5 A Refer to Option Package Contents on page 9 for more information 2 The drive has only two ground terminal screw holes I Two ground wires should share the same ground terminal when connecting three options ...

Page 18: ...ble shielding does not contact other wiring Insufficient insulation may cause a short circuit and damage the option or drive Figure 7 Figure 7 Prepare Ends of Shielded Cable 6 Wire the customer supplied analog input signal to terminal block on the option according to Figure 8 Refer to Figure 29 for the AI A3 Option connection diagram Refer to Table 5 for a detailed description of the option termin...

Page 19: ... onto the drive Users may also choose to route the option wiring through openings on the front cover of some models Remove the perforated tabs on the left side of the front cover as shown in Figure 9 A to create the necessary openings on these models Refer to the Peripheral Devices Options section of the drive instruction manual for more information Figure 9 Figure 9 Wire Routing Examples A B GEM_...

Page 20: ...front covers C E and the keypad D NOTICE Do not pinch cables between the front covers and the drive Failure to comply could cause erroneous operation Figure 10 Figure 10 Replace the Front Covers and Keypad 9 Set drive parameters in Table 6 for correct option performance C D E GEM_IO_conditional_E コピー fm 20 ページ ２０２２年１月１９日 水曜日 午前９時５６分 ...

Page 21: ...l packaged with the drive 2 Make sure that the drive functions correctly Refer to Figure 11 for an exploded view of the drive with the option and related components for reference in the installation procedure Figure 11 Figure 11 Drive Components with Option A Insertion point for CN5 connector F LED Status Ring board B AI A3 option G Connector CN5 A C Included screws H Connector CN5 B D Drive front...

Page 22: ...rm the drive is safe 1 Shut off power to the drive wait the appropriate amount of time for voltage to dissipate confirm all charge indicator LEDs extinguish then remove the front cover D including the keypad E Refer to the manual packaged with the drive for details on cover removal NOTICE Observe proper electrostatic discharge ESD procedures when handling the option drive and circuit boards Failur...

Page 23: ... temporary placement holes Refer to the manual packaged with the drive for details on removing the LED Status Ring board NOTICE Do not remove the LED Status Ring board cable connector Failure to comply could cause erroneous operation and damage the drive Figure 13 Figure 13 Remove the LED Status Ring Board F Drive front view Temporary placement holes AI GEM_IO_conditional_E コピー fm 23 ページ ２０２２年１月１９...

Page 24: ...on other product series Do not use the ground wire or the extra screw 2 Install the option to ports CN5 B and CN5 C on the drive for monitoring purposes only and input levels will be displayed in monitors U1 21 to U1 23 The option will not set the frequency reference or replace the drive analog input with higher resolution inputs when connected to ports CN5 B or CN5 C Figure 14 Figure 14 Insert th...

Page 25: ...Figure 17 Connect Cable Wiring Insulation Shield Shield sheath Option terminal Customer supplied analog input signal FE Insulate with electrical tape or heat shrink tubing AI Option terminal block Preparing wire ends Screwdriver blade size about 5 5 mm 0 21 in When not using crimped insulated sleeves Pull back the shielding and lightly twist the end with fingers keeping the ends from fraying Wire ...

Page 26: ...cover of the drive D including the keypad E Figure 18 Figure 18 Replace the LED Status Ring Board Front Cover and Keypad F Install the keypad to the drive after replacing the keypad connector and then the keypad connector At that time insert the keypad connector tab into the drive Keypad connector Tab D E AI GEM_IO_conditional_E コピー fm 26 ページ ２０２２年１月１９日 水曜日 午前９時５６分 ...

Page 27: ...rd to route option wiring when using connector CN5 B NOTICE Do not pinch cables between the front cover or the LED Status Ring board and the drive Failure to comply could cause erroneous operation 8 Set drive parameters in Table 6 for correct option performance Use the open space provided inside the LED Status Ring board to route option wiring F AI GEM_IO_conditional_E コピー fm 27 ページ ２０２２年１月１９日 水曜日...

Page 28: ...the drive 2 Make sure that the drive functions correctly Refer to Figure 19 for an exploded view of the drive with the option and related components for reference in the installation procedure Figure 19 Figure 19 Drive Components with Option A Drive grounding terminal FE F Ground wire B Option card G Option modular connector CN1 C Included screws H Insertion point for connector CN5 B D Drive front...

Page 29: ...de energized The charge indicator LED will extinguish when the DC bus voltage is below 50 Vdc When all indicators are OFF measure for unsafe voltages to confirm the drive is safe 1 Shut off power to the drive wait the appropriate amount of time for voltage to dissipate then remove the keypad B and front covers A Refer to the manual packaged with the drive for details on keypad and cover removal NO...

Page 30: ...e Option AI A3 Installation Manual 2 Remove the screw B installed in the drive grounding terminal A Figure 21 Figure 21 Remove the Screw from the Drive Grounding Terminal A Drive grounding terminal FE B Included screw A B GEM_IO_conditional_E コピー fm 30 ページ ２０２２年１月１９日 水曜日 午前９時５６分 ...

Page 31: ...e end of the included ground wire C to the ground terminal on the drive Tighten the screw to a correct tightening torque 0 5 N m to 0 6 N m 4 4 in lb to 5 3 in lb Note Route ground wire on the right side of the stud D Figure 22 Figure 22 Connect the Ground Wire A Drive grounding terminal FE C Ground wire B Included screw D Stud B A D C GEM_IO_conditional_E コピー fm 31 ページ ２０２２年１月１９日 水曜日 午前９時５６分 ...

Page 32: ...rew B to put it in place Tighten the screw to a correct tightening torque 0 5 N m to 0 6 N m 4 4 in lb to 5 3 in lb Note 1 Only two screws are necessary to install the option on FP605 drive 2 The option package contains three screws and three ground wires Figure 23 Figure 23 Install the Option A Option C Connector CN5 B Included screw B A C GEM_IO_conditional_E コピー fm 32 ページ ２０２２年１月１９日 水曜日 午前９時５６分...

Page 33: ...e ground terminal and installation hole on the option Tighten the screw to a correct tightening torque 0 5 N m to 0 6 N m 4 4 in lb to 5 3 in lb Note Refer to Figure 24 for instruction about crimp terminal orientation C and wire routing Figure 24 Figure 24 Connect the Ground Wire A Ground wire C Crimp terminal B Included screw A B C GEM_IO_conditional_E コピー fm 33 ページ ２０２２年１月１９日 水曜日 午前９時５６分 ...

Page 34: ...nto electrical terminals WARNING Fire Hazard Tighten all terminal screws according to the specified tightening torque Loose electrical connections could result in death or serious injury by fire due to overheating electrical connections Tightening screws beyond the specified tightening torque may cause erroneous operation damage the terminal block or cause a fire NOTICE Heat shrink tubing or elect...

Page 35: ...inal functions Figure 27 Figure 27 Connect Cable Wiring Option terminal block Preparing wire ends Screwdriver blade size about 5 5 mm 0 21 in When not using crimped insulated sleeves Pull back the shielding and lightly twist the end with fingers keeping the ends from fraying Wire crimping ferrule terminals or not soldered ends Loosen the screws and insert the wire into the opening on the terminal ...

Page 36: ...and the keypad B NOTICE Do not pinch cables between the front covers and the drive Failure to comply could cause erroneous operation Figure 28 Figure 28 Replace the Front Covers and Keypad 10 Set the drive parameters in Table 6 for correct option performance A Drive front cover B Keypad B A GEM_IO_conditional_E コピー fm 36 ページ ２０２２年１月１９日 水曜日 午前９時５６分 ...

Page 37: ...605 drives The ground wire is not necessary for installation on GA700 GA800 CR700 and CH700 drives Terminal signal Screw Size Tightening Torque N m in lb Bare Wire Ferrule Type Terminals Wire Type Recommended Gauge mm2 Applicable Gauges mm2 Recommended Gauge mm2 Applicable Gauges mm2 V1 V2 V3 AC FE M2 0 22 to 0 25 1 95 to 2 21 0 75 18 AWG Stranded wire 0 25 to 1 0 24 to 17 AWG Solid wire 0 25 to 1...

Page 38: ...2 mm in 0 25 24 AWG AI 0 25 6YE 10 5 13 32 0 8 1 32 2 5 64 0 34 22 AWG AI 0 34 6TQ 10 5 13 32 0 8 1 32 2 5 64 0 5 20 AWG AI 0 5 6WH 14 9 16 1 1 3 64 2 5 3 32 Terminal Function Signal Level Description Voltage Current DIP switch Linear Accuracy V1 1 Default setting is for voltage input 2 At an ambient temperature of 25 C 77 F Analog signal input 1 10 to 10 V or 4 to 20 mA Input terminals for an ana...

Page 39: ... is input Set parameter F2 01 to 0 to increase the accuracy of A D conversion while using the functions for terminals A1 to A3 of the drive as they are with their current settings The function for terminal A1 of the drive is replaced in terminal V1 on the option The function for terminal A2 of the drive is replaced in terminal V2 on the option The function for terminal A3 of the drive is replaced ...

Page 40: ... mA AI A3 V3 voltage input 10 to 10 V or current input 4 to 20mA Current input I position Voltage input V position Current input I position Voltage input V position Current input I position Voltage input V position H3 13 Primary filter Terminal V1 input switch S1 Terminal V2 input switch S2 Terminal V3 input switch S3 H3 13 0 0 0 H3 13 Primary filter H3 13 H3 13 H3 13 Primary filter 0 H3 08 H3 07 ...

Page 41: ...ally When you select the signal level set the DIP switch S1 to S3 on the AI A3 option card to align with the input source and set these parameters F2 04 Terminal V1 Signal Level Select F2 08 Terminal V2 Signal Level Select F2 12 Terminal V3 Signal Level Select Figure 32 shows the analog input for terminal A1 and Figure 33 shows the additional input for AI A3 terminal V1 Figure 31 Figure 32 Analog ...

Page 42: ...bined input signal of 100 yields a frequency reference 50 of the maximum frequency reference A combined input of 200 yields a frequency reference equal to the maximum output frequency Example 2 If the gain in F2 02 is set to 200 and the bias in F2 03 is set to 0 a combined input signal of 50 yields a frequency reference equal to the maximum output frequency Increasing the combined input signal of ...

Page 43: ...dded Together 2 3 Additional Channels 3 Default 0 Range 0 1 2 3 F2 02 368 RUN 2 Analog Input Option Card Gain Sets the gain for the input signal to the analog card Default 100 0 Min 999 9 Max 999 9 F2 03 369 RUN 2 Analog Input Option Card Bias Sets the bias for the input signal to the analog card Default 0 0 Min 999 9 Max 999 9 F2 04 3160 3 Terminal V1 Signal Level Select Sets the input signal lev...

Page 44: ...put to MFAI terminal V3 Default 100 0 Min 999 9 Max 999 9 F2 15 316B 3 Terminal V3 Bias Setting Sets the bias of the analog signal input to MFAI terminal V3 Default 0 0 Min 999 9 Max 999 9 H3 02 434 Terminal A1 Function Selection Selects the function assigned to analog input terminal A1 Default 0 Range 0 to 32 H3 03 411 RUN Terminal A1 Gain Setting Sets the level of the selected input value that i...

Page 45: ...in 0 00 Max 2 00 1 When the option is not installed in the drive the functionality of analog input terminals A1 to A3 on the drive are enabled regardless of the setting of F2 01 2 This parameter is only enabled when F2 01 is set to 1 Analog Input Function Selection 3 Channels Added Together 3 This parameter is available only with FP605 No Hex Name Description Analog Output Level Unit U1 21 77 AI A...

Page 46: ...ion into the drive according to Installation Procedure on page 11 Keypad Display Fault Name oFb01 Option Card Fault CN5 B Option is not properly connected Cause Possible Solution Option in drive port CN5 B was changed during run De energize the drive and plug the option into the drive according to Installation Procedure on page 11 Keypad Display Fault Name oFb02 Option Fault CN5 B Two identical op...

Page 47: ...een set while an option is installed H1 2 External Reference 1 2 Selection b1 15 3 Option PCB The action for the analog card is set for separate terminal input F2 01 0 Make sure parameters are set properly Keypad Display Fault Name oPE07 Multi Function Analog Input Selection Error Cause Possible Solution At least two analog input terminals are set to the same function i e at least two of these par...

Page 48: ...13 at the same time set F2 01 2 These parameters are set at the same time when F2 01 2 F2 05 F2 09 F2 13 H3 40 H3 41 H3 42 C PID Setpoint H6 01 2 The settings for F2 05 F2 09 and F2 13 overlap when F2 01 2 Set the parameters correctly to prevent overlap Set F2 01 2 The settings for F2 05 F2 09 F2 13 and the settings for these parameters overlap when F2 01 2 H3 02 H3 06 H3 10 H3 40 H3 41 H3 42 H7 3...

Page 49: ...Limit the length of wiring under 10 m 32 ft Separate the control wiring to the option main circuit wiring and power lines Option Card 1 Not available with FP605 2 When connecting two PG option cards use both CN5 B and CN5 C When connecting only one PG option card use the CN5 C connector 3 Not available for the application with Motor 2 Selection 4 Not available with 1000 Series products with a capa...

Page 50: ...BP C730600 78D YASKAWA AC Drive Option AI A3 Installation Manual Interface Circuit Figure 33 Figure 34 Interface Circuit TB1 V1 V2 V3 AC 10 kΩ 10 kΩ 250 Ω Signal processor S1 to S3 AI GEM_IO_conditional_E コピー fm 50 ページ ２０２２年１月１９日 水曜日 午前９時５６分 ...

Page 51: ... mark in combination with other devices it is ultimately the responsibility of the user to ensure compliance with CE standards Verify that conditions meet European standards after setting up the device EMC Guidelines Compliance This option is tested according to European standards EN 61800 3 2004 A1 2012 and complies with EMC guidelines The CE marking is declared based on the harmonized standards ...

Page 52: ...r CE Compliance 1000 Series GA700 GA800 CR700 CH700 L1 L2 L3 L1 L2 L3 R CN5 B CN5 C CN5 A CN5 B CN5 C CN5 A S T PG Drive EMC filter PG option DI DO AI AO I O option SI Communication option Encoder I O device Master Cable clamp Enclosure panel Three phase power supply Cable clamp Cable clamp A1 GEM_IO_conditional_E コピー fm 52 ページ ２０２２年１月１９日 水曜日 午前９時５６分 ...

Page 53: ... Option Installation for CE Compliance FP605 3 Ground the largest possible surface area of the shield to the metal panel Yaskawa recommends using cable clamps Figure 37 Figure 38 Ground Area A Braided shield cable C Cable clamp conductive B Metal panel Three A1000 C B A GEM_IO_conditional_E コピー fm 53 ページ ２０２２年１月１９日 水曜日 午前９時５６分 ...

Page 54: ...pedance 250 Ω Input resolution 12 bit 1 4096 Linear Precision 0 1 at 25 C 77 F Ambient Temperature 10 C to 50 C 14 F to 122 F Humidity 95 RH or lower with no condensation Storage Temperature 20 C to 60 C 4 F to 140 F allowed for short term transport of the product Area of use Indoors and free from Oil mist corrosive gas flammable gas and dust Radioactive materials or flammable materials including ...

Page 55: ...ble regional local and municipal laws and regulations WEEE Directive The wheelie bin symbol on this product its manual or its packaging identifies that you must recycle it at the end of its product life You must discard the product at an applicable collection point for electrical and electronic equipment EEE Do not discard the product with usual waste GEM_IO_conditional_E コピー fm 55 ページ ２０２２年１月１９日 ...

Page 56: ...tion July 2020 4 0 Back cover Revision Address October 2018 3 0 All Addition Applicable product series Revision Reviewed and corrected entire documentation Back cover Revision Address October 2017 2 0 Back cover Revision Address April 2017 1 0 All Addition Applicable product series Revision Reviewed and corrected entire documentation Back cover Revision Address April 2016 First edition MANUAL NO T...

Page 57: ... co th YASKAWA ELECTRIC CHINA CO LTD 22F Link Square 1 No 222 Hubin Road Shanghai 200021 China Phone 86 21 5385 2200 Fax 86 21 5385 3299 www yaskawa com cn YASKAWA ELECTRIC CHINA CO LTD BEIJING OFFICE Room 1011 Tower W3 Oriental Plaza No 1 East Chang An Avenue Dong Cheng District Beijing 100738 China Phone 86 10 8518 4086 Fax 86 10 8518 4082 YASKAWA ELECTRIC TAIWAN CORPORATION 12F No 207 Section 3...

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