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GA800 Drive

AC Drive for Industrial Applications

Installation & Primary Operation

Catalog Code: GA80UTxxxxxxx

6-Phase/12-Pulse 400 V Class: 75 to 600 HP

PDF

Summary of Contents for T103

Page 1: ...GA800 Drive AC Drive for Industrial Applications Installation Primary Operation Catalog Code GA80UTxxxxxxx 6 Phase 12 Pulse 400 V Class 75 to 600 HP PDF...

Page 2: ...This Page Intentionally Blank 2 YASKAWA TOEPC71061782C GA800 Drive Installation Primary Operation...

Page 3: ...rackets to Move the Drive 15 Installation Position and Clearances 16 Install Single Drive 16 Removing Reattaching Covers 16 Removing Reattaching the Cover Using Procedure A 17 Removing Reattaching the...

Page 4: ...TC Input 51 Set Output Signals for MFAO Terminals FM AM 51 Switch ON Termination Resistor for MEMOBUS Modbus Communications 52 11 Drive Control Duty Modes and Programming 52 Control Method Selection 5...

Page 5: ...Using the Safe Disable Function 75 Safe Disable Circuit 75 Connect Safe Disable Input Contacts to Multiple Drives 75 Enabling and Disabling the Drive Output Safe Torque Off 78 Safe Disable Monitor Ou...

Page 6: ...uality of our products in compliance with standards and specifications that are described in the manual Yaskawa does not offer other warranties either explicit or implied Injuries property damage and...

Page 7: ...mponent in the protective earthing conductor the drive can cause a residual current When a residual current operated protective or monitoring device prevents direct or indirect contact always use a ty...

Page 8: ...duct for special purposes such as machines or systems used for passenger cars medicine airplanes and aerospace nuclear power electric power or undersea relaying WARNING Injury to Personnel When you us...

Page 9: ...e Figure 4 1 Nameplate Example How to Read the Catalog Code Use the information in Figure 4 2 and Table 4 1 to read the drive catalog code Figure 4 2 Drive Catalog Code Table 4 1 Catalog Code Details...

Page 10: ...s side by side Use C6 01 Normal Heavy Duty Selection to select Normal Duty rating ND or Heavy Duty rating HD Table 4 2 Rated Output Current 6 Phase 12 Pulse 400 V Class Model Heavy Duty Rating HD C6 0...

Page 11: ...g inputs 1 2048 of the maximum output frequency 11 bit signed Output Frequency Resolution 0 001 Hz Frequency Setting Signal Main speed frequency reference 10 Vdc to 10 Vdc 20 k 0 Vdc to 10 Vdc 20 k 4...

Page 12: ...n Torque Compensation Frequency Jump Upper Lower Limits for Frequency Reference DC Injection Braking at Start and Stop Overexcitation Braking High Slip Braking PID Control with Sleep Function Energy S...

Page 13: ...ransportation Surrounding Area Pollution degree 2 or less Install the drive in an area without Oil mist corrosive or flammable gas or dust Metal powder oil water or other unwanted materials Radioactiv...

Page 14: ...drive dimension information refer to the Technical Reference manual document number SIEPC71061737 For IP55 UL Type 12 Heatsink External Mounting dimension information refer to the Installation Manual...

Page 15: ...ipment Refer to Using the Hanging Brackets to Move the Drive on page 15 for information about how to use suspension systems wires or hanging metal brackets to move the drive Using the Hanging Brackets...

Page 16: ...kawa representative for more information about installing drive models on their side A Vertical installation B Horizontal installation Figure 6 1 Installation Orientation Install Single Drive Use the...

Page 17: ...ectrical shock Remove the Front Cover 1 Remove the keypad and the keypad connector then insert the end of the keypad connector that has the tab into the keypad connector holder on the front cover A Ke...

Page 18: ...energized The charge indicator LED extinguishes when the DC bus voltage decreases below 50 Vdc When all indicators are OFF remove the covers before measuring for dangerous voltages to make sure that t...

Page 19: ...10 Remove the Front Cover Reattach the Front Cover Wire the drive and other peripheral devices then reattach the front cover Note Wire the grounding terminals first main circuit terminals next and co...

Page 20: ...r can fall and cause moderate injury Figure 6 13 Loosen the Terminal Cover Mounting Screws 2 Pull the terminal cover away from the drive Figure 6 14 Remove the Terminal Cover Reattach the Terminal Cov...

Page 21: ...ARNING Sudden Movement Hazard Set the MFDI parameters before you close control circuit switches Incorrect Run Stop circuit sequence settings can cause serious injury or death from moving equipment WAR...

Page 22: ...al Installation 22 YASKAWA TOEPC71061782C GA800 Drive Installation Primary Operation Standard Connection Diagram for 6 Phase 12 Pulse Drives Figure 7 1 Standard Drive Connection Diagram 6 Phase 12 Pul...

Page 23: ...ve Sinking Mode Internal power supply Install the jumper to close the circuit between terminals SC SP NOTICE Damage to Equipment Do not close the circuit between terminals SC SN If you close the circu...

Page 24: ...ound the drive Motor and Main Circuit Connections WARNING Electrical Shock Hazard Do not connect terminals R L1 S L2 T L3 R1 L11 S1 L21 T1 L31 U L1 V L2 W L3 or 3 to the ground terminal If you connect...

Page 25: ...aking resistor connections If you connect a braking resistor to the incorrect terminals it can cause damage to the drive and braking circuit and serious injury or death Wire Gauge and Torque Specifica...

Page 26: ...0 16 95 24 M8 15 3 135 4 4 1 0 25 50 M8 9 11 79 7 97 4 T168 R L1 S L2 T L3 R1 L11 S1 L21 T1 L31 1 1P 2 4 1 0 25 50 18 M6 3 1 3 8 28 33 U T1 V T2 W T3 4 0 2 0 4 0 70 95 33 M8 20 175 3 1 0 6 3 0 16 95...

Page 27: ...L2 T L3 R1 L11 S1 L21 T1 L31 2 0 2P 2 2 0 300 70 150 M12 35 310 U T1 V T2 W T3 4 0 4P 2 0 300 70 150 M12 35 310 3 3 0 4P 2 250 35 120 M12 35 310 1 0 1 0 300 50 150 M12 32 40 283 354 T568 R L1 S L2 T L...

Page 28: ...n the manual Do not use bent or crushed wires Remove the damaged end of the wire before you use it Incorrect connections can cause death or serious injury from fire Do not solder stranded wire Soldere...

Page 29: ...Relief Example Table 7 3 Recommended Wiring Tools Screw Size Screw Shape Adapter Bit Torque Driver Model Tightening Torque Torque Wrench Model Manufacturer M5 Bit F BIT SL 1 2X6 5 70 PHOENIX CONTACT...

Page 30: ...iring the Main Circuit Terminal Block Note After the wiring do not twist or shake the electrical wires too much Be sure to use only wires with the correct size stripped wire length and tightening torq...

Page 31: ...2 Wire the closed loop crimp terminal to the main circuit terminal block Figure 7 9 Install the Electrical Wire 3 Tighten the nut to the specified torque Figure 7 10 Tighten the Terminal Block Nut 4 P...

Page 32: ...er Run Stop commands and the frequency reference command REMOTE Use the control circuit terminals or serial transmission to operate the drive Use the frequency reference source entered in b1 01 and th...

Page 33: ...these properties Nominal voltage 3 V Operating temperature range 20 C to 85 C 4 F to 185 F M Insulation Sheet An insulating sheet is attached to the keypad battery to prevent battery drain Remove the...

Page 34: ...8 Keypad Names and Functions 34 YASKAWA TOEPC71061782C GA800 Drive Installation Primary Operation Keypad Mode and Menu Displays Figure 8 2 Keypad Functions and Display Levels...

Page 35: ...ng Mode Set b1 08 0 Disregard RUN while Programming to reject the Run command from an external source while in Programming Mode default Set b1 08 1 Accept RUN while Programming to accept the Run comma...

Page 36: ...example in Programming Mode or when is flashing C RUN Illuminated The drive is in regular operation Flashing 1 The drive is decelerating to stop The drive received a Run command with a frequency refe...

Page 37: ...f necessary 5 Run the motor without a load 6 Make sure that the drive is operating correctly and make sure that the host controller is sending commands to the drive 7 Connect the load 8 Run the motor...

Page 38: ...lithium battery or an equivalent battery with these properties Nominal voltage 3 V Operating temperature range 20 C to 85 C 4 F to 185 F Nominal battery life 2 years 20 C 68 F ambient temperature 3 Se...

Page 39: ...en push 6 Push or to select C1 01 then push 7 Push or to select the specified digit then push or to select the correct number Push Default to set the parameter to factory default Push Min Max to show...

Page 40: ...ive is energized Control Circuit Terminal Block Functions Hx xx parameters set functions for the multi function input and output terminals WARNING Sudden Movement Hazard Correctly wire and test all co...

Page 41: ...it will cause damage to the drive External power supply No jumper necessary between terminals SC SN and terminals SC SP S2 MFDI selection 2 ON Reverse run OFF Stop S3 MFDI selection 3 External fault...

Page 42: ...S4 to PTC and set DIP switch S1 3 to V to set terminal A3 for PTC input AC Frequency reference common 0 V E G Connecting shielded cable Output Terminals Refer to Table 10 2 and Table 10 3 for a list...

Page 43: ...al Communication Terminals Type Terminal Terminal Name Function Signal Level Modbus Communication D Communication input output MEMOBUS Modbus communications Use an RS 485 cable to connect the drive No...

Page 44: ...Control Circuit Wire Gauges and Tightening Torques Terminal Block Terminal Screw Size Tightening Torque N m lbf in Bare Wire Crimp Ferrule Recomm Gauge mm2 AWG Applicable Gauge mm2 AWG Recomm Gauge mm...

Page 45: ...m other control circuit wiring If contact output terminal wiring is adjacent to other control circuit wiring it can cause incorrect operation of the drive and equipment from electrical interference Us...

Page 46: ...s to the correct tightening torque Connections that are too loose or too tight can cause incorrect operation and damage to the drive Incorrect connections can also cause death or serious injury from f...

Page 47: ...loose or too tight can cause incorrect operation and damage to the drive Incorrect connections can also cause death or serious injury from fire Refer to Figure 10 9 for information to prepare terminal...

Page 48: ...al type voltage current V voltage input D DIP switch S4 A3 Sets MFAI or PTC input AI analog input Control I O Connections This section gives information about the settings for the listed control circu...

Page 49: ...k Sinking current mA 10 8 Vdc to 16 5 Vdc 1 0 k or more 16 mA maximum A External power supply B Load Impedance C Sinking current Figure 10 13 Wiring to Use Pulse Train Output in Sinking Mode Set Sink...

Page 50: ...evel A1 Voltage input S1 1 V Default H3 01 0 0 V to 10 V 0 to 100 input impedance 20 k 1 10 V to 10 V 100 to 100 input impedance 20 k Current input I 2 4 mA to 20 mA 0 to 100 input impedance 250 3 0 m...

Page 51: ...I Set MFAI Terminal A3 to PTC Input Set terminal A3 as an MFAI or as the PTC input for motor overload protection Use DIP switch S4 to set the input function Figure 10 15 Location of DIP Switch S4 Term...

Page 52: ...in termination resistor for the RS 485 interface Figure 10 17 Location of DIP Switch S2 Table 10 10 MEMOBUS Modbus Communications Termination Resistor Setting DIP Switch S2 Description ON The built i...

Page 53: ...ning WARNING Injury to Personnel Rotational Auto Tuning rotates the motor at 50 or more of the motor rated frequency Make sure that there are no issues related to safety in the area around the drive a...

Page 54: ...r PM The parameter is available when operating the drive with EZ Open Loop Vector Control RUN You can change the parameter setting during drive operation Note Gray icons identify parameters that are n...

Page 55: ...e deceleration time at start C2 04 020E S Curve Time End of Decel Sets the S curve deceleration time at completion C6 01 0223 Normal Heavy Duty Selection Sets the drive duty rating 0 Heavy Duty Rating...

Page 56: ...20 mA 3 0 to 20 mA H3 02 0434 Terminal A1 Function Selection Sets the function for MFAI terminal A1 H3 03 0411 RUN Terminal A1 Gain Setting Sets the gain of the analog signal input to MFAI terminal A...

Page 57: ...bias of the monitor signal that is sent from MFAO terminal FM H4 04 0420 Terminal AM Analog Output Select Sets the monitoring number to be output from the MFAO terminal AM H4 05 0421 RUN Terminal AM A...

Page 58: ...s mark appears on products in the United States and Canada It shows UL approval indicating that it has been determined that the product complies with safety standards after undergoing strict inspectio...

Page 59: ...terminals are correctly connected The metric wire gauge values are provided as reference information from equivalent AWG sizes and not exactly the same sizes as the AWG kcmil values Obey local safety...

Page 60: ...ting semiconductor protection fuses on the input side for branch circuit protection Refer to 6 Phase 12 Pulse 400 V Class on page 61 for more information about recommended fuses WARNING Electrical Sho...

Page 61: ...C Uses the LVLC power supply in the drive Pulse train output MP AC Uses the LVLC power supply in the drive Use the UL Listed class 2 power supply for external power supply Pulse train input RP AC Uses...

Page 62: ...tection Enter the motor rated current written on the motor nameplate Auto Tuning the drive will automatically set E9 06 to the value input for Motor Rated Current L1 01 Motor Overload oL1 Protection N...

Page 63: ...Hz base frequency The overload tolerance decreases as motor speed decreases because the cooling fan speed decreases and the ability of the motor to cool decreases in the low speed range The overload...

Page 64: ...d at 100 load will cause motor overload 4 PM Variable Torque Use this setting for PM motors with derated torque characteristics The overload tolerance decreases as motor speed decreases because the co...

Page 65: ...s than commercial line power the drive will detect oL1 The drive triggers a fault relay output and the motor coasts to stop L1 02 Motor Overload Protection Time No Hex Name Description Default Range L...

Page 66: ...Fault relay output terminal MA MC turns ON and MB MC turns OFF 3 Alarm Only The keypad shows oH3 and the drive continues operation The output terminal set for Alarm H2 01 to H2 03 10 activates L1 04 M...

Page 67: ...7 The customer must display the CE Mark on the final device containing this product Customers must verify that the final device complies with EU standards EU Declaration of Conformity Go to www yaskaw...

Page 68: ...ls and 3 to connect options to the drive WARNING Sudden Movement Hazard Make sure that the polarity is correct before you send a Run command If the drive incorrectly detects the polarity the drive can...

Page 69: ...nce 100 m 328 ft maximum Normal Duty rated current value Refer to the instruction manual for each device for recommended wire gauges to connect peripheral devices or options to terminals and 3 Contact...

Page 70: ...70 2 35 70 M10 20 177 95 95 240 M10 18 23 159 204 T371 R L1 S L2 T L3 R1 L11 S1 L21 T1 L31 95 1 2 70 150 M12 35 310 U T1 V T2 W T3 120 2 70 150 M12 35 310 3 70 2 35 150 M12 35 310 120 120 240 M12 32...

Page 71: ...askawa recommends connecting semiconductor protection fuses on the input side for branch circuit protection WARNING Electrical Shock Hazard After the drive blows a fuse or trips a GFCI do not immediat...

Page 72: ...within this period and will have no serious impact on the environment the human body or property The environment friendly use period for this product is 15 years This period is not the product warran...

Page 73: ...Unified Standards Functional Safety IEC EN 61508 2010 SIL3 IEC EN 62061 2005 A2 2015 SILCL3 IEC EN 61800 5 2 2007 SILCL3 Machine Safety ISO EN ISO 13849 1 2015 Cat 3 PL e EMC IEC61000 6 7 2014 EN61000...

Page 74: ...energized and there is no cover over the electronic circuits it can cause serious injury or death WARNING Sudden Movement Hazard Although the Safe Disable function is in operation gravity or other ext...

Page 75: ...circuit has two isolated channels terminals H1 and H2 that stop the output transistors The input can use the internal power supply of the drive Set the EDM function to one of the MFDO terminals H2 xx...

Page 76: ...nect Safe Disable contacts These conditions limit the number of units to connect External power supply capacity Number of MFDIs used Supply current to the external sensors HC Drive 1 SN H1 H2 E G HC D...

Page 77: ...2 1 This is when you use a maximum of 150 mA 2 24 V 12 mA is necessary for each drive Use the this formula to calculate the number of units to connect n Number of units to connect Iomax Maximum curre...

Page 78: ...terminals H1 and H2 are only open for less than 3 ms Going from Safe Torque Off to Usual Operation The safety input will only release when there is no Run command During Stop When the Safe Disable fun...

Page 79: ...ing the Safe Disable Function After you replace parts or do maintenance on the drive first complete all necessary wiring to start the drive then test the Safe Disable input with these steps Keep a rec...

Page 80: ...ain the drive and peripheral devices regularly to extend the life of the drive and decrease performance deterioration decrease early wear and decrease drive failures Regular examinations and maintenan...

Page 81: ...he braking transistor is high the regeneration power or repetition frequency is high Install a braking unit CDBR series Install a regenerative converter Increase the deceleration time bUS Option Commu...

Page 82: ...ns that rotate the motor from the load side in the opposite direction of the speed reference The drive will not detect this fault if F1 19 0 Deviation 4 Detection Selection Disabled E5 11 Encoder Z Pu...

Page 83: ...ct Yaskawa or your nearest sales representative to replace the board FAn1 Drive Cooling Fan Fault The cooling fan stopped operating correctly Examine cooling fan operation Re energize the drive Examin...

Page 84: ...ontact Yaskawa or your nearest sales representative The acceleration time is too short Calculate the torque necessary during acceleration related to the load inertia and the specified acceleration tim...

Page 85: ...Card Error Occurred at Option Port CN5 A A fault occurred in the option card 1 De energize the drive 2 Make sure that the option card is correctly connected to the connector 3 If the problem continue...

Page 86: ...nk Overheat The ambient temperature is high and the heatsink temperature of the drive is more than the oH1 detection level Measure the ambient temperature Increase the airflow in the control panel Ins...

Page 87: ...xcitation deceleration Decrease the value set in n3 13 OverexcitationBraking OEB Gain Decrease the value set in n3 21 HSB Current Suppression Level oL2 Drive Overload The load is too large Decrease th...

Page 88: ...rive Perform Deceleration Rate Tuning The acceleration time is too short Make sure that sudden drive acceleration does not cause the fault Increase the values set in C1 01 C1 03 C1 05 or C1 07 Acceler...

Page 89: ...or your nearest sales representative If drive input power is correct and the fault stays replace the control board or the drive For information about replacing the control board contact Yaskawa or you...

Page 90: ...ontrol board contact Yaskawa or your nearest sales representative Minor Faults Alarms This section gives information about the causes and possible solutions when a minor fault or alarm occurs Use the...

Page 91: ...lection was outside the range of H2 27 Comparator 2 Lower Limit and H2 28 Comparator 2 Upper Limit Examine the monitor value and remove the cause of the error CrST Cannot Reset The drive received a fa...

Page 92: ...d the external fault and remove the cause 2 Clear the external fault input in the MFDI The wiring is incorrect Correctly connect the signal line to MFDI terminal S6 External Fault H1 06 2C to 2F is se...

Page 93: ...ower the ambient temperature Remove objects near the drive that are producing too much heat oH2 External Overheat H1 XX B An external device sent an oH2 1 Find the external device that output the over...

Page 94: ...ected wires in the encoder cable and repair problems PGoH Encoder PG Hardware Fault The encoder cable is disconnected Correct any disconnected wires in the encoder cable rUn Motor Switch during Run Th...

Page 95: ...ulti Function Inputs 1 to 4 Correct the parameter settings oPE05 Run Cmd Freq Ref Source Sel Err The setting to assign the Run command or frequency reference to an option card or the pulse train input...

Page 96: ...eedforward d2 02 0 0 Frequency Reference Lower Limit 0 0 Correct the parameter settings These parameters are set at the same time b5 01 1 2 Enabled Standard Enabled D Feedforward b5 11 1 PID Output Re...

Page 97: ...ble to set H2 01 to H2 03 1xx Inverse output of xx when using output functions for logic operations H2 60 H2 63 H2 66 F These parameter pairs are set incorrectly H2 21 Comparator 1 Lower Limit H2 22 C...

Page 98: ...Injection or n8 57 1 HFI Overlap Selection Enabled make sure that the motor does not rotate in reverse at start If there is unusual noise in the low speed range 10 or less increase n8 41 in increment...

Page 99: ...r inductance were not in the applicable range 1 Make sure that the input motor nameplate data is correct 2 Do Auto Tuning again and correctly set the motor nameplate data Er 20 Stator Resistance Error...

Page 100: ...er restore did not end correctly Restore the parameters CSEr Control Mode Mismatch The keypad is broken Replace the keypad dFPS Drive Model Mismatch You tried to restore parameters to a different driv...

Page 101: ...n History Date of Publication Revision Number Section Revised Content September 2021 2 17 Addition Australian Standard April 2021 1 All Revision Reviewed and corrected entire documentation 7 Addition...

Page 102: ...TRICO DO BRASIL LTDA 777 Avenida Piraporinha Diadema S o Paulo 09950 000 Brasil Phone 55 11 3585 1100 www yaskawa com br In the event that the end user of this product is to be the military and said p...

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