YASKAWA GA500 series AC micro frequency converter

YASKAWA GA500 series AC micro frequency converter

Product basic information

1. Model and specification system

Product identification: The model prefix is CIPR-GA50Cxxxxxxxx, which distinguishes key attributes such as region, voltage level, input type, rated current, EMC filter configuration, etc. through model coding (e.g. region code B represents China, 4 represents three-phase 400V level).

Power coverage:

200V single-phase input: 0.1-4.0kW, suitable for small single machine equipment (such as micro pumps and small fans);

200V three-phase input: 0.1-22kW, suitable for small and medium-sized industrial machinery (such as conveyor belts and mixers);

400V three-phase input: 0.37-30kW, meeting the power requirements of medium and large equipment such as compressors and machine tool spindles.

Core performance indicators: Maximum output frequency of 590Hz (lower in some control modes), speed control range of 1:10 to 1:100 (depending on the control mode), default protection level of IP20/UL Open Type, support for switching between normal load (ND) and heavy load (HD).

2. Key terms and safety signs

Core terms:

Control Class: V/f (Voltage Frequency Ratio Control), OLV (Open Loop Vector Control), AOLV/PM (Advanced Open Loop Vector Control for Permanent Magnet Motors), EZOLV (Simple Open Loop Vector Control);

Interface classes: MFAI (Multi functional Analog Input), MFDI (Multi functional Digital Input), MFAO (Multi functional Analog Output), MFDO (Multi functional Digital Output);

Load categories: ND (normal load, suitable for intermittent operation), HD (overload, suitable for continuous high load scenarios).

Classification of safety signs:

and

Warning: Serious danger (such as serious injury or fire caused by equipment misoperation);

CAUTION: Minor injury (such as collision caused by component falling);

NOTICE: Equipment damage (such as wiring errors causing frequency converter failure).

Installation Guide (Mechanical+Electrical)

1. Mechanical installation specifications

(1) Environmental requirements

Temperature: IP20/UL Open Type is -10 ° C~+50 ° C, IP20/UL Type 1 is -10 ° C~+40 ° C, freezing is prohibited;

Humidity: ≤ 95% RH and no condensation, to avoid internal short circuits caused by condensation;

Altitude: Maximum 1000m, with a 1% reduction in output current for every 100m increase in the 1000-4000m range;

Environmental cleanliness: Pollution level 2 (IEC 60664-1), free of impurities such as oil mist, dust, corrosive gases, metal powders, etc.

(2) Installation operation

Installation method: Supports vertical, horizontal, and rotary installation. For small models (such as B001-B012) installed horizontally, an external cooling fan is required;

Installation gap: Reserve ≥ 100mm vertically and ≥ 30mm horizontally for a single frequency converter. When installing side by side, set parameter L8-35=1 and align the top of the drive for easy fan replacement;

Disassembly and assembly of components: The front cover needs to be unlocked with a straight screwdriver with a blade width of ≤ 2.5mm and a thickness of ≤ 0.4mm. The keyboard can be disassembled by pressing the right buckle. Remote installation requires a dedicated extension cable (up to 3m in length).

(3) Heat dissipation and protection

Heat dissipation requirements: The driver needs to be cooled naturally or by an external fan, and when installed horizontally, the airflow direction should be ensured to be unobstructed;

Temporary protection: During installation, a temporary cover plate is needed to cover the driver to prevent foreign objects such as metal shavings and wire heads from entering the interior.

2. Electrical installation specifications

(1) Main circuit wiring

Terminal function:

Input terminals: L/L1, N/L2 for single-phase use; Three phase use R/L1, S/L2, T/L3;

Output terminals: U/T1, V/T2, W/T3 (connected to motor);

Auxiliary terminals:+1,+2 (connected to DC reactor, default jumper needs to be removed), B1, B2 (connected to braking resistor);

Grounding terminal: For 200V class, the grounding resistance should be ≤ 100 Ω, for 400V class, it should be ≤ 10 Ω, and the minimum cross-sectional area of the protective grounding wire should be 10mm ² (copper core).

Wire selection:

Material: UL certified copper core wire, temperature resistance of 75 ℃, voltage resistance of 600V;

Specification: Choose 0.75-25mm ² according to different models, such as 2.5mm ² for B001 and 25mm ² for 4060;

Tightening torque: 0.5-0.6N · m for M3 screws, 1.5-1.7N · m for M4 screws, and 5-5.5N · m for M6 screws to avoid overheating or damage to terminals due to excessive looseness.

(2) Control circuit wiring

Signal mode:

Input mode: MFDI supports Sink/Source modes, which can be switched between SC-SP (Sink mode) or SC-SN (Source mode) jumper. It is prohibited to close both SC-SP and SC-SN simultaneously;

Input signal: Digital input (S1-S7) supports forward rotation, reverse rotation, fault reset and other functions, while analog input (A1/A2) supports 0-10V voltage signal or 4-20mA current signal (A2 terminal is switched through DIP switch);

Output signal: Digital output (MA/MB/MC) is relay output, analog output (AM) supports 0-10V/4-20mA signal, pulse output (MP) maximum 32kHz.

Wiring requirements:

Wire type: Shielded twisted pair cables are required for control circuits to avoid electromagnetic interference;

Length limit: Control circuit wiring ≤ 50m, Safe Disable input wiring ≤ 30m;

Isolation requirements: The distance between the control circuit and the main circuit should be ≥ 30cm, avoiding parallel wiring, and the shielding layer should be grounded at one end (driver side).

(3) Special wiring precautions

Braking resistor: can only be connected to terminals B1 and B2, and+1 or - terminals are prohibited. ERF type braking resistors need to be set with parameter L8-01=1;

EMC filter: The built-in filter model (suffix E) needs to be grounded to the neutral line, otherwise it may cause leakage exceeding the standard;

Lightning protection and surge: MCCB (molded case circuit breaker) or RCM/RCD (residual current monitor) should be installed at the input end to avoid short circuit and surge damage.

Startup and Debugging Process

1. Operation preparation

(1) Parameter settings

General Setting Mode (SrUP): Contains 26 core parameters, including control mode (A1-02), acceleration and deceleration time (C1-01/C1-02), motor rated parameters (E2-01~E2-04), load type (C6-01), etc., suitable for quick configuration;

Application Preset (A1-06): To automatically optimize parameters for specific scenarios such as fans, pumps, and cranes, it is necessary to first initialize the parameters through A1-03 (2-wire/3-wire system);

Parameter backup and recovery: Parameters can be backed up locally through the keyboard, and can be quickly written when changing drives to avoid duplicate configurations.

(2) Keyboard operation

Mode switching: LOCAL (keyboard control)/REMOTE (external control) can be switched through the LO/RE keys. Before switching, ensure that there are no running commands to avoid sudden startup;

Core button functions:

RUN/STOP: Start/Stop, STOP key has the highest priority (can be disabled through o2-02);

Arrow keys: adjust parameter values or switch menus;

ESC/ENTER: Return to the previous menu/confirm parameter settings;

RESET: Reset the fault (the cause of the fault needs to be eliminated first).

2. Auto Tuning

(1) Tuning type and applicable scenarios

Core Requirements for Parameter Setting of Motor Type Tuning Method

Induction motor rotation tuning T1-01=0, motor disconnected from load, load rate ≤ 30%, motor nameplate parameters need to be input

Induction motor static tuning T1-01=1. The motor cannot rotate. During the tuning period, the motor does not rotate without power and only detects electrical parameters

Induction motor inter line resistance tuning T1-01=2 wiring distance exceeds 50m, compensating for the influence of line resistance

PM motor rotation tuning T2-01=4 motor disengages load, automatically detects stator resistance, d/q-axis inductance and other parameters

PM motor static tuning T2-01=1 motor fixed, suitable for scenarios where the load cannot be disconnected

PM motor high-frequency injection tuning T2-01=5 is only applicable to IPM motors, and the motor nameplate parameters need to be input first

Control circuit deceleration rate tuning T3-00=2 automatically optimizes deceleration time to prevent overvoltage faults

Control circuit KEB tuning T3-00=3 optimizes dynamic braking parameters and adapts to KEB Ride Thru function

(2) Tuning operation steps

Input the motor nameplate parameters (rated power, voltage, current, number of poles, fundamental frequency);

Confirm that the motor is disconnected from the load (rotation tuning) or firmly fixed (static tuning);

Enter Auto Tuning mode (AfUn) through the keyboard and select the corresponding tuning type;

Start tuning, during the rotation tuning period, the motor will rotate (at a speed of about 50% of the rated speed), and personnel are prohibited from approaching;

After tuning is completed, the system automatically updates the motor parameters, and the modification results can be viewed through the Verify menu.

3. Test Run

(1) No load test

Operation process: Set the frequency to 6Hz → Start the driver → Gradually increase the rated frequency (10Hz each time) → Observe the motor status;

Inspection items: Motor direction (if incorrect, replace U/T1 and V/T2 wiring), vibration (no abnormal shaking), output current (≤ 30% of rated current), no abnormal noise.

(2) Load testing

Operation process: Connect the load → Set the actual operating frequency → Start the driver → Run continuously for more than 30 minutes;

Inspection items: acceleration/deceleration response (no lag), torque output (meeting load requirements), driver temperature (≤ 85 ℃), parameter stability (no drift);

Fine tuning optimization: If vibration occurs, adjust n1-02 (anti oscillation gain), if torque is insufficient, adjust C4-01 (torque compensation gain), and if overvoltage occurs, extend deceleration time (C1-02).

(3) Test Run Checklist

Power supply voltage: The input voltage is within the allowable range on the driver nameplate;

Wiring correctness: The phase sequence of the main circuit and the polarity of the control circuit signal are correct;

Protection function: Simulate overload and overcurrent scenarios, the driver needs to trigger protection and alarm normally;

Control signal: External control signals (such as limit switches, PLC commands) can respond normally.

Standard compliance and safety requirements

1. Main compliance standards

(1) EU CE certification

Applicable directives: Low Voltage Directive (LVD 2014/35/EU), Electromagnetic Compatibility Directive (EMC 2014/30/EU), Machinery Directive (MD 2006/42/EC);

Compliance requirements:

LVD: Complies with EN 61800-5-1:2007, insulation class II, overvoltage category III;

EMC: The built-in filter model must meet EN 61800-3:2004/A1:2012 standards for radiation and conducted disturbances;

MD: Cooperate with safety circuits (such as Safe Disable) to achieve PL e (Cat. III) safety level.

(2) UL certification in the United States and Canada

Applicable standards: UL 61800-5-1, Canadian Electrical Code (CEC);

Compliance requirements:

Branch circuit protection: designated semiconductor fuses (such as FWH-25A14F for B001 and FWH-200B for 4060) must be used;

Control circuit: UL certified Class 2 power supply is required, and the wire is NEC Class 1 conductor;

Motor protection: Electronic thermal protection must comply with NEC standards, and external thermal overload relays are required when driving multiple motors.

(3) Chinese standards

RoHS compliance: restrict six hazardous substances including lead, mercury, cadmium, etc., provide a list of hazardous substances and recycling labels;

Safety standard: Complies with GB/T 12668.2-2013 (Variable Speed Electrical Transmission Systems).

2. Core security requirements

(1) Electrical safety

Power off operation: Before wiring and maintenance, all power sources must be disconnected, and the capacitor must be discharged (the indicator light is off and the voltage is ≤ 50Vdc), waiting for at least 5 minutes;

Grounding requirements: The protective grounding wire must be firmly connected, virtual connection is prohibited, and it should not be shared with high current equipment such as welding machines for grounding;

Leakage protection: Drivers with built-in EMC filters may experience leakage currents exceeding 3.5mA, requiring the use of Type B RCM/RCD.

(2) Mechanical safety

Installation protection: The driver should be fixed on non combustible materials such as metal, and it is forbidden to cover the ventilation openings. There should be no flammable materials around;

Operation protection: Before testing and running, personnel and obstacles around the equipment need to be removed, and components such as couplings and shaft keys need to be installed;

Emergency stop: An emergency stop circuit must be configured independently of the driver to ensure that the power can be quickly cut off in case of a malfunction.

(3) Functional safety

Safe Disable function: Safe torque shutdown is achieved through H1, H2, and HC terminals, using Source mode with a wiring length of ≤ 30m;

Prevent sudden startup: The 3-wire control system needs to set A1-03=3330 and b1-17=0 to avoid automatic startup after power on;

Fault reset: After the fault occurs, it is necessary to first investigate the cause (such as overload, short circuit) before resetting. It is forbidden to force a reset directly.

Operation and maintenance

1. Network communication

(1) Supporting protocols and configurations

Core protocol: MEMOBU/Modbus (RS-485 interface), supports master-slave architecture, can communicate with PLC, touch screen and other devices;

Communication parameters: maximum baud rate of 115.2kbps, data format of 8-bit data bits+1-bit stop bit+no checksum (configurable);

Terminal resistor: The last driver in the network needs to enable the built-in 120 Ω terminal resistor through DIP switch S2 to reduce signal reflection.

(2) Communication function

Data exchange: capable of reading driver operating parameters (output frequency, current, voltage), modifying control parameters, and receiving external control commands;

Fault reporting: When the drive fails, the fault code can be actively reported through the communication protocol for remote diagnosis;

Multi machine linkage: supports networking of multiple drivers to achieve synchronous control (such as multi motor linkage in assembly lines).

2. Troubleshooting

(1) Fault classification and handling principles

Fault types: serious faults (such as overvoltage ov, overcurrent oC, motor overload oL1), minor faults/alarms (such as undervoltage UV, overheating OH), parameter errors (such as incorrect oPE parameter range);

Processing procedure:

Record fault codes (read through keyboard or communication);

Power off for cooling, check wiring (main circuit phase sequence, control circuit signal);

Verify parameters (motor parameters, protection parameters, control mode);

Test the load (whether it is stuck or overloaded);

If unable to troubleshoot, contact YASKAWA technical support.

(2) Common troubleshooting solutions

Fault code, fault cause, and solution

OV decelerates too quickly, brake resistor fault, high grid voltage prolongs deceleration time (C1-02), check the wiring and resistance of the brake resistor, and detect the grid voltage

Overload of oL1 motor, incorrect motor parameter settings, poor cooling to reduce load, re-enter motor nameplate parameters, clean drive ventilation port

Check the insulation between the motor winding and cable, replace the driver, and verify the control signal for oC output short circuit, IGBT fault, and abnormal control circuit

STPo PM motor out of step, excessive load, tuning parameter error to reduce load, perform Auto Tuning again, adjust n8-45 (speed feedback gain)

Low UV input voltage, phase loss, MCCB trip detection of grid voltage, inspection of input wiring, troubleshooting of MCCB trip cause

3. Regular maintenance and disposal

(1) Regular maintenance project

Daily inspection (daily): operating status (no abnormal noise or vibration), indicator lights (no alarm), ventilation openings (no blockage);

Regular inspection (every 6 months): Wiring terminals (no looseness or overheating), cooling fan (normal rotation), capacitors (no bulging or leakage);

Replacement parts: The cooling fan has a service life of 2-5 years (depending on the model) and needs to be replaced according to the manual process to avoid poor heat dissipation.

(2) Storage and disposal

Storage requirements: ambient temperature -20 ℃~+70 ℃, humidity ≤ 95% RH, avoid direct sunlight, regularly power on (power on for 30 minutes every 3 months);

Scrap disposal: Follow the WEEE directive, classify and dispose of electronic components (such as capacitors, circuit boards) and metal casings, prohibit arbitrary disposal, and dispose of hazardous substances in accordance with local regulations.

Summary of Key Parameters (Core Commonly Used)

Parameter category, parameter number, parameter name, default value, adjustment scenario

Control mode A1-02: Select 0 (V/f) for high-precision control (OLV) and 5 (OLV/PM) for PM motor

Load Type C6-01: Normal/Heavy Load Select 0 (HD), Intermittent Load Select 1 (ND), Continuous High Load Maintain 0 (HD)

Acceleration and deceleration time C1-01 Acceleration time 1 1.0 If the startup impact is large, it will be extended, and if quick startup is required, it will be shortened

Acceleration and deceleration time C1-02 deceleration time 1 1.0 deceleration overvoltage will be extended, and if a quick stop is required, the braking resistor will be used to shorten it

Carrier frequency C6-02, carrier frequency selection 1 (2kHz). If the motor noise is high, it will increase, and if the heat dissipation is poor, it will decrease

Motor Protection L1-01 Motor Overload Protection: Select 0 (disabled) for multiple motor drives and 1-6 (suitable for load type) for single motors according to the control mode

Torque compensation C4-01: Torque compensation gain 1.00. If the low-speed torque is insufficient, it will increase, and if the vibration is reduced, it will decrease

Anti oscillation N1-02 anti oscillation gain 1.00 increases with motor vibration and decreases with insufficient torque