Yaskawa General Inverter Drives Manual
Below you will find brief information for Thyristor Converter Unit Varispeed-505 ZII CDMR-ZII. The Varispeed-505 ZII CDMR-ZII is a thyristor converter unit for varispeed non-reversing operation of industrial DC motors. This manual describes in details the installation, wiring, testing and maintenance of the equipment. It is also necessary for troubleshooting, and therefore should be kept field for ready reference. For details on DC motors, refer to "Instructions for Industrial DC Motors" (TOE-C435-3).
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INDUSTRIAL USE THYRISTOR CONVERTER UNIT
Varispeed-505 ZI1 Drive
INSTRUCTIONS
MODEL CDMR-ZII
Before initial operation, read these instructions thoroughly, and retain for future reference.
YASKAWA
TOE-S505-30B
When properly installed, operated and maintained, this equipment will provide a lifetime of optimum operation . It is mandatory that the person who operates, inspects, and maintains this equipment thoroughly read and understand this manual .
IMPORTANT
. Make no withstand voltage test on the VS-505ZII because it incorporates semi-conductor electronic circuits .
If megger tests are necessary, make them only in accordance with the instructions given in this manual .
. Do not tamper with potentiometers of the power units since they were pre-set at the factory before shipment .
Varispeed-505ZII (VS-505ZII) is a thyristor converter unit for varispeed non-reversing operation of industrial DC motors .
For correct operation of VS-505ZII, users must throughly read these instructions . This manual is also necessary for maintenance and troubleshooting, and therefore should be kept field for ready reference .
For details on DC motors, refer to "Instructions for Industrial DC Motors" (TOE-C435-3) .
Type CDMR-ZII
(Type S)
230V, 105A
681-50
Type CDMR-ZII
(Type M)
230V, 260A
Type CDMR-ZII
(Type L1
230V, 550A
RECEIVING / 2
STORAGE / 2
Location / 2
INSTALLATION / 2
WIRING / 2
Component Arrangement in VS-505ZII / 2
CONTENTS
Terminal Sizes and
Carrying Currents / 2
No-Load Operation / 5
Full-Load Operation / 5
Interconnections / 2
Cautions when Wiring / 2
Adjustment / 6
TEST RUN / 4
MAINTENANCE / 9
Check before Test Run / 4
Periodic Inspection / 9
Parts Replacement / 9
Cautions in Replacing
Control Circuit Board / 12
Troubleshooting Guide / 13
SPARE PARTS / 14
REFERENCE / 14
RECEIVING
The equipment has been put through severe tests at the factory before shipped . After unpacking, however, check and see the following .
" Its nameplate data meets your requirements .
" It has sustained no damage while in transit .
" Fastening bolts and screws are not loosened .
" Devices built in the cabinet are not damaged or missing .
STORAGE
If the equipment is temporarily stored or machine stops for an extended length of time, the following precautions should be taken .
LOCATION
Store the equipment under the following conditions.
" Free from rainfall and drops of water
" Clean and dry
" Free from corrosive gas and liquid
" Ambient temperature : -100 C to 400 C
" Less vibration
INSTALLATION
stall the equipment by proper procedure in keeping the equipment in good working condition .
WIRING
Make connections in reference to the interconnection diagram furnished on your order and the following .
Figs . 2 to 4 show component arrangement in the
VS-505Z]l
TERMINAL SIZES AND CARRYING
CURRENTS
Table 1 shows the size and the current carrying capacities of the terminals of VS-505ZII . Select leads with sufficient current carrying capacity .
Refer to Cautibns when Wiring .
Table 1 Terminal Size and Current Capacity
C Dh1R-Z11 age put
V kW
230
90
105
180
25
35
45
260
420
550
50
90
105
180
260
420
550
AC Main
Circuit
Car-
Ter
Size
rent
A minal Cur-
Size
DC Main
Circuit
Carrying Terrying rent
A
I
Field
Circuit
Car-
Terrying minal Cur-
Size rent
A
M6
M6
M6
M8
M8_
_ 21 M5
25
29 _M8 i
~_ -
35-
`
37M8 45
74
86
M8
M8
90
105
104 i 1-'
-
460
M10
M10
M12
M12
M8
M8
M8
M10
M10
M12
M12
147
213
41
74
86
147
213
343
449
M10
M10
M12
M12
M8
M8
M8
M10
M10
180
260
M12 _, 420
N112
I
550
180
260
420
550
50
90
105
M4
M4
M4
M4
I
22
25
12
22
M4
' 25
Note :
1.'l'erminal size other than listed above is M4 and current capacity is 2A or below.
2,l1ule of thumb of AC main circuit power capacity
12 x/
X
E x 1 (VA)
E: Supply voltage is AC main circuit current
INTERCONNECTIONS
Make connections of VS-505ZII with associate units according to the interconnection diagram separately furnished .
CAUTIONS WHEN WIRING
Main Circuits
Use 600 V PVC insulated wires or cabtyre cables with the current carrying capacities of the combined DC motor for AC main circuit terminals
(U, V, W) and DC main circuit terminals (P, 1) .
Field Circuits
Use 600 V PVC insulated wires or cabtyre cables with the current carrying capacities of the combined DC motor for field power circuit terminals
(Uo . Wo . U1, W1) and field circuit terminals (J,
K) . Use stranded wires of cross-section 5 .5 mmz or larger for field circuit terminals (J, K) .
Signal Circuits
Use shielded wires or twisted wires of twisting pitches 20 mm or smaller for the speed setting circuit terminals (11 to 16), speed feedback terminals (3 to 5), tachometer circuit terminals (38 to 40) .
Fig . 1 Pitch of Twisted Wire
D -_
I
20 MM
MAX.
DETECTION
CONNECTOR
(a)
Control Circuit
Fig. 2 Type CDMR-ZII, -5 (230V, 150A)
(b) Power Circuit
PROTECTIVE
(2 FOR 220 V
(a)
Control Circuit
Fig . 3 Type CDMR-ZII, -M (230V, 260A)
(b) Power Circuit
(a) Control Circuit
Fig . 4 Type CDMR-Z11, -L (230V, 550A)
(b) Power Circuit
WIRING
(Cont'd)
Separation of Signal Cables from main
Circuit Cables
To avoid inductive interference from other cables, run the shielded or twisted wires (1 to 53) separate from main circuit cables (U, V, W : U0,
WO ; P , N; J, K) in a bundle or thru a
CAUTION
After wiring, check interconnections .
Make insulation resistance tests using a 500V megger . Connect VS-505ZII main circuit terminals ( U, V, W; Uo,
Wo ; U
1,
W
1;
P, N ; J, K) with common lead . Measure the insulation resistance between common lead and the ground . When the test result is 2 MSS or more, it means that wiring is successful .
TEST RU N
When the VS-505ZII has been correctly installed and wired, the unit shall be tested through a test run as follows .
If trouble is found during the test run, refer to "Check Before Test Run" and "Troubleshooting Guide" for necessary measures . If the cause of the trouble cannot be located, or repair is impossible, notify our service station, giving the details of trouble conditions .
CHECK BEFORE TEST RUN
Make the following checks prior to the test run .
Table 2 Check before Test Run
Check Points
Interconnections between
VS-505ZII and Associate Units
DC Motor
" Correct wiring .
Check Items
" Tightening of terminal screws .
VS-505ZII
Supply Voltage at Input
Terminals of
VS-505ZII
" Disconnection from the driven machine.
" Removal of thrust block .
" Remove inspection covers and blow out with air to clean commutator . (Fig . 5)
" Adhesion of dirt or dust on the enclosure .
" Smooth hand rotation of thyristor cooling fan.*
" Check items in "Cautions in Operation" on the back of the control board door .
" Correct connection of the shunt connector to the voltage selecting tap. (Fig . 6)
" Corrent setting of the frequency selector switch . (Fig . 7)
" Correct adjustment of potentiometers on the control board UPCB) Refer to red paint .
" Voltages of any two of phases U, V, W are within the values on Table 3. Check with a tester .
" Terminal Uo and
U1 and Wu nd Ware connected .
" Rotating direction of the motor blower meets with the arrow marked on the blower
*VS-505ZII of larger capacity than 230V . 45A or 460V, 90A are provided with a thyristor cooling fan .
Fig . 5 Inspection Window of DC Motor
Either 230V or 460V at 105A or below
200 or 4E V , plug the housing in the upper tap .
2(KAI
1(RIV~
~n1G ~-__n
141 VL___J
AKA P-_
-
_
i
l
-A L__-J v
44uV
When supp ly voltage is
r- ?
;HRIV
4(KIV
20%
1111\
When supply voltage is housing in the right tap .
r-~
~lRl
UKn yw
11W
Fig . 6 Tap Selection of Control Supply Voltage
681-200
" When supply frequency is 50Hz, slide the switch key down .
" When :supply frequency is 60Hz, slide the switch key up .
Fig . 7 Selection of Supply Frequency
Tabl,e 3 Supply Voltage Allowable Range
Nominal
Supply
Voltage
220 V
220 V
400 V
440 V
Supply
Frequency
50/60 Hz
50/60 Hz
50/60 Hz
50/60 Hz
Permissible
Voltage
Variation
170 - 220 V
187 - 242 V
340 - 440 V
374 - 484 V
Voltage
Selectoer
Tap
200 V
220 V
400 V
440 V
NO-LOAD OPERATION
After making the checks specified before test run, thoroughly check the environment to the system for safety .
Check the polarity of DC tachometer generator feedback voltage .
When the motor is running forward, the polarity of VS-505ZII signal terminal 3 (4 : OV) is minus and it is plus during reverse running of the motor .
Then, run the motor without load according to Table 4 .
Before starting full-load operation, stop the power supply, couple the DC motor to the driven machine, and check the motor and the driven machine for safe and obstruction-free conditions .
Table 5 gives full-load operation procedure .
Table 5 Full-load Operation
Orde r l
2
3
4
5
Operation
Set the speed at zero .
Turn on the main circuit power supply .
Turn on increase that the correctly operation signal and gradually the speed . Check to be sure motor and driven machine are running .
Turn off the operation signal .
Turn off main circuit power supply .
Table 4 No-load Operation
Order
1
2
5
4
(,
3
7
8
9 operation
Set the speed reference at zero .
Turn on main circuit power supply .
Check
Items i
-
I
Smooth rotation of the thyristor cooling fan .*
Smooth rotation of the blower for DC motor.
Rotating direction of the blower meets with the marking on the blower .
Make an operational sequence and check to be sure that operation is ready .
(Turn on ready signal, motor cooling fan
ON /OFF signal .)
Turn-on the operation signal .
Gradually, increase the speed setting value .
I
-
-
Smooth acceleration of DC motor .
No abnormal odor, smoke, vibration and noise on DC motor .
No brush chattering and sparking at the brushes .
Remove the hand-hole cover and check tht- commutator .
To avoid excessive temperature rise of DC motor winding in frame 112, 132, reclose the window within 5 minutes.
Gradually, turn the speed setting potentiometer clockwise .
Smooth acceleration of DC motor.
Increase the speed setting value to the maximum .
DC motor rotates at the maximum speed . Check with a speedometer .
Change the speed to various values .
Turning speed setting potentiometer rapidly during acceleration or deceleration changes motor speed smoothly .
10
Turn off the operation signal .
DC motor stops . (It stops suddenly by VS-505ZII with a dynamic bra king function .)
11
Turn off the main circuit powe r supp ly .
I -
*VS-505ZII, rated 230V, 45A and above and 460V, 90A and above are provided with a thyristor cooling fan .
TEST RUN
(cont'd)
ADJUSTMENT
Do not tamper unnecessarily with the potentiometers on the control circuit board since they have been adjusted at the factory before shipped .
Adjuster Locations and Functions
Adjuster locations on the control circuit board and functions are shown in Fig . 8 and Table 7 .
The characteristics of control circuit board check terminals are shown in Fig . 9 and Table 6.
O
0
®Ltn
® `®r®
®L
0
Cllt1C l17 Clll
0
CH 6
0116
\~CH 9
C1110
V
GB
Cll 1
C112
C li 3
I /
Cl14
-w
O
OHIO cxu ees"~I,/ all
~e0
G8
80
'0
JPDC-C036
0
(a) Type JPDC-C035 (b) Type JPDC-C036
Fig . 8 Adjuster Locations on
Control Circuit Board
CH 14
/11116
0 :-1111 7
0
JPDC-C036
CHn CHI4
CHI6 CHI7 a
0
(a) Type JPDC-C035 (b) Type JPDC-C036
Fig . 9 Control Circuit Board
Check Terminals
Table 6 Control Circuit Board Check Terminals
Signal Names
Phase shifter input
Current limit
Speed feedback
CH5
CH6
Current command CH7
CH8
c
e. Gate block
CH9
GB
L
Current controller output
CH10
.
eo
CH11
Stable power supply
CH12
CH13
CH14
CH 15
CH16
Unstable power supply
CH17
Current command
CHI
c
Current feedback CH2
.p Phase shifter u.
input
CH3
Check
Terminals
Normal Values
+1 to +5 .5V at 60Hz,
+1 to +6.5 V at 50 Hz when controlling when gate blocked
+3 V/100% current limit
-6 V/100% speed
-3 V/100% command
+6 V /100% command
(Gateblock by OCL) OV normal, -24V at gateblock
0 V normal, +12 V at gateblock
Approx . -1 V at gateblock
0 to +6 V when controlling
+3 V/100% current
0 V (SG)
+15 V
-15 V
+24 V
-24 V
+24 V (pulse amplifier power supply)
Voltage value according to field current .
Approx . +5 V at 60 Hz, approx . +6 V at 50 Hz when field blocked
Allowable variation range : f20%
Ex .
-6 V/5 A
+ 3 V /5 A
+1 to +5 V at 60 Hz,
+1 to +6 V at 50 Hz when controlling
Table 7 Control Circuit Board Adjuster Locations and Functions
Type of
Adjuster Adjuster
Adjusters Location Names
1 ACCEL
Adjuster Functions Adjusting Method
2 DECEh
Acceleration time adjustment . i Clockwise rotation increases a(Celeration i time .
Deceleration time " adjustrne " nl .
Clcic kwis, rotation ine i-ease " 5 doce " le " r .itinn
3
4
5
GAIN
NMAX
LIMIT
Potentiometers
6
7
8
9
10
11
12
13
22
IFB
SM
AM
BIAS
KIPP
OL%
OLT
I REF
PSB
ASR G .rrrr .i d juslm e " nl .
Speed feedback adjustrru " nt
Currant limitalu m
S peed l imitation
CIoc .kwi- rotation increases g .iin .
Clockwise " rotation clecrvases ~peed .
Clockwise rotation increases limit value .
Main circuit current feedback Clockwise rotation decreases current .
adjustment .
Speedomete r adjustment .
Am meter a djust ment .
ASR offset adjustment .
Phase shift lag limit adjustment
Cloc kw ise rotation increases pointer swing .
- e
VOILELger~ (H) voltage
Clockwise rotation advances shift lag .
Setting overload detection start point .
Setting overload .
Setting field current
Phase shifter operating point adjustment
Clockwise rotation increases overload detection start po int .
Clockwise rotation increases operation time .
Clockwise rotation inc reases t he curr e nt .
Clockwise rotation advances phase .
Specifications
3 - 75 sec
3 75 sec
_-
-
-6/100% speed
0 -
125%
-
+3V/100% current
1 mADC max
1 mADC max
-
155°el
(Standard)
110%
(Standard)
150% . 60 sec
(Standard)
-
Adjustable b,-t%% een
90 and 160°el
Potentiometers selection
(Open)
Slide switch
14
15
16
©3
17
18
®
1FBR-
4FBR
SFBR-
SFBR
1SW
ACTG/
DCTG
A - D
E
F
H
Rough adjustment of field current detection voltage level .
Rough adjustment of main circuit detection voltage level .
Supply frequency selector .
Selection of ACTG and DCTG according to Type of TG .
Rough adjustment of speed detection voltage level .
Selection of soft start operation
Selection of BIAS
Selection of LIMIT
__
Selection of 50 Hz or 60 Hz .
For AC tack-gen, select ACTG, and for
DC tack-gen, select DCTG .
Selection of the voltage level according to type of lath-gen and motor rated speed .
El
E2 Soft start
-
Fl
AS R BIAS A djustment
F2 1AC R BI AS Adjus tmen
111 Currant limitation
112 Spied limitation
Possible 19
20
©
©
21
28
J
K
L
M
N
P
Selection of start interlock zero-speed condition
Selection of motor stopping method
Selection of use of exciter according to motor field .
Selection of field block due to motor overheat .
Selection of zero-speed condition at motor cooling fan stopping .
Selection of Pl and P of ACR control
-
Kl
K2 Gate block at stop command .
Ll
Gale block at zero speed when dec elerating to stop .
Exc iter used .
L2 _
MI Field blocked .
M2
Field not blocked .
N 1
_
Field half-reduced after motor zero-speeds by stop operation .
2 'F'ie d a l -reduce " _
=tc_ .)oc
PI
P 2
PI control
P c ontrol
29
01-IN
Shortcircuit jumper
_
30 OP Olxn ial application
Short E~capt for the above
Note : The adjusters of the circled numbers are provided with the control circuit board
Type JPDC-C036 (ET000491X) only .
-----
_
Refer to motor specifications .
-
-
-
-
-
-
-
-
-
-
-
-
_-
-
-
-
-
-
--
-
-
-
-
-
-
TEST RUN (cont'd)
Adjustment Procedure
NMAX (Speed feedback adjustment)
To adjust the DC motor speed exactly to the reference speed, proceed as follows .
1 . Prepare the tachometer having required accuracy .
2 . Operate the DC motor at no load (or less variation) .
3. Measure the speed reference voltage with a voltmeter . Correct the voltage to that of desired motor speed .
4 . Measure the motor speed with a tachometer.
5 . If the speed does not reach the desired speed, turn NMAX counterclockwise to increase the speed .
6 . If speed exceeds the desired speed, turn
NMAX clockwise to decrease the speed .
LIMIT (Limit value adjustment)
1 . Current limitation (Speed control)
Connect the plug-connectors F and H to F 1 and
Ell on the control circuit board, respectively .
When the voltage at CH 5 is +3V, 100°% current limit value is obtained . Current limit value can be set within the range of 0% to 250% by LIMIT .
2 . Speed limitation (Current control)
Connect the plug-connectors F and H to F2 and
H2 on the control circuit board, respectively .
When the voltage at CH 5 is +6V, 100% current limit value is obtained . Current limit value can be set within the range of 0% to 125% by LIMIT .
PSB (Phase shifter operating point adjustment)
PSB sets the phase shifter operating point .
1 . When the current controller (ACR) is integral-controlled
Connect the plug selector P on the control circuit board at P1 . Turn PSB fully counterclockwise .
2 . When the current controller (ACR) is ratiocontrolled
Connect the plug selector P on the control board at P2 . Turn PSB clockwise gradually with reference current at OV (OV at CH 10) , and set at the position where main circuit current is ready to start .
Adjustment of Field Current
The manner of adjusting field current when field current is constant differs from that when field weakening control is made .
Constant Field Current
1 .
Connect DC ammeter to field circuit .
2 . Adjust the potentiometers (1FBR to 4FBR) and IREF on the control circuit board so that ammeter indicates rated field current .
Field Weakening Control
Proceed as follows to adjust field current in combination with field adjuster type JGSM-51-'-_',
1 . Connect DC ammeter to field circuit and
DC voltmeter to output terminals ® and
2 . Select the potentiometer (from 1FBR to 4FBR ) which corresponds to the desired voltage level of field current detection . Remove those potentiometers not being used .
3. Turn the potentiometer ]REF on the control board and' FORCE FLD and V LIMIT of the field adjuster fully counterclockwise .
4 . Set the minimum field weakening current using I REF . Set-value should be 80% field weakening; current at maximum speed .
5 . Set the rated field current (field intensifying) using FORCE FLD of field adjuster .
6 . Increase speed reference gradually after motor starts .
The voltage across terminals ® and
O increases
Turn V LIMIT clockwise gradually so that the limited value is motor rated voltage (220V or
440V) .
681-13
Firs . 10 Field Adjuster Type JGSM-51-L'
MAINTENANCE
VS-505Z11 requires almost no daily inspection .
To keep the correct and successful operation, periodic maintenance operations should be performed . The users should prepare their own maintenance programs based on the following guidelines .
PERIODIC INSPECTION
Table 8 Periodic Inspection
Inspection
Item
Inspection
Item
Inspection
Procedure
What to do
Thyristor " Noise cooling fan
General
" Check for any Replace.
intermittent or Rule of thumb unusual noise. for cooling fan replacement :
15,000 hours of operation .
" Dust or dirt.
" Check for dust " Clean with clogging or dirt adhesion .
" Check for loosening of screws or nuts: an electrical cleaner .
" Tighten .
PARTS REPLACEMENT
Field Thyristor
With all the Models, thyristor modules consisting of a thyristor and a diode are used as the field thyristor . Replace them as follows .
The same replacement procedure applies to all the models .
1 . Loosen the bus bar screws and the lead clamping screws, and unclamp the leads . In this case .
mark all the terminals for identification .
(Fig .
11)
2 . Loosen the two clamping screws, and remove the thyristor module .
3 . Check the replacement thyristor module for type and capacity, and install it by reversing the removal procedure, making connections to the terminals identified by the marks made before removing the old thyristor module .
Main Circuit Thyristor
230V, 25A System (Fig . 12)
The system uses a thyristor module comprising two thyristors . Replace it as follows .
1 . Remove the 6 bus bar clamping screws, and remove the bus bar .
2 . Loosen all the thyristor lead screws, and U11clamp all the leads . In this case, mark the terminals for identification .
3 . Remove the two thyristor clamping scre%ks .
4 . Check the replacement thyristor module for type and capacity, and reinstall it by reversing the disassembly procedure, identifying the terminals by means of the marks made prior to disassembling .
NOTE
When installing the thyristor module, apply thermal compound JOINTAL Z
(made by Nippon Light Metal Co .,
Ltd .) to the thyristor mounting surface (reverse side) .
Fig . 12 Main Circuit Thyristor
Fig . 13 Bus Bar Removal
Fig . 1 1 Field Thyristor (230V, 25A)
MAINTENANCE
(cont'd)
230V, 35 to 105A System, 460V, 50 to 105A
System
1 . Remove the 6 bus bar mounting screws, and remove the bus bar . The leads connected to the bus bar need not be removed . (Fig . 14)
2 . Loosen the thyristor connecting screws, and unclamp the leads . In this case, mark the terminals for identification .
3 . Remove the two thyristor clamping screws .
4 . Check the replacement thyristor for type and capacity, and reinstall it by reversing the disassembly procedure, identifying the terminals by means of the marks made prior to disassembling .
NOTE
When installing the thyristor, apply thermal compound JOINTAL Z (made by
Nippon Light Metal Co. , Ltd .) to the thyristor mounting surface (reverse side) .
BUS BAR
6 . Clean the contact surfaces of the new thyristor and the fin, and thinly coat these surfaces with thermal joint compound (JOINTAL
Z, made by Nippon Light Metal Co ., Ltd .) .
7 . Align the fin locating pin and the thyristor locating hole, after making sure that the polarity of the thyristor is correct .
finger-tighten the clamping nuts . Then, tighten them alternately through 1/4 turn at a time, three times each with a socket wrench . Now, the thyristor fin has been installed .
q, Tighten the control circuit board mounting; screws,
Then, mount the thyristor module by reversing the disassembling procedure, tightening the screws firmly .
Fig . 14 Main Circuit Thyristor
(230V, 105A)
230V, 180 to 550A, 460V, 180 to 550A System
In these systems, flat thyristors are used . The thyristor modules differ in shape depending upon capacity, but their replacement procedure is the same, as given below .
1 . Remove the 6 clamping screws for thyristor gate cathode terminal, and free the leads . In this case, mark the terminals for identification .
(Fig . 15)
2 . Remove the mounting bolts (5 for 260A and below and 7 for 420A and larger systems) for the thyrisotr module, and remove the main circuit thyristor .
3. Place the main circuit thyristor module on a work bench, and loosen the control circuit board mounting screws (Fig . 16) for the thyristor assembly to be replaced, and then, loosen the gate wiring screws .
4 . Loosen the fin mounting nuts alternately, turning 1/4 turn at a time . Then, remove the leaf spring .
5 . Remove the fin and take out the thyristor .
1 0
THYRISTOR MODULE
MOUNTING BOLTS (2 LOWER ONES)
Fig . 15 Main Circuit Thyristor Assembly
(230V, 260A System)
FIN MOUNTING
NUT
FIN LOCAT-
ING PIN
(a)
GATE WIRING
SCREW
POWER
CIRCUIT
BOARn
With Thyristor Removed
LEAF SPRING
POWER
CIRCUIT
BOARD
MOUNTING
(b) Thyristor
Fig . 16 Thyristor Replacement
Replacement of Main Circuit Fuse
230V, 25 to 105A, 160V, 50 to 105A System
1 . Remove the fuse blown indicating microswitch with the leads by pulling upward . (Fig . 17)
2 . Remove the two fuse mounting bolts .
3 . Mount a replacement fuse by reversing the, removing procedure, after checking its model and capacity .
Surge Absorber Fuse Replacment
1 . Pull the fuse element and r-e-lnovc it . (Fig . 1I1) its model and capacity .
SURGE
ABSORBER
M LINTING
SCREWS (3)
LEAD
CIRCUIT
FUSE
Fig . 17 Main Circuit Fuse (230V,25A)
230V, 180 to 550A, 460V, 180 to 550A systems
(Fig . 15)
1 . Loosen the two lead clamping screws, and free the four leads of the fuse-blown indicating microswitch . (Fig . 18)
2 . Remove the two fuse mounting bolts, and remove the fuse together with the fuse-blown indicating microswitch .
3 . Check the replacement fuse for model and capacity, and install it by reversing the disassembling procedure .
Fig . 19 Surge Absorber Fuse
Surge Absorber Replacement
2 . Check the replacement surge absorber for model and capacity . Mount three surge absorbers after connecting M4 pressure terminals to their leads as shown in Fig . 20 .
Fig . 20 Surge Absorber with
Pressure
Terminals Connected to Leads
FUSE
MOUNTING
BOLTS (2)
Fig . 18 Main Circuit Fuse Assembly
MAINTENANCE
(Cont'd)
Thyristor Cooling Fan
Using for 230V. 25A and 460V. 50A ratings are self-cooled . Replace the fans as follows. (Fig . 21)
1 . Disconnect the power leads.
2 .
Unscrew the two fan mounting screws, and dismount the fan .
3. Remove the fan by reversing the disassembling procedure .
Control Circuit Board Replacement
Disconnect all the leads from the terminals . In this case mark the terminals for identification . Then .
unplug the connectors shown in Fig. 22, and loosen the 6 control circuit board mounting screws.
Mount the replacement board by reversing the disassembling procedure . Plug-in the connectors firmly.
(a)
FAN
230V, 45 - 105A
460V, 90 - 105A
POWER SUPPLY
LEADS (2)
FAN
MOUNTING
SCREWS
(b)
FAN
230V, 180 - 260A
460V, 180 - 260A
FAN
FAN
MOUNTING
SCREWS(2)
(c)
230V, 420/550A ; 460V, 420/550A
Fig . 21 Thyristor Cooling Fan
(a)
Type JPDC-C035
CONTROL
CIRCUIT
MOUNTING
SCREWS (6)
FLAT CABLE
CONNECTOR
CONTROL
POWER
SUPPLY
CONNECTOR
(b) Type JPDC-C036
Fig . 22 Control Circuit Board
CAUTIONS IN
REPLACING CONTROL
CIRCUIT BOARD
Make sure that the type of the new control circuit board agrees with the nameplate and potentiometer settings of new control circuit board are the same as the old one. Refer to the nameplate "Cautions in
Operation" posted on the inside of the control board door of VS 505Z 11 . See Table 7 Adjuster Locations on the Control Circuit Board and Functions .
TROUBLESHOOTING GUIDE
Table 9 Troubleshooting Guide
Trouble
OCI, lamp
ON
Control board
Possible Cause
Too low setting of
"OL%," "OLT".
Too high setting; of
"L1MI I .,
Incorrect Setting of
-
Is setting dial at the positiois indicated by lock paint?
Refer to
Check Methoc
Table 6 and 7 .
Readjust .
What to do
Set the setting dial to the position of lock paint .
_ c s.
a
° u, v
FU lamp
ON
Thyristor
Motor and Overloaded driven Locking.
machine
Defective (deterio rated)
Layer shorting in motor .
Grounding of motor circtut.
Thyristor Defective (deterio-
Motor
Control circuit board rated).
Layer shorting in motor.
Grounding of motor circuit .
Defective (phase control circuit) .
Check thyristor (Fig. 25).
Replace thyristor. (See Main
Circuit Th ristor on page 10 .)
Check load current.
Adjust load .
Check load for locking .
Repair driven machine.
Run motor with terminals (P) and N) dis. Repair motor.
connected . If OCL lamp does not light, the motor and its circuit are defective .
Measure resistance between terminal P)
(or N) and ground (E) with a multitester.
If the reading is nearly - on the largest scale of the tester, the circuit is normal .
Check thyristor (Fig . 25).
" Repair motor.
" Correct wiring .
Reset .
Replace thyristor.
See Main Circuit
Th ristor on page 10 .)
Operate only board with (P) and N) disconnected . If fuse is not blown, motor circuit is defective.
Measure resistance across terminal P) (or " Repair motor.
N) and ground (E) with a multitester, and " Correct wiring .
if the reading is nearly - on the largest scale of the tester, the circuit is normal .
(See Note .)
To replace fuses (1FL,
2FU, 517U) .
refer to
Replacement if the motor is normal, replace of ThYristor control circuit board .
Protection
Refer to Replacement of Control Fuse .
Circuit Board on page 11 .
FL lamp
ON
THG lamp
ON
Fuse
Motor-
Control board
Motor
Defective (deteriorated) .
Layer shorting in field winding .
Grounding of field circuit .
Defective
Over
-loading.
!Main
circuit
Field circuit
Blocked air filter .
Disconnect terminals (J) and (K), and measure resistance between terminal (J) and (K) of motor- with a multitester .
If the reading is co, field circuit is disconnected .
Measure resistance across terminal (.I or K and ground (E) with a multitester, and if the reading is nearly - on the largest scale of the te ster, the circ uit is normal .
" Repair motor.
" Replace fuse . (3rU or 4FU) .
Check load current .
Check field current.
I the motor is normal, replace contro' board . See Replacement of Control
CO- CUi1
Board on page 11 .
Adjust load.
Run motor without load, anc see if it locks. Repair motor .
Check load for locking.
Read ust. See Adjustment on Nape 6 .
Adjust load .
Refer to the instructions for Industrial
MCF lamp Motor
ON
TCF lamp
ON
Surge fuse blown
Insufficient cooling with blower .
Check the blower for correct running direction .
Cooling blower stop . Check fan for locking or overloading .
Check thermal relay for tri pin,, .
Thyristor cooling fan stop .
Where the fan is provided with failure senser.
Main CKT Excessive surge.
Check fan for locking or overloading .
Check fuses (3FU, VU) .
Repair or replace fan.
Replace the thyristor cooling an . See
Replacement of Thyristor Cooling Fan .
on ",a :,e 11 .
Eliminate cause of surge . Replace surge and fuse . See Replacement of Surge of
Absorber Fuse and Replacement of
Sur e~ e Absorber .
Note : If the reading is not
W , accurate measurement with a 500 V megger is required . Reading must be 3 megohms or above.
SPARE PARTS
Table 10 lists the recommended spare parts for one VS-505ZII, keep always minimum insurance spare parts on hand to protect the unit against costly downtime . When ordering spare parts, specify complete nameplate" rating and description (type, code no . , etc .) of the parts required, and quantity desired .
Type SS
Type S
T M
Type L
Type S
Type M
Type L
y
(Code
No
(SCR195)
)
Q~ry (Code
No.)
Table 10 Spare Parts for Control Panel
Qty (Code
No
)
Q ty
Fan
Field Thyristor
Diodo y
(Code
No)
0' ~ (Code
No
)
Qty
Surge Absorber
Type
(Code o ) ~~ (Code
No)
Q.ty
230 V
25 A
35 A
230 V
45 A
230 V
90 A
230 V
105 A
230 V
180 A
260 A
420 A
550 A
TM55DZ-H
(SCR197)
N105CH08
(SCR259)
3
6
460 V
90 A
(SCR244)
(SCR201)
PK90HB-160
(SCR245)
TM90D%2H
(SCR202)
3
460V
180A
260 A
460 V
420 A
460 V
550 A
N280CH16
(SCR266)
6
60FHS-110
(FU644)
(FU612)
CS5F-450
(FU614)
CS5F-600
(FU616)
60FHS-110
(FU644)
CS5F-600
(FU616)
2
3
_30
2
2
B3F
(AN 130)
5915PC-22T-
(FAN131)
(FAN107)
-
7556MXV
(FANI11)
DTA
(FAN107)
1
1
TM20RA-H
(SCR192)
2
2
TNR23G-
(XX140)
102K
(XX167)
3
1PDC-C035
(ETC490X) or
(ETC491X)
3
(ET
C 0 X)
(ETC49490X)
(ETC491X)
1
)
(REFERENCE)
ROUGH CHECK OF THYRISTORS
Where thyristors normally function, the following values are obtained .
More than several hundreds of kiloohms across
(A) and
W .
Several ohms to several hundreds of ohms across
(G) and
M .
G
CAUTION I N CHECKING FLAT
THYRISTORS
Apply pressure 5 to 10 kg across thyristor polarities A and K so as to insure positive thyristor internal connections . Measure the resistance using a tester as shown in Fig . 23 (a) and (b) .
(a) Resistance across Thyristor
Terminals (A) and (K)
Thyristor fails if 0 or N is dicated on the even either tester (x 1 : range)
(b) Resistance across Thyrtstor
Terminals (G) and (K)
Fig . 23 Rough Check of Thyristors
Thyristor fails m is indicated on the even either tester (x t range)
14
I
211CB J11 DC-1 1 038
I' 12
PA
OV
1'1, I'2
P3,1`41
PA
H
*2
R~
P18
P20
31C
'~ '
1'0 CONTROL CARD
K
G
K 2'
G2
K
G 1
1
K2
G2
3-PHASE AC INPUT POWER SUPPLY
200/220V 50/6011/ r
1THM
110A
3
Fll
Fl'
!l
li il
l)H
~3 a
FU
2C1 80/0 .2A
M
K 211G 2
.3
200/22111' i
12THM
II
1ZNR
3ZNR
2ZNR
IT
-.
*4
~:.
mo.
,
IU
16
15
I
.-
11
1
.
9.
1
.
1
9
14
13
4
3
6
m
K
K I IL
4TIl~1
N
12
11
17
3 CT 100/0 .2A
W,
W1
13THM lR
500
2R
500
1FAN
Note : Asterisk shows the connections between main circuit
It Indicates that "1 of main circuit is connected to '1 of control circuit .
2PC B u u
1' A
R
1' ., 18
_y
IJ
H
*5
N9, P IL)
FLU
H
*6
m
.03
y
o-__
FIl
H
*3
31
+48V
+ 24 V
0.
I
CONTACT
RATING
220VAC 1
5A
RUN
M'"ON
COM
DB'-
ON
24VDC 1 5A
Nt. ;A/t`tP
PREPARATION 1
I
FAULT
NO
COM
NC
r--
L
i i
1 .D C_ONT t44 JGSM-51
= _ ~6131415
IFB
*
H
lilt-
±
^
i
GB b
0 tG
1 0
3A . . .3 .4 .5 _U
n -
4F v a o
» SPEED
A n
+6V/1011"/
7~
+101'/1011% '14
25K it r, ~' i tnn of l;r
3i .'t K
:i
Cli h
I-st/1ooMoN
ACCF.I.
Ut:CFL
23 I 3 r.z
C148
.
I
+-
A~1 i
GAI
IREF
571
12 3
0 I
OCL
CHI
CH2
RESET'
OCH 11
+31'/100%1
Clf90
,
~
ACR
CH10
L1M1T
1 N R 200 K
2N'R 2M
NC' 2 .2p
1CR :6 .8K
2 CR :510 K
CC :2 .2p
SELECTOR SNITCH W
ACR
1rS
FKIP
I's
PA
P A1 u
TYPE: JI'DC-C(i)
9
F
lFROM
I POWER I'CB
H
*5
H
*6
-
B r. 2 n
0~
Z~
0 m m z r_
Z
Note : Asterisk shows the connections between main circuit and control circuit . It indicates that "`1 of main circuit is connected to il of control circuit .
q0___
FM (KICF)
00
I'I
Ic1
H
H
33
31
F'. OV
+48V
LOGIC CIRCUIT
CONTACT RATING
201 RI N
ON
22lIVAC 15A
24 VDC 1 .-)A
COM
DR
(1N
PREPAI;ATION
FAI l .l'
NO
Cf1U
NC
I
I
I
I
I
L
= i FLD C(1NT
144 JC
P n
<o
IFB
#
H
111 ---+
1
1 r n t o
~n ri
+61 /11)0"/0
+hl lI
, n11~I
+IItV/100%
+151/100°/
SPEED
REFERENCE
FROM CONTROL
TRANS1 : 0RMER
4
15K
16
DCP
IFS
ACCEL.
UFCFI
L2
C118
)0
El
1
L;
N
+ 481'
+2-11
5a 52 il
Notc : Astrrisk shows the connectv)n, hi-twecn main circuit and control circuit . It uulu,ltrti
Il.,,il '
1 of mall, cli t Lilt IN connectecl to
-lot control (u(uit
CII1
ACI{
F' K I1'
S I I{'~e
I b
1~~1 ~' -91'11
I
I
I NMI
IJ
*5
`
VIII>II1l
H
*6
J
I
I I;(111
,111111! ; P( I ;
H
(
REFERENCE)
(Contid)
I
Signal Name
Ready signal
Opel'dtlun signal
Table 11 Functions of External Control Terminals for Input
0 0-
-° o_'
Terminal
No .
27
28
Function
"Close"
"Open"
Field intentiilying .
Gate block --Field half-I-eduCCd .
" Close" --- Spcod reference "ON " -Acceleratlun to speed reference value.
block.
28
29
3 Main circuit M input answer back signal
4 Motor overheat signal
5 Field block signal
6 Motor blower
ON/OFF sig nal
7 External gate block signal
8 External (OCL) failure reset
9 Fuse blown detection signal
(inside)
10, Thyristor cooling fan stop signal
(inside)
11 Speed reference
-° o-
30 "Close" --- Gate block released .
Terminals 30 and 31 (or 32) short-circuited unless used .
-~-
__o
0
34
35 o-
36
__o__o_ __
49 - 50
-0 o-
_o0-
"Open" --- Gate block .
"Close" --- Normally .
"Close" --- Field block . (Field circuit clipped at KIPP phase .)
"Close" --- Field intersifying .
"Open" --- Gate block-Field_ current half-reduced .
"Close" --- Gate block .
48 - 49
"Close --- Normally .
"Open" --- Reset .
Terminals 48 and 49 short-circuited when reset button in the unit is used .
R1 - R2 With failure detection cooling fan (option) .
"Open" --- Normally .
"Close " --- Gate block .
_
R3 - R4 "Open" --- Normally .
"Close" --- Gate block .
12 External current reference
( + Forward torque .
- Reverse torque) flit
12
14
15
+6V/100%N
+6V / 100%N
+1 0V/100%N
+15V/100%N
16
OV (SG) l7
--3V/100% Ia
. Soft start command possible .
3 to 75 sec . (Variable)
" Accel . time, decel . time adjustable independently .
_-
18 OV (SG)
13 Speed feedback signal
14 Automatic field weakening current command
1 Output received from field controller Type JGSM-51
O
0 V (SG)
Note : l . Use highly reliable contact for input interface signal considering that the load is 48VDC, IOmA .
2 .
Provide a noise killer at both ends of coil when relay, contactors, etc . are used .
3 .
The terminals of the circled numbers are provided with the control circuit board Type JPDC-C036
(ET000491X) only .
1 Rc"ady signal
2 Operation signal
3 Failure signal
Table 12 Functions of External Control Terminals for Output
Signal Name
__o o-
19-0
I24-o~ a
25
4 Zero-speed detection signal
5 Main circuit current detection signal
~2-1 o-
Terminal
No .
22-23 (_contact signal closed when operation is ready .
(PREP light ON .)
Function
Allowable contact capacity :
220VAC, 1 .5A
L4VDC, 1 .5A
19-20-21
NO contact --- For M input command .
NC contact --- For DB in p ut command
24-25-26 Contact signal closed (or opened) when failure occurs .
46 "ON" at motor speed 1% or below (-6V/100% NFB )
37 +6V/100% Ia
(Allowable load impedance : 3 kQ)
6 Individual failure detection signal
7 Speedometer
Motor overheat
Thyristor cooling fan stop
Thyristor overcurrent and overload
Fuse blown
Field lost
8 Main circuit ammeter
9 Control power supply
4
42
43
38-39
40-39
51
52
53
31,32
33
"ON" b motor overheat .
"ON" by thyristor cooling fan stop .
"ON" by thyristor overcurrent overload .
"ON" by fuse-blown .
"ON"' by field loss .
Connected to 1 mA DC meter (2 kit or below) .
(Full scale at maximum speed)
Connected to 1 mA DC meter (2 kQ or below) .
(Full scale at 150% load)
-15V
OV (SG)
+15V
+24V
+48V
OV (POWER OV)
*Allowable rating 24VDC . 50mA .
Note : The terminals of the circled numbers are provided with the control circuit board Type JPDC-C036 (ET000491X) .
Isolated from other control power supply .
Varispeed-505 ZU Drive
INSTRUCTIONS
TOKYO OFFICE Ohtemachi Bldg, 1-6-1 Ohtemachi, Chiyoda-ku, Tokyo, 100 Japan
Phone (03) 3284-9111 Telex YASKAWA J33530 Fax (03) 3284-9034
YASKAWA ELECTRIC AMERICA, INC
Chicago-Corporate Headquarters 2942 MacArthur Blvd Northbrook, IL 60062-2028, U S A
Phone (708) 291-2340 Fax (708) 498-2430
Chicago-Technical Center 3160 MacArthur Blvd Northbrook, IL 60062-1917, U S A
Phone (708) 291-0411 Fax (708) 291-1018
MOTOMAN INC.
805 Liberty Lane West Carrollton, OH 45449, U S A
Phone (513) 847-6200 Fax (513) 847-6277
YASKAWA ELETRICO DO BRASIL COMERCIO LTDA
Rua Conde Do Pmhal 8-5', Andar Sala 51 CEP 01501-Sao Paulo-SP, Brasil
Phone (011) 35-1911 Fax (011) 37-7375
YASKAWA ELECTRIC EUROPE GmbH
Am Kronberger Hang 2, 65824 Schwalbach, Germany
Phone (49) 6196-569-300 Fax (49) 6196-888-301
Motoman Robotics AB
Box 130 S-38500 Torsbs, Sweden
Phone 0486-10575 Fax 0486-11410
Motoman Robotec GmbH
KammerfeldstrajOe 1, 85391 Allershausen, Germany
Phone 08166-900 Fax 08166-9039
YASKAWA ELECTRIC UK LTD .
3 Drum Mains Park Orchardton Woods Cumbernauld, Scotland, G68 9_D U K
Phone (236)735000 Fax (236)458182
YASKAWA ELECTRIC KOREA CORPORATION
8th Floor Seoul Center Bldg, 91-1, Sogong-Dong, Chang-ku, Seoul, Korea 100-070
Phone (02)776-7844 Fax (02)753-2639
YASKAWA ELECTRIC (SINGAPORE) PTE LTD.
Head Office' CPF Bldg, 79 Robinson Road # 13-05, Singapore 0106, SINGAPORE
Phone 221-7530 Telex (87) 24890 YASKAWA RS Fax 224-5854
Service Center . 221 Henderson Road, # 07-20 Henderson Building Singapore 0315, SINGAPORE
Phone 276-7407 Fax 276-7406
YATEC ENGINEERING CORPORATION
Phone (02) 563-0010 Fax (02) 567-4677
SHANGHAI OFFICE Room No 8B Wan Zhong Building 1303 Yan An Road (West), Shanghai 200050, CHINA
Phone (86) 212-1015 Fax (86) 212-1015
Phone (02) 563-0010 Fax (02) 567-4677
YASKAWA
YASKAWA ELECTRIC CORPORATION
TOE-S505-30B
® Printed in Japan March 1995 83-4 0 5TA
68145.681-50.681-59 .681-71

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Key features
- Varispeed non-reversing operation
- Industrial DC motor control
- Detailed installation instructions
- Wiring diagrams and procedures
- Test run and maintenance guidelines
- Troubleshooting guide