安川(YASKAWA)505W2系列变频器英文说明书

安川(YASKAWA)505W2系列变频器英文说明 书 关于书的成语关于读书的排比句社区图书漂流公约怎么写关于读书的小报汉书pdf Varispeed -505WII INDUSTRIAL USE THYRISTOR CONVERTER UNITS Before initial operation, read these instructions thoroughly, and retain for future reference. YASKAWA When properly installed, operated and maintained, this unit will • Do not tamper with potentiometers of the power units since provide a lifetime of optimum operation. It is mandatory that the they were preset at the factory before shipment. person who operates, inspects, and maintains this equipment thoroughly reads and understands this manual and has In his Varispeed-505WII (VS-505WII) is a thyristor converter unit for possession at all time. varispeed reversible operation of industrial DC motors. For correct operation of VS-505WII, users must thoroughly IMPORTANT read these instructions. This manual is also necessary for • Make no withstand voltage test on the VS-505WII because it maintenance and troubleshooting, and threfore should be kept filed for ready reference. Incorporates semi-conductor electronic circuits. • If insulation resistance tests are neccessary, make them only In accordance with the Instructions given in this manual. For details on DC motors, refer to "Instructions for Industrial DC Motors" CTOE-C435-3B). 682-227 Type CDMR-WI (Type Type CDMR-WI Type CDMR-WH M) 230 V, 260 A (Type L) (Type S) 460 V, 420 A 460 V,105 A CONTENTS Interconnections ............................... 4 MAINTENANCE ..................... 10 RECEIVING ................................. 3 Cautions when Wiring ..................... 4 STORAGE ..................................... 3 Periodic Inspection .................... 10 TEST RUN ..................................... 5 LOCATION ................................... 3 Parts Replacement ..................... 10 Check before Test Cautions in Replacing INSTALLATION .......................... 3 Run .................................................. 5 Control Board............................. 14 WIRING ......................................... 3 Troubleshooting Guide .…14 No-Load Operation.......................... 6 Component Arrangement in VS-505WII ..................................... 3 SPARE PARTS ......................... 15 Full-Load Operation ........................ 6 Terminal Sizes and Carrying REFERENCE ................................16 Adjustment ...................................... 6 Currents ...........................................4 2 • Free from corrosive gas and liquid RECEIVING • Ambient temperature: 0?C to 40?C The equipment has been put through severe tests at the factory • Less vibration before shipped. After unpacking however, check and see the 9following INSTALLATION • Its nameplate data meets your requirements. Select a location described in STORAGE and install the equipment • It has sustained no damage while in transit. by proper procedure in keeping the equipment in good working • Fastening bolts and screws are not loosened. condition. • Devices built in the cabinet are not damaged or missing. STORAGE WIRING If the equipment is temporarily stored or machine stops for an extended length of time, the following precautions should be Make wiring in reference to the interconnection diagram furnished taken. on your order and the following. COMPONENT ARRANGEMENT IN LOCATION VS-505WH Figs. 1 to 3 show component arrangement in the Store the equipment under the following conditions. • Free from rainfall and drops of water VS-505WE. • Clean and dry POWER CIRCUIT BOARD (2PCB) CONTROL CIRCUIT BOARD "PCBl THYRISTOR CONNECTOR COOLING FAN MAIN CIRCUIT POWER CIRCUIT EXTERNAL BOARD (2PCB) TERMINAL CONNECTOR NAMEPLSNUBBER BOARDS ATE (4PCB) "CAUTIONS CONTROL CIRCUIT IN BOARD (1PCB) OPERA- OPERATION TION" THYRISTOR INDICATINC CONTROL PROTECTIVLIGHT SUPPLY CONTROL E VOLTACK POWER FUSE FUSE BLOWN SELECTOCONNECTOR (2 FOR DETECTION R OCL RESET 220 V CONNECTOR TAP PUSHBUTTON CLASS, 3 FOR SURGE CURRENT 440 V CLASS) ABSORBEDETECTION 682-217 RS CONNECTOR MAIN CIRCUIT FAILURE FUSES (?) EXTERNAL INDICATING TERMINALS LICHTS (6) SURGE ABSOR (a) Control Circuit (b) Main Circuit BEERS (3) MR—Wit, -S (460 V, 115 A) Fig. 1 Type CD CONTROL CIRCUIT BOARD (1PCB) THYRISTOR CONNECTOR POWER CIRCUIT COOLING y BOARD (2PCB) FAN B \ ILSNUBBER POWER CIRCUIT flBnSBEBEEKMfiBV.BOARD BOARD (2PCB) (UPCB) RflS CONNECTOR EXTERNAL CONTROL THYRISTOR TERMINALS CONTROL CIRCUIT PROTECTIVE F(55) BOARD (1PCB) FUSE J^(2 FOR 220 V CLASS, 3 FOR U40 V OPERATION CLASS) INDICAT 丨 NC LIGHT CONNECTOR FUSE BLOWN DETECTION CONNECTOR OCL RESET ? DETECTION CONNECTOR INDICATING CEORECPLLICHTS (6) MAIN CIRCUIT N;T3UCBLDEXTERNAL ORTERMINAL ESGETAREPEPB郎 SlFioS(a) Control Circuit (b) Main Circuit onER (FTlr 5Fig. 2 Type CDMR-WE, -M (230 V, 260 A) 3 up&BS TBolam3)elcassC apn S( AAVN THYRISTOR WIRING (Cont'd) COOLINC POWER CIKCUI FAN BOARD (2PCB) CONTROL CIRCUIT BOARD (1PCB) CONNECTOR POWER CIRCUIT BOARD (2PCB) THYRISTOR CONNECTOR PROTECTIVE FUSE (2 FOR 220 V CLASS, 3 FOR EXTERNAL NAMEPLATE 440 V CLASS) CONTROL "CAUTIONS TERMINALS IN OPERA- (55) LOPERATION INDICATING ON OL ^RLIGHT TRC FUSE BLOWN CT DETECTION OWP ERCONNECTOR CE ERF-SECURRENT cCUR s DETECTION ONBCONNECTOR NE BSUTOR ) SURGE MAIN CIRCUIT EXTERNAL ABSORBERS TERMINALS USN(3) CLCE_iO2 Control Circuit (b) Power Circuit (a) Atp PFig. 3 Type CDMR-WE, -L (460 V, 420 A) USs? tTo ONTERMINAL SIZES AND CARRYING CURRENTS INTERCONNECTIONS F AITable 1 shows the size and the current earring capacities of the lhMake connections of VS-505WI with associate units according to the interconnection diagram separately furnished. terminals of VS-505WII. Select leads with sufficient current carrying capacity. Refer to "Cautions when Wiring". L CAUTIONS WHEN WIRING ICTable 1 Terminal Size and Current Capacity Main Circuits Use 600 V PVC insulated wires or cabtyre cables with the current CDMR-WI Field AC Main DC Main HCircuit carrying capacities of the combined DC motor for AC main circuit Circuit Circuit terminals (U, V,W) and DC main circuit terminals (P, N). Car Rated Rated Ter Car Ter Ter Car rying Volt minal rying minal minal rying Out Cur age Size Cur Size Size Cur put rent V rent rent kW A A A 230 25 M4 21 M5 25 M4 12 Field Circuits 35 M8 29 M8 35 Use 600 V PVC insulated wires or cabtyre cables with the current 45 M8 37 M8 45 carrying capacities of the combined DC motor for field power circuit 90 M8 74 M8 90 terminals (Uo, Wo? Ui, Wi) and field circuit terminals (J, K). Use 105 M8 86 M8 105 2stranded wires of cross-section 5.5 mm or larger for field circuit 180 M10 147 M10 180 M4 22 terminals (J, K). 260 M10 213 M10 260 420 M12 343 M12 420 M4 25 550 M12 449 M12 .550 460 50 M8 41 M8 50 M4 12 90 M8 74 M8 90 Signal Circuits 86 105 M8 M8 105 Use shielded wires or twisted wires of twisting pitches 20 mm or 180 M10 147 M10 180 M4 22 smaller for the speed setting circuit terminals (6 to 10), speed 260 M10 213 M10 260 feedback terminals (2, 3), tachometer circuit terminals (50 to 52). 420 M12 343 M12 420 M4 25 550 M12 449 M12 550 Notes : ? Terminal size other than listed above is M4 and current capacity is 2 A or below. • Rule of thumb of AC main circuit power capacity 1.2 x/3 x e X I (VA) E : Supply voltage I : AC main circuit current Fig. 4 Pitch of Twisted Wire 4 Separation of Signal Cables from Main Circuit Cables To avoid inductive interference from other cables, run the shielded or twisted wires (1 to 55) separate from main circuit cables (U, V, W; U o, W , , Wi, P, N; J, K) in a bundle or thru a duct. 0 COMMUTATOR CAUTION After wiring, check interconnections. Make insulation resistance tests using a 500 V megger. Connect VS-505WE main circuit terminals (U, V, Fig. 5 Inspection Window of DC Motor W; Uo? Wo; Ui, Wi, P, N; J, K) with common lead. Measure the insulation resistance between common lead and the ground. When the test result is 2 Mf2 or more, it means that wiring is good. ’ • When supply voltage is 200 TEST RUN or 400 V, plug the shunt When the VS-505WE has been correctly installed and wired, the connector 220V 2U0V unit shall be tested through a test run as follows. right-hand side tap. i. _ j 440V If trouble is found during the test run, refer to "Check Before • When supply voltage is 200 1111Test Run and Troubleshooting Guide" for necessary measures. or 440 V, plug the shunt If the cause of the trouble cannot be located, or repair is impossible, connector in the left-hand notify our service station, giving the details of trouble conditions. side tap. 440V Fig. 6 Tap Selection of Control Supply Voltage 50Hz CHECK BEFORE TEST RUN Make the following checks prior to the test run. Table 2 Check before Test Run Check Points Check Items 60Hz • Correct wiring Interconnec-• Tightening of terminal screws tions between VS-505WIE and For 50 Hz, slide the switch key up. For Associate 60 Hz, slide the DC Motor • Disconnection from the driven machineUnitsswitch key down. • Removal of thrust block • Remove inspection covers and blow out with air to clean commutator. (Fig. 5)Fig. 7 Power Frequency Selector Switch VS-505WE • Adhesion of dirt or dust on the enclosure• Smooth hand rotation of thyristor cooling fan * 1111• Check items in Cautions in Operation on the back of the control board door• Correct connection of the shunt connector to the Table 3 Supply Voltage Allowable Range voltage selecting tap (Fig. 6)• Correct setting of the frequency selector switch Supply Nominal Permissible Voltage (Fig. 7)Frequency • Correct adjustment of potentiometers on the Supply Voltage Selector control board (1PCB) Refer to red paintVoltage Variation Tap 200 V 50/60 Hz 170 - 220 V 200 V Supply Voltage • Voltages of any two of phases U, V, W are within 220 V 50/60 Hz 187 - 242 V 220 V at Input the values on Table 3. Check with a tester.• Terminals U and Ui and W。and Wi are connected. 0fTerminals of • Rotating direction of the motor blower meets 400 V 50/60 Hz 340 - 440 V 400 V VS-505WHwith the arrow marked on the blower.440 V 50/60 Hz 374 - 484 V 440 V * VS- 505WI of larger capacity than 230 V, 45 A or 460 V, 90 A are provided with a thyristor cooling fan. 5 ADJUSTMENT TEST RUN (Confd) Do not tamper unnecessarily with the potentiometers on the NO-LOAD OPERATION control circuit board since they have been adjusted at the factory before shipped. After making the checks specified before test run, thoroughly check the environment of the system for safety. Adjuster Locations and Functions Check the polarity of DC tachometer generator feedback Adjuster locations on the control circuit board and functions are voltage. When the motor is running forward, the polarity of shown in Fig. 8 and Table 6. The characteristics of control circuit VS-505WII signal terminal 2 (3 : 0 V) is minus and it is plus during board check terminals are shown in Fig. 9 and Table 7. reverse running of the motor. Then, run the motor without load according to Table 4. FULL-LOAD OPERATION 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 4 No-load Operation Order Operation Check Items 1 Set the speed reference at zero. 2Turn on main circuit power Smooth rotation of the suppy.thyristor cooling fan. * Smooth rotation of the blower for DC motor.Rotating direction of the blower meets with the marking o 1 ___ ]o on the blower.1111 3Indication light PREP on the Make an operational se- control board (1PCB) turns on.quence and check to be sure Fig, 8 Adjuster Locations on Control Circuit Board that operation is ready- (Turn on ready signal, motor cooling fan ON /OFF signal 4 Turn-on the operation •) signal.5 Gradually, increase the Smooth acceleration of DC Table 5 Full-load Operation speed setting value.motor •No abnormal odor, smoke, Order Operation vibration and noise on DC 1 Set the speed at zero. motor. 6Remove the hand-hole cover No brush chattering and 2 Turn on the main circuit power supply. and check the commutator.sparking at the brushes.To avoid excessive tem 3 Derature rise of DC motor 32, Turn on operation signal and gradually increase the speed. winding in frame 112,] Check to be sure that the motor and driven machine are reclose the windowwithin 5 minutes.correctly running. 7Gradually, turn the speed Smooth acceleration of DC setting potentiometer motor.4 Turn off the operation signal. clockwise. 8Increase the speed setting DC motor rotates at the maximum 5 Turn off main circuit power supply. value to the maximum .speed. Check with a speedometer.9 Change the speed to various DC motor speed corresponds values.with the set values.10 DC motor suddenly stops. Turn off the operation signal. 11 Turn off the main circuit power supply* VS-505WII. rated 220 V. 45 A and above and 460 V. 90 A and above are provided with a thyristor cooling fan. 6 Table 6 Control Circuit Board Adjuster Locations and Functions Typc AdjusteAdjustAdjusting Method Adjuster Function Specificationr er of s Accel time adjustment at fwd run. (Decel LocatioName ? RATE 3-75 sec Adjusttime adjustment at rvs run.) Clockwise^rotation n 3-75 sec Decel time adjustment at fwd run ? RATE ers increases acccl time. Clockwi&e rotation increases decel Lime. (Accel time adjustment at rvs run.) Clockwisc rotation increases GAIN ASR Gain adjustment. Speed feedback adjustment. Clockwise rotation ? 6 V/100% speed NMAX decreases speed. ____________ ACR Gain adjustment. Clockwise rotation IGAIN increases gain. __________ +3 V/100% Main circuit current Clockwisc rotation 1FB Clockwise rotation Speed and current limit value at feedback adjustment. _________ decreases current. forward run. increases limit value. current 150% 150% (Standard) Clockwise rotation Speed and current limit value at ,F LIMIT rse run. increases limit value. R LIMIT (Standard) 17 - 0.84 times Clockwise rotation Counter electromotive CEMF increases force compensation._________ Potenti gaiAmmeter adjustment. Speedometer adjustment. mADC max ometers Clockwise rotation ckwisse rotation increases pointer mADC max AM SM Clswing. n. poincreases oc NOFS ASR offset adjustment. 12 ir Qvoltage_____ ? voltage ointex* swing. IOFS ACR offset adjustment* 13 ^voltage 155?eZ (Standard) Clockwise rotation advances shift lag limit. Phase^hift lag limit KIPP adjustment (Adjustable) Adjustment of phase shifter Clockwise rotation 15 PSB operation advances 110% ^Standard) point. phaseSetting overload Clockwise rotation OL% . detection start point. increases overload detection start T50%, 60 sec (Standard) point. Setting overload Clockwise rotation 17 OLT increases operation time. ___ detection time. Rough adjustment of field 1FBR 0% - 10% (Adjustable) Setting zero current Clockwise rotation 20 cur. Open the resistor according Refer to motor 18 ZCD 4FBR 7% (Standard) increases detection level. detection level. Rough adjustment of main 5FBR to specifications. rent detection voltage specifications . 21 Setting field current- Clockwise rotation 9FBR circuit level. (Current IREF 22 1SW N- current detection increases field current. (Speed control) Slide controvoltage level. 2SW Supply frequency selector. DO HZ ToTTT ResistoSwitch l) Rough adjustment of speed Selection of the voltage Control Method selector r 24 detection voltage level • A - D level^ according to type of Selectitach-gen and motor rated on Selection of soft El speed. ________________________ 25 (Open) E2 Soft start start FT control P control FI PI control Selection of PI or P control HI operatioSelection of El or P control H2 26 PI control 27 Selection of zero-speed J1 Gate block after by by n Plug SelectioASR control method condi- motor reached zero ACR control method 28 n speed by stop tion at motor overheat. J7 Immediate gate block • operation. KZ Without W3tIT K1 Selection of start Field half-reduced after Li 29 Selection of zero-speed motor zero-speed by interlock stop operation. (Gate cTondi tion at motor blower zero-speed -block) tz Field half-reduced Immediately. stop • 30 (Gate block) condition. Exciter used. Selection of exciter 31 M2 Exciter not used. according to type of motor field. _______________________ Open Speed control by voltage detection. Speed control by 32 OPN AC tach-gen. Short- circuit ShortOther than the above. Jumper - Shor circu ited? 33 OPS Other than the above rt circuited Adjustment Procedure TEST RUN (Cont'd) NMAX (Speed feedback adjustment) 0 ^CHIO -CHll :CH12 To adjust the DC motor speed exactly to the reference speed, 、CHI3 proceed as follows. the tachometer having the required the DC 1. Prepare accuracy. ,H16 2. Operatmotor at no load (or less e 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. t zC^CH17^CH18 Hi 19 H22 CH23 CH2A H20CH2S Terminals Fig. 9 Control Circuit Check H1 Table 7 Control Board Check Terminals Signal Name Check Normal Value Terminals CH22 OV (SG) Stable power supply CH24 +15 V CH2S -15 V CH19 +24 V Unstable power supply CH20 -24 V Allowable voltage [unction range: ?20% CH23 +24 V (Pulse aimplifier supply) CH4 ?6 V/100% command ( 0 Forward, ? Reverse) Speed reference CH5 +6 V/100% command ( ? Forward, ? Reverse) Speed feedback CH3 76 V/100% speed ( ? Forward, ? Reverse) Forward CH9 -3 V/100% command Current command Reverse CH8 +3 V/100% current limit (+6 V/100% speed limit) Current limit Forward CH7 Reverse (Speed limit) CH6 Main Current feedback CH18 +3 V/100% current Circuit Current limiter output CH2 0 to +6 V when controlling Approx. -1 V at gate block Power Phase shifter input CH16 +1 to +5.5 V at 60 Hz, +1 to +6.5 V at Approx. +5.5 V at 60 Hs +6.5 V at v50 Hz when controlling. 50 Hz at gate block. Counter electromotive force input CHI 0 - ?5 V Overload detection start point CH21 110% (Approx. -1.65 V) Zero-current detection CH15 approx. +12 V at 0 V at load current conduction 0 A of load 9current. Pulse amplifier power Forward CH12 0 V at reverse operation. Approx • +24 V at forward operation. supply Reverse CH13 0 V at forward operation. Approx • +24 V at reverse operation. Gate block (at failure) CH14 0 V normals approx. -12 V at gate block. u U / w V 八 ~( Phase shifter synchronicatioti U V, W: Main circuit 9 power supply w Current command CHll Voltage according to Ex. •6 V/5 A Field Current feedback CH17 field current. +3 V/5 A Power Phase shifter input CH10 +1 to +5 V at 60 Hz, +1 to H V at SO Approx. +5 V at 60 Hz? 托 V at 50 Hz when controlling. Hz at fidd block. 6. If the speed exceeds the desired speed, turn NMAX clockwise SYNCHROSCOPE SCREEN to decrease the speed. ADJUST THE SWEEP SPEED' ADAPTED TO THE MOTOR FLIMIT (Forward limit value adjustment) RLIMIT ACCELERAITON TIME TO (Reverse limit value adjustment) BRING THE CURVES TO A CONVENIENT POSITION. 1. Current limitation (Speed control) Slide the control method selector switch (1SW) on the control circuit board to N. When the voltages at CH7 (forward) and CH6 (reverse) are +3 V, 100% current limit value is obtained. Current limit value can be set within the range of 0% to 250% by F LIMIT and R LIMIT. MOTOR 2. Speed limitation (Current control) ACCELERATION Slide the control method selector switch (1SW) on the control circuit Fig. 10 CEMF Adjustment CURRENT PTIMUM board to I. When the voltages at CH7 (forward) and CH6 (reverse) COMPENSATION are +6 V, 100% speed limit value is obtained. Speed limit value can ATION be set within the range of 0% to 250% by F LIMIT and R LIMIT. CEMF compensation reduces the loss time due to Forward/Reverse selection to as the same level as the integral control of ACR. Turn CEMF fully counterclockwise, and during motor acceleration by current limit gradually turn it clockwise until the voltage at CH2 on the control circuit board stabilizes. PSB (Phase shifter operating point adjustment) Field Current Adjustment PSB sets the phase shifter operating point• Field current adjustment is required for checking the setting at the 1. When the current controller (ACR) is integral-controlled factory or for fine adjustment. To change the setting, selection of Connect the plug selector F on the control circuit board at FI. Turn resistors (1FBR to 4FBR) on the control circuit board is required. PSB fully counterclockwise. 1. For constant field current 2. When the current controller (ACR) is ratio- controlled a. Connect a DC ammeter to the field circuit. Connect the plug selector F on the control circuit board at F2. Turn b. Adjust so that the ammeter indicates the rated field PSB clockwise gradually with reference current at 0 V (0 V at CH2), current with IREF on the control circuit board. (Refer to the and set at the position where main circuit current is ready to start. test report or nameplate data.) 2. For field weakening control CEMF (Counter electromotive force compensation) Field weakening control is made for the VS-505WH combined with Current loop is vulnerable to counter electromotive force. In order to field weakening control unit type JGSM-51- ?. obtain optimum performance a compensating electromotive force va. Connect DC ammeter to the field circuit and DC voltmeter to has to be biased on the phase shifter, depending on the control output terminals P, N. mode. b. Turn IREF on the control circuit board and FORCE FLD and V LIMIT of field controller fully counterclockwise. 1. When the current controller (ACR) is ratio- controlled c. Set the minimum field weakening current by IREF. In this Adjust CEMF, observing the motor acceleration current with a case, set the current at 80% field weakening current at maximum synchroscope. Turn CEMF fully counterclockwise, and turn CEMF speed. (See the test report.) clockwise gradually until optimum value shown in Fig. 10 is obtained. d. Set the rated field current (field intensifying by FORCE FLD. 2. When the current controller (ACR) is integral- con t rolled (See the test report or nameplate data.) e_ After the motor starts, gradual increasing the speed reference increases the voltage across P and N and governs it at some value. Turn V LIMIT clockwise gradually so that the governed value is the rated voltage. 9 Field Thyristor Replacement MAINTENANCE With all the Models, thyristor modules consisting of a thyristor VS-505WH requires almost no daily inspection. To keep the and a diode are used as the field thyristor. Replace them as correct and successful operation, periodic maintenance follows. operations should be performed. The users should prepare 1. Remove the four mounting screws of field snubber board their own maintenance programs based on the following (3PCB) , lead clamping screws, control power connector. Then, guidelines. remove snubber board. See Fig. 11. PERIODIC INSPECTION 2. Remove lead clamping screws connecting to thyristor, and remove the leads from thyristor. Table 8 shows the minimum inspection items and the In this case, mark all terminals for identification. See Fig. 12. procedures. 3. Remove thyristor mounting screws (2) and remove thyristor module. 4. Check the type and capacity of new thyristor module against the requirements. Install it by reversing the removal procedure, Table 8 Periodic Inspection making connections to the terminals identified by the marks made before removing the old thyristor module. Coat the thyristor Inspection Inspection Inspection What to do Remarks Part Item Procedure mounting surface with joint compound, JOINTAL Z made by Nippon Light Metal Co.,Ltd. • Noise Replace. Rule of thumb Thyristor • Check for cooling for cooling fan any inter-Main Circuit Thyristor Replacement fan replacement: mittent or VS-505WI, 230 V at 25 A 15,000 hours of unusual • Vibratio• Fee] by operation.nThe unit uses a thyristor module consisting of two thyristors. noise. hand. Replace it as follows. General• Clean with • Dust or • Check an electri-dirtfor dust 1. Remove snubber board (4PCB) mounting screws (5) and or cal cleanerclogging dirt adhesion. lead clamping screws. Remove snubber board. (Fig. 13) • Tighten. • Loose • Check terminal loose screws or 2. Remove bus bar mounting screws and lead clamping screws for screws or nuts. nuts connected to thyristor. Remove bus bar and leads. (Fig. 14) In this case, mark the terminals for identification. 3. Remove two thyristor clamping screws and thyristor. PARTS REPLACEMENT 4. Check the replacement module for type and capacity, arid • Replace the parts required after checking the trouble and reinstall it by reversing the disassembly procedure, identifying the correcting it according to TROUBLESHOOTING GUIDE. terminals by means of the marks made prior to disassembling. • Turn off the power before part removal or mounting. SNUBBER BOARD MTC SCREWS (**) BOARD (3PCB) CLAMPING CONTROL FIELD THYRISTOR CONNECTOR THYRISTOR MTC SCREWS Fig. 11 Field Thyrsitor Assembly Fig. 12 With Snubber Board Removed 10 Main Circuit Thyristor Replacement VS-505WI, 230 V at 180 to Main Circuit Thyristor Replacement VS-505WI，230 V at 35 to 550 A, 460 V at 180 to 550 A 105 A, 460 V at 50 to 105 A The unit uses a thyristor module consisting of two thyristors. Replace The VS-505WH uses a flat thyristor module as a power module. it as follows. For 180 A and 260 A, one power module is employed, and for 420 A, and 550 A, three power modules are employed. Proceed as 1. Remove snubber board (4PCB) mounting screws (5) and follows. remove snubber board. (Fig. 15) 2. Remove bus bar mounting screws and lead clamping screws 1. Remove the clamping screws for thyristor gate (Cl) and cathode connected to thyristor. Remove bus bar and leads. (Fig. 16). In this (K) terminals (24 for 260 A or below, and 8 for 420 A or more), and case, mark the terminals for identification. free the leads. Remove fuse mounting bolt(s) (3 for 260 A or below and 1 for 420 A or more). (Fig. 17) 3. Remove two thyristor clamping screws and thyristor. 2. Loosen power module mounting bolts (7 for 260 A or below, 8 4. Check the replacement module for type and capacity, and for 420 A or more) , and remove the power module. reinstall it by reversing the disassembly procedure, identifying the terminals by means of the marks made prior to disassembling. Coat the thyristor mounting surface with joint compound, JOINTAL Z made by Nippon Light Metal Co. , Ltd. (4PCB) MTG SCREWS (5) Fig. 15 Main Circuit Thyristor Assembly (460 V, 105 A) Fig. 13 Field Thyristor Assembly (230 V, 25 A) THYRISTOR THYRISTOR CLAMPINC SCREWS Fig. 14 With Snubber Board Removed Fig. 16 With Snubber Board Removed 11 MAINTENANCE (Contd) 9. Tighten the snubber board mounting screws. Then, mount the 3. Place the main circuit thyristor module on a work bench. thyristor module by reversing the disassembling procedure, Remove the snubber board (4PCB- U, V, W) mounting screws (3 for tightening the screws firmly. 260 A or below, 4 for 420 A or more),and take out the snubber board. (Fig. 18) 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 leaf spring. 6. Clean the contact surfaces of the new thyristor and the fin, and thinly coat these surfaces with joint compound,JOINTAL Z made by Nippon Light Metal Co. , Ltd. 7. Align the fin locating pin and the thyristor locating hole, after THYRISTOR making sure that the polarity of the thyristor is correct. CATE (C) CATHODE (K) TERMINALS 8. Keeping the leaf spring and the fin in parallel ,finger-tighten the MTC clamping nuts. Then, tighten them alternately through 1/4 turn at a BOLTS (8) time, three times each with a socket wrench. Now, the thyristor fin has been installed. 682-236 SNUBBER BOARD BOARD MTC SCREWS (4) Fig. 17 Main Circuit Thyristor (460 V, 420 A) MOUNTINC NUT THYRISTOR LOCATING THYRISTOR (RED) THYRISTOR LOCATING (WHITE) 3(K) THYRISTOR .,. 662-239 (b) Thyristor (a) With Thyristor Removed Fig. 18 Thyristor Replacement Thyristor Protective Fuse Replacement 230 V at 25 to 105 A, 460 V at 50 to VS-505W 105 A FUSE BLOWN 1. Pull up the fuse blown indicating microswitch with the leads INDICATINC MICROSWITCH connected. (Fig. 19) 2. Remove the two fuse mounting bolts. 3. Mount the replacement fuse by reversing the removing procedure, after checking it for model and capacity. 682-221 Fig. 19 Main Circuit Fuse Assembly (460 V, 105 A) 12 Thyristor Protective Fuse Replacement 2_ Check the replacement surge absorber for model and capacity. Mount three surge ab- VS-505WI, 230 V at 180 to 550 A, 460 V at 180 sorbers after connecting M4 pressure termi- to 550 A nals to their leads as shown in Fig • 22. 1. Remove the two lead clamping screws of the fuse-blown indicating mocroswitch and free the leads. (Fig. 20) Fig. 22 Surge Absorber 2. Remove the two fuse mounting bolts, and remove the with Pressure Terminals fuse together with the fuse-blown indicating microswitch. Connected to Leads 3. Check the replacement fuse for model and capacity, and J* install it by reversing the disassembling procedure. Thyristor Cooling Fan Replacement To replace a thyristor cooling fan with a new one, proceed as FUSE MOUNTING follows. (Fig. 23) The VS-505WH units rated 230 V, 25 A; 460 V, 50 BOLTS (2) A are selfcooled type. FUSE-BLOWN INDICATING MICROSWITCH 1. Remove the cooling fan power lead. 2. Unscrew the two fan mounting Screws and dismount the fan. MICROSWITCH LEAD CLAMP-ING SCREWS 11^ 3. Remove the fan by reversing the disassembling procedure. POWER SUPPLY LEADS (2) FAN MOUNT INC SCREWS w*, 682-218 Fig. 20 Main Circuit Fuse Assembly (460 V, 420 A) (a) 230 V, 45 to 105 A; 460 V, 90/105 A Surge Absorber Fuse Replacement 1. Pull the fuse element and remove it. (Fig. 21 ) 2. Mount the replacement fuse, after checking its model and capacity. POWERFAN - SUPPLY LEADSMOUNT,Mr. ^ _ W' ? SCREWS (b) 230 V, 180/260 A; 460 V, 180/260 A SURCE ABSORBER ABSORBER MOUNTING SCREWS (3) POWER SUPPLY LEADS (3) Fig. 21 Surge Absorber Fuse FAN MOUNT-ING SCREWS (2) Surge Absorber Replacement (c) 230 V, 420/550 A; 460 V, 420/550 A Fig. 23 1. Remove three surge absorber mounting screws and remove surge absorber. Thyristor Cooling Fan 13 MAINTENANCE (Cont'd) Control Circuit Board Replacement Disconnect all the leads from the terminals. MOUNTINC Then, unplug the connectors shown in Fig. 24, and remove the 6 control SCREWS (61 circuit board mounting screws. EXTERNAL CONTROL Mount the new board by reversing the disassembling procedure. TERMINALS (2PCB) CONNECTOR Plug-in the connectors firmly. CAUTIONS IN REPLACING CONTROL CIRCUIT BOARD Make sure that the type of the new control circuit board agrees with the FUSE-BLOWN nameplate and potentiometer settings of new control circuit board are DETECTION CONNECTOR CONNECTOR the same as the old one. Refer to the nameplate "Cautions in CURRENT Operation" posted on the Inside of the control circuit board door of DETECTION CONNECTOR VS-505WII. See Table 6 "Adjuster Locations on the Control Circuit Board and Functions". Fig. 24 Control Board TROUBLESHOOTING GUIDE Table 9 Troubleshooting Guide Possible cause Check method Failure indicating Control PREP lamp ON • ________ printed lamp OFF Check the external operation sequcncc. board Rcplace the control board. See Replacement of Operation sequence failure. Control Board. Control Too low setting of Is setting dial at the positions indicated by Set the setting dial to the OCL position of lock paint. _______ printed "OL%,__ "OLT". lock paint ? ____________________________ lamp ON board Too high setting of FUMIT," "RLIMIT" Refer to Tables 6 and 7. Readjust. Incorrect setting of IFBDefective (deterio- Check thyristor (Fig. 25). Thyristor Replace thyristor. (See Main~ " rated). Circuit Thyristor on page 9.) Overloaded. Load. " Adjust la Check load current. Motor and Repair motor. Run motor without load, and see if it locks. driven Locking. Repair driven machine* Check load for locking. machine Repair motor. Run motor with terminals (P) and (Ndis- 】Layer shorting in connected. If OCL lamp does not light, motor • the motor and its circuit are defective. Grounding of motor Repair Measure resistance between terminal fP5^ motor. circuit. (or N) and ground (E) with a multitester. 00Correct If the reading is nearly on the largest winng. scale of the tester, the circuit is nornal. Check thyristor (Fig. 25) Defective (deterio-(See Main Circuit Replace thyristor. FU Thyristor rated). lamp Thyristor on page Operate only board with (P) and (N) dis-Repair motor. ON Layer shorting in connected. If fuse is not blown, motor circuit is motor. defective. Grounding of motor To replace "RcpMeasure resistance across terminal (P) (or N) and motor • aT fuses (1FU, ground (?) with a multitester, and if the reading is circuit. irrect Corr2FU. nearly on the largest scale of the tester, the winng. e circuit is normal. (See Note.) _________________ 5FU). refer to Defective (phase If tfiemotor is normal • ReplacemeContrcontrol circuit). replace contnl circuit board • nt of ol Refer to Replacement of circuit ThyristControl Circuit Board on board page 13. or Protection Defective (deterio- Fuse Fuse. rated)^ _________ Repair motor. Layer shorting in FL Measure resistance across terminal J and K Replace fuse. (3FU or 4FU). field winding. lamp with converter terminal J and K disconnected ON with a tester. If it indicates • jt means* field #circuit is disconnected. Measure resistance across terminal (J or K】 and Grounding of field ground (G) with a multitester and if the reading is tcircuit • nearly • on the largest scale of the tester, the circuit is normal. If the motor is normal^replace control board. Control See Replacement of Control Board on page circuit 13. __________________________________ board Adjust load. Check load current. Main circuit OveTHG r Check field current. ^ickd】ust_ See Adjustment on page 7. Field circuit ms lamp loadRun motor without load, and see if it locks. RepLock: ON ai u Check load for locking. just load. to the instructions for Industrial Blocked air filter. AdDC Motors (TOE-C43S-3). ___ iui Correct wiring. Check the blower for correct runnin'g Insufficient cooling direction. with Check fan for locking or overloading. Repair or replace fan. Cooling blower stop MCF lamp blower.Check thermal relay for tnpping. CheckTfan for locking or overloading. Thyristor cooling fan stop. Where Replace the Thyristor cooling fan.See TCF the fan is provided with failure Replacement of Thyristor Cooling Fan, lamp sensor on page 12. Elimina ON iate cause of surge.Replace surge Check fu?es (3FU, 4FU). Main CKT Excessive surge , Surge and fuse. See Replacement of Surge of absorbeAbsorber Fuse and Replacement of r fuse ^urge_Absorber^__ blown Note: If the reading is not •, accurate measurement with a S00 V megger is required. Reading must be 3 megohms or above. 14 SPARE PARTS specify complete nameplate rating and description (type, code Table 9 lists the recommended spare parts for one VS-505WH, no. , etc.) of the parts required, and quantity desired. keep always minimum insurance spare parts on hand to protect the unit against costly downtime. When ordering spare parts, Table 10 Spare Parts for Control Panel Thyristor Fan Surge Main circuit Thyristor Surge Absorber Field Thyristor Control Absorber Converter Thyristor Prolcctivc fuse I'usc Diode Board Circuit Q'lQ'iy Q'ly Q'ty Q'ty Q'ty T>pe Q-. (Code Unit Type Type (Code No ) Type (Code Type (Code Type (Code Type (Code Type (Code V.v No ) ^ ? No ) No ) No.) No ) CDMll-WII No.) Type SS TM20DA-II 230 V (SCR195) 25 A TM25DZ-H60FHS-55 230 V (FU642) 35 A Type S (SCR196) 6 FCF2-20 i 230 V 4715PC-22T (FU599) 45 A -B30-B00 (1"\N130) TM55DZ-H6onis-no 230 V (SCR197) (FU644) 90 A 60F1IS-150TM90DZ-H 2 2 1 TM20RA-H 2 TNH23G471K 3 JPDC-C041 230 V (PU615) (SCH198) (SCIU92) (XXI10) (ETCS172) 105 A rypc M N105CH08 CS5K-200 59151^-227 230 V (SCK259) (FU609) -B30-IUK) 180 A ,(FANI31) N195CH08 12 CS5F-350 KCI'2-30 230 V (FU612) 260 A . Type L (SCR261) CS5F-450 (FU600) 230 V MIUV18- (FU614) 420 A DTA (FAN107) 553PA80 CS5F-600 230 V (SCR263) (1*U616) 550 A PK55HB-160 60FHS-110 - 460 V (SCR244) 50 A Type S (FUM) FCP2-20 460 V /TM55DZ-2H\ 90 A V(SCR201) / 60FHS-150 (KU599) TM20KA-11 TNR23G102K JPDC-C041 . 460 V PK90HB-160 HN4556M(FU645) 105 A (SCH245) V (FAN /TM90DZ-2II\ 110) V(SCH202)) Type M N105CH16 ?J 2 7556MXV 1 (SCR192) 2 (XX167) 3 '160 V CS51-200 (P,TCS172) | (SCK260) 180 A (TU609) N195CH16 12 CS5F-350 FCK2-30 (FAN111) ! 460 V (FU612) 260 A Type L (SCR262) CS5F-450 (FU600) i 460 V MHW18- (FU6H) 420 A DTA I (PAN 107) CS5F-600553PA160 1 460 V (FU616) (SCR264) i 550 A 15 (REFERENCE) ROUGH CHECK OF THYRISTORS Where thyristors normally function, the following values are obtained. More than several hundreds of kiloohms across (A) and (K). Several ohms to several hundreds of ohms across (G) and (K). 0) TESTER TESTER TESTER Thyristor fails 00Thyristor if 0 or is in-00 dicated on the fails if 0 or even either is indicated tester (x 1 on the even range) either tester AC POWEF (x 1 range) 200/220V (a) Resistance across thyristor terminals (b) Resistance across thyristor terminals (A) and (K) (G) and (K) Fig. 25 Rough Che ck of Thyristors ELEMENTARY DIAGRAM OF THYRISTOR CONVERTE R UNIT W1 (TYPE CDMR-WH, 230 V, 90 A) { SUPP1FAN LY TUO" m Ul 50/60 Hz 3x 2x x 2CT 1PCB 2PCB JPDC-P050 5>: -80/0.n 2PCB ---- — FPA rsi--|S9-6 3 ? 1 7 4 FU 2A ----- —RPA ?200/2JPDC-P053 I ^110A si:—iA 20V ;(W'l1PCB ^4PCB SELECT3PCB ~ w 2PCB — ur )PftP AA- PRPTEHAA- - 8THM HL PI .iDi? -PAl P13 yII~KrcllFR- 7THM 1 -KG1 TI v 1PCB 2 P12|R1 RR^ID4 FR G2I Pll wd 212K2 R G K fK; ? 2 FS- P2i P9FS1PCB G\ 121- 3CT 16P15 RS^?- Ki 8THM T i _____ i! 100/0.2A KP10RPl2 , P7FT FT- S 1PCB -C3G ------------ CZllPCB 3- 1R 2R 2 500 500 18P8|RRT—— T CONTROLLER P20 JPDC-C041 Fig. 26 Main Circuit 16 FROM POWER PCB H IFB ? FROM H DC TC 2POWER PCB —__________________^CH25_ 画 15V + 15V0V-15V ^ (P) (o) (n) Fig. 27 Control Circuit 〈REFERENCE〉(Cont'd) FUNCTIONS OF EXTERNAL CONTROL TERMINALS Table 11 Functions of External Control Terminals for Input Signal Name Terminal Function No. 1 Ready signal —o o— 30 "Close" ------- Field intensifying. "Open" -------- Gate block Field half-reduced. 2 Operation signal —0o— 29 "Close" --------Speed reference "ON" -> Acceleration to speed reference value. "Open" -------- Speed reference "OFF" + Stop by regenerative braking -*? Gate block. 29 "RUN"-------- Speed reference "ON" + Acceleration to speed —0 — -ftf reference value. 28 "STOP" -------- Speed reference "OFF" + Stop by regenerative braking + Gate block• H3 -5~o- 27 Quick stop at Close" in case of soft start operation. Quick stop signal "Close" -------- Speed reference "OFF" + Stop by regenerative braking + Gate block. 11114 —o~o— Close ----- Gate block 26 Main circuit M input Terminals 26 and 35 (or 36) short-circuited released. answer back signal unless used. 5 33 "Open" -------- Gate block. Motor overheat signal 1111 Close ----- Normally. (Field circuit clipped at KIPP Field block signal —o o— 32 "Close" -------- Field block. phase.) 7 -5-0- 31 "Close" -------- Field intensifying. Motor blower ON /OFF "Open" -------- Gate block + Field current half-reduced. signal 11118 46 _ 47 Close ----- Gate block. External gate block signal 9 -Q Q— 45 - 46 "Close" -------- Normally. External (OCL) failure Terminals 45 and 46 short- circuited when "Open" -------- Reset. reset reset button in the unit is used. "Open" -------- Normally. 10 —oo— R1 - R2 Fuse blown detection 11signal (inside) "Close ------- Gate block > 11 ~o o- R3 - R4 With failure detection cooling fan (option). Thyristor cooling fan stop 11"Open ------- Normally. signal (inside) "Close" -------- Gate block.. 12 Speed reference 6 ?6 V/100%N • Soft start command possible. (? Forward, G 7 士6 V/100%N • 3 to 75 sec. (Variable) Reverse) 8 ?10 V/100%N 9 士 15 V/100%N • Accel, time, decel. time ad 10 0 V (SG) justable independently. 12 16 V/100%N Terminals 11 and 12 short- circmted. 13 ?6V/100%N 13 14 ?3 V/100% la External current reference (? Forward torque, 0 Reverse torque) 15 0 V (SG) 14 2-3 DCTG 2 (-), 3 (+) _ ? Speed feedback signal 15 CEMF compensation 48 Forward: -6 V/l00% Va Reverse: +6 V/100% Va 16 1 Output received from iield controller Type JGSM-51. Automatic field weakening current command 17 5 • Output from Type JGSM-55 Speed feedback (Voltage When reversible operation by ACTG. (OPN: Open) feedback) • Output from type JGSM-53 When speed controlled by voltage detection. (OPN: Open) Notes: 1, Use highly reliable contact for input interface signal considering that the load is 48 VDC, 10 mA. 2. Provide a noise killer at both ends of coil when relays, contactors, etc. are used. 18 Table 12 Functions of External Control Terminals for Output Signal Name Terminal Function No. 1 Ready signal —o~ 24 - 25 Contact signal closed when Allowable contact capacity: operation is ready. 220 VAC, 2 A 24 VDC, 2 A (PREP light ON.) 2 Operation signal 21-22-23 NO contact -------- For M input command. 193 Failure signal - V/100% la """ (Allowable load impedance: 3 k^) ?12 V Max 6 Speed reference signal 11 3,6 V/100% N Terminals 11 and 12 short-circuited • 7 Speed feedback signal 4 Input from Type JGSM-55 when reversible operation by ACTG. (OPN: Open) 8 39 Indi Thyristor cooling fan stop "ON" by thyristor cooling fan stop. vidual 40 failure "ON" by thyristor overcurrent Thyristor overcurrent and overload. detec overload Field lost 41 "ON" by field loss. tion Motor overheat 42 "ON" by motor overheat. signal Fuse blown 43 "ON" by fuse-blown. 9 Speedometer 50 - 51 Connected to 1 mA DC meter (2 kf2 or below). (Full scale at maximum speed) 10 Main circuit ammeter - 51 Connected to 1 mA DC meter (2 or below). (Full scale at 150% load) 11 Control power supply 53 -15 V 54 0 V (SG) 55 +15 V "............................................................................................ 38 +24 V 37 0 V( POWER 0 V) 35, 36 +48 V Isolated from other control 34 0 V (POWER 0 V) power supply. * Allowable rating 24 VDC, 50 mA. (24 VDC power supply required externally.) 19 Varispeed-505WII INDUSTRIAL USE THYRISTOR CONVERTER UNITS TOKYO OFFICE Ohtemachi Bldg, 1-6-1 Ohtemachi, Chiyoda-ku, Tokyc, 100 Japan Phone (03) 3284-9111 Telex YASKAWA J33530 Fax (03) 3284-9034 SEOUL OFFICE Seoul Center Bldg, 91-1, So Kong-Dong, Chung-ku, Seoul, Korea Phone (02) 776-7844 Fax (02) 753-2639 TAIPEI OFFICE Shen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road, Taipei, Taiwan Phone (02) 563-0010, -7732 Fax (02) 567-4677 YASKAWA ELECTRIC AMERICA. INC. . SUBSIDIARY Chicago-Corporate Headquarters 2942 MacArthur Blvd Northbrook, Illinois 60062-2028, USA Phone (708) 291-2340 Fax (708) 498-2430 Chicago-Technical Center 3160 MacArthur Blvd Northbrook, Illinois 60062-1917, USA Phone (708) 291-0411 Fax (708) 291-1028 Los Angeles Office 5626 Corporate Avenue Cypress, CA 90630. USA Phone (714) 828-9692 丁elex (230) 678396 YASKAWAUS TS丁N Fax (714) 82!8-1165 New Jersey Office Riverdale One, 44 Route 23 North, Suite 5 Riverdals, NJ 07457-1619 Phone (201) 835-9512 Fax (201) 835-9511 YASKAWA ELECTRIC EUROPE GmbH SUBSIDIARY Niederhochstadter Strafe 73. W 61476 Kronberg-Oberhochstadt. Germany Phone (06173) 938-0 Telex 415660 YASE D Fax (06173) 68421 YASKAWA ELETRICO DO BRASIL COMERCIO LTDA. • SUBSIDIARY Rua Conde Do Pinhal 8-5*, Andar Sata 51 CEP 01501-Sao Paulo-SP, Brasil Phone (011) 35-1911 Fax (011) 37-7375 YASKAWA ELECTRIC (SINGAPORE) PTE. LTD. CPF Bldg, 79 Robinson Road No 13-05, Singapore 0106 Phone 2217530 Telex (87) 24890 YASKAWA RS Fax (65) 224-5854 YASKAWA ELECTRIC CORPORATION Y YASKAWA TOE-S505-20C ? Printed in Japan October 1993 63-4 0 5TA 發 682-215