YASKAWA INVERTER

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Introduction Market of General purpose Inverters

Drives Industry Market Growth in Japan

350 300
Units x 10,000
Export Domestic

Drives up to 75 kW
840 767 751

250 200 150 100 50 0

644
Tens of thousands

715

286

262 225

260

202
Hundred million

98 127 2003

118

109

120

93 109 2002
3% 15%
Units

144

151

166

1000 900 800 700 600 500 400 300 200 100 0 2007 2008

Hundred million yen

2004

2005

2006

Shipments by capacity in 2008

23% 51% up to 0.75 kW 0.75 kW to 4 kW 4 kW to 15 kW 15 kW to 75 kW

Amount

24%

31%

27%

26%
4 Data from JEMA

Inverter Market Shares (FY 2009 )

World
Data estimated by Sales Promotion Section

Japan
This share represents No. of units produced in Japan.

C.T 4.8%

Others 25.8% Rockwell Total 12.1% 2,342M US$ ABB 10.0% Mitsubishi Fuji 9.8% 9.6%
Siemens 7.9%

Yaskawa 12.8%

Hitachi 5.9%

Others 6.0%

Mitsubishi Toshiba 9.5% Total 30.5% 1.813million units Yaskawa 23.7% Fuji 24.3%

ToshibaToshiba-Schneider 7.2%

Global Share by Region

Europe
12.8%

USA
15.8%

No.1 Global Share

(fiscal year 2009)
Japan
H 1.7% G 2.8% Others 15.2% F 7.8% E 8.6%

Yaskawa 14.1%
A 13.0% B 12.8%

17.4%

\ 395.9 billion 2009

D 11.4% C 12.5%

China
11.0%

Asia
17.0%

*Data has been gathered and analyzed by Yaskawa.

History of Yaskawa General-purpose Inverters GeneralYear of 1968

Worlds First

VS-610 VS-610B

Thyristor inverter (current type)

1969
Thyristor inverter (current type)

Worlds Varispeed G7 First

3-level

Year of 2000

1974
Worlds First

2009 Varispeed A1000 2008 VS mini V1000 2008 VS mini J1000

VS-616T VS-616G, H VS-616H

PWM transistor inverter (analog)

1980
PWM transistor inverter (analog)

1984
PWM transistor inverter (digital)

Worlds VS-616G, GLN First

1987

PWM transistor inverter (IGBT, low-noise type)

1000th

1989 3rd Generation VS-616G3, etc. 1995 5th Generation VS-616G5, etc.

Generation

PWM transistor inverter

Year of 2000 to 2010

PWM transistor inverter

RELIABILITY OF THE YASKAWA INVERTER

Yaskawa Japan produced the inverter unit about 60,000 units per month. We made the follow up record from field trouble for every month. The calculation is base on Fit unit. (where; 1Fit = 10-9Hrs.) For the Yaskawa Inverter ,the reliability target is 250 Fit and has been achieved the target. Example of Reliability; (Some customer adopt 100 units in their factory which operated 8000 Hrs/Yr.) The reliability result =100 units*250Fit*8000Hrs(1yr Operating Hrs) (base on 100 units) =102units*250*10-9*8*103 = 0.2 unit/Yr = 1units/5Yrs.

Inverter Principle and Characteristics

Inverter Configuration
Whats a drive? A device that converts frequency and voltage

Basic Circuitry in an Inverter Drive

AC voltage Constant frequency, constant voltage Rectifier Circuit (converter section changing AC to DC) DC Bus (capacitors smooth out the waveform) Inverter Circuit (inverter section changes DC back into AC)

AC voltage Variable frequency, variable voltage

Motor

Control circuit section

Actual Output Voltage Waveform

The waveform created in the switching patterns on the previous page is a square wave. A sine wave, however, is more preferable for accurate motor control. In the diagram below, IGBT switching creates the waveform, a technique called, pulse width modulation (PWM). PWM is capable of creating a waveform very similar to a sine wave. Output voltage (V) is low when frequency (f) is low. EDC 0 V Basic wave

Output voltage (V) is high when frequency (f) is high. EDC

VoltageVoltage-type Inverter Control Method

(Ed: DC voltage)
Control Method

Output Frequency
Ed Ed

Features
Voltage control is needed for the converter. Motor current distortion is excessive, resulting in torque ripple. Frequency and voltage can be controlled only in the inverter section. Smooth operation is possible at a low speed.

P A M M ethod
(Pulse Amplitude Modulation)
Output Voltage Waveform Average Output Voltage Ed Ed

P W M M ethod
(Sinusoidal Wave Approximate)

PWM: Pulse Width Modulation

When the above Output power frequency is 60 Hz, the number of pulses per cycle is 14. Therefore, carrier wave (carrier frequency) is obtained as 6014 = 840 Hz. Since the actual inverter has this carrier frequency of 15 kHz, the number of pulses per cycle is 250 pulses (1500060).

12

Main Semiconductor Power Elements Used for Inverters

Name

Diode

Thyristor

GTO (Gate Tum Off Thyristor)

Bipolar Power Transistor

(Power Metal Oxide (Insulated Gate Bipolar Semiconductor. Field Tr.) Effect Tr.)

IGBT

Power MOS FET

Anode
Symbol

Collecto r Gate Base Emitter

Drain

Gate Source

Cathode
Characteristics Voltage, Current Waveform

General high-voltage, High-voltage, large-current rectifier large-current converter circuits section Inverter section, chopper section attached with commutation circuit

Features, Application

High-voltage, large-current inverter section, chopper section

Medium voltage, medium current high-speed switching, inverter section

Medium voltage, medium current high-speed switching, inverter section

Low-voltage, smallcurrent high-speed switching, inverter section

13

Main Circuit and Control Circuit

AC
Voltage Current Voltage Current
Smoothing circuit Rectifier circuit or DC bus (diodes) (capacitors) Inverter conversion circuit (IGBTs)

DC AC
Voltage Current

AC power supply

S T

IM

FWD run REV run Multi-function input

Analog monitor

Multi-function analog output (output frequency, current, etc.) Output terminals Fault output

Input terminals

Sequence common Analog input (speed setting) Digital Operator

Multi-function contact output (running, speed agree, etc.) Pulse train output

Pulse train input Serial communication input

Features of Control Mode

Specifications

Varispeed G7
Flux Vector Control
Current vector control with PG

V/f Control
Voltage/frequency control (open-loop)

V/f Control with PG Feedback

Voltage/frequency control with speed compensation

Open-loop Vector Control

Current vector control without PG

Basic Control Speed Detector

Option Card for Speed Detection

Not needed Not needed 1:40 150% at 3 Hz 2 to 3% Disabled Disabled

Multi-drives Replacement for existing motor of which motor constants are unknown Auto-tuning is enabled only for line resistance.

Needed (pulse generator) Needed 1:40 150% at 3 Hz 0.03% Disabled Disabled

Simplified feedback control Applications where pulse generator is attached on the machine shaft

Not needed Not needed 1:200 150% at 0.3 Hz 0.2% Enabled Enabled
Any variable speed drives

Needed (pulse generator) Needed 1:1000 150% at 0 min-1 0.02% Enabled Enabled
Simplified servo drives High-accuracy speed control Torque control 15

Speed Control Range

Starting Torque
Speed Control Accuracy

Torque Limit
Torque Control

Typical Applications

Operation Characteristics

16

Acceleration
Output Frequency f

Motor speed N 0 Overload capacity when inverter capacity is equal to motor capacity 0

Excessive Slip Overload capacity when inverter capacity is increased

Rated Current 0 0

Rated Current

(a) Proper Acceleration Time

(b) Short Acceleration Time

17

Stall Prevention during Acceleration

Inverter Output Frequency [Dotted line shows the set accel. ratio.]

Accel. time becomes longer automatically.

t

Motor Speed Peak current is limited to within the specified value. Motor Current

18

Stall Prevention during Running

To avoid overloading by rapid fluid temperature in hydraulic machines. Avoid overloading by decreasing output frequency.

Inverter Output Frequency

t

Load

19

Actual Stall Prevention Function

RUN Signal

DC Voltage Inverter Output Frequency

Edc.

OVOA Motor Current

20

10

Stall Prevention during Deceleration

Inverter Output Frequency [Dotted line shows the set decel. ratio.] Decel. time becomes longer automatically.

Motor Speed

DC Voltage

DC bus voltage is limited to within specified value.

21

DC Injection Braking
N, f N, f N, f

N F

DC Injection Braking Time

N F F

Free Run N

DC Current

DC Current

t 0 DC Injection Braking Starting Frequency

DC Injection Braking Time

(a) Frequency Deceleration (Example of DC Injection Braking Before Stop)

(b) All-area DC Injection Braking

(c) Coasting to a Stop

22

11

Typical Inverter Input Current Waveform in Each Power Supply Method (1)
Circuit Pattern Input Current Waveform Input Current Spectrum Harmonics Content

No countermeasures taken
P + N
1 5

88%
Harmonics Order

AC reactor inserted
P + N
1 5 7 11

38%

DC reactor inserted
P + N
1 5 7 11

33%
23

Typical Inverter Input Current Waveform in Each Power Supply Method (2)
Circuit Pattern Input Current Waveform Input Current Spectrum Harmonics Contents

12-phase rectification
P +

12%
N
1

Harmonics Order PWM control converter

P + N
1

3%

24

12

Inverter Drive Units Selection

Capacity Selection
Check Item

What to Decide

Load type and characteristics Machine specifications Operation method Motor selection Inverter capacity selection Inverter model selection Inverter selection Peripheral units, options Investment effect Investment effect Final specifications

Motor Type

Motor Output Inverter Output

Inverter Model Peripheral units, Options Enclosure

26

13

GeneralGeneral-purpose Inverter Series

From General Industrial-use to Consumer Equipment IndustrialHigh-graded Function Current Vector Control (0.4 to 300 kW)

Varispeed G7
High Performance Vector Control (0.4 to 630 kW)

Varispeed A1000
Compact Vector Control Control (0.1 to 18.5 kW)

Varispeed V1000
Compact V/f control Drive (0.1 to 5.5 kW)

Varispeed J1000

Peripheral Devices and Their Connections

(1) Power supply transformer (7) DC reactor (2) Circuit breaker or (3) Leakage breaker (4) Contactor (6) Noise filter (8) Noise filter (12) Zero phase reactor

(5) AC reactor

(9) Contactor

(14) Motor

(11) Contactor for commercial power backup (10) Braking resistor unit

(13) Thermal relay

14

How to Select Peripheral Devices

No.
1 2

Name
Power transformer Circuit breaker

Purpose and Selecting Points

Transformer capacity Inverter capacity 1.5 Breaks accidental current (shortcircuit current). Rated current inverter rated current 1.5 Described in the inverter catalog. Grounding protection High frequency leak current protection for electric shock accident & leakage current fire. 1. Use a breaker provided with countermeasures for high frequency leakage current. 2. Increase sensitivity current. 3. Decrease inverter carrier frequency. Since the inverter has the contactor function, any contactor is not needed except for special cases. When a braking resistor is used, insert a contactor to make thermal trip circuit. Perform RUN/STOP at the inverter side and set the contactor to Always ON to use. For high frequency current suppression and improvement of power factor Install a reactor to protect the inverter when the power supply capacity is large. Prevent radio noise generated by inverter section Used when an electrical brake is needed (when the required braking torque exceeds 20%). Used for backup at inverter failure or when commercial power supply is used for normal operations. Not needed when one motor is driven by one inverter. (Connected when more than two motors are used.)

Leakage breaker

Contactor

5 7 6 8 9 10 11 12 13

AC reactor DC reactor Noise filter or Zero-phase reactor Braking unit Braking resistor unit Contactor for commercial power backup Thermal relay

29

Inverter Functions and Advantages

30

15

Advantages of Inverter Applications (1)

No. Advantage Can control speeds of the specified constant-speed type motors. Soft start/stop enabled.
f

Technical Details Number of revolutions changes when squirrel-cage-type motor terminal voltage and frequency are changed. Accel/decel time can be set freely from a low speed. (0.01 to 6000 seconds).
t

Main Precautions Since a standard motor has temperature rise that becomes greater at a low speed, torque must be reduced according to frequency. Set proper accel/decel time after performing load operation.

2
Cushion Start Cushion Stop

Highly frequent f start/stop enabled.

t

Little motor heat generation since smooth accel/decel is enabled with little current.

Motor or inverter capacity frame must be increased depending on the accel/decel capacity. Check the accel/decel time and load J. When applying the inverter to an elevating unit, use a motor with a brake to hold mechanically for stand still.

FWD/REV run enabled without main Inverter circuit contactor. 4

FWD Run RUN Command FWD Run REV Run

Because of phase rotation changes by transistor, there are no moving parts like conventional contactors so that interlock operation can be assured.

REV Run

31

Advantages of Inverter Applications (2)

No. Advantage Can apply an electrical brake.
f

Technical Details Since mechanical energy is converted into electrical energy and absorbed in the inverter at decel, the motor can automatically provide braking force. DC current is applied to the motor around zero-speed so that it becomes dynamic braking, to completely stop the motor. Since the inverter drives squirrel-cage motors, it can be used easily for explosionproof, waterproof, outdoor or special types of motors. Commercial power supply can provide up to 3600 min-1 (2-pole at 60Hz) or 3000 min1 (2-pole, at 50Hz). A general-purpose inverter can increase frequency up to 400 Hz (12000 min-1) while a high-frequency inverter can increase it up to 3000 Hz (180000 min-1).

Main Precautions Braking force is approx. 20% when only the inverter is used. Attaching a braking resistor (optional) externally can increase the braking force. Pay attention to the capacity of the resistor. An explosionproof motor in combination with an inverter is subject to explosionproof certification. The speed of a general-purpose motor cannot be increased by simply increasing the frequency. (It can be applied without being changed if frequency is approx. 120 Hz.) Mechanical strength and dynamic balance must be examined. 32

5
t Electrical Braking

Can control speeds of the motor under adverse atmosphere.

High-speed rotation enabled.

V

60Hz

120Hz

400Hz

16

Advantages of Inverter Applications (3)

No. Advantage The speeds of more than one motor can be controlled by one inverter.
IM

Technical Details The inverter is a power supply unit to the motor, therefore, as many motors as the capacity allows can be connected. These motors do not have to be the same capacity.

Main Precautions The number of motor revolutions differs depending on each motor characteristics or load ratio even at the same frequency. (Among general-purpose motors, speed deviation of 2 to 3% can be considered.) Synchronous motors have the same number of revolutions.

8
IM

Inverter
IM

Power supply capacity can be small when the motor is started up. 9

Large current (5 or 6 times larger Transformer capacity (kVA) than the motor rating) does not = 1.5 inverter output capacity flow as with a commercial power supply start. Current can be limited to at most 100 to 150% by low-frequency start. Output freq. can be set regardless of power supply freq. 50/60Hz.

10

Number of revolutions becomes constant regardless of power supply frequency.

33

Motor and Power Supply Current in Inverter Drives

100% Voltage (100% Speed)

Inverter Output Voltage 150% Inverter Output Current Inverter Input Current 150% 100% Current 100% Current

t
34

17

Optimum Energy-saving Plan for Facility EnergyApplied Load Fans Pumps Blowers (Any Variable Torque Load) Extruders Conveyors, etc. (Any Constant Torque Load) Cranes Elevators, etc. Rewinders General Machines Concept of Energy-saving Replace with a more efficient motor. Reduce a redundancy of the facility for the actual loads. Abate the head loss at valves or dampers. Change to more efficient drives. Replace the primary voltage control, secondary resistance control, eddy-current coupling (VS motors) with a more efficient control method(Frequency Control). Collect the regenerative energy at lowering by using the inverter power supply regenerative function. Collect the regenerative energy of the rewinders. Replace with a more efficient motor. Reduce the starting energy. (Use the inverter as a starter to stop the operations positively whenever the load ratio is low.) (2) (1) (1)

(3)

(4) (4) (2) (5)a

35

Chapter 7 Harmonics, Noise & Surge Voltage

36

18

Difference between Harmonics and Noise

Frequency Band Main Source Transmission Path Noise High frequency (10 kHz or more) Inverter section Electric wire (conduction) Space (radiation) Induction (electrostatic, electromagnetic Distance, wiring distance Voltage variation ratio Switching frequency Sensor malfunction Radio noise Change the wiring route. Install a noise filter. Install INV. in a screened box Harmonics 40th to 50th harmonics (up to several kHz) Converter section Electric wire

Influence Generating Amount Failure Corrective Actions

Line impedance Current capacity Overheat of capacitor for P.F improvement Overheat of generator Install a reactor. 12-phase rectification Sinusoidal wave power regeneration converter
37

Harmonics and Noise Sources

Harmonics Current Generated by Rectifier Circuit Bridge Rectifier
Commercial Power

Noise Generated by High-speed Switching

Motor
+ Smoothing Capacitor

Converter Section

Inverter Section

38

19

Surge Voltage Suppression by Filter

(a) Test Circuit
PWM Inverter

IM
Filter Expanded Diagram

Expanded Diagram [Inverter Output]

[Motor Input]

(b) Result of Waveform Observation (5s/div, 250/div)

Without Filter

With Filter

Inverter Output

Motor Input

39

Features of 3-level control 3The solution to 400V class inverter drive problems 1. Low surge voltage Suppresses motor surge voltage, eliminating the need for the motor surge voltage protection. 2. Low electrical noise (Radiated, Conductive) 3. Low acoustic noise 4. Electrolytic corrosion of motor bearings due to shaft voltage

40

20

Actual Measurement of Shaft Voltage

(Rotor) (Opposite to Directcoupling Side) (Direct-coupling Side) (Stator)

V: Measuring Device R: Non-inductive Resistor (1k )

(a) Example of Shaft Voltage Measuring Circuit

Shaft Voltage (mV)
Inverter: PWM Motor: 3.7 kW, 200 V, 4 poles V/f characteristics: Constant torque

Inverter Commercial Power Drives Commercial Power Supply Drives

(Hz) Inverter Drives

41

(b) Example of Shaft Voltage Measurement (between Shafts)

(c) Shaft Voltage Waveform

New Inverter Technology

The diagram below illustrates five steps that can be taken to improve motor control and inverter drive performance: Reducing the loss generated in the inverter unit; and concern circuitry and the control method used for high-efficiency performance; covers improvements to drives power supply side; involves a new approach to power conversion.

How to improve inverter efficiency Reducing loss Improving PWM control Improving inverter output voltage waveform Improving the drives input power factor New power conversion method

New power conversion method

Drive section

Reducing component losses Improving output voltage

Motor

AC power supply Speed sensor Processing section

Improving input power factor Improving PWM control

No. U030701-Page 42

21

Reducing Inverter Component Loss

One way to improve inverter efficiency is to reduce loss from various components. The circle graphs below show the amount of loss generated from each component in the drive. About 10 years ago, the loss generated from IGBT (Insulated Gate Bipolar Transistor) switching in the main circuit exceeded 60% of all loss. Recent improvements in switching technology have now minimized loss from IGBTs down to 40%.
1.0% 0.8% 0.2% 5.3% 1.5% 8.1%

BEFORE
15.3% 8.6% 11.6%

NOW
22.0% 12.4%

60.8%
Rectifier diode Main circuit fuse IGBTs Discharge resistance Smoothing capacitors Control power supply Others

1.1% 0.2% 7.6% Rectifier diode Main circuit fuse IGBTs Discharge resistance

43.6%
Smoothing capacitor Control power supply Others

Improving the switching characteristics of the IGBT device has reduced the power loss to the half of what it was 10 years ago. In addition to reducing power consumption for the control power supply and control circuit, inverter efficiency is 9o% better than in the past.
No. U030701-Page 43

Improvements with PWM Control

The high carrier frequency used in PWM (pulse width modulation) increases the amount of IGBT switching loss. Yaskawa has created a 2-phase modulation method to minimize this switching loss. As shown below, the 2-phase modulation method stops switching when current is large. This way, one of the 3 phases is always in the stopped status. Using this 2-phase PWM control method can reduce the switching loss by approx. 30%.

High-efficiency PWM control: 2-phase modulation

Output voltage Output current Output voltage Output current

Switching loss is not generated in the 2-phase modulation method since IGBT switching does not occur in this area.

(a) 2-phase modulation

(b) 3-phase modulation

Employing 2-phase modulation can reduce IBGT switching loss by approximately 30%.

No. U030701-Page 44

22

Improving the Output Voltage Waveform

Although high carrier PWM control makes the output current waveform very close to sinusoidal, the actual voltage waveform created is still a group of square waves. The surge voltage generated at rising and falling edges of this square waves causes trouble. A surge suppression filter is normally attached between the inverter and the motor in order to prevent the motor insulation from being damaged by surge voltage. This filter is called RLC filter, and is is composed of a resistor, reactor, and a capacitor. A large filter is not needed if the inverter and motor are close together. If they are far apart, however, a large capacity filter is needed. For example, with the motor capacity of 75 kW, the filter consumed power is 0.3 kW, 1.4 kW and 12.6 kW when the wiring length is 30 m, 100 m and 300 m, respectively. As the distance gets longer, the required capacity is sharply increased. Additionally, the size of the filter also becomes larger, it will be necessary to examine where to install. To omit this filter, 3-level control inverters have been devised. Using these inverters can solve the problem of . Furthermore, this control method can reduce the remaining 3 failures (, and ) at the same time.

Common Problems
Motor insulation damaged by surge voltage Peripheral devices malfunctioning due to noise generated by the inverter Earth leakage breaker malfunctioning due to leakage current Motor bearings corroded by shaft current
No. U030701-Page 45

Solved with 3-level control!

What Is 3-Level Control?

Conventional Drives: 2-level control Voltage control by 6 transistors Varispeed G7: 3-level control

A EB
VPN Voltage control by 12 transistors U V W VPN /2

Circuit configuration

VPN

F C D

Phase voltage

U V W VPN

VPN

Line voltage

VPN : DC bus bar voltage = AC input voltage

No. U030701-Page 46

Voltage fluctuation reduced to half of conventional model

VPN /2

23

Principle of 3-Level Control Method

In conventional 2-level control, 2 transistors are used for each phase, making a total of 6 transistors for 3 phases to switch DC bus bar voltage VPN. Phase voltage turns ON and OFF depending on the size of VPN, and changes according to it. In the 3-level control, 4 transistors are used per phase, for a total of 12 transistors for 3 phases. The illustrations below shows how transistors switching works during one phase. In this figure, voltage P appears in phase U when transistors A and B turn ON. Then O appears in phase U through diodes E and F when transistors B and C turn ON. N appears when transistors C and D turn ON. It means that phase U can take three states: P, N, and O. This is how 3-level control was named. While voltage fluctuates between P and N in 2-level control, it fluctuates between P & O, and between O & N in 3level control. Therefore, phase voltage turns ON and OFF depending on the size of VPN/2, which is half of VPN during 2-level control. This creates an output waveform very close to a perfect sine wave. Surge voltage is cut in half when voltage fluctuation becomes half, which means that noise and leakage current is also cut in half, resulting in reduction of shaft current.

(a) Circuit configuration during for one phase

P VP N E VP N O VPN F C D N VPN : DC bus bar voltage B Phase U
(phase U appears below)

(b) Switching patterns

A B C D Potential Level P Level N Level O
VPN 2

A Motor

P O N

No. U030701-Page 47

Comparison of Surge Voltage Waveform in 3-level Control Method The following figures show the output voltage waveforms of 400 V class inverter 2-level control and 3-level control, respectively. In the 2-level control method, the peak value of the waveform is almost 1200 V, while it is limited to 770 V in the 3-level control method. Since this value is lower than the insulation voltage of the 400 V class motor, the existing motors can be driven by an inverter without using surge suppression filters.

1200 V peak VPN

Suppression effect 770 V peak VPN

(a) 2-level control surge voltage waveform

(b) 3-level control surge voltage waveform

No. U030701-Page 48

24

Comparison of Radiation Noise in 3-level Control Method

These graphs show noise levels. In the frequency bandwidth between 30 MHz and 300 MHz, the noise level is limited to 20 dB at the maximum. This reduces the effects on surrounding peripheral devices caused by noise.

100
Level dBV/m

100
Level dBV/m

80 60 40 20 0 30 50 70 100 200 Frequency (MHz)

80 60 40

Max. 20 dB down 20

300

30

50

100 70 200 Frequency (MHz)

300

No. U030701-Page 49

Comparison of Leakage Current in 3-level Control Method

The graphs below compare leakage current in 2-level and 3-level control. Leakage current in the 3-level control method is almost the half of that in the 2-level control method. Less leakage current means fewer faults with the leakage breaker.

11A 11A 5A

(a) Leakage current in 2-level control method

(b) Leakage current in 3-level control method

No. U030701-Page 50

25

 No Surge Suppression Filter Needed Because of Surge Reduction 3-level control contributes to energy saving because there is no need for a surge suppression filter that would otherwise consume power.
Surge suppression filter Reactor AC power supply Not needed!

Motor Capacitors Inverter Varispeed G7 Heat energy Resistors

Wiring distance

Configuration of surge suppression filter

Consumed power WR of the resistor is calculated as follows: Cf: Capacitor size is determined by cable type or wiring length E: DC bus bar voltage (600 V at 440 Vac input) fi: Inverter carrier frequency 2: Multiplied by 2 for charging and discharging of capacitor No. U030701-Page 51

WR =

CfE2 fi2

Power Consumption of Surge Suppression Filter

Energy saved because no filter is used
Operating conditions: Motor specifications: 440 V, 75 kW When 100sq polyethylene sheath cable is used

90 80 70
Consumed power of resistor WR (kW)

60 50 40 30 20 15 1 0 0
0

Consumed power WR of resistor for wiring distance

Long distance drastically increases power consumption

200

400

600

800

1000

Wiring length (m)

How wiring length affects power consumption of a surge suppression filter resistor No. U030701-Page 52

26

Maintenance and Inspection

Failure Patterns
Failure (t) Ratio Service Lifetime

Specified Failure Ratio 0 ta tb t Accidental Failure Period Wear-out Failure Period

Initial Failure Period

27

Daily Inspection and Periodical Inspection

Place Whole Item Peripheral environment Whole unit Power supply voltage Whole Connected conductor, Power supply Transformer, Reactor Terminal stand Smoothing capacitor Relay, Contactor Resistor Control Circuit, Protective Circuit Cooling System Display Operation check Componen t check Whole Capacitor Checking Item Ambient temperature, humidity, dust, hazardous gases, oil mist, etc. No excessive vibration or noise. Check that main circuit voltage or control voltage is normal. Megger check between main circuit terminal and ground terminal No loose connections No traces of overheating in components Clean. No distortion in conductor No breakage or deterioration (cracks, discoloration, etc.) in cables No odor, excessive beats or noise No damages No liquid leakage No projection (safety valve) or bulge Measure electrostatic capacity and insulation resistance. No chattering at operations Timer operation time No roughness on contacts No crack in resistor insulating material No disconnection Balance of output voltage between each phase by inverter single-unit operation No failure in protective or display circuit by sequence protection test No odor or discoloration No excessive corrosion No traces of liquid leakage or deformation No excessive vibration or noise No loose connections Clean the air filter. All lamps lights correctly. Clean. Indicated values are correct. Daily

(From JEMA Information)

Schedule Periodical 1-yr 2-yr

Main Circuit

Cooling fan Display Meter

55

Component Replacement Guidelines

Name Cooling fan Smoothing capacitor Breaker, relay Timer Fuse Aluminum capacitor on PC board Standard Replacement Period 2 to 3 years 5 years 10 years 5 years Replace. Replace on investigation. Determine what to do on investigation. Determine after checking the operation times. Replace. Replace on investigation. Method

Note : Operational Conditions Ambient temperature : Annually 30 in average Load ratio : 80% or less Operation ratio : 12 hours or less per day

56

28

Precautions on Measurement
Inverter Input Voltage Approximate Waveform Element All effective values All effective values Meter Moving iron type voltmeter Moving iron type ammeter

Current

Output

Voltage

Fundamental Rectifier type wave effective voltmeter (Model YEW2017, etc.) value All effective values Moving iron type ammeter *

Current

* Clamp meters available on markets have differences in characteristics between manufacturers. Especially, measured values tend to be extremely small at low frequency. 57

Purpose and Types of Protective Functions

Inverter Protection Overcurrent OC Overvoltage OV Grounding GF

Protection

Main circuit undervoltage UV1 Cooling fin overheat OH Braking transistor error rr Inverter overload OL2 Motor Overheat Protection Others Motor overload OL1 Overtorque detection OL3/OL4 lit CPU error CPF

Warning

Operation status is not proper. Prediction of protective function operation

Overtorque detection OL3/OL4 (blinking) Undertorque detection UL3/UL4 (blinking) Inverter overheat prediction OH2 Radiation fin overheat prediction OH 58

29

Level at Which Protective Function Operates

Current
200% Inverter output overcurrent : OC Overload anti-time-interval characteristics 160% 150% Stall prevention level during running Stall prevention level during acceleration

DC Voltage
Approx. 410 V (Approx. 820 V) Approx. 380 V (Approx. 760 V) Approx. 365 V (Approx. 730 V) Main circuit overvoltage : OV Voltage at stall prevention during deceleration

Voltage at braking

100%

Inverter rated output current

Approx. 190 V (Approx. 380 V)

Main circuit undervoltage : UV1

Can be changed.

Voltage in the parentheses shows 400-V series.

59

NOTE :

30