Core Overview

This document is the installation manual for the Yaskawa U1000 series 24V power supply option (model PS-U10L/PS-U10H), which mainly introduces the functions, driver adaptation, installation process, operation verification, and safety specifications of the option. It provides users with full process guidance from receiving inspection to after-sales support, and is suitable for professional installation and maintenance personnel.

Core parameters and adaptation range of options

1. Option model and function definition

Model identification: This option includes two models – PS-U10L and PS-U10H, with the name “24V Power Supply” clearly indicating its core function: to provide a separate 24V DC power supply for the control circuit when there is no power supply for the main circuit of the drive, only supporting power supply for the control circuit, and unable to supply power to the main circuit of the drive 🔶 2-5 🔶 2-8 🔶 2-89.

Core purpose: With this option, users can access network communication, navigate digital operators, read I/O data, and view fault/parameter data while the main power is disconnected; If parameters need to be modified, the driver parameter o2-19 (UV state parameter writing selection) must be set to “1 (enabled)”, otherwise the parameters cannot be modified even if the control circuit is powered on 🔶 2-91.

2. Adapt to the driver model and software version

According to document table 1 (Compatible Drive Models), the compatibility relationship between options and drives is as follows:

Option Model Adaptation Driver Series Driver Model Identification (Key Characters) Remarks

PS-U10L U1000, U1000L, Z1000U models containing “2” (such as CIMR-U  2 , CIMR-Z  2 ) require the driver software version to meet the standard

PS-U10H U1000, U1000L, Z1000U models containing “4” (such as CIMR-U , CIMR-Z  4 ) require the driver software version to meet the standard

The specific software version requirements are: U1000 series requires S5171, S1017 and above; U1000 crane specific models require S6412 and above; U1000L series requires S6213 and above. If the driver version is not met, it may cause the option to not work properly 🔶 2-96.

3. Key specifications and certification of options

On page 42 of the document (Table 4 Option Specifications), specify the technical parameters of the options and indicate the safety certification standards they comply with:

Electrical parameters: Input working voltage 24Vdc ± 20% (range 19.2V-28.8V), input current 1.9A, power consumption 38W, output holding time exceeding 50ms after power failure;

Environmental parameters: Operating temperature -10 ℃~+50 ℃ (14 ℉~122 ℉), short-term transportation and storage temperature -20 ℃~+60 ℃ (-4 ℉~140 ℃), weight 0.2kg (0.4lbs.), installation environment needs to match the specifications of the drive environment 🔶 2-431;

Certification standards: Compliant with UL (USA/Canada) and CE (Europe) certifications, with UL certification based on UL508C standard and CE certification in accordance with the Low Voltage Directive (2006/95/EC) and EMC Directive (2004/108/EC), following harmonized standards such as IEC/EN 61800-5-1 and EN 61800-3 🔶 2-431 🔶 2-499.

 Detailed explanation of the entire installation process (including preparation, steps, and requirements)

1. Receipt inspection and installation preparation

(1) Receiving inspection items

After receiving the option, the user needs to complete three core checks: 1 Check if the appearance of the option is damaged during transportation. If damaged, immediately contact the transportation company (Yaskawa warranty does not include transportation damage); 2. Check if the option model is consistent with the order (refer to Figure 3 in the document for the location of the model identification); 3. Confirm that the packaging contents are complete, and the specific list is as follows 🔶 2-103 🔶 2-104 🔶 2-105,:

Item name, quantity, and purpose

Signal/power transmission between one option connecting cable and the driver

M3 screws with 3 options for fixation (some installation methods require the use of screws)

The installation method of the six parts of the stud (such as C, D, E, F) includes option fixing

6 zip ties for organizing cables to avoid clutter or pressure

Installation Manual (TOBPC73060095. pdf) 2 copies of technical guidance (including both Chinese and English versions)

Option body (PS-U10L/PS-U10H) 1 core functional component

If you receive an incorrect model or option that does not work properly, you need to contact the supplier for assistance.

(2) Essential Tool List

The document clearly lists the required tools and specifications for installation. Missing or using non compliant tools may result in installation failures:

Cross screwdriver: M4 metric specification, or # 1, # 2 American standard specification, used for disassembling/installing drive cover screws;

One letter screwdriver: blade thickness 0.4mm, blade width 2.5mm, used for wiring operation of option terminal block TB1;

Wire stripping pliers: used to strip the insulation layer of cables to ensure good contact between the wiring terminals;

Wrench: Open end wrench, ring wrench or ratchet wrench (diameter 6mm), used to tighten bolts, the tightening torque should be controlled at 0.5-0.7N · m 🔶 2-109;

Attention: The document does not include cable pre-processing tools (such as crimping pliers), and users need to prepare them themselves.

2. Classification of installation methods and operating steps

The document categorizes installation methods into six types, A-F, based on the differences in drive models. The core differences lie in the option fixing method (only screws/screws+studs), cable connection interface (CN1 direct connection/CN19 adapter), and installation position. The following are the key information and general steps for each type of method:

(1) Installation method classification and driver adaptation

Installation method: Adapt to driver model (example) Fixed method: Cable connection interface corresponds to document page number

A U1000 2  0028-2  0081, 4  0011-4  0077; U1000L 20028-20068； Z1000U 2  0028-2  0081 M3 screw option only, CN1 direct connection to driver reserved interface 22

B U1000 2  0104, 2  0130, 4  0096, 4  0124; U1000L 2  0081, 2  0104; Z1000U 2  0104, 2  0130 only M3 screw option CN1 direct connection to driver reserved interface 25

C U1000 2  0154, 2  0192, 4  0156, 4  0180; Z1000U 2  0154, 2  0192 screw+stud option CN1 connected to driver CN19 28 via cable A

D U1000 2  0248, 4  0216, 4  0240; Z1000U 2  0248, 4  0216 screw+stud options CN1 connected to driver CN19 31 via cable B

E U1000 40302-40414； Z1000U 4  0302-4  0414 screw+stud option CN1 connected to driver CN19 34 via cable C

F U1000 4A0477-4A0930； Z1000U 4A0477-4A0930 screw+stud option CN1 connected to driver CN19 37 via cable B

(2) General installation steps (taking method A as an example, differences in other methods have been marked)

Power off and discharge: Disconnect all power sources from the drive, wait for the internal capacitor to discharge (at least 5 minutes until the CHARGE indicator light on the drive goes out), confirm that there is no dangerous voltage, and then remove the digital operator (F), front cover (E), and terminal cover (G). The removal steps should refer to the manual provided with the drive;

Option fixing: Use the M3 screw inside the package to fix the option in the designated position of the driver (refer to Figure 4 in the document for the position), ensuring that it is firmly fixed and not loose;

Cable connection: Pull out the loose end of the reserved connection cable for the driver, insert it into the CN1 interface of the option, pay attention to the interface direction, and reverse insertion may damage the connector or driver;

Cover plate reset: Reinstall the driver front cover, terminal cover, and digital operator to ensure that the cables are not squeezed by the cover plate and to avoid insulation layer damage causing short circuits;

External power supply wiring: Go to the “Wire the Option” section on page 40 of the document and connect an external 24V power supply to the option terminal block TB1 (terminal definition: 24=+24VDC input, 0=0V, FE=ground). The wiring steps are as follows:

Loosen the TB1 terminal screw with a straight screwdriver;

Peel off the insulation layer of the cable (with a bare length of about 5.5mm, to avoid the wire ends from unraveling);

Insert the cable into the corresponding terminal and tighten the screw (torque 0.22-0.25N · m);

Wrap the cable shielding layer with heat shrink tubing or electrical tape to avoid short circuits caused by contact with other circuits 🔶 2-393;

(3) Special installation requirements (for C-F method)

Fixed difference: The C-F method requires the installation of screws (tighten with a 6mm wrench, torque 0.5-0.7N · m) first, and then fix the option with screws;

Cable differences: C method uses connection cable A, D/F method uses connection cable B, E method uses connection cable C, and the cables need to be sorted according to the document diagram (such as Figure 23, 27) and fixed with zip ties to avoid cable entanglement or compression.

3. Key wiring specifications

Power requirements: The external 24V power supply must be UL Listed Class 2 certified (or equivalent) to avoid the risk of electric shock or fire caused by the use of non certified power supplies. The power supply must be able to provide at least 3A current (the instantaneous current when the option is powered on is twice the conventional value, lasting for about 0.5 seconds);

Cable specifications: Shielded twisted pair cables are required for control cables, with a recommended wire diameter of 0.75mm ² (18AWG). The suitable wire diameter range for single strand cables is 0.25-1.5mm ² (24-16AWG), and the suitable wire diameter for crimping terminals is 0.25-0.5mm ² (24-20AWG);

Shielding treatment: The cable shielding layer needs to be grounded at one end (connected to the driver grounding terminal) to avoid circulating current caused by double ended grounding, and the grounding area should be as large as possible (refer to Figure 40 in the document);

Operation verification and troubleshooting

1. Run verification steps

After installation and wiring are completed, the following steps should be taken to verify whether the option functions properly:

Power on the main circuit of the driver and confirm that the external 24V power supply has been connected to the TB1 terminal of the option, and that the option is properly connected to the driver cable;

Disconnect the power supply of the main circuit of the drive, and the option should supply power to the control circuit of the drive;

Observe the red LED indicator light on the option. If it lights up, it indicates that the option is working properly;

When checking the digital operator of the drive, it should briefly display “Fdv” or “AUv” (undervoltage prompt) for about 10 seconds. This prompt is a normal phenomenon, indicating that the control circuit has been powered through the option 🔶 2-413;

2. Handling of abnormal situations

If the option LED does not light up: check if the external 24V power supply is normal (voltage range 19.2-28.8V), if the TB1 terminal wiring is loose or reversed, and if the option is in good contact with the driver cable;

If there is no “Fdv/AUv” prompt on the operator: first confirm that the wiring is correct, then check if the driver parameter o2-19 is set correctly. If it is still abnormal, it may be a problem with the option or driver, and contact Yaskawa after-sales service;

In addition, Table 3 (Power Supply and Control Circuit) of the document specifies the operation of the control circuit and driver under different power states, which can be used to assist in fault diagnosis:

Driver main circuit power options, power supply status, driver control circuit operation status, driver operation possibility

ON, ON, can run normally

ON/OFF can run

OFF/ON can access data (parameters/faults) but cannot run

OFF: Stop running and cannot run

Core Security Standards

(1) Electrical safety

Prohibited live operation: During installation, wiring, and maintenance, all power sources must be disconnected and the capacitor must be discharged (at least 5 minutes). The CHARGE light must be turned off before operation, otherwise it may cause electric shock death or serious injury 🔶 2-133;

Authorization operation requirements: Only authorized personnel who have received training are allowed to install and maintain. Unauthorized personnel operation may cause safety accidents;

Prohibited from modifying equipment: It is not allowed to modify the driver body or option circuit without authorization. Modifying will result in the expiration of the warranty, and Yaskawa will not be responsible for any damage caused by this;

(2) Fire prevention and equipment protection

Terminal torque requirements: All terminal screws must be tightened to the specified torque (such as TB1 terminal 0.22-0.25N · m, screw 0.5-0.7N · m). Too loose may cause poor contact, heat generation, and fire, while too tight may damage the terminals 🔶 2-149;

Static electricity protection: When in contact with options, drivers, or circuit boards, it is necessary to follow the ESD (electrostatic discharge) protection process (such as wearing an anti-static wristband) to avoid static electricity damaging the circuit;

Environmental restrictions: It is prohibited to expose options or drivers to halogen disinfectants, and they should not be stored in fumigated wooden packaging to avoid chemical damage to electrical components 

Question 1: What is the core difference between the 240V and 480V models of GA800 frequency converter? How to choose the corresponding model based on motor power and input power when selecting?

Answer:

Core difference:

Power range: The maximum power of the 240V model is 150HP (such as 2360ABM, ND 150HP/360A), and the maximum power of the 480V model is 1000HP (such as 4H12AAM, ND 1000HP/1200A);

Output current: Under the same HP, the current of the 480V model is about half of 240V (such as 10HP ND, 240V is 30A, 480V is 17.5A);

Adaptation scenarios: 240V is suitable for low-power loads (such as small fans and pumps), and 480V is suitable for medium to high-power equipment (such as compressors and large machine tools).

Selection method:

Confirm input power supply: If it is 240V 3-phase, refer to the “240V Drives” table (Table 1); If it is 480V 3-phase, refer to the “480V Drives” table (Table 2);

Match motor power and performance requirements: If the motor requires strong torque (such as lifting equipment), choose the HD model; If you need to drive a larger motor (such as a regular conveyor belt), choose the ND model;

Example: 480V 30HP motor (requiring strong torque), corresponding to HD model 4044ABM (HD 25HP/39A, ND 30HP/44A), with protection code 4044BBM if IP20 is selected.

Question 2: What is the difference between dynamic braking of GA800 frequency converter and regenerative braking of R1000? Which industrial scenarios are they applicable to?

Answer:

Core Differences: | Comparison Dimensions | Dynamic Braking | R1000 Regenerative Braking | | Energy Processing | Energy Consumption through Resistors (Heating) | Energy Feedback to the Grid (Energy Saving) | | Duty Cycle | 3% (3 seconds within 100 seconds) or 10% (10 seconds within 100 seconds) | 25% (25 seconds within 100 seconds, 100% rated current x 60 seconds) | Component Requirements | Braking Resistors+Transistor Modules (Some models have built-in) | R1000 Module+Current Suppression Reactor+Power Coordination Reactor+Fuse | Cost and Complexity | Low Cost, Simple Wiring | High Cost, Additional Kit Required|

Applicable scenarios:

Dynamic braking: suitable for scenarios with low braking frequency and low energy demand, such as ordinary machine tools (intermittent braking), small elevators (short-term deceleration), typical models such as 240V 10HP with R7510 resistor (3% duty cycle);

R1000 regenerative braking: suitable for scenarios with frequent braking and high energy recovery requirements, such as elevators (frequent start stop), centrifuges (continuous deceleration), and winding machines (constant tension control). Typical kits include R1000-480-50HP (compatible with 480V 50HP motors).

Question 3: What are the differences in protective features and installation requirements for Type 1, Type 12, and Type 3R enclosures in the GA800 configuration package? How to choose the appropriate configuration package for outdoor pump stations?

Answer:

Shell characteristics and installation requirements: | Shell type | Protection level | Core protection capability | Installation requirements | Environmental restrictions | | Type 1 | IP30 (after adaptation) | Anti solid foreign object (≥ 2.5mm), anti finger contact | Must be installed in a clean room, can be wall mounted/independently installed, heat sink optional internal/external | Temperature -10~+40 ℃, humidity ≤ 95% (no condensation) | | Type 12 | IP54 (heat sink external) | Anti dust intrusion, anti splashing liquid | Must be installed in a Type 12 independent shell, heat sink external (to avoid dust accumulation) | Temperature -10~+50 ℃, pollution level 2 (IEC 60721-3-3) | | Type 3R | IP54 (weatherproof) Waterproof, anti snowflake, anti solid foreign object (≥ 2.5mm)| Can be installed outdoors, optional 12/18/30 inch independent legs (to prevent ground moisture) | Temperature -10~+50 ℃ (optional 50 ℃ adaptation), avoid direct exposure to sunlight|

Selection plan for outdoor pump station:

Shell selection: Type 3R (weatherproof), model prefix G8C3 (ND) or G8C6 (HD);

Power options: Select 100kAIC circuit breaker (M)+input fuse (F) to meet the overload requirements of the pump station motor;

Environmental adaptation: Add S+4 (50 ℃ environmental adaptation)+S+3 (space heater, anti condensation);

Control options: Add T+D (EtherNet/IP communication, remote monitoring of pump station)+Y (Hand/Off/Auto switch, on-site manual control);

Complete model example: G8C3B065PMFTDEYS4 (480V 50HP ND, Type 3R, 100kAIC circuit breaker+EtherNet/IP+50 ℃ adaptation).

Overview

This document is the GA800 Industrial AC Inverter Selection Guide (document number SL. GA800.01) released by Yaskawa USA in 2021. It introduces the multi voltage levels (240V/480V/600V), dual duty ratings (Normal Duty/Heavy Duty), and corresponding model parameters of GA800 inverters, covering core data for inverter selection (such as output current, power range), supporting components (reactors, filters, braking units, etc.), configuration package solutions (Type 1/12/3R enclosure), technical parameters (overload capacity, protection level, etc.), as well as training services and sales terms, providing comprehensive selection support for Yaskawa salespeople, distributors, and partners.

GA800 inverter core selection parameters

1. Voltage and power range (key numbers)

Voltage level, phase number, power range (HP), core model example, applicable scenarios

240V Class 3-phase 1-150 2004ABM (1HP ND), 2360AWM (150HP ND) low-power motors, such as small pumps/fans

480V Class 3-phase 1-1000 4002ABM (1HP ND), 4H12AAM (1000HP ND) medium and high-power equipment, such as compressors/machine tools

600V Class 3-phase 125-500 5125ABM (125HP ND), 5472AWM (500HP ND) high-voltage industrial scenarios, such as large transmission systems

Scenarios where harmonic reduction is required for 480V 12 Pulse 3-phase 75-1000 T140AAM (100HP ND) and 4H12AAM (1000HP ND), such as medical equipment

2. Performance rating and overload capacity

Normal Duty (ND): Suitable for larger motors, overload capacity of 110% rated current x 60 seconds

Heavy Duty (HD): Stronger torque, overload capacity of 150% rated current x 60 seconds

Example: 240V model 2030ABM, ND 10HP (30A), HD 7.5HP (25A)

3. Model coding rules (taking “GA80U 2 004 ABM” as an example)

Encoding segment meaning optional values/description

GA80U series identification fixed prefix (Americas region)

2 voltage levels 2=240V, 4=480V, 5=600V, T=12 pulse 480V

004 output current corresponds to ND rated current (unit: A, here it is 4A)

A protection level A=IP00, B=IP20, W=Type 12 flange

B environmental specification B=humidity/dust protection (compliant with IEC 60721-3-3 Class 3C2/3S3)

M EMC filter M=Not used (A=Not used, some models in the document default to no filter)

Single/three-phase input adaptation and component selection

1. Single phase input configuration (requires reduced capacity, some require reactors)

Taking 240V single-phase input as an example, the core parameters are as follows (excerpt from Table 5):

Drive model (GA80U) without reactor (ND/HD) with reactor (ND/HD) Input reactor model (Open)

2004… 1/3HP（1.5A）/1/2HP（2.2A） -/- URX000303

2008… 3/4HP（3.2A）/1HP（4.2A） -/- URX000307

2030… 2HP（6.8A）/5HP（15.2A） -/- URX000323

2. Core supporting components

(1) Reactor and Filter

Component Type Impedance Options Installation Form Core Function Example Model (480V)

DC Bus Reactor 3%/5% Open/Enclosed Type 1 reduces DC side transients and decreases THD URX000033 (3% Open) and URX000215 (3% Enclosed)

AC Input Reactor 3%/5% Open/Enclosed Type 1 suppresses input side harmonics and protects the frequency converter  URX000288（3% Open）、URX000551（3% Enclosed）

AC Output Reactor 3% Open/Enclosed Type 1 reduces motor side voltage spikes and is compatible with long cables  05P00620-0014（Open）、05P00620-0016（Enclosed）

EMC Input Filter – Integrated to EN 61800-3 C2 level, reduces electromagnetic interference B84743A00008R176 (8A), B84243A6180Z000 (180A)

(2) Braking unit

Dynamic braking:

3% duty cycle: operates for 3 seconds within a 100 second cycle, with resistance models such as R7504 (240V) and R7508 (480V)

10% duty cycle: operates for 10 seconds within a 100 second cycle, requiring the use of transistor modules (such as CDBR-21100D) and resistors (such as URS000275)

Regenerative braking (R1000):

Suitable voltage: 240V (5-150HP), 480V (5-500HP)

The kit includes: R1000 module, current suppression reactor, power coordination reactor, fuse

Example: R1000-480-50HP kit, including R1000 module model 4A0035AAA

(3) Control and Feedback Attachment

Attachment Type Function Description Model Example

I/O adapter AI-A3: 3 additional analog inputs (13 bits+symbol) AI-A3

Motor feedback card PG-X3: Incremental encoder interface (line driven type) PG-X3

Network Communication Card SI-P3: PROFIBUS-DP Communication Interface SI-P3

Operation keyboard with Bluetooth LCD keyboard: supports mobile APP control-

Remote Cable UWR0052: Keyboard Remote Cable (3m) UWR0052

GA800 configuration package scheme (Type 1/12/3R)

1. Configure the core parameters of the package (taking 480V Type 1 ND as an example)

Rated current (A), nominal HP (ND), basic model, optional power options, optional control options

2.1 G8C1B002 E (standard circuit breaker), C (65kAIC circuit breaker), T+C (PROFINET), T+H (PROFIBUS)

40 30 G8C1B040 P+EX (3% Bus Reactor), F (Input Fuse), T+D (EtherNet/IP), A (Analog Input)

180 150 G8C1B180 M (100kAIC circuit breaker), R (3% Line reactor), T+Q (Modbus TCP), X (PG-X3 feedback)

2. Shell type and environmental adaptation

Shell type, protection level, applicable environmental temperature range, special options

Type 1 IP30 (adapted) cleanroom (such as electronic workshop) -10~+40 ℃ space heater, blower starter

Type 12 IP54 (external heat sink) for dusty environments (such as machinery factories) -10~+50 ℃ external heat sink adapter

Type 3R IP54 (weatherproof) outdoor/humid environment (such as pump station) -10~+50 ℃ (optional 50 ℃ adaptation) independent support leg (UUX000923, 12 inches), lightning arrester

Technical parameters and environment Derating

1. Key technical specifications

Project specification description

Output frequency 0-590Hz

Control mode: open-loop/closed-loop vector, open-loop/closed-loop V/f

Motor compatibility sensitive motor, surface permanent magnet motor (SPM), built-in permanent magnet motor (IPM), synchronous reluctance motor

Standard I/O with 8 digital inputs (24Vdc), 3 analog inputs (0 ± 10V/4-20mA), and 3 relay outputs

Safe Torque Off (STO), SIL3 (IEC 62061), PLe (ISO 13849-1)

Certified UL, CSA, CE, RCM, RoHS, SEMI-F47, IEEE1668

2. Derating rules for the environment

Temperature Derating:

When the ambient temperature is greater than 40 ℃ (Type 1)/greater than 50 ℃ (IP20), for every 1 ℃ increase, the output current will decrease by 2%

Altitude Derating:

≤ 1000m: No capacity reduction

1000-4000m: For every 1000m increase, the output current decreases by 8%

Voltage Derating (altitude>2000m):

Neutral grounding system: No need to reduce capacity

Non neutral grounding system: higher voltage level needs to be selected (such as 600V frequency converter for 480V scenario)

Basic information of the document

Applicable models: 200V level (single-phase input 0.1-4.0kW, three-phase input 0.1-18.5kW), 400V level (three-phase input 0.37-18.5kW) CIMR-V series frequency converters.

Core purpose: To guide users in correctly installing, operating, and debugging frequency converters, ensuring safe and stable operation of the equipment.

Copyright and Revision: First published in 2007, latest revised in December 2016, including updates to safety standards, functional supplements, and more.

Key content of core chapters

1. Safety instructions and warnings

Risk classification: Clearly define three types of warnings: Warning (fatal/serious injury), CAUTION (minor/moderate injury), and NOTICE (equipment damage).

Core taboos: Do not modify equipment, touch terminals before discharge, and operate by non professionals; Strict adherence to grounding regulations is required (leakage current exceeding 3.5mA, grounding conductor cross-section ≥ 10mm ² (copper)/16mm ² (aluminum)).

Special risk: During the rotation self-tuning period, the motor may suddenly start, and after power failure, it is necessary to wait for the capacitor to fully discharge (at least 5 minutes).

2. Mechanical installation

Environmental requirements: Indoor installation, temperature -10~+50 ℃ (adjusted according to protection level), humidity ≤ 95%, no condensation, no dust, oil pollution, vibration and other interference.

Installation specifications: Vertical installation is required to ensure heat dissipation, and 30mm (on both sides) and 100mm (up and down) heat dissipation space should be reserved around the equipment.

Acceptance and verification: After receiving the goods, check that the equipment is not damaged and verify the nameplate to confirm that the model is correct.

3. Electrical installation

Wiring specifications: The main circuit power supply is connected to R/L1, S/L2, T/L3 (only R/L1, S/L2 are used for single-phase), the motor is connected to U/T1, V/T2, W/T3, and it is forbidden to connect the power supply to the output terminal.

Cable requirements: The control circuit should use shielded twisted pair cables to avoid mixing with the main circuit cables; The specifications of the main circuit cables need to match the model (such as 2.5mm ², 6mm ², etc.).

EMC compliance: A designated EMC filter must be installed on the input side, and the grounding surface must be repainted to ensure low impedance.

4. Keyboard operation and startup debugging

Keyboard functions: including RUN/STOP start and stop keys, parameter setting keys, mode switching keys (LOCAL/REMOTE), LED indicator lights to display running status, faults, and other information.

Start up process: Install wiring → Power on → Select control mode (V/f, open-loop vector, etc.) → Set load type (standard/heavy load) → Motor self-tuning (or manually input motor parameters) → I/O configuration → Trial operation → Load operation.

Mode selection: V/f control is suitable for multi motor drive, open-loop vector control is suitable for high-precision speed regulation, and open-loop vector control of permanent magnet motor focuses on energy saving.

5. Key parameters and troubleshooting

Core parameters: including frequency reference (b1-01), acceleration and deceleration time (C1-01/C1-02), motor rated current (E2-01), overload protection (L1-01), etc.

Troubleshooting: List common faults (such as overcurrent, overvoltage, overload) and their corresponding causes and solutions, including troubleshooting methods for programming errors (oPE series) and self-tuning errors (Er series).

Safety disable function: Compliant with SIL2/PL safety standards, controlled through HC and H1 terminals, the motor torque is cut off within 1ms when disconnected, requiring professional personnel to wire and debug.

6. UL/cUL compliance requirements

Installation restrictions: Pollution level ≤ 2, ambient temperature -10~+50 ℃ (depending on protection level).

Wiring specification: Use UL certified copper wire, and the terminal tightening torque must comply with the standard (such as 0.8-1.0N · m for M3.5 terminals).

Protection configuration: The input side needs to be equipped with a specified type of fuse (such as Class J/T/CC), and the motor overload protection is set through parameters E2-01 and L1-01.

Precautions for use

Operators must possess professional qualifications and strictly adhere to the safety regulations outlined in the manual.

The equipment needs regular inspection and maintenance, with daily safety function checks. It is recommended to replace it after 10 years of use.

When the safety disable function is not used, the HC and H1 terminals must be kept short circuited; Modifying the equipment will result in the expiration of the warranty.

Core advantages and features

1. High performance and high reliability

Adopting a 32-bit high-speed processor, the program processing speed is doubled compared to the previous generation, coupled with large capacity memory, to meet the computational needs of complex applications.

No cooling fan design, natural cooling is used to deal with the heat generated during high-speed operation, reducing mechanical failure points.

Equipped with a large capacity FPGA to enhance self diagnostic capabilities, and equipped with battery backup memory with ECC (error checking and correction) function to ensure data reliability.

2. Comprehensive compatibility

The software, size, and bus interface specifications are fully compatible with the previous generation CP-317, and all optional modules of the original CP-317 can be used directly.

Only a single operating module (CPU) needs to be replaced to upgrade the existing system, without the need to restructure the overall configuration, reducing upgrade costs.

3. Flexible scalability

Supports single CPU or dual CPU configuration (Changan installation base can accommodate 2 CPUs), dual CPUs can independently run different software, support synchronous/asynchronous scanning, and easily transfer up to 32K words of data through shared registers.

Up to 4 racks can be expanded, and various communication and I/O modules can be connected through expansion modules (EXIOIF). Some modules (such as LIO-01, AI-01, etc.) can be configured without restrictions.

Supports various open field networks such as PROFIBUS-DP, FL Net, DeviceNet, etc., to meet the communication needs of different industrial scenarios.

4. Convenient operability

Paired with CP-717 Engineering Workstation (EWS), it supports desktop (via CP-215 real-time network/Ethernet) and laptop (via RS-232C/Ethernet) connections, covering the entire process from system design to maintenance.

Support programming methods such as ladder diagrams and Sequential Function Diagrams (SFC), provide visual programming and online monitoring functions, simplify coding and debugging of complex configurations.

Equipped with functions such as direct parameter adjustment, data tracking (in list/chart format), and rapid fault location, it enhances operational efficiency.

Key specification parameters

1. Power supply and environment

Power module options: PS-01 (100VAC/100VDC), PS-02 (200VAC), PS-03 (24VDC), with voltage fluctuation range of ± 15%~± 20%, supporting instantaneous power outage within 10ms.

Working environment: temperature 0 ° C~55 ° C (24-hour average ≤ 50 ° C), humidity 5%~95% RH (non condensing), no corrosive gases, vibration and impact resistance in accordance with JIS B 3502 standards.

Grounding requirements: protective grounding resistance ≤ 100 Ω, insulation resistance ≥ 5M Ω (500VDC).

2. Performance parameters

Memory configuration: The program memory is equivalent to 128K steps, and the data memory includes 32768 words of input/output registers, 1024 words of system registers, etc. The battery backup can retain data for more than 1 year.

Running speed: Relay command 0.05 μ s/step, addition and subtraction operation 0.1 μ s/step, multiplication and division operation 0.1 μ s~0.3 μ s/step.

Supports data types such as bits, integers, double precision integers, real numbers, etc., with 133 built-in instructions covering program control, numerical operations, I/O control, and other functions.

Main components and models

1. Core components

CPU module (87317-3500x-S060y): Supports single/multiple CPU configurations.

Power modules: PS-01 (100VAC/100VDC), PS-02 (200VAC), PS-03 (24VDC).

Communication module: covering CP-213/215/216/217/218 and other series, supporting Ethernet, RS-232C/485, PROFIBUS-DP and other protocols.

I/O module: including digital input (DI-01), digital output (DO-01), analog input (AI-01), analog output (AO-01), etc., supporting local I/O and extended I/O connections.

2. Installation and Cable

Installation base: MB-01 (long base, single/multi CPU configuration), MB-03 (short base, single CPU configuration).

Expansion cables: EXIO expansion cables, 2000 I/O expansion cables, etc. are available, with lengths ranging from 0.5m, 1.0m, 1.5m, and other specifications.

Applicable scenarios

Mainly used for centralized control in industrial scenarios such as steel plants, water supply and drainage plants, and sewage treatment plants, it can serve as the main control station for medium and large factories, achieving integrated control of equipment such as frequency converters, sensors, and actuators. It supports networking and linkage with HMI (such as CP-519, CP-5800), other PLCs, computers, and other equipment.

Document Fundamentals and Product Overview

Document positioning: Yaskawa VARISPEED-626M5656MR5 series user manual, mainly used for vector control inverters/converters with power regeneration function for machine tools, guiding installation, maintenance, troubleshooting, and specification inquiry.

Product model and specifications:

Product Type Model Voltage Level Power Range (kW) Power Range (HP) Remarks

Variable frequency drive (VS-626M5) CIMR-M5 200V level 3.7/2.2-37/30 5/3-50/40 including M5A (independent drive), M5N (NC system)

Variable frequency drive (VS-626M5) CIMR-M5 400V level 5.5/3.7-45/37 7.5/5-60/50 including M5A (independent drive), M5N (NC system)

Converter (VS-656MR5) CIMR-MR5 200V class 3.7/2.2-37/30 5/3-50/40, including MR5A (without 24V control power supply) and MR5N (with 24V control power supply)

Converter (VS-656MR5) CIMR-MR5 400V class 5.5/3.7-45/37 7.5/5-60/50 including MR5A (without 24V control power supply), MR5N (with 24V control power supply)

Warranty information:

Warranty period: 12 months after delivery to the customer or 18 months from the date of shipment from the Yaskawa factory, whichever comes first.

Warranty scope: Only covers faults caused by defects in Yaskawa craftsmanship or materials, excluding improper maintenance, modification, and use beyond specifications.

Regional restrictions: Warranty services are only free within Japan and require payment overseas.

Safety regulations and operating taboos

Definition of Security Level:

Warning: Potential hazardous situation that, if not avoided, may result in death or serious personal injury (such as opening the cover with electricity, not grounded).

CAUTION: Potential hazardous situation that, if not avoided, may result in minor/moderate personal injury or equipment damage (such as grabbing the front cover during transportation or installing on flammable materials).

Core security precautions:

Power off operation: Before wiring or disassembling the digital operator (JVOP-132), the power must be turned off and the capacitor must be discharged (refer to the warning label time, usually 5 minutes).

Grounding requirements: 200V level grounding resistance ≤ 100 Ω, 400V level grounding resistance ≤ 10 Ω. It is strictly prohibited to share the ground with welding machines and high current equipment.

Temperature control: The ambient temperature of the frequency converter/inverter should be ≤ 55 ℃ (131 ° F), and the inlet temperature of the heat sink should be ≤ 45 ℃ (113 ° F). A fan or cooling device should be installed.

Operation taboos:

Do not connect the power supply to the output terminals of the frequency converter (U/T1, V/T2, W/T3), otherwise it will damage the internal components.

Do not connect phase-shifting capacitors, LC/RC noise filters, or electromagnetic switches in the output circuit, as it may cause damage or overcurrent to the frequency converter.

Do not modify the product, otherwise the warranty will expire and may cause electric shock/injury.

Equipment installation and wiring

Delivery Confirmation (CAUTION):

Check if the model is consistent with the order (verify the nameplate), if there is no transportation damage to the appearance, if screws or other components are loose, and if damaged/missing equipment is not allowed to be installed.

Installation requirements:

Environment: Indoor, no corrosive/explosive gases, no dust/metal particles, avoid direct sunlight, vibration acceleration ≤ 2.5G (10-60Hz).

Installation material: It must be installed on non combustible materials such as metal.

Distance requirement (to ensure heat dissipation):

Equipment type, left and right spacing, up and down spacing, note

External heat dissipation type ≥ 120mm ≥ 120mm Side spacing ≥ 5mm

Open chassis type ≥ 150mm ≥ 150mm Side spacing ≥ 5mm

Wiring specifications:

Main circuit wiring: Use the specified wire diameter (such as 200V level frequency converter CIMR-M5A23P7, main circuit wire diameter ≥ 2mm ²), and the terminal screw torque meets the requirements (such as M5 screw 2.35N · m).

Control circuit wiring: Separate the control signal line from the power line, with a length of ≤ 20m, and use shielded twisted pair to avoid wiring in the same conduit.

Core functions and operations

Digital Operator (JVOP-132):

Function: Display operating status (motor speed U1-01, torque reference U1-04), set control constants, fault reset, single machine trial run.

Operation mode: Set from positions 1 to 37, with 11 being the digital operator operation mode, which can achieve jog (5% rated speed) and forward/reverse control.

Trial operation process:

Check the power supply voltage (200V level 3-phase 200-230V, 400V level 3-phase 400-460V).

(NC system) Set YENET1200 node address (rotary switch SW1).

Connect the control power supply and confirm that the frequency converter displays “-” and the inverter displays “- U”.

Connect the main circuit power supply, the inverter display changes to “- b”, and the CHARGE light is on.

Check the direction of the motor cooling fan (standard intake from the load side).

Send RUN signal to confirm the motor direction (counterclockwise when viewed from the load end during forward rotation) and no abnormal vibration/noise.

Directional control:

Encoder directional control:

Resolution: 360 °/4096=0.088 °, repeatability accuracy ± 0.2 °.

Applicable scenario: The load shaft is connected 1:1 to the motor shaft and requires a load shaft encoder (such as NE-1024-2MDF-068).

Magnetic sensor directional control:

Repetition accuracy ± 0.2 °, using magnet (MG-1378BS) and magnetic sensor (FS-1378C), detection range ± 15mm.

Troubleshooting and Maintenance

Common faults and solutions:

Fault code, fault type, cause, and handling measures

AL-01 inverter overcurrent output short circuit, ground fault check wiring, confirm no short circuit

AL-11 main circuit overvoltage input voltage is too high, load inertia is large. Check the power supply and adjust the acceleration time from C1 to 10

AL-20 winding switching fault switching was not completed within the specified time. Check the contactor wiring and confirm the C1-25 motor code

Maintenance cycle:

Daily inspection: motor abnormal noise, vibration, ambient temperature, display screen values.

Regular inspection:

Remarks on component replacement cycle

Cooling fan has accumulated 20000 hours of operation over 2-3 years

Filter capacitor for 5 years at an ambient temperature of 30 ℃

Motor bearings disassembled and inspected for wear after 12000 hours/2 years

Overview

This document is a multifunctional/positioning control manual for the Yaskawa AC servo drive HR series (model CACR-HR, including rack mounted CACR-HR □□ BAB and base mounted CACR-HR □□□ BB), covering in detail the model identification, rated specifications (such as motor output power 0.07-8.2HP, drive input voltage 100-230VAC), mechanical characteristics (allowing radial/axial loads, anti vibration and anti impact performance), wiring connections (typical connections and terminal definitions for main circuit/control circuit/encoder/brake power supply, etc.) of the servo motor (M/F/G/D/S/R/P series) and servo drive I/O signal operation (2CN/5CN input/output signal timing and function), serial communication (RS422 protocol, supporting baud rates such as 9600/4800), parameter setting (100 parameters, including core parameters such as position loop gain Kp and speed loop gain Kv), display/monitoring function (LED indicator light and 7-segment digital tube status display), installation and wiring specifications, trial operation and maintenance (battery replacement, troubleshooting), while emphasizing safety precautions (such as opening the cover after 5 minutes of power outage, anti electric shock/anti scald measures), providing comprehensive guidance for the selection, installation, debugging and maintenance of servo systems.

Product Model and Configuration

1. Analysis of servo motor models (taking USAGED-13A2 as an example)

Explanation of the meaning of model segmentation

USA product prefix Yaskawa servo motor identification

G series (fully enclosed self cooling type, IP65 protection)

ED structural characteristics with encoder

13 output specification 1.3kW (corresponding to 1.7HP)

A-axis end specification with keyway

2 encoder types incremental 8192P/R

2. Analysis of servo drive models (taking CACR-HR03BAB12 as an example)

Explanation of the meaning of model segmentation

CACR-HR Product Series Yaskawa HR Series Servo Drivers

03 Output capacity 300W (0.4HP)

BAB installation and power supply B=rack mounted, A=single-phase, B=200VAC

12th Design Version 12th Design

3. Matching principle between motor and driver

Power matching: The output capacity of the driver needs to cover the rated power of the motor (such as a 300W motor matched with HR03 series driver).

Voltage matching: 100V motor (R series DS model) matches HR □□ BAB11 driver, 200V motor matches HR □□ BAB12/BB driver.

Encoder matching: The absolute encoder motor requires the driver to support battery backup (the HR series panel comes with a 3.6V battery).

Rated specifications and mechanical characteristics

1. Core specifications of servo motors (examples by series)

Motor series model example Rated output Rated speed Rated torque Peak torque Encoder type

M-series USAMED-03B2 0.3kW (0.4HP) 1000r/min 2.84N · m 8.92N · m incremental 8192P/R

S-series USASEM-15A2 1.5kW (2.1HP) 3000r/min 4.90N · m 13.7N · m incremental 2048P/R

R series (200V) USAREM-05CS 500W (0.67HP) 3000r/min 1.59N · m 4.76N · m absolute formula 8192P/R

P Series USAPEM-07CW 750W (1.0HP) 3000r/min 2.39N · m 7.06N · m Absolute 1024P/R

2. Core specifications of servo drive

Driver model input power output current (continuous/peak) control mode protection function

CACR-HR03BAB12 single-phase 200-230VAC 2.7A/7.8A full wave rectification+PWM sine wave drive OC, OV, OL, PG disconnection, etc

CACR-HR15BB three-phase 200-230VAC 11.7A/33.0A full wave rectification+PWM sine wave drive OC, OV, OL, phase loss (O-PH), etc

CACR-HR05BAB11 single-phase 100-115VAC 5.5A/16.3A full wave rectification+PWM sine wave drive OC, OV, OL, battery low voltage (BATALM), etc

3. Mechanical characteristics (motor)

Allowable load: Radial load 78.4-1764N (such as S series 02A model 78.4N, M series 60B model 1764N), axial load 39.2-588N.

Environmental tolerance:

Temperature: 0-40 ℃ for operation, 20-60 ℃ for storage;

Vibration: below 15 μ m (10-50Hz);

Protection level: IP44 (S/R series), IP65 (M/F/G/D/P series, excluding shaft ends).

Connection and wiring

1. Typical connection circuit

Main circuit connection: three-phase/single-phase power supply → circuit breaker (MCCB) → noise filter → servo driver (R/S/T) → motor (U/V/W).

Control circuit connection:

I/O signals: 2CN (servo enable SVON, start AST), 5CN (manual operation MCW/MCCW);

Encoder: 3CN (A/B/C phase signals,+5V power supply);

Serial communication: 4CN (TXD/RXD, RS422 protocol).

2. Definition of Key Terminals (Taking 2CN as an Example)

Terminal number, signal name, type, and function

8 SVON input servo enable, main circuit transistor unlocked when ON, motor powered on

Automatic operation/zeroing start with 16 AST inputs, valid rising edge, must be maintained for ≥ 5ms

15 STOP input temporarily stops, when ON, the motor decelerates and stops according to the parameter settings

11 ALM output fault alarm, transistor cutoff during fault (normally ON)

12 BK output brake release, when servo ON, ON, release motor brake

3. Wiring specifications

Cable selection:

Main circuit: 1.25-8mm ² copper core wire (e.g. 8mm ² for HR60BB);

Signal circuit: 0.2mm ² shielded twisted pair (DP8409123 and other dedicated wires are used for encoder lines).

Grounding requirements:

Driver FG terminal → grounding electrode (Class 3 grounding, resistance ≤ 100 Ω);

Motor frame ground → driver FG terminal to avoid common ground interference.

Noise control:

Install a noise filter on the power side (such as HR03BAB with LF-205A);

The distance between power lines and signal lines should be ≥ 30cm, and wiring in the same conduit is prohibited.

Functional operations (I/O, communication, parameters)

1. I/O signal operation

Input signal timing: SVON, AST and other signals need to maintain a stable level of ≥ 5ms to avoid false triggering;

Output signal status:

POS1 (positioning completed): ON when the deviation between the current position and the target position is ≤ P6 (positioning completed width, 1-250 units);

NEAR (positioning proximity): ON when the deviation is ≤ P45 (positioning proximity width, 0-3000 units).

2. Serial communication (RS422)

Communication specifications:

Baud rate: 9600/4800/2400/1200Baud (default 9600);

Data format: 1 start bit+7 data bits+1 even check bit+1 stop bit.

Core command:

SVON: Servo Enable;

MOV ± nnnnnn: Absolute positioning (± 8-bit position data);

ZRN: Start back to zero;

PRMpp=± nnnnnnnn: Set parameters (pp=parameter number).

Multi axis control: Supports 16 axes and specifies the control object through axis addresses (1-16).

3. Parameter Setting (Example of Core Parameters)

Parameter Number, Parameter Name, Unit Range, Function Description

P1 position loop gain Kp s ⁻¹ 0-200 adjusts position control response speed, the larger the value, the faster the response (prone to oscillation)

P2 speed loop gain Kv × 2.5Hz 1-200 adjustment speed control response speed, matching system rigidity

P4 1st feed rate x 1000 units/minute 1-240000 reference speed in automatic/manual mode

When the deviation of the width unit 1-250 after P6 positioning is ≤ this value, the POS1 signal is ON

P7 motor selection -0-79 matching motor model (e.g. 32=USAREM-A5CS)

P8 encoder pulse P/R (× 4) 4096-32768 encoder pulse per revolution (absolute 8192P/R set to 32768)

Display/Monitoring and Maintenance

1. Display function

LED indicator light:

MAIN (red): residual voltage in the main circuit (slowly extinguishes after power failure);

RUN (green): Control power supply is normal (+5V normal);

ALM (red): Fault alarm (check the 7-segment digital tube code when it lights up).

7-segment digital tube:

Normal state: Display current position (PUN) and speed (NFB);

Fault status: Display code (such as OC=overcurrent, OL=overload, BAT=low battery).

2. Trial operation process

Preparation stage:

Check the wiring (main circuit/control circuit is not loose) and parameters (P7/P8/P9 matching motor and encoder);

Absolute encoder reset: Short circuit the specific pin of the encoder and release it after powering on for ≥ 2 minutes.

Test operation:

Servo Enable: Send SVON command, confirm that RUN light is on and ALM light is off;

Jogging test: Send JOG+1000 command (1000 units/minute) to confirm that the motor rotates smoothly;

Positioning test: Send MOV+10000 command and confirm that POS1 signal is ON after positioning is completed.

3. Maintenance and troubleshooting

Battery replacement: Replace the absolute encoder battery (3.6V) when the voltage is ≤ 3.3V, and replace it after power failure (to avoid data loss).

Common troubleshooting:

|Alarm code | Fault cause | Handling measures|

|OC (overcurrent) | Main circuit overcurrent (≥ 1.2 times peak current) | Check if the motor wiring and load are stuck|

|OL (overload) | Motor overload (exceeding allowable load inertia) | Reduce load inertia and acceleration rate|

|PG (Encoder Disconnected) | Encoder Cable Loose/Disconnected | Check 3CN Wiring and Encoder for Damage|

|BAT (low battery) | Absolute encoder battery voltage low | Replace 3.6V lithium battery (such as CR2450)|

Installation and environmental requirements

Motor installation:

Installation method: Both horizontal and vertical can be used, with axis centering deviation ≤ 0.03mm;

Axial load: The radial/axial load shall not exceed the specifications in Table 3.9 (such as M series 03B model radial 490N).

Driver installation:

Rack mounted (BAB): vertically installed, with a spacing of ≥ 10cm (for heat dissipation);

Base type (BB): vertically installed, avoiding direct sunlight/condensation environment.

Environmental restrictions:

Temperature: driver 0-55 ℃, motor 0-40 ℃;

Humidity: 20% -80% RH (without condensation);

Dust: Do not use in dusty or corrosive gas environments.

The entire process of starting the communication module

Step 1: Prepare using the machine

Essential equipment: MP2000 series controller, communication module, communication partner device, dedicated cable, computer with MPE720 installed

Controller compatibility: MP2200 (JEPMC-BU2200/BU2210, maximum of 8 modules), MP2300 (JEPMC-MP2300, maximum of 3 modules), MP210M (JAPMC-MC2140, expansion board required, maximum of 8 modules), MP2500MD (JEPMC-MP2540-D , expansion board required, maximum of 8 modules)

Step 2: Module installation and disassembly

Installation steps: Power off → Remove the machine controller battery cover → Remove the optional module cover → Align the guide rail and insert the module → Install the cover → Power on

Disassembly steps: Power off → Backup program → Remove cable → Remove battery cover → Remove cover → Use battery cover protrusion to pry module → Pull out module

Step 3: Communication Manager Settings

Supported port types: Serial (RS-232C), Ethernet, Ethernet (LP), CP-215

Key setting example (Ethernet): Set the computer IP to 192.168.1.2 and subnet mask to 255.255.255.0; Set the Logical PT to Ethernet and fill in the computer IP address for the Communication Manager

Step 4: Automatic Configuration Execution

Trigger method: Set “CNFG” to ON and restart MP2200/MP2300; MP210M/MP2500MD operated through the MPE720 menu

Result difference:

CNFG Initiate Results

The ON module has been updated, and all communication modules are configured according to default settings

The ON/OFF module has been updated, with existing modules retaining their configuration and new modules using default settings

Step 5: MPE720 Startup and Transfer Definition

Ver.6: Online → Communications Setting → Select Logical Port → Set Parameters

Ver.5.xx: Start MPE720 → Open PLC folder → Properties → Network → Check OnLine → Select logical port

Transfer definition: Open the module composition definition screen → double-click the corresponding module → set parameters → save to flash memory

Detailed explanation of transmission mode and protocol

Classification of transmission modes

Mode applicable communication mode (module) core characteristics

Information transmission RS-232C (all), Ethernet (218IF-01/02), MPLINK (215AIF-01) event triggered, using MSG-SND/MSG-RCV functions

Engineering transmission RS-232C (all), Ethernet (218IF-01/02), MPLINK (215AIF-01) panel commands+MPE720 for program transmission

Link Transport MPLINK (215AIF-01) regularly sends and receives, only supported by 215AIF-01

Core Communication Protocol

MEMOBU: Yaskawa standard, main controller specifies sub controller address communication, function codes include 01H (read winding), 03H (read hold register), etc., supporting 1-2000 bits (bit data), 1-125 words (word data)

Extended MEMOBU: MEMOBU extension, adding function codes such as 09H (extended read hold register), transmitting 1-508 words at once, supporting MEMOBU/general information mode

MELSEC: Compatible with Mitsubishi A-series, supports communication between CPUs and fixed buffer communication, with function codes corresponding to ACPU universal commands (such as WR → 01H/02H)

MODBUS/TCP: Industrial Ethernet protocol, supports 1-2000 bits (read winding), 1-125 words (read register), 218IF-01/02 automatic conversion protocol

No steps: Directly transfer data from the M register, divided into word (1-254 words) and byte (1-508 bytes) units, with no response

Serial communication (taking 217IF-01 as an example)

Ports and protocols

Interface: RS-232C (PORT, 9-pin), RS-422/485 (14 pin)

Supporting protocols: MEMOBU, MELSEC, OMRON, Stepless, Stepless FD (Full Duplex, Maximum Received 5080 Words)

Transmission definition parameters

Example of Parameter Setting Content

Transmission Protocol MEMOBU/MELSEC/OMRON/Stepless MEMOBU

Master (Address 0)/Slave (Address 1~63) Slave, Address 1

Baud rate 9600/19200bps 19200bps

Data length 7/8 bits 8 bits

Parity Even/Odd/None Even

Connection Example

Connected to MELSEC: RS-232C (pin 2=TXD, 3=RXD) of 217IF-01 connected to Mitsubishi AJ71UC24 (pin 2=RXD, 3=TXD), MELSEC set station number 01, baud rate 19200bps

Connected to frequency converter: RS-485 (pin 3=RX+, 4=RX -, 8=TX+, 9=TX -) of 217IF-01 is connected to VS-616G5, and frequency converter H5-01=1 (address) H5-02=9600bps

Key module characteristics (218IF-01/02, 260IF-01)

218IF-01 module

Interface: RS-232C (PORT), Ethernet (10Base-T, RJ45)

Specification: Ethernet transmission speed of 10Mbps, half duplex; RS-232C maximum transmission 15m

Ethernet settings: IP address (default 192.168.1.1), subnet mask, connection parameters (TCP/UDP, ports 256~65535)

218IF-02 module

Interface: RS-232C (PORT), Ethernet (100Base TX/10Base-T)

Advantages: Supports Ethernet (LP) ports, higher engineering communication speed, maximum transmission of 100m (100Base TX)

260IF-01 module

Communication: DeviceNet, supports Explicit protocol, main controller settings

Specification: Maximum number of nodes 64, transmission speed 125/250/500kbps

Key issues

Question 1: There are two triggering methods for the automatic configuration of MP2000 series communication modules. Which controllers are they applicable to? What are the differences in configuration results?

Answer:

Applicable controllers:

Dial switch trigger: suitable for MP2200 and MP2300, triggered by turning on the “CNFG” toggle switch of the machine controller and restarting the power supply;

MPE720 operation trigger: applicable to MP210M and MP2500MD. After starting MPE720, select Order → Self Configure All Modules/Module Self Configuration on the Module Configuration screen to trigger.

Differences in configuration results:

Specific operation results of triggering method

The dip switch (MP2200/MP2300) CNFG=ON, Initiate=ON module composition definition is updated, and all detected communication modules are configured according to default values

The dip switch (MP2200/MP2300) CNFG=ON and Initialize=OFF modules constitute a definition update. Modules that already have transmission definitions retain their current definitions, while newly detected modules use default values

MPE720 (MP210M/MP2500MD) automatically configures all module composition definitions and updates them. Existing defined modules retain their current definitions, while newly detected modules use default values

MPE720 (MP210M/MP2500MD) automatically configures a single module with only selected module configurations and transmission definitions. Existing definitions are reserved, and newly detected ones use default values

Question 2: What are the core differences in functionality and usage between the IF-01 module, which supports two protocols: Stepless and Stepless FD?

Answer: The core differences between the two are reflected in communication methods, number of channels, data processing capabilities, etc., as follows:

Comparing dimensions without steps or steps FD

Communication method: Half duplex (cannot transmit/receive simultaneously), Full duplex (can transmit/receive simultaneously)

1 information channel (MSG-SND/MSG-RCV dual-use) 2 channels (1 dedicated for sending and 1 dedicated for receiving)

The maximum data size for both sending and receiving is 254 words. Sending 254 words and receiving a maximum of 5080 words (20 buffers, each buffer containing 508 words)

Data exception handling: If one byte in one message is abnormal, all data will be discarded. Only the abnormal byte will be discarded, and normal data will be retained. The exception will be reported to the MSG-RCV function

Wiring requirements: Half duplex wiring (such as RS-485 2-wire system), full duplex wiring (such as RS-485 4-wire system, separate transmission/reception lines)

Suitable for simple one-way communication scenarios that require high-speed simultaneous transmission and reception, such as real-time data acquisition and control

Channel number setting: MSG-SND/MSG-RCV are both set to 1. MSG-SND is set to 1, and MSG-RCV is set to 2

Question 3: The Ethernet communication of the IF-01 module supports two connection types, TCP and UDP. How to choose? What are the precautions for using these two types under a step-by-step protocol?

Answer:

Selection criteria for connection type:

TCP: a connection type protocol that requires the establishment of a connection, supports data confirmation, error retransmission, flow control, and has high communication quality. It is suitable for scenarios that require high data reliability, such as control instruction transmission;

UDP: A connectionless protocol that does not require establishing a connection, has simple processing, fast communication speed, and is suitable for scenarios that require high real-time performance and can tolerate a small amount of data loss (such as real-time status monitoring).

Notes under the Stepless Protocol:

Attention to TCP usage:

TCP is a byte stream protocol, and continuous transmission of data may result in the synthesis of data packets. The receiving side cannot recognize the data boundary and measures need to be taken (such as setting a transmission interval of more than 1 second, establishing command response protocols, and avoiding packet segmentation);

Each connection only has one receive buffer, and before receiving data, the MSG-RCV function is used to read out old data to avoid new data overwriting old data.

UDP usage precautions:

No connection confirmation, sending to a non-existent socket will result in an error. It is necessary to ensure that the other party’s device is online and the port is correct;

The receiving interval should be greater than twice the execution period of the MSG-RCV function (if the function period is less than 5ms, the sending interval should be set to 12ms or more) to avoid data coverage.

Core Conclusion

This document is the “Operation Guide” for Yokogawa’s AQ1100A/AQ1100B/AQ1100D Optical Loss Test Suite (OLTS) multi field tester (manual number IM AQ1100-02EN, 11th edition, November 2024), which covers equipment packaging inspection, safety specifications, component functions, measurement preparation, basic operation, and detailed specifications. It clarifies the wavelength differences of the three models (AQ1100A supports 2 single-mode wavelengths, AQ1100B supports 3 single-mode wavelengths, AQ1100D supports 2 multi-mode+2 single-mode wavelengths), emphasizes laser safety (Class 1/3R), battery (739882 lithium battery) and AC adapter usage specifications, and provides user registration and firmware. Update and provide global contact information to assist users in completing core operations such as optical power measurement, light source output, and automatic loss testing.

Product model and packaging content

(1) Model difference

The core difference between the three models lies in the supported wavelength range, and the suffix code determines the language, power meter type, and functional options:

Model Core Wavelength Applicable Scenarios

AQ1100A Single Mode (SM) 1310nm/1550nm Conventional Single Mode Fiber Loss Test

AQ1100B single-mode (SM) 1310nm/1550nm/1625nm multi wavelength single-mode fiber testing (including 1625nm monitoring wavelength scenario)

AQ1100D multi-mode (GI) 850nm/1300nm+single-mode (SM) 1310nm/1550nm supports both multi-mode and single-mode fiber testing simultaneously

Suffix code description: Language category (- HE English/- HC bilingual, etc.), power meter category (- SPM standard/- HPM high input/- PPN PON specific), functional category (/VLS visible light source/- LAN Ethernet, etc.).

(2) Accessories List

Standard accessories: 739874 AC adapter, 739882 lithium battery, hand strap (B8070CX), shoulder strap (B8070CY1,/SB option model), corresponding standard power cord, instruction manual, etc;

Optional accessories: Soft pack (SU2006A), connector adapter (SC/FC/LC models), spare battery (739882), etc., need to be purchased separately.

Safety operation standards

(1) Laser safety

Laser grade: Class 1 (measuring light source, high safety level), Class 3R (visible light source/VLS option, 650nm, output power 5mW);

Prohibited behaviors: staring directly at laser/reflected light without wearing protective equipment, disconnecting optical fibers when the light source is working, and not covering unused optical interfaces with protective covers.

(2) Power safety

Battery (739882 lithium battery): only used for AQ1100 series, only charged through the host, charging time ≤ 5 hours (timeout stop charging); Before replacement, the host needs to be turned off and the AC adapter disconnected. If it is not used for a long time (≥ 1 week), it is necessary to remove the storage (in an environment of 10-30 ℃, 40% -50% battery is optimal).

AC adapter: special model 739874, input voltage 90~264VAC (50/60Hz), confirm that the host is powered off before connection, and remove the battery for long-term AC power supply.

(3) Other safety requirements

Prohibited from use in flammable environments and disassembly of the host (only authorized personnel from Yokogawa can repair it);

The optical interface needs to use connectors that meet the specifications (such as SC/FC/LC), and should be slowly aligned when inserted to avoid mechanical impact.

Core operating procedures

(1) Preliminary preparation

Power connection: The AC adapter needs to be connected to the power cord first, then to the host DC interface, and finally plugged into a power outlet; Battery installation requires unlocking the battery cover, aligning with the electrode, inserting and locking it;

Fiber optic connection: Clean the connector end face before connection (it is recommended to use NTT-AT special cleaning agent), and select the corresponding optical port according to the wavelength (port 2 for single-mode wavelength and port 3 for multi-mode wavelength);

Power on: Press the power button, preheat for ≥ 5 minutes after turning on, the ON LED green indicates running, and the red indicates low power.

(2) Basic Function Operations

Optical power meter (OPM): After turning on, enter the menu through MENU → OPM LS, perform zero calibration (ZERO SET), set wavelength, modulation mode (CW/270Hz, etc.), unit (dBm/W, etc.), and record and store data (CSV format).

Light source output: Set the wavelength and modulation mode through MENU → OPM LS, press the LS key or soft key to turn on/off the light source, and the screen will display the laser on indicator.

Automatic loss test: The host serves as both the light source and the optical power meter. The steps are: zero point calibration → connect the light source port and the power meter port with a short fiber for optical power calibration → connect the tested fiber → press the Loss Test START button to start the test, and the results can be saved in CSV format.

(3) Data and peripheral management

Storage: Supports internal storage (110MB user available space), USB storage, file formats including CSV (data), screenshots, etc;

Peripheral Connection: USB interface supports printer/USB flash drive/PC (Mini-B port for PC control),/LAN option models support Ethernet remote control and IP testing.

Key specification parameters

Project specifications

Display screen 5.7-inch color TFT LCD (640 × 480 pixels)

The size and weight are approximately 217.5mm (W) × 157mm (H) × 74mm (D), with a weight of approximately 1kg (including battery)

Optical power meter range – SPM: -70~+10dBm (CW); -HPM：-50~+27dBm（CW）； -PPN：1310/1490nm（-70~+10dBm）、1550nm（-50~+27dBm）

Single mode output power of light source: -3ddB ± 1dBm; Multimode (AQ1100D): -20dBm ± 1dBm

Working environment temperature 0~45 ℃ (AC power supply 0~40 ℃, charging 0~35 ℃), humidity 20%~85% (no condensation)

Packaging content and equipment model description

Classification and Model of Core Equipment

The core components of the equipment include the host, OTDR unit, and optional modules. The model suffix determines the language, function, and interface type

AQ7280 host suffix:

Example of suffix type explanation

Language suffix differentiation operation interface language – HE (English), – HM (Chinese), – HC (bilingual in Chinese and English)

Function suffix additional function options/MNT (monitoring function),/SMP (intelligent mapping function),/LAN (Ethernet)

OTDR unit model: Supports 2-4 wavelengths, covering different application scenarios, with the following key parameters (some models):

OTDR Unit Model Wavelength (nm) Dynamic Range (dB) Laser Level Remarks

AQ7282A 1310/1550 38/36 Class 1 2 wavelength, suitable for short distance testing

AQ7283A 1310/1550 42/40 Class 1 2 wavelength, dynamic range higher than AQ7282A

AQ7283E 1310/1550/1625 42/40/40 Class 1 3 wavelength, 1625nm port with built-in filter

AQ7283J 1310/1383/1550/1625 42/39/40/40 Class 1M/3R 4 wavelength, 1310nm is a 3R class laser

AQ7282M 850/1300 (multimode) 25/27 Class 1/3R 2-wavelength multimode, 850nm is a 3R class laser

Optional modules:

OPM module (optical power meter): AQ2780 (power range -70~+10dBm), AQ2781 (high power -50~+27dBm);

VLS module (visible light source): AQ4780 (wavelength 650 ± 20nm, output power ≥ 5mW, Class 3R).

Accessories List

Standard accessories: 739883 lithium battery pack, B8070CX hand strap, B8107DE2 bracket cover (to prevent foreign objects when the module is not installed), M4 × 5 screws, relevant manuals;

Optional accessories (purchased separately): 739860 soft carry bag, 739874 AC adapter, SU2005A series connector adapter (SC/FC/LC), 735050 series functional license (such as 735050-FST fiber surface testing).

Safety operation standards

Laser safety (core risk point)

The equipment uses a laser light source, and the laser level is divided into Class 1 (most OTDR units, high safety level) and Class 3R (some wavelengths, such as 850nm of AQ7282M, should be avoided from direct view);

Prohibited behaviors: staring directly at the laser or its mirror reflection light without wearing protective equipment, disconnecting the optical fiber when the laser output is turned off, and not covering the protective cover of unused optical interfaces;

Special requirement: When cleaning the equipment, the power must be turned off to avoid accidental laser output.

Power Safety

Battery (739883 lithium battery):

Exclusive use: Only for AQ7280 host, cannot supply power to other devices, only use the host for charging;

Charging specifications: The charging time is about 6 hours (when turned off), and it may take more than 15 hours to charge when turned on (after 15 hours, the protection circuit will stop charging). If it is not fully charged within the time limit, stop using it and contact the dealer;

Replacement and Storage: Before replacement, the host needs to be turned off and the AC adapter disconnected. If it is not used for a long time (≥ 1 week), it should be fully charged and removed. The storage environment should be at 10-30 ℃ (to avoid full/low power storage, 40% -50% battery is optimal).

AC adapter:

Special model: Only use 739874 adapter, input voltage 90~264VAC (50/60Hz);

Connection specification: Before connecting, confirm that the host is powered off. When using AC power for a long time, remove the battery to avoid putting the adapter/power cord under pressure or near heat sources.

Other safety requirements

Prohibit the use of equipment in flammable gas/steam environments;

Do not disassemble the host or remove the casing (only authorized personnel from Yokogawa can repair);

Optical interface protection: Only use connectors that meet specifications (such as SC/FC/LC), and align them slowly when inserting to avoid shaking left and right or forcefully inserting (to prevent damage to the interface).

Equipment operation process

Pre preparation (before startup)

Component installation (all require power-off operation):

OTDR unit: Align the host connector and press it until it clicks, then use a coin/screwdriver to tighten the screw (with a torque of about 0.6N · m) to fix it;

OPM/VLS module: Remove the slot cover of the host module, insert the module until it clicks, and fix it with screws (torque 0.6N · m);

Battery: Open the host battery cover (loosen the screws and slide to remove), align the terminals and insert the battery, cover the battery cover back and tighten the screws;

SD card: First, remove the battery, open the SD card cover and insert it (press until it clicks), then reinstall the battery.

Connect peripherals:

Fiber optic: Clean the connector end face (using a specialized cleaning agent, such as NTT-AT products), align it with the optical interface and insert it (confirm that the port wavelength matches, such as AQ7283E’s 1625nm output from PORT2);

Other: USB interface for connecting USB flash drive/printer/PC (Mini-B port for PC control/storage access), Ethernet port (optional) for remote control.

Startup and Basic Operations

Power on: Press the power button on the front of the host. After normal startup, the ON LED (green) will light up and the screen will display the main interface. It is recommended to preheat for at least 5 minutes (to ensure measurement accuracy);

Main interface operation:

Function selection: Select OTDR, OPM, VLS and other functions through the knob/directional keys/touch screen, press ENTER or soft key to confirm;

Measurement mode: Taking OTDR as an example, Simple mode (only requires automatic configuration of wavelength, distance range/pulse width, etc.), Average measurement (start by pressing AVG key to improve signal-to-noise ratio, can be manually stopped);

Screen interaction: The touch screen supports clicking (selecting), dragging (adjusting display ratio), and pinching (zooming waveform), with soft keys corresponding to the menu on the right, and the ESC key returning to the previous level.

Data Management and Fault Handling

Data storage: Measurement results can be stored in formats such as SOR (waveform), CSV (data), BMP/JPG (image), etc., supporting internal storage (≥ 1000 waveforms), USB/SD card;

Abnormal startup handling: If the startup is not completed properly, check the AC adapter connection, battery installation, and power button pressing time (≥ 2 seconds). If the issue persists, contact the dealer for repair.

Key specification parameters

Host core specifications

Project specifications

Display screen 8.4-inch color TFT LCD (capacitive touch), resolution 800 × 600 pixels

Interface USB2.0 (TYPE A × 2, TYPE B (Mini) × 1), LAN (optional, 10/100BASE-T), SD card slot (supports SDHC)

Size approximately 287mm (W) × 210mm (H) × 80mm (D) (excluding protruding parts)

Weight approximately 2.2kg (including battery, excluding OTDR unit/module)

Working environment temperature -10~50 ℃ (AC power supply 0~40 ℃, battery charging 0~35 ℃), humidity 0~90% (no condensation), altitude ≤ 4000m

Key parameters of OTDR unit (universal)

Sampling resolution: minimum 2cm;

Sampling points: maximum 256000 points;

Distance measurement accuracy: ± (0.75m+measurement distance × 2 × 10 ⁻⁵+sampling resolution);

Event dead zone: approximately 0.6m (typical value when pulse width is 3ns);

Attenuation dead zone: about 3.5-4m (typical value when the pulse width is 10ns).

Module specifications (OPM/VLS)

Module model, core parameters, and specifications

AQ2780 (OPM) power range CW: -70~+10dBm; CHOP：-70~+7dBm

AQ2781 (high-power OPM) power range CW: -50~+27dBm; CHOP：-50~+24dBm

AQ2780V (OPM+VLS) VLS parameter wavelength 650 ± 20nm, output power ≥ 5mW (CW/CHOP mode)

AQ4780 (VLS) laser class 3R, modulation mode CW/approximately 2Hz CHOP