YASKAWA Power Regenerative Unit R1000 Series

YASKAWA Power Regenerative Unit R1000 Series

Core specifications of the product

Model coverage:

200V three-phase series: models 2A03P5~2A0105, suitable for motor power of 5~141HP, rated output current of 14~413A;

400V three-phase series: models 4A03P5~4A0300, suitable for motor power of 5~422HP, rated output current of 7~629A;

All models are designed for "Normal Duty" and optimized for energy regeneration scenarios with variable torque loads.

Core features: Supports 120 ° excitation control, MEMOBU/Modbus communication, PID closed-loop control, automatic fault restart, maintenance life monitoring, and complies with international standards such as UL 508C, IEC/EN 61800-5-1, as well as CE and RoHS compliance requirements.

Receiving and unboxing inspection

1. Safety precautions

It is prohibited to transport equipment through the front cover or terminal cover to avoid damage caused by the main body falling;

When handling equipment and circuit boards, it is necessary to follow the electrostatic discharge (ESD) process to prevent circuit damage.

2. Model and nameplate verification

Key information on the nameplate: model (such as CIMR-RU2A0073AAA), rated capacity, input/output specifications, software version, serial number, and place of origin (Japan);

Model interpretation: Taking "CIMR-RU2A0073AAA" as an example, "RU" represents the R1000 series, "2A" is the 200V level, "0073" is the rated output capacity code, and "AAA" is the standard configuration.

3. Classification of enclosure types

IP20/UL Type 1: Suitable for indoor wall mounted or control cabinet installation, retaining IP20 protection even after removing the top protective cover;

IP00/Open Type: It needs to be installed inside a protective panel, without additional shell protection, and relies on external environmental isolation.

Mechanical Installation: Environmental Requirements and Operating Standards

1. Installation environment requirements

Specific requirements for environmental dimensions: Remarks

Temperature IP00 model: -10~+50 ℃; IP20 model: -10~+40 ℃ overheating requires capacity reduction to avoid severe temperature fluctuations

Humidity ≤ 95% RH, no condensation to prevent moisture and short circuit of the circuit board

Altitude ≤ 1000 meters (without capacity reduction); 1000~3000 meters: For every 100 meters increase, the capacity is reduced by 1%. At high altitudes, the heat dissipation capacity needs to be evaluated

Vibration low-power models (2A03P5~2A0053, etc.): 10-20Hz (9.8m/s ²), 20-55Hz (5.9m/s ²); High power models (2A0073~2A0105, etc.): 20~55Hz (2.0m/s ²) Avoid direct contact with vibration sources

The surrounding environment should be free of dust, oil mist, metal debris, corrosive gases, and direct sunlight. Installation on flammable surfaces or placement of flammable materials is prohibited

2. Installation method and spacing requirements

Installation direction: Only supports vertical installation. Tilting can cause poor heat dissipation and damage to internal components.

Single installation spacing:

Up and down direction: at least 120mm (heat dissipation space);

Left and right direction: at least 30mm (wiring and heat dissipation);

Rear: It should be tightly attached to the enclosed surface to avoid the dispersion of cooling airflow.

Side by side installation (with drive):

Ordinary side by side: minimum spacing of 50mm, top aligned;

Tightly side by side (only for low-power models 2A03P5~2A0028, etc.): spacing of 2mm, parameter L8-35=1 needs to be set, while considering capacity reduction.

3. Precautions for lifting and protection

High power models (2A0073, 2A0105, etc.) are equipped with lifting rings and are only used for temporary installation. Long term suspension is prohibited;

When lifting vertically, it is necessary to first fix the front cover, terminal block and other components. The vibration/impact during suspension should not exceed 1.96m/s ², and flipping or leaving unattended is prohibited.

Electrical installation: wiring specifications and safety requirements

1. Main circuit wiring (prevention and control of core risk points)

Terminal differentiation:

Input terminals (R/L1, S/L2, T/L3): connected to three-phase power supply, matched with equipment voltage level (200V level connected to 200~240V, 400V level connected to 380~480V);

Output terminals (+, -): Connect to the DC bus of the driver, be careful not to reverse the positive and negative poles;

Voltage detection terminals (r1/11, l/21, t1/31): detect the phase sequence and voltage of the input power supply, and take power from the primary side of the power coordination reactor.

Wiring requirements:

Wire specifications: Select according to the rated current of the model. For example, 2A03P5 uses 14AWG (American standard) or 3.5mm ² (European standard) wire, 4A0300 uses 300kcmil wire, and circular crimping terminals are required;

Tightening torque: M4 screws 2.1~2.3N · m, M8 screws 5.4~6.0N · m, excessive tightening may damage the terminals;

Grounding: Independently grounded, not sharing grounding wire with high current equipment such as welding machines; Grounding resistance of 200V level ≤ 100 Ω, 400V level ≤ 10 Ω.

2. Control circuit wiring (anti-interference and functional configuration)

Digital input (S1~S8):

Support sinking/sourcing mode, switched through SC-SP/SC-SN jumper, default sinking mode;

Default functions: S1 (forced operation), S2 (automatic operation), S3 (external fault), S4 (fault reset), customizable through H1 series parameters.

Analog inputs (A1~A3):

A1/A3 default voltage input (0~10V/-10~10V), A2 default current input (4~20mA), switched through DIP switch S1;

For signal assignment, it is necessary to set the gain (H3-03/H3-07/H3-11) and bias (H3-04/H3-08/H3-12) to match the signal range.

Communication interfaces (R+, R -, S+, S -):

Supports RS-422/RS-485 for MEMOBU/Modbus communication, with the maximum transmission distance being related to the baud rate (up to 115.2kbps);

The terminal resistor needs to be enabled at the end of the bus (DIP switch S2 set to ON), and the communication line needs to be wired separately from the main power line.

3. Handling of special wiring scenarios

Long cable wiring: When the length of the control circuit analog signal line is ≤ 50 meters, and the main circuit cable is>50 meters, the carrier frequency should be reduced to avoid leakage current flowing through the large trigger protection;

12 pulse rectification configuration: The 4A0930/4A1200 models require the removal of jumper wires such as R/L1-R1/L11, and an external 3-winding transformer.

Start programming and operation: from parameter setting to trial run

1. Use of digital operator (core control interface)

Button functions:

RUN/STOP: Local start/stop, with the STOP key having the highest priority;

LO/RE: Switch between local/remote control, only operable during shutdown;

F1/F2: Switch display data/help menu, ESC returns to the previous level, ENTER confirms parameters.

Display interpretation:

Status display: "Rdy" (ready), "FWD/REV" (forward/reverse), ALM light (alarm/fault);

Monitoring interface: can view parameters such as DC bus voltage (U1-52), input current (U1-55), power (U1-57), etc.

2. Core parameter configuration (classified by application scenario)

(1) Basic initialization

Parameter A1-03 (initialization parameter):

0: No initialization;

1110: User defined initialization;

2220: 2-wire control initialization;

3330:3 wire system control initialization;

5550: oPE04 fault reset.

(2) Operation mode and control configuration

B1-02 (run command selection): 0 (numeric operator), 1 (numeric input), 2 (communication), 3 (tab);

C7-16 (minimum running time): In forced running mode, set the minimum holding time from start to stop (default 1.00 seconds);

L5-01 (number of fault restarts): 0-10 times, supports automatic restarts after overcurrent, overvoltage and other faults.

(3) Protection parameter configuration

L2-05 (undervoltage detection level): default 190V for 200V level, default 380V for 400V level, adjustable as needed;

L8-02 (overheating alarm level): default 85~140 ℃ (random variation), exceeding this temperature triggers an oH alarm;

L8-35 (installation method selection): 0 (IP00 model), 1 (tightly arranged), 2 (IP20 model), 3 (external heat sink).

3. Trial operation process (phased verification)

(1) No load trial operation

Step: Disconnect the load → Set as local control → Set low frequency (such as 6Hz) → Start the equipment → Check the motor direction, vibration, and current (should be 50% lower than the rated current) → Gradually increase the frequency to the rated value and observe the stability of operation.

(2) Test run with load

Preparation: Connect the load, confirm that the emergency stop circuit is effective, and check the PID feedback signals (such as pressure and flow sensors);

Operation: Start from low frequency (such as 20Hz), monitor input current (U1-55), DC bus voltage (U1-52), adjust PID parameters (b5-02 proportional gain, b5-03 integration time) to optimize response speed.

Troubleshooting and maintenance: ensuring long-term stable operation

1. Common faults and solutions

Possible causes and solutions for fault codes

OC (overcurrent) motor short circuit/insulation damage, short acceleration and deceleration time, load blockage check motor winding, extend acceleration and deceleration time, reduce load or increase model size

OV (overvoltage) input voltage is too high, deceleration is too fast, brake resistor is not connected, check power supply, prolong deceleration time, install brake resistor

OL2 (overload) load exceeds rated torque, excessive regenerative energy reduces load, optimizes regenerative energy distribution, and replaces high-capacity models

CE (communication error) loose communication line, mismatched baud rate, noise interference check wiring, unified communication parameters, strengthened shielding and grounding

EF3 (external fault S3) S3 terminal wiring error, external device fault verification H1-03 parameter setting, troubleshooting external device faults

2. Regular maintenance plan

(1) Daily inspection (daily)

Appearance: No abnormal noise, odor, or vibration, and the cooling fan is running normally;

Display: No alarm code, stable parameters such as current and voltage;

Environment: Confirm that the temperature and humidity meet the installation requirements and there is no dust accumulation.

(2) Regular maintenance (by cycle)

Maintenance project cycle operation requirements

Check the blade wear of the cooling fan after running for 20000 hours or 10 years, replace it with a fan of the same model, and reset the parameter o4-03

Measure the capacitance of the main circuit capacitor after 5-7 years of operation. If it is lower than 80% of the initial value, it needs to be replaced. Monitor the lifespan through U4-05

Check the torque of the main and control circuit terminals every 6 months to prevent looseness and heating during terminal tightening

Clean the radiator with compressed air every 3 months after power failure to avoid clogging the air duct

3. Maintain monitoring function

Parameters U4 series: U4-03 (fan running time), U4-04 (fan life percentage), U4-05 (capacitor life percentage), U4-06 (soft charging relay life). If it is less than 20%, it needs to be replaced in advance.

Peripheral equipment and communication configuration

1. Standard configuration and peripheral equipment

Required equipment: power coordination reactor, current suppression reactor, fuse (model needs to be matched according to the model);

Optional devices: 24V power supply (PS-A10LB/HB), USB replication unit (JVOP-181), LED operator (JVOP-182), communication tab (MECHATROLINK-II, CC Link, etc.).

2. MEMOBU/Modbus communication configuration

Communication parameters:

H5-01 (slave address): 0~FFH, default 1FH, ensure unique address;

H5-02 (baud rate): 0 (1200bps)~8 (115200bps), default 3 (9600bps);

H5-03 (checksum): 0 (no checksum), 1 (even checksum), 2 (odd checksum), default 0.

Communication function: Supports reading monitoring data, writing parameters, controlling operation/stop, fault reset, and can be remotely controlled through PLC or upper computer.