Varispeed-501)W11

INDUSTRIAL USE THYRISTOR CONVERTER UNITS

Before initial operation, read these instructions thoroughly, and retain for future reference.

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 When properly installed, operated and maintained, this . Do not tamper with potentiometers of the power units
unit will provide a lifetime of optimum operation. It is since they were preset at the factory before shipment.
mandatory that the person who operates, inspects, and
maintains this equipment thoroughly reads and Varispeed-505W11 (VS-505WII) is a thyristor converter
understands this manual and has in his possession at unit for varispeed reversible operation of industrial DC
all time . motors .

IMPORTANT For correct operation of VS-505WII, users must

thoroughly read these instructions . This manual is also
. Make no withstand voltage test on the VS-505WII necessary for maintenance and troubleshooting, and
because it incorporates semi-conductor electronic threfore should be kept filed for ready reference .
circuits .
. If insulation resistance tests are neccessary, make
For details on DC motors, refer to "Instructions for
them only in accordance with the instructions given in
Industrial DC Motors" (TOE-C435-3B).
this manual.

682-215 682-227

682-234

Type CDMR-W11 Type CDMR-WIL Type CDMR-W11

(Type S) (Type L) (Type M)
460 V, 105 A 460 V, 420 A 230 V, 260 A

CONTENTS

RECEIVING . . . . . . . . . . . . 3 Interconnections . . . . . . . . . . . 4 MAINTENANCE . . . . . . . . 10

STORAGE . . . . . . . . . . . . . . 3 Cautions when Wiring . . . . . . 4 Periodic Inspection . . . . . . . 10
LOCATION . . . . . . . . . . . . . 3 TEST RUN . . . . . . . . . . . . . . 5 Parts Replacement . . . . . . . 10
INSTALLATION . . . . . . . . . 3 Cautions in Replacing
Check before Test
WIRING . . . . . . . . . . . . . . . . 3 Run . . . . . . . . . . . . . . . . . . . . 5 Control Board . . . . . . . . . . . 14
Component Arrangement No-Load Operation . . . . . . . . 6 Troubleshooting Guide . . . . 14
in VS-505WH . . . . . . . . . . . . 3
Full-Load Operation . . . . - 6 SPARE PARTS . . . . . . . . . . 15
Terminal Sizes and
Carrying Currents . . . . . . . . . 4 Adjustment . . . . . . . . . . . . . . 6 REFERENCE. . . . . . . . . . . . 16

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 RECEIVING " Free from corrosive gas and liquid
" Ambient temperature : OOC to 400 C
" Less vibration
The equipment has been put through severe
tests at the factory before shipped . After un-
packing, however, check and see the following . INSTALLATION
" Its nameplate data meets your requirements .
" It has sustained no damage while in transit . Select .a location described in STORAGE and in-
" Fastening bolts and screws are not loosened . stall the equipment by proper procedure in keep-
" Devices built in the cabinet are not damaged ing the equipment in good working condition .
or missing .
WIRII4G
STORAGE Make wiring in reference to the interconnection
If the equipment is temporarily stored or ma- diagram furnished on your order and the follow-
chine stops for an extended length of time, the ing .
following precautions should be taken .
COMPONENT ARRANGEMENT IN
LOCATION VS-505 WII

Store the equipment under the following condi- Figs . 1 to 3 show component arrangement in
tions . the VS-505WII .
" Free from rainfall and drops of water POWER CIRCUIT
" Clean and dry BOARD (2PCB)

THYRISTOR
PROTECTIVE
FUSE
(2 FOR 220 V
CLASS, 3 FOR
440 V CLASS)

(a) Control Circuit (b) Main Circuit

Fig. 1 Type CDMR-WI[, -S, (460 V, 115 A)
CONTROL CIRCUIT
BOARD (1PCB) THYRISTOR
CONNECTOR POWER CIRCUIT COOLING
BOARD (2PCB) FAN

NAMEPLATE
"CAUTIONS THYRISTOR
I N OPERA- PROTECTIVE
TION" FUSE
CONTROL (2 FOR 220 V
SUPPLY CLASS, 3 FOR
VOLTAGE 440 V CLASS)
SELECTOR
TAP

MAIN CIRCUIT
EXTERNAL
TERMINAL

(a) Control Circuit (b) Main Circuit

Fig . 2 Type CDMR-WII, -1V[ (230 V, 260 A)

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 WIRING (Cont'd)

SURGE MAIN CIRCUIT

ABSORBERS EXTERNAL TERMINALS

Control Circuit (b) Power Circuit

Fig . 3 Type CDMR-WII:, -L (460 V, 420 A)

TERMINAL SIZES AND CARRYING CURRENTS INTERCONNECTIONS

Table 1 shows the size and the current earring capacities Make connections of VS-505WII with associate
of the terminals of VS-505WII . Select leads with units according to the interconnection diagram
sufficient current carrying capacity . Refer to "Cautions separately furnished.
when Wiring".

Table 1 Terminal Size and Current Capacity CAUTIONS WHEN WIRING

AC Main DC Main Field Main Circuits

CDMR-W11 Circuit
Circuit Circuit
Use 600 V PVC insulated wires or cabtyre cables
Car- Car- Car-
Rated Rated with the current carrying capacities of the com-
Ter - rying Ter- rying Ter- rying
Volt- Out- bined DC motor for AC main circuit terminals
minal Cur- minal Cur- minal Cur- (U, V, W) and DC main circuit terminals (P, N) .
e
age put
rent Size rent Size rent
V kW A
A A
25 M4 21 M5 25 Field Circuits
35 M8 29 M8 35
45 M8 37 M8 45 M4 12 Use 600 V PVC insulated wires or cabtyre cables
90 M8 74 M8 90 with the current carrying capacities of the com-
230 105 M8 86 M8 105 bined DC motor for field power circuit terminals
180 M10 147 M10 180
M4 22 (Uo, W o, U1 , Wl) and field circuit terminals (J,
260 M10 213 M10 260 K) . Use stranded wires of cross-section 5.5
420 M12 343 M12 420 mm2 or larger for field circuit terminals (J, K) .
M4 25
550 -M12 449 M12 .550
50 M8 41 M8 50
90 M8 74 M8 90 M4 12 Signal Circuits
105 M8 8 'M8 105
460 180 M10 147 M10 180 22 Use shielded wires or twisted wires of twisting
M4
260 M10 213 M10 2&0 pitches 20 mm or smaller for the speed setting
420 M12 343 M12 420 circuit terminals (6 to 10) , speed feedback ter-
M4 25
550 M12 449 M12 550 minals (2, 3), tachometer circuit terminals (50 to
Notes 52) .
- Terminal size other than listed above is M4 and
current capacity is 2 A or below.
Rule of thumb of AC main circuit power capacity
1 .2XF XEXI (VA)
E : Supply voltage
I : AC main circuit current
Fig . 4 Pitch of Twisted Wire
4

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 Separation of Signal Cables from Main
Circuit Cables

To avoid inductive interference from other cables,

run the shielded or twisted wires (1 to 55)
separate from main circuit cables ( U , V, W ; U o , WO ;
U1, W 1 ; P, N ; J, K) in a bundle or thru a duct .

CAUTION

After wiring, check interconnections . Make in-

sulation resistance tests using a 500 V megger .
Fig . 5 Inspection Window of DC Motor
Connect VS-505WIE main circuit terminals (U, V,
W ; U o, W o ; U1, W 1 ; P, N ; J, K) with common
lead . Measure the insulation resistance between
common lead and the ground . When the test
result is 2 MSZ or more, it means that wiring is
good.

TEST RUN
When the VS-505WIL has been correctly installed
and wired, the unit shall be tested through a

D
test run as follows .
If trouble is found during the test run, re-
fer to "Check Before Test Run" and "Trouble-
shooting Guide" for necessary measures . If the
cause of the trouble cannot be located, or repair
is impossible, notify our service station, giving Fig . 6 Tap Selection of Control
the details of trouble conditions . Supply Voltage

50Hz
CHECK BEFORE TEST RUN

Make the following checks prior to the test run .

Table 2 Check before Test Run

Check Pomts Check Items
60Hz
Interconnec- " Correct wiring
tions between " Tightening of terminal screws For 50 Hz, slide
vs- 505WE the switch key up .
and Associ- For 60 Hz, slide
ate Units the switch key down .
DC Motor " Disconnection from the driven machine
" Removal of thrust block
" Remove inspection covers and blow out with
air to clean commutator . (Fig . 5)

VS-505WII " Adhesion of dirt or dust on the enclosure Fig . 7 Power Frequency Selector Switch
" Smooth hand rotation of thyristor cooling
fan
" Check items in "Cautions in Operation" on
the back of the control board door Table 3 Supply Voltage Allowable Range
" Correct connection of the shunt connector
to the voltage selecting tap (Fig . 6)
Nominal Permissible Voltage
" Correct setting of the frequency selector Supply
switch (Fig . 7) Supply Voltage Selector
Frequency
" Correct adjustment of potentiometers on the Voltage Variation Tap
control board (1PCB) Refer to red paint
200 V 50/60 Hz 170 - 220 V 200 V
Supply Volt- " Voltages of any two of phases U, V, W are
age at Input within the values on Table 3. Check with a 220 V 50/60 Hz 187 - 242 V 220 V
Terminals of tester .
VS-505WR " Terminals Uo and U1 , and Wo and W, are 400 V 50/60 Hz
connected .
340 - 440 V 400 V
" Rotating direction of the motor blower meets 440 V 50/60 Hz 374 - 484 V 440 V
with the arrow marked on the blower .

* VS- 505WE of larger capacity than 230 V, 45 A or 460 V , 90

A are provided with a thyristor cooling fan.

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 TEST RUN (Cont'd ) ADJUSTMENT
Do not tamper unnecessarily with the potentiometers on
NO-LOAD OPERATION the control circuit board since they have been adjusted
After making the checks specified before test run, at the factory before shipped.
thoroughly check the environment of the system for
safety. Adjuster Locations and Functions

Check the polarity of DC tachometer generator Adjuster locations on the control circuit board and
feedback voltage. When the motor is running forward, functions are shown in rig. 8 and Table 6. The
the polarity of VS-505WIl signal terminal 2 (3 : 0 V) is characteristics of control circuit board check terminals
minus and it is plus during reverse running of the motor. are shown in :Fig. 9 and Table 7.
Then, run the motor without load according to
Table 4.

FULL-LOAD OPERATION
Before starting full-load operation, stop the power
supply, couple the DC motor to the driven machine, and
check the motor and the driven machine for safe and
obstruction-free conditions . Table 5 gives full-load
operation procedure.

9
Table 4 No-load Operation
0

Order Operation Check Items

1 Set the speed reference
at zero .
2 Turn on main circuit Smooth rotation of the
power suppy . thyristor cooling fan .
Smooth rotation of the

sx V~
blower for DC motor.
Rotating direction of the
blower meets with the mark-
ing on the blower .
0
3 Make an operational se- Indication light "PREP" on
quence and check to be the control board (1PCB)
sure that operation is turns on .
Fig . 8 Adjuster Locations on
ready. (Turn on ready
signal, motor cooling fan Control Circuit Board
ON /OFF signal .)
4 Turn-on the operation
signal .
5 Gradually, increase the Smooth acceleration of DC
speed setting value. motor. 'fable 5 Full-load Operation
No abnormal odor, smoke,
vibration and noise on DC Order Operation

6 Remove the hand-hole

cover and check the
I motor.
No brush chattering and
sparking at the brushes .
1 Se t the speed at zero .
2 Turn on the main circ uit power supply .
commutator .
To avoid excessive temperature rise of DC motor 3 Turn on operation signal and gradually
winding in frame 112, 132, reclose the window increase the speed. Check to be sure
within 5 minutes .
that the motor and driven machine are
7 Gradually, turn the Smooth acceleration of DC correctly r unning .
speed setting potentiom- motor.
eter clockwise . 4 Turn off the operation signal .
8 ' Increase the speed set- DC motor rotates at the 5 Tu rn of f main circuit power supply .
ting value to the maxi- maximum speed . Check
mum . with a speedometer .
9 Change the speed to DC motor speed corre-
various values . sponds with the set values .
10 Turn off the operation DC motor suddenly stops .
signal .
11 Turn off the main cir-
cult power supply .

* VS-505W11. rated 220 V. 45 A and above and 460 V. 90 A and above are
provided with a thyrlstor cooling fan.

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 Table 6 Control Circuit Board Adjuster Locations and Functions
Type : o Adjuster Adjuster
Adjuster Function Adjusting Method Specifications
Adjusters Location Name
Clockwise rotation increases 3 - 75 sec
1 ~+ RATE Accel time adjustment at fwd run.
(Decel time adjustment at rvs run.) accel time .
time adjustment at fwd run 3 - 75 sec
2 (D RATE Decel
(Accel time adjustment at rvs run.)
Clockwise rotation increases decel time .

3 NGAIN ASR Gain adjustment . Clockwise rotation increases GAIN

4 NMAX Speed feedback adjustment . Clockwise rotation decreases ±6 V/10046 specA

s"geed .
ACR Gain adjustment . Clockwise rotation increases
5 IGAIN
gain .
Main circuit current feedback Clockwise rotation decreases +3 V/100% current
6 IFB current.
adjustment .
Speed and current limit value at Clockwise rotation increases 150% (Standard)
7 F LIMIT
forward run. limit value .
8 R LIMIT Speed and current limit value at Clockwise rotation increases 150% (Standard)
reverse run. li mit value .
Counter electromotive force Clockwise rotation increases 0. 17 - 0.84 times
9 CEMF
Potenti- compensation . gain .
ometers Speedometer adjustment . Clockwise rotation increases 1 mADC max
10 SM .pointer swin : .
Ammeter adjustment. Clockwise rotation increases pointer 1 mADC max
11 AM swing.
12 NOFS ASR offset adjustment .
evolt.i z- e
13 IOFS ACR offset adjustment.
t-volta,", .-e
Phase shift lag limit adjust- Clockwise rotation advances shift lag 155oek Standard
14 KIPP
ment limit
PSB Adjustment of phase shifter Clockwise rotation advances 90'-k - li_T1i°eZ
15
operation point . :, hase . (Adjustable)
Setting overload detection Clockwise rotation increases 110% Standard
16 OL% start point. overload detection start
.,oint.
Setting overload detection Clockwise rotation increases 150%, 6.0 sec (Standard)
17 OLT
time. o .eration time .
Setting zero current detec- Clockwise rotation increases 0% - 10n (Adjustable)
18 ZCD detection level. 7% (Standard)
tion level.
Setting field current . Clockwise rotation increases
19 IREF
field current .
Resistor 20 1FBR - Rough adjustment of field cur-
Selection 14FBR rent detection voltage level . Open the resistor according Refer to motor specifi-
(Open) 21 5FBR - Rough adjustment of main circuit to specifications . cations .
9FBR current detection voltage level .
Control Method selector (Speed N-1 Current
Slide 22 1SW
Switch ~M® control)
50 Hz- " 0 Hz
control)

Rough adjustment of speed Selection o the voltagelevel

24 A- D detection voltage level. according to type of tack-gen
and motor rated s ., eed .
E Selection of soft start El
25
operation E2 Soft start
Selection of PI or P control by © PI control
26 F
ACR control method "A P control
H Selection of PI or P control by © Pcmntrol
27 ASR control method © P1 control
Plug
Selection Selection of zero-speed condi- J1 block after motor
J tion at motor overheat . reached zero speed by
28
stop o .eration .
~~ ime(giate gate block .
Selection of start interlock ©Wit
29 K
zero-speed condition . ~~ Without
Selection of zero-speed cord- Field half-reduced after
tion at motor blower stop . ttiotor zero-speed by stop
30 L _operation. (Gate block)
-
Field half-reduced immediately.
(Gate block)
Selection of exciter according I©Exciter used .
31 M to type of motor field. © Exciter not used .
Open " Speed control by
voltage detection .
" Speed control by AC
Short- 32 OPN tach-gen .
circuit Short-
Jumper circuited other than the above.
Open - Special application .
33 OPS -- Short- Other than the above .
circuited

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 TEST RUN (Cont'd) Adjustment Procedure

N MAX (Speed feedback adjustment)

To adjust the DC motor speed exactly to the

reference speed, proceed as follows .
1 . Prepare the tachometer having the required
accuracy .
2 . Operate the DC motor at no load (or less
variation) .
3. Measure the speed reference voltage with a
voltmeter. Correct the voltage to that of desired
motor speed .
4. Measure the motor speed with a tachometer .
5 . If the speed does not reach the desired speed,
turn NMAX counterclockwise to increase the
speed.
Fig . 9 Control Circuit Check Terminals

Table 7 Control Board Check Terminals

Check Normal Value
Signal Name Terminals
CH22 OV (SG)

Stable power supply CH24 +15 V

CH25 -15 V
CH19 +24 V
CH20 -24 V Allowable voltage
Unstable power supply function range : ±20%
+24 V (Pulse amplifier
CH23
supply)
CH4 :6 V/100% command (8 Forward, (+ Reverse)
Speed reference CH5 ±6 V/100% command ((D Forward, (DReverse)
Speed feedback CH3 ;6 V /100% speed (0
Forward, + Reverse)
Forward CH9
Current command Reverse CH8 -3 V/100% command

Current limit Forward CH7 +3 V/100% current limit

(Speed limit) Reverse CH6 (+6 V/100% speed limit)

Main Current feedback CH18 +3 VI100% current

Circuit Approx
bl ock . -1 V at gate 0 to +6 V when controlling
Power Current limiter output CH2

Approx . +5 .5 V at 60 Hz, +1 to +5 .5 V at 60 Hz,

Phase shifter input CH16 +6 .5 V at 50 Hz at gate +1 to +6 .5 V at 50 Hz
block. when controlling .

Counter electromotive force input CH1 0 - ±5 V

Overload detection start point CH21 110% (Approx: -1 .65 V)

+12 V at
Zero-current detection CH15 0 V at load current conduction, approx .
0 A of load current.
0 V at reverse opera- Approx . +24 V at forward
Forward C1112 operation .
Pulse amplifier power tion .
supply 0 V at fozwaz~d opera- Approx . +24 V at reverse
Reverse CH13 operation .
tion .
Gate block (at failure) CH14 0 V normal, :!pprox . -12 V at gate block.
u
u U

Phase shifter synchronization v ar U, V, W: Main circuit

power supply w w4/_~s 11 y input power supply .

Current command CH11 Voltage according to ~ -6 V/5 A

field current. +3 V/5 A
Current feedback CH17
Field +1 to +5 V at 60 Hz,
Power Approx . +5 V at 60 Hz,
Phase shifter input CH10 +6 V at 50 Hz at field +1 to +6 V at 50 Hz
block. when controlling .

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 6. If the speed exceeds the desired speed, turn SYNCHROSCOPESCREEN
NMAX clockwise to decrease the speed . ADJUST THE SWEEP SPEED
ADAPTED TO THE MOTOR
ACCELERAITON TIME TO
FLIMIT (Forward limit value adjustment) BRING THE CURVES TO A
CONVENIENT POSITION .
RLIMIT (Reverse limit value adjustment)

1. Current limitation (Speed control)

Slide the control method selector switch (1SW) on
the control circuit board to N . When the voltages MOTOR
ACCELERATION
at CH7 (forward) and CH6 (reverse) are +3 V, CUR1tENT
100% current limit value is obtained . Current limit
value can be set within the range of 0% to 250% by
F LIMIT and R LIMIT .

2. Speed limitation (Current control) Fig . 10 CEMF Adjustment

Slide the control method selector switch (1SW) on

the control circuit board to I . When the voltages CEMF compensation reduces the loss time due to
at CH 7 (forward) and CH 6 (reverse) are +6 V, Forward/Reverse selection to as the same level
100% speed limit value is obtained . Speed limit as the integral control of ACR . Turn CEMF fully
value can be set within the range of 0% to 250% counterclockwise, and during motor acceleration
by F LIMIT and R LIMIT . by current limit gradually turn it clockwise until
the voltage at CH2 on the control circuit board
stabilizes .
PSB (Phase shifter operating point adjustment)

PSB sets the phase shifter operating point . Field Current Adjustment
Field current adjustment is required for checking
1 . When the current controller (ACR) is inte- the setting at the factory or for fine adjustment .
gral-controlled To change the setting, selection of resistors (1FBR to
Connect the plug selector F on the control circuit 4FB R) on the control circuit board is required .
board at Fl . Turn PSB fully counterclockwise . 1. For constant field current
2 . When the current controller (ACR) is ratio- a. Connect a DC ammeter to the field circuit .
controlled b . Adjust so that the ammeter indicates the
Connect the plug selector F on the control circuit rated field current with IREF on the control
board at F2 . Turn PSB clockwise gradually with circuit board . (Refer to the test report or
reference current at 0 V (0 V at CH 2) , and set nameplate data .)
at the position where main circuit current is
ready to start . 2. For field weakening control

Field weakening control is made for the VS-505WII

CEMF (Counter electromotive force compensation) combined with field weakening control unit type
JGSM-51- D .
Current loop is vulnerable to counter electro-
motive force . In order to obtain optimum per- a . Connect DC ammeter to the field circuit and
formance, a compensating electromotive force has DC voltmeter to output terminals P, N .
to be biased on the phase shifter, depending on
the control mode . b . Turn IREF on the control circuit board and
FORCE FLD and V LIMIT of field controller
fully counterclockwise .
1 . When the current controller (ACR) is ratio-
controlled c . Seat the minimum field weakening current by
Adjust CEMF, observing the motor acceleration IREF. In this case, set the current at 80% field
current with a synchroscope . Turn CEMF fully weakening current at maximum speed . (See the
counterclockwise, and turn CEMF clockwise test report .)
gradually until optimum value shown in Fig . 10 d . Set the rated field current (field intensifying
is obtained . by FORCE FLD . (See the test report or name-
2 . When the current controller (ACR) is inte- plate data .)
gral-controlled e . Alter the motor starts, gradual increasing
the speed reference increases the voltage across
P and N and governs it at some value . Turn V
LIMIT clockwise gradually so that the governed
value is the rated voltage .

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 Field Thyristor Replacement
MAINTENANCE
With all the Models, thyristor modules consisting
VS-505WIl requires almost no daily inspection . of a thyristor and a diode are used as the field
To keep the correct and successful operation, thyristor . Replace them as follows .
periodic maintenance operations should be per-
formed . The users should prepare their own 1 . Remove the four mounting screws of field
maintenance programs based on the following snubber board (3PCB), lead clamping screws,
guidelines . control power connector. Then, remove snubber
board . See Fig . 11 .
PERIODIC INSPECTION
2 . Remove lead clamping screws connecting to
Table 8 shows the minimum inspection items and thyristor, and remove the leads from thyristor.
the procedures . In this case, mark all terminals for identification .
See Fig . 12.
3. Remove thyristor mounting screws (2) and
remove thyristor module .
Table 8 Periodic Inspection
Inspection Inspection Inspection What to do Remarks 4 . Check tY;Ie type and capacity of new thyristor
Procedure
Part Item module against the requirements . Install it by
Thyristor " Noise " Check for Replace . Rule of thumb
cooling any inter- for cooling fan reversing the removal procedure, making con-
fan mittent or replacement : nections to the terminals identified by the marks
unusual
noise .
15,000 hours
of operation . made before removing the old thyristor module .
" Vibration " Feel by Coat the thyristor mounting surface with joint
hand . - compound, JOINTAL Z made by Nippon Light
General " Dust or . Check for Clean with Metal Co. , Ltd .
dirt dust clogging an electri-
cal cleaner
or dirt
adhesion. Main Circuit Thyristor Replacement
" Loose ter- , Tighten .
minal " Check for VS-505W 1, 230 V at 25 A
screws or loose screws
nuts or nuts . The unit uses a thyristor module consisting of
two thyristors . Replace it as follows .
1 . Remove snubber board (4PCB) mounting
PARTS REPLACEMENT
screws (5) and lead clamping screws . Remove
snubber board. (Fig . 13)
. Replace the parts required after checking the
trouble and correcting it according to TROUBLE- 2. Remove bus bar mounting screws and lead
SHOOTING GUIDE . clamping screws connected to thyristor . Remove
bus bar and leads . (Fig . 14) In this case, mark
. Turn off the power before part removal or
mounting . the terminals for identification .

3 . Remove two thyristor clamping screws and

thyristor.

4 . Check the replacement module for type and

capacity, and reinstall it by reversing the dis-
assembly procedure, identifying the terminals by
means of the marks made prior to disassembling .

THYRISTOR
MTG SCREWS

Fig . 11 Field Thyrsitor Assembly

Fig . 12 With Snubber Board Removed

10
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 Main Circuit Thyristor Replacement Main Circuit Thyristor Replacement

VS-505W 1, 230 V at 35 to 105 A, 460 V at 50 to VS-505 W 1, 230 V at 180 to 550 A, 460 V at 180 to
105 A 550 A
The unit uses a thyristor module consisting of
two thyristors . Replace it as follows . The VS-505WIE uses a flat thyristor module as a
power module . For 180 A and 260 A, one power
module is employed, and for 420 A, and 550 A,
1 . Remove snubber board (4PCB) mounting
three power modules are employed . Proceed as
screws (5) and remove snubber board. (Fig . 15)
follows .
2 . Remove bus bar mounting screws and lead
1 . Remove the clamping screws for thyristor
clamping screws connected to thyristor . Remove
gate (C) and cathode (K) terminals (24 for 260 A
bus bar and leads . (Fig . 16) . In this case, mark
or below, and 8 for 420 A or more), and free the
the terminals for identification .
leads . Remove fuse mounting bolt(s) (3 for 260
A or below and 1 for 420 A or more) . (Fig . 17)
3. Remove two thyristor clamping screws and
thyristor .
2. Loosen power module mounting bolts (7 for
4 . Check the replacement module for type and 260 A or below, 8 for 420 A or more) , and remove
the power module .
capacity, and reinstall it by reversing the dis-
assembly procedure, identifying the terminals by
means of the marks made prior to disassembling .
Coat the thyristor mounting surface with joint
compound, JOINTAL Z made by Nippon Light
Metal Co . , Ltd .

S14UBBER
BOARD
SNUBBER MTG
BOARD SCREWS (5)
.TG
SCREWS (5)

Fig . 13 Field Thyristor Assembly (230 V, 25 A) Fig . 15 Main Circuit Thyristor Assembly
(460 V, 105 A)

BUSBAR-

THYRISTOR
CLAMPING -
SCREWS

Fig . 14 With Snubber Board Removed Fig . 16 With Snubber Board Removed

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 MAINTENANCE (Cont'd )

3 . Place the main circuit thyristor module on a 9 . Tighten the snubber board mounting screws .
work bench . Remove the snubber board (4PCB- Then, mount the thyristor module by reversing
U, V, W) mounting screws (3 for 260 A or below, the disassembling procedure, tightening the
4 for 420 A or more), and take out the snubber screws firmly .
board . (Fig . 18)

4 . Loosen the fin mounting nuts alternately,

turning 1/4 turn at a time . Then, remove the
leaf spring .

5. Remove the fin and take out the leaf spring .

6 . Clean the contact surfaces of the new thy-

ristor and the fin, and thinly coat these surfaces
THYRISTOR
with joint compound, JOINTAL Z made by Nippon GATE (G)
Light Metal Co ., Ltd . CATHODE (K)
TERMINALS

7. Align the fin locating pin and the thyristor

locating hole, after making sure that the polarity
of the thyristor is correct.

8 . Keeping the leaf spring and the fin in paral-

lel, finger-tighten the clamping nuts . Then,
tighten them alternately through 1/4 turn at a
time, three times each with a socket wrench .
Now, the thyristor fin has been installed . Fig. 17 Main Circuit Thyristor
(460 V, 420 A)

K (RED)

G (WHITE)

THYRISTOR

681-193

(a) With Thyristor Removed (b) Thyristor

Fig . 18 Thyristor Replacement

Thyristor Protective Fuse Replacement

VS-505W 11, 230 V at 25 to 105 A, 460 V at 50 to

105 A

1 . Pull up the fuse blown indicating microswitch

with the leads connected. (Fig . 19)

2. Remove the two fuse mounting bolts . FUSE

3. Mount the replacement fuse by reversing the

removing procedure, after checking it for model
and capacity .

Fig . 19 Main Circuit Fuse Assembly

12 (460 V, 105 A)

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 Thyristor Protective Fuse Replacement 2 . Check the replacement surge absorber for
model and capacity . Mount three surge ab-
VS -505W 1, 230 V at 180 to 550 A, 460 V at 180 sorbers after connecting M4 pressure termi-
to 550 A nals to their leads as shown in Fig . 22.
1 . Remove the two lead clamping screws of the
fuse-blown indicating mocroswitch and free
the leads . (Fig . 20) Fig . 22 Surge
Absorber with Pres-
2 . Remove the two fuse mounting bolts, and sure Terminals
remove the fuse together with the fuse-blown Connected to Leads
indicating microswitch . )k,
IL

3. Check the replacement fuse for model and

capacity, and install it by reversing the disas-
sembling procedure . Thyristor Cooling Fan Replacement

To replace a thyristor cooling fan with a new one,

proceed as follows . (Fig . 23) The VS-505WIL
units rated 230 V, 25 A ; 460 V, 50 A are self-
cooled type .

1. Remove the cooling fan power lead .

2 . Unscrew the two fan mounting screws and

dismount the fan .

3 . Remove the fan by reversing the disassembl-

ing procedure .

Fig . 20 Main Circuit Fuse Assembly

(460 V, 420 A)

Surge Absorber Fuse Replacement (a) 230 V, 45 to 105 A; 460 V, 90/105 A

1. Pull the fuse element and remove it . (Fig . 21)

2. Mount the replacement fuse, after checking
its model and capacity .

POWER SUPPLY
LEADS (2)
r..

(b) 230 V, 180/260 A; 460 V, 180/260 A

FAN
Fig . 21 Surge Absorber Fuse

Surge Absorber Replacement

(c) 230 V, 420/550 A ; 460 V, 420/550 A
1 . Remove three surge absorber mounting
screws and remove surge absorber . Fig. 23 Thyristor Cooling Fan
13

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 MAINTENANCE (Cont'd )
Control Circuit Board Replacement

Disconnect all the leads from the terminals.

Then, unplug the connectors shown in Fig. 24, and remove the
6 control circuit board mounting screws . EXTERNAL
CONTROL
TERMINALS
Mount the new board by reversing the disassembling
procedure. Plug-in the connectors firmly.

CAUTIONS IN REPLACING CONTROL CIRCUIT BOARD

FUSE-BLOWN
Make sure that the type of the new control circuit board agrees DETECTION
CONNECTOR
with the nameplate and potentiometer settings of new control
CURRENT
circuit board are the same as the old one. Refer to the DETECTION
nameplate "Cautions in Operation" posted on the inside of the CONNECTOR

control circuit board door of VS-505WII. See Table 6 "Adjuster

Locations on the Control Circuit Board and Functions" . Fig . 24 Control Board

TROUBLESHOOTING GUIDE
Table 9 Troubleshooting Guide
Trouble Possible cause Check method What to do
PREP lamp Control Failure indicating
OFF printed lamp ON . _
board Operation sequence Check the external operation sequence . Replace the control board . SeeReplace-
failure . ment of Control Board .
OCL lamp Control Too low setting of Is setting dial at the positions indicated Set the setting dial to the
ON printed "OL%," "OLT" . b lock " dint? position of lock dint .
board Too high setting of
"FLIMIT," "RLIMIT" Refer to Tables 6 and 7. Readjust .
Incorrect setting of
"IFB':
Thyristor Defective deterto- Check thyristor (Fig . 25) . Replace thyrtstor . (See Main
rated). Circuit Th rtstor on page 9 . )
Motor and Overloaded . Check load current . A iust loa . Reset .
driven Locking . Run motor without load, and see if it locks Repair motor .
machine Check load for locking .
Layer shorting in Run motor with terminals P and N dis- Repair motor .
motor . connected . If OCL lamp does not light,
the motor and its circuit are defective .
Grounding of motor Measure resistance between terminal P) " Repair motor .
circuit . (or N) and ground (E) with a multitester . " Correct wiring .
If the reading is nearly - on the largest
scale of the tester, the circuit is normal .
U lamp Thyristor Defective deterto- Check thyrtstor (Fig . 25) Replace thyrtstor . (See Main Circuit
ON rated). Th rtstor on page 9 .
Motor Layer shorting in Operate only board with (P) and (NT-1- s- Repair motor .
motor. connected . If fuse is not blown, motor
circuit is defective .
Grounding of motor Measure resistance across terminal I' or " repair motor . To replace
circuit . N) and ground (E) with a multitester, and " Correct wiring . fuses (1FU,
if the reading is nearly m on the largest ZFU . 5FU),
scale of the tester, the circuit is normal . refer to
ot; (See Note .) Replacement
Control Defective phase Ifthemotor isnormal . replace of Thyristor
circuit control circuit) . control circsut board . Refer Protection
"O board to Replacement of Control Fuse .
c Circuit Board on page 13 .
c Fuse Defective deterio-
rated). _
FL lamp Motor Layer shorting in Measure resistance across terminal J and " Repair motor .
ON field winding . K with converter terminal J and K dis- " Replace fuse . (3FU or 4FU) .
connected with a tester . If it indicates
m, it means- field circuit is disconnected .
Grounding of field Measure resistance across terminal (.I or K
circuit . and ground (E) with a multitester, and if
the reading is nearly m on the largest
scale of the tester, the circuit is normal .
Control Defective. If the motor is normal, replace control
circuit board . See Replacement of Control
[board Board on pa _ e 13 .
THG lamp Motor Over Main circuit Check load current . ' Ad ust load .
ON loading . Field circuit Check field current . Head ust . See Adjustment on page 7 .
Locking . Run motor without load, and see if it locks . Re it motor .
_'J .
Check load for lockmf-.-, . A .'
Blocked air filter . Refer to the instructions for Industrial
DC Motors (TOE-C435-3) .
Insufficient cooling Check the blower for correct running Correct wiring .
with blower . direction .
MCF lamp Motor Cooling blower stop . Check fan for locking or overloadinE; . Repair or replace fan.
ON _Check thermal relay for tri . .in
TCF lamp Thyristor cooling an stop . or
Check fan for locking overloading . Replace the thyristor cooling fan . See
ON Where the fan is provided with Replacement of Thyristor Cooling Fan,
failure sensor on page 12 .
Surge Main CKT Excessive surge . Check fuses 3FU, 4FU . Eliminate cause of surge . Replace surge
absorber and fuse . See Replacement of Surge of
fuse blown Absorber Fuse and Replacement of
Sure Absorber .
Note : If the reading is not m . accurate measurement with a 500 V megger is required . Reading must be 3 megohms or above .
14

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 SPARE PARTS
Table 9 lists the recommended spare parts for specify complete nameplate rating and descrip-
one VS-505WII, keep always minimum insurance tion (type, code no . , etc .) of the parts requir-
spare parts on hand to protect the unit against ed, and quantity desired .
costly downtime . When ordering spare parts,

Table 10 Spare Parts for Control Panel

Thyristor Main circuit Thyristor Surge Absorber Field Surge Control Circuit
Fan
Converter Thyristor Protective fuse Fuse Thyristor Diode Absorber Board

Type (~' ty Type , Type Type . Type Type . T%pe ' t -`

CI)MlT WII (Code No ) (Code No ) Q ty (Code No ) I Q~ty (Code No .) Q ty (Code No) Q,ty (Code No .) Q tY (Code No) Q
230 V TM20DA-II
Type SS
25 A (SCR195)
230 V 60 FHS-55
35 A TM25DZ-H (FU642)
230 V (SCR196) FCI"2-20
6
45 A (FU599)
Type S 4715I'C-22T
230 V
90 A
TM55D7,-H
(SCR197)
60FIIS-110
(FU644)
I -1330-1300
(FAN130) '
230 V TM90D/.-1-1 60FIIS-150 2 .~ 1 TM20RA-Ii 2 'I'NR23G471 ' 3 JPDC_C041 ' I
105 A (SC1?198) (FU615) I (SC IZ192) (XX110) (FTCa1 ;2)
230 V N105CH08 CS5F-200 -~
180 A (SCR259) (FU609) 59151'C-22T
Type M I -1330-13tH) ,
230 V CS5F-350 (FAN 131)
260 A N195CH08 (FU612) FCF2-30
12
230 V (SCR261) CS5F-450 (FU600)
420 A (FU614) MlI.W18-
Type
L 230 V 553PA80 CS5F-600 (FAN107)
550 A (SCR263) (FU616)
460 V PK55IIB-160 -
50 A (SCR244) 60FIiS-110
460 V rI'M55DZ-21i (FU644 )
90 A 1(SCR201) 6 PCF2-20
Type S (FU599)
PK90HB-160 HN4556MV
460 V (SCII245) 60FHS-150 (FAN110) '
105 A (TM90Dl,-211 (FU645)
\(SCH202)
1 TM20IZA-l1 2 TNR23GIO2 J1'DC-CO-11 '
3 3
.160 V N105CI116 CS5F-200 ' (SCR192) (X X167) (ETCa172) ; 1
180 A (SCR260) (FU609) 7556MXV
Type M
460 V CS5F-350 (F ANI 11)
2(i0 A N195CII16 (FU612) FCF2-30 j
12
460 V (SCR262) CS5F-450 (FU600)
420 A ( FU614 ) MRW18- i
Type L
460 V 553PA160 CS5F-600 (fTAN107)
550 A (SCR264) (FU616) i

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 (REFERENCE)
ROUGH CHECK OF THYRISTORS

Where thyristors normally function, the following

values are obtained .
More than several hundreds of kiloohms across Several ohms to several hundreds of ohms across
(A) and (K) . (G) and (K) .

Thyristor fails Thyristor fails

i f 0 or - is in- if 0 or - is in-
dicated on the dicated on the
even either even either
tester (x 1 0 tester (x 1 S2
range) ran ge )

(a) Resistance across thyristor (b) Resistance across thyristor

terminals (A) and (K) terminals (G) and (K)

Fig . 25 Rough Check of Thyristors

ELEMENTARY DIAGRAM OF THYRISTOR CONVERTER UNIT

(TYPE CDMR-W II, 230V, 90A)

AC POWER SUPPLY
200/220V 50/60Hz

W1

N3,4
Y1,

1PCB Y5
I R1
Il R .)
JPDC-P05()
IPA FPA~ ,
RPA RPA i
G1

1PCB

P15 G1
FS
K1
K2
G2

FT G1
CONTROLLER
K1 500 500 JPDC-CO41
RT=4-p18
P19, P20

----------- ~----------

Fig . 26 Main Circuit

16
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 -P . 0V
-+48V
LOGIC CIRCUIT CONTACT RATING

7,
HALT ._27 220VAC 2A
23 RUN 24 VDC 2A FK
PREPARATION O M-ON S FROM
IREF ACR QRFI POWER PCB
H
COM CHIT
STOP 0 RUN
9
Z~TF
' FLD CONT
PREPARATION : i{---------- _
4
L JGSM-51 9} T ~-
20, NA
O ULT 6131415__l-i _ i
pno FBR
FLD ROCK
Flu (MCF)
CUM
NC
- -24V
CH17
aoaa 10

4 51 52 49 ©I2 3a s SELECTOR SWITCH n n n !ij4dj I IFLDIFB

FuH 50Hz4y60Hz, NH 1
©FBR ESE
REVERSING CONTROLLER
TCFH
CH12
OCL
ZC
FPA
RPA
0
CH15 llms llms
CH131Q
DC TG 20 - 3+0 A
PS
6

nv/ I(X)% FROM

POWER PCB
uw/ I(X)% H
15v/ I(X)%
SPFEO
REFERENCE

FROM CONTROL
TRANSFORMER

RT
v

TYPE :JPDC-CO41
+15V OV -15V
(P)

Fig . 27 Control Circuit

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 (REFERENCE) (Cont'd)

FUNCTIONS OF EXTERNAL CONTROL TERMINALS

Table 11 Functions of External Control Terminals for Input

Signal Name Terminal

Function
1 Ready signal - 30 "Close" --- Field intensifying .
"O "men" --- Gate block + Field half-reduced .
0-
-°

2 Operation signal 29 "Close" --- Speed reference "ON" -; Acceleration to speed

--0 reference value .
"Open" --- Speed reference "OFF" - Stop by regenerative
braking + Gate block .
29 "RUN" --- Speed reference "ON" -} Acceleration to spee,"
reference value .
j j 28 "STOP" --- Speed reference "OFF" -" Stop by regenerative
~ braking - Gate block .
3 Quick stop 27 Quick stop at ' Close' in case of soft start operation .
signal -oo- "Close" --- Speed reference "OFF" -} Stop by regenerative
braking -r Gate block .
4 Main circuit M 2 "Close" --- Gate block Terminals 26 and 35 (or 36)
input answer back ~0- released . short-circuited unless used .
signal
5 Motor overheat 33 "Open" --- Gate block .
si nal - - "Close" --- Normally .
" Field block signal 3 "Close" --- Fie143 block . (Field circuit clipped at PP
-° °- phase .)
7 Motor blower 31 "Close" --- Field intensifying .
ON /OFF signal °- "Open" --- Gate block -~ Field current half-reduced .
8 External gate _ 4 - 47 "Close" --- Gate block .
block signal
9 External (OCL) 45 - 46 "Close" --- Normally. Terminals 45 and 4 " short-
failure reset ~~- "Open" --- Reset . circuited when reset button in
the unit is used .
10 Fuse blown R1 - R2 "Open" --- Normally .
detection signal "Close" --- Gate block .
(inside)
11 Thyristor cooling R3 - R4 With failure detection cooling fan (option) .
fan stop signal __0 "Open" --- Normally .
(inside) "Close" --- Gate block 
12 Speed reference t& V /100$N " Soft start commnw" -"zei~~z : e.
( 0+ Forward, (D 7 -4 V '100
"" " 3 to 75 sec . (Variable)
Reverse) 8 ±10 V /100%N
9 f15 7100%N Accel . time, decel. time ad-
10 0 V (SG) justable independently .
12 *6 V / 100$N Terminals 11 an,. 1 short-
circuited.
13 ± 6 V/1000/6 N
13 External current
reference ( (D 14 ±3 V/100% Ia
Forward torque,
0 Reverse 15 0 V (SG)
torque)
14 Speed feedback - DCTG 2 3 (+)
signal
15 CEMF compensation 48 Forward : 4 V/1U0% Va
Reverse: +6 V/100% Va
1" Automatic field 1 Output received from field controller Type JGSM-51 .
weakening current
command
17 Speed feedback 5 " Output from Type JGSM- 5
(Voltage feedback) When reversible operation by ACTG . (OPN : Open)
" Output from type JGSM-53
When speed controlled by voltage detection .
(OPN : OP, en)
Notes
1. Use highly reliable contact for input interface signal considering that the load is 48 VDC, 10 mA .
2. Provide a noise killer at both ends of coil when relays, contactors, etc. are used .

1 8

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 Table 12 Functions of External Control Terminals for Output

Signal Name Terminal

Function
1 Ready signal 24 - 25 Contact signal closed when
..-0 operation is ready . Allowable contact
(PREP light ON .) capacity
2 Operation signal zz
o- 3 21-22-23 NO contact ---- For
command .
input
220 VAC, 2 A
24 VDC, 2 A
3 Failure signal 19~~ 18-19-20 Contact signal c ose " or
0-1-° opened) when failure occurs .
4 Zero-speed 44 "ON" at motor speed 1% or below (±6 V/100% NPB) .
detection si nal
5 Main circuit current detec- 49 - V 100 Ia
tion signal (Allowable load impedance : 3 k9Z)
±12 V Max
6 Speed reference signal 11 -6 V/100% N Terminals 11 an(A 12
short-circuited .
7 Speed feedback signal 4
Input from Type JGSM- when revers1p e operation
b ACTG . (OPN : Open)
8 Thyristor cooling 39 "ON" by thyristor cooling
Indi-
fan stop fan stop .
vidual
Thyristor overcur- 40 "ON" by thyristor overcur-
failure rent
detec- and overload rent overload.
Field lost 41 "ON" b fiel d loss .
tion
Motor overheat 42 "ON" b motor overheat .
signal
Fuse blown 43 "ON" b fuse-blown.
9 Speedometer 50 - 1 Connected to 1 mA DC meter (2 kQ or below) .
(Full scale at_maximum speed)
10 Main circuit ammeter - 1 Connected to 1 mA DC meter (2 kQ or below) .
(Full scale at 150% load)
11 Control power supply 53 -15 V
54 0 V (S G)
55 +15 V
38 +24 V
37 0 V ( POWER 0 V
~~ +48 V Isolate(A from other
EP 34 V POWER TV control r,rpr~C-~ 1 ~1y .

*Allowable rating 24 VDC, 50 mA . (24 VDC power supply required externally .)

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 Varispeed-505NA/II
INDUSTRIAL USE THYRISTOR CONVERTER UNITS

TOKYO OFFICE Ohtemachi Bldg, 1-6-1 Ohtemachi, Chiyoda-ku, Tokyc, 100 Japan
Phone (03) 3284-9111 Telex YASKAWA J33530 Fax (03) 3284-9034
SEOUL OFFICE Seoul Center Bldg, 91-1, So Kong-bong, Chang-ku, Seoul, Korea
Phone (02) 776-7844 Fax (02) 753-2639
TAIPEI OFFICE Shen Hsiang Tang Sung Chiang Building 10F 146 Sung Chiang Road, Taipei, Taiwan
Phone (02) 563-0010, -7732 Fax (02) 567-4677
YASKAWA ELECTRIC AMERICA, INC. - SUBSIDIARY
Chicago-Corporate Headquarters 2942 MacArthur Blvd Northbrook, Illinois 60062-2028, U S A
Phone (708) 291-2340 Fax (708) 498-2430
Chicago-Technical Center 3160 MacArthur Blvd Northbrook, Illinois 6()062-1917, U S A
Phone (708) 291-0411 Fax (708) 291-1028
Los Angeles Office 5626 Corporate Avenue Cypress, CA 90630, U S A
Phone (714) 828-9692 Telex (230) 678396 YASKAWAUS TSTN Fax (714) 8'8-1165
New Jersey Office Riverdale One, 44 Route 23 North, Suite 5 Riverdal s, NJ 07457-1619
Phone (201) 835-9512 Fax (201) 835-9511
YASKAWA ELECTRIC EUROPE GmbH SUBSIDIARY
Niederhochstadter Strafle 73, W 61476 Kronberg-Oberhochstadt. Germany
Phone (06173) 938-0 Telex 415660 YASE D Fax (06173) 68421
YASKAWA ELETRICO DO BRASIL COMERCIO LTDA . - SUBSIDIARY
Rua Conde Do Pinhal 8-5', Andar Sala 51 CEP 01501-Sao Paulo-SP, Br'Esil
Phone (011) 35-1911 Fax (011) 37-7375
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD .
CPF Bldg, 79 Robinson Road No 13-05, Singapore 0106
Phone 2217530 Telex (87) 24890 YASKAWA RS Fax (65) 224-5854

YASKAWA ELECTRIC CORPORATION

YASKAWA

TOE-S505-20C
® Printed in Japan October 1993 63-4 0 5TA
682-215

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