Yaskawa
eLearning
Welcome to Yaskawa America's
eLearning Module for the
J1000 Drive Features and Benefits.
Hello, my name is Chris Hammock and I am an
engineer in the Technical Training Department
at Yaskawa America.
I will be your instructor today as we go
through this eLearning module.
Yaskawa has started a new generation of
Microdrives with the V1000.
The J1000 is our second offering which
which improves upon the J7.
The main focus of the engineers at Yakawa
was to double the life of their
already robust Microdrive, the J7.
Assuming the J1000 is properly sized
and installed and operating at
40 degrees Celsius ambient temperature and
driving a consistent load
not exceeding 80% of drive rated current,
the J1000 will probably last
as much as 10 years or more.
To achieve such performance even
the normal wear items of a drive such as
Cooling Fans and Bus Capacitors
were designed to a tougher standard. also
Also circuit boards are interconnected
using a solderless joint design,
which tests prove increased that drives
vibration tolerance from 20 to 50 Hertz.
To improve quality even further,
a complete revision of Yaskawa drive
production lines has taken place and human error
has been reduced by installing the most advanced
robotic technology available.
A good way to extend the life of drive components
is to reduce the heat that they are subjected to.
Yaskawa drives engineers utilized a special
thermal simulation program to help them optimize
the locations of certain components
and improve airflow within the drive.
The diagram shown here detail how the
maximum expected Heatsink temperature
was reduced by 7 degrees Celsius
by just rearranging select components.
The next step in reducing the heat within the
drive is to make the Heatsink cooling more efficient.
Yaskawa drives utilize a Heatsink design
that promotes air turbulence
while the air flows over the Heatsink.
The turbulence allows the cooling air to spend
more time in contact with the fins.
This keeps the drive cooler.
The design also incorporates features
that promote the chimney effect
which has been proven to increase
conventional cooling for electronics.
Yaskawa engineers strove to simplify the
construction of the J1000.
The number of mechanical parts in the J1000 was
reduced by up to 35% over the J7 drive
and by over 50% when compared to the
comparable larger 7th generation Yaskawa drive.
The reduction in mechanical parts will improve
the expected drive lifetime by reducing the
chances of mechanical wear and tear.
The J1000 also gave the engineers a chance
to reduce building costs by reducing the
number of screws used in assembling the drive.
The quantity of necessary assembly screws
was reduced by up to 54 percent
over the last generation.
the J1000's design truly is superior to our
already industry-leading Microdrive line
partially due to this 50% reduction in
mechanical parts, in most cases.
The reduction in numbers of parts helps us
increase our Mean Time Between Failure rating
and helps us to reduce the chance
of parts shortages due to vendor issues.
That means Yaskawa will always have
the drive you need in stock.
For those of us that are familiar with
Yaskawa's part numbering system,
there is one major change with the new generation.
Previous Yaskawa part numbers included the drives power rating in the
part number.
Starting with the V1000,
Yaskawa uses the drive's output
current rating in the part number
in place of the power rating.
The current number will correspond to the
normal duty output current rating of the drive.
Arguably, the most important specifications
of the J1000 are the available power ranges
and the Normal Duty
and Heavy Duty current capabilities.
I would also like to point out that
Yaskawa does offer single-phase J1000s
up to 3 horsepower and that the J1000
can go up to 7.5 horsepower with three-phase power.
As I mentioned before,
the J1000 features a Dual Duty setting
although you may find this feature in
larger, full function drives it is
uncommon in a Microdrive.
When set to Heavy Duty, the drive will allow
for 150% of rated current for up to
one minute and offer a high Carrier Frequency
for quiet operation.
For J1000 models with output current capacities of
one amp through six amps,
the Carrier Frequency defaults to 10 kHz.
For models that output 10 amps or 20 amps
the default setting is 8 kHz.
If the drive is set for Normal Duty the
overload is reduced to 120% for one minute,
but at a higher continuous 100% rating.
The Carrier Frequency will default to 2 kHz
and a current D rate will be applied if the
Carrier is raised above 2 kHz.
The effect is that using the Normal Duty
setting will allow the J1000 to
adequately power a larger motor than the
J7 drive with its Single Duty setting
would be able to.
The limitation is the reduced overload capabilities
so knowing the application is a requirement.
Let's use an example to illustrate
what we just covered.
The motor we want to drive
is a 230 volt 3 horsepower motor
that will be rotating a fan.
The motor's full load current rating is 9.6 amps.
If we are going to drive this motor with the
J7, it would require using a 3 horsepower
model that has a continuous current
rating of 11 amps.
If however we use a J1000, we have
the choice of Normal or Heavy Duty.
Because this is a fan application,
we don't require much overload,
so 120% overload will be plenty.
Therefore a 2 horsepower J1000
configured for Normal Duty
will meet the requirements of the motor.
It should be noted that the Normal Duty setting
isn't just for fans and pumps but even for
constant torque applications as long as
the overload required doesn't go above
120% of the Normal Duty current rating.
Another exciting feature of the J1000 is the
the possibility of Side-by-Side mounting of the drives.
Side-by-Side mounting means more drives
can fit into a smaller space thus saving
money on cabinets and enclosures.
Even when the ambient temperature is not optimal
or the output transistors are working
harder and faster, producing more heat
tight installations are still possible
with a current de-rate.
Parameter L8-35 will tell the J1000
whether the installation is indeed a
Side-by-Side installation and
if the protection times need to be shortened.
If the ambient temperature can
be kept at 40 degrees Celsius or below
and the Carrier Frequency is acceptable
at two kilohertz, then Side-by-Side
operation is possible without any de-rate
for a drive configured for Heavy Duty
the minimum separation between J7 drives
is thirty millimeters.
That minimum gap has decreased drastically
to 2mm between J 1000 drives.
The superior thermal design of the J1000
allows the drive to operate in high temperature
applications with little to no de-rate.
The J1000 arrives from the factory with the
open chassis specification.
Operation under this spec requires no de-rate
up to 50 degrees Celsius,
even the NEMA Type 1, a more airflow
restrictive specification only necessitates
a 15% de-rate at the same temperature.
Having a higher ambient temperature capability
may translate to a smaller enclosure
and maybe a smaller cooling device.
The J1000 offers a new variation on motor
thermal protection that will help users meet
upcoming specifications.
Per the National Electric Code,
drives will need to go a step further
to protect the insulation of motors adequately.
The new specification requires that
Overtemperature Protection offers a memory
selection that will retain the elapsed I squared t
thermal protection time, even if the
drive is powered down.
It is expected that UL will write this same
requirement into their next 508C update.
Yaskawa will meet the requirement by
offering the user the choice whether to
hold the I squared t value at power down
or not with the factory default state
being that the I squared T value is held.
A downside to some drive installations
is the amount of audible noise generated
by the motor at low carrier frequencies.
Usually the lower the carrier frequency
the louder the sound.
The J1000 offers a new carrier frequency
selection that helps reduce the amount of acoustic
noise while using lower carrier frequencies.
The Swing PWM setting sweeps the carrier
frequency over a range of frequencies so
the noise is distributed over the whole spectrum.
this distribution reduces those peak levels
and thus reduces the maximum decibels.
The new Swing PWM setting is
centered around the 2 kHz frequency.
It is mainly targeted at drives set for
Normal Duty since audible noise
for a J1000 set for Heavy Duty can be
reduced by using a higher Carrier Frequency
such as 8 kHz.
Even for Heavy Duty, a lower Carrier Frequency
like the Swing PWM selection may be desirable
since a lower Carrier Frequency means
decreased output transistor heating.
For examples of a 2kHz Carrier
and Swing PWM Carrier setting.
The J1000 will offer a new braking function that
is an improvement over the High Slip
Braking used by our last generation drives.
The new High Flux Braking function
will be enabled via a parameter but will not
not require a digital input to initiate.
The function manipulates the motor's
magnetic field to increase energy loss
in the motor and prevent an
Overvoltage Fault while the motor decelerates.
The two oscilloscope captures
show the contrast between braking
with and without High Flux Braking.
The decel time without an Overvoltage Fault
is nearly cut in half with no extra equipment
to purchase like is required with Dynamic Braking.
The amount of braking time that can be cut
by High Flux Braking will be dependent
on the motor's characteristics
and the application's duty cycles.
The most important improvement offered by
High Flux Braking over previous solutions is
that reacceleration is possible without
coming to a complete stop.
To complete our description of the new
High Flux Braking feature there are a few pieces
of information that are important.
For one, the Stall prevention function is
mutually exclusive with High Flux Braking
so there is a chance that without proper adjustment
an Overvoltage Fault can still happen if
the decel rate is set too short.
Also, because motor losses and consequently
motor heating is part of how High Flux Braking
works, it should be noted that the extra
heating will not be figured in when calculating
the OL1 thermal protection time.
It is important that the user be aware that
there is a duty cycle limitation to High Flux Braking
that is akin to the limitation of full load
across the line starts.
For the last few years, Yaskawa has been
pursuing RoHS compliance for its products.
The V1000 was our first standard product
that offered it throughout the capacity range.
The J1000 now follows suit.
RoHS compliance is an environmental standard
that restricts or eliminates certain
dangerous metals from being used in
products knowing that later when the
product reaches the end of its lifecycle,
disposal of the product may have an
unwanted environmental impact.
RoHS compliance is mandatory throughout
Europe and is on the very near horizon
in Canada and California.
Yaskawa anticipates that it will be the
world standard in the years to come.
The J1000 will ship standard with the
non-removable, five digit LED Keypad.
Unlike the J7's keypad, the J1000 Keypad
will have a Shift/RESET key,
making navigation more like the other
Yaskawa drives that use LCD Keypads.
The Shift/RESET Key will also function as
a Reset for Dry Faults.
The optional remote LED Keypad requires
the optional RS-232C board for use.
The design of the J1000 gave Yaskawa engineers
the chance to correct an issue that befell the J7 drive.
Though the Heatsink fans of all J7s worked just fine,
when the time came to replace the older fans
at the end of their lifespan, users found that
the bottom mounted fans were hard to get
to due to the fact that some of the
drives power wiring was hanging directly
in the path of the users hands as they
tried to access the fan.
Now with the J1000, all of the Heatsink fans are
mounted on top of the Heatsink for ease
of accessibility yet able to withstand
the heat coming off the Heatsink.
On top of this, fan replacement requires no
tools or removal of the drive.
This is true for any size J1000.
The J1000 offers many improvements over
its predecessor, here is a rundown of some of
those improvements since the days of the J7.
Some of the improvements are monumental
and some are smaller changes
that may actually be just as important
to some users.
Some of the items listed are functions
that one would expect from a more
full-featured drive, not a Microdrive.
Also of note, but may be hard to understand
is the Common Control Board.
In the past, the J7 needed different
control boards - one for the larger sizes
and one for the smaller sizes.
This led to multiple versions of any software
written for the drive which slowed
development of custom programming.
Separate versions of software is
not an issue for the J1000
because it uses a single control board
for all sizes and voltages.
Monitors in a Yaskawa drive are the drives way
of telling the user the status of the
drive operation via the Keypad display.
The J1000 monitors will seem familiar
to users of Yaskawa seventh generation drives,
but with some new twists and new Monitors.
Most of your basic Monitors can
be found within the U1 group of Parameters
with a new monitor shown here in orange.
The U2 monitors will remain the Fault Trace.
The new twist on the Fault Trace is that a drive
parameter initialization will no longer reset it.
To clear the Fault Trace, set O4-11 equal to 1.
The U4 drive Monitors are new to the next
generation of Yaskawa drives and are targeted at
at helping the maintenance person
better anticipate drive issues.
The user will be able to find out the expected
remaining lifetime of four of the drives major
wear items, including Cooling Fans, Bus Capacitors,
Soft Charge Relay and the Output Transistors.
The expected lifetime will reflect factors
such as Load, Temperature and Carrier Frequency
among others.
The U4 Monitors also include information
for operators wishing to find out how hard
the drive and motor are working by displaying
the Heatsink temperature and Peak Current.
Another advance warning feature of the J1000
is a new High Current Alarm.
If, during operation, the drive outputs
more than 150% of drives rated output current,
the Keypad will display characters
HCA for High Current Alarm.
It is also possible to turn on a digital
output in case of any drive alarm which
would include the High Current Alarm.
Because this is only an alarm,
drive operation will not be interrupted
during the alarm.
But high currents can lead to faults
which will shut down operation.
Therefore, it can be useful to be aware
of high current situations that might be
remedied by adjusting a parameter.
Other Yaskawa drives have offered
built-in, multi-drop serial communication
in the past.
This includes the J1000's predecessor.
The improvement Yaskawa made
was to the transmission speed.
We doubled it from the specs of the J7
to 38,4000 bits per second.
The RS-232C Option Board will also be
available providing the connection port
for the Remote Keypad, Y-Stick and Drivewizard Plus.
As mentioned in the previous slide,
the USB Copy Unit or Y-Stick needs the
RS-232C board for connection to the drive.
With the Y-Stick, you can save a set
of parameters to it and load them into
other similar J1000s.
You can also use it as a pass-through
connection to a PC with DriveWizard Plus.
With the new generation of drives
comes a new generation of software.
Enter DriveWizard Plus.
The new and improved DriveWizard Plus
currently supports the V1000
as well as the J1000 and will support the
subsequent drives from the new generation.
The seventh generation drives will continue to use
DriveWizard 6.1 because there is no backward
compatibility for DriveWizard Plus
and the seventh generation drives.
DriveWizard Plus has a new interface that
offers many ways to customize your layout.
The tools available within the
new layout are new as well.
There is also better trending and
graphing of drive Monitors with faster
update times for serial connections.
The Tab style layout makes it possible for
the user to easily jump between
different monitoring options such as
graphical monitoring or spreadsheet monitoring.
DriveWizard Plus allows the user
to program a Run routine
for the drive to follow too.
The program can be run once or
continuously looped through.
Notice that the J1000 requires the optional
RS-232 Board to connect to DriveWizard Plus.
A J1000 drive software simulator
is available on our website at Yaskawa.com
The simulator is a program that will mimic
operation of an actual J1000 drive.
All of the Keypad buttons that exist on the
J1000 will be clickable on the simulator
which means that the virtual J1000
will be programmable just like the real drive.
Both analog and digital inputs can be
manipulated as well.
And the analog and digital outputs
are displayed so that their operation
can be tracked.
The simulator will even be able to
replicate the operation of a loaded motor.
The benefit of this free software
is in the ability for users to test and
troubleshoot J1000 operation without
having an actual drive in front of them.
It is also an excellent tool for
teaching others how to use the J1000 drive.
The software is available at
www.yaskawa.com
A copy of the software will also ship with
with the drive on the product CD.
Shown on this slide are
other options for use with the J1000.
Check yaskawa.com
for release dates.
This concludes my presentation
of the proud new addition to the
Yaskawa family of drive solutions.
Thank you for viewing this
Yaskawa eLearning module.
I hope the information presented was
informative and helpful.
If you would like additional training,
please contact us through any
of the methods shown on this slide.
Thanks again and have a great day!