AN.A1000.01

YASKAWA AC Drives-A1000Applying Integrated 6-Phase/12-Pulse Drivesto 3-Phase Source ApplicationsApplication Note

DOCUMENT NO. AN.A1000.01

Applicable Products:Models: CIMR-AU4T0058 to AU4T0675

YAContents1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 IMPORTANT CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 RECONFIGURING A1000 INTEGRATED 6-PHASE/12-PULSE DRIVES. . . . . . 6

Copyright 2013 YASKAWA AMERICA, INC.

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior SKAWA Application Note AN.A1000.01 Applying Integrated 6-Phase/12-Pulse Drives to 3-Phase Source Applications 3

written permission of Yaskawa. No patent liability is assumed with respect to the use of the information contained herein. Moreover, because Yaskawa is constantly striving to improve its high-quality products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, Yaskawa assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication.

1 Overview1 Overview

Purpose and Intended AudienceThe purpose of this application note is to provide the user with basic instructions to reconfigure A1000 series 6-phase/12-pulse AC drives for use with 3-phase/6-pulse sources. This document provides the following information.

A summary of important considerations for reconfiguration A general diagram of a typical 12-pulse configuration Two options for reconfiguring the 12-pulse system Maximum applicable motor capacities for different input voltage conditions Expected amperage in the system for 380 V to 480 V input range Wiring and Branch Circuit Protection (BCP) recommendation for Heavy Duty (HD) and Normal Duty (ND) operations AC line reactor recommendation for HD and ND operations

IntroductionA1000 series 6-phase/12-pulse drives are used to lower total demand distortion (TDD) as stipulated by IEEE 519-1992. This is achieved by mitigating the current harmonics using 12-pulse rectification which eliminates the 5th and 7th harmonics, the dominant harmonics in standard 3-phase/6-pulse configurations. A1000 series 6-phase/12-pulse drives can be used in two hardware configurations to lower TDD.

1. Standard 12-pulse configuration, consisting of a 3-winding (-Y) isolation transformer to achieve less than 15% input current harmonic distortion. Refer to Figure 1.

2. Hybrid 12-pulse configuration, consisting of a 2-winding isolation transformer and a balance reactor with matching impedance to achieve less than 12% input current harmonic distortion. Refer to Figure 2.

The drives two built-in 6-pulse diode modules are utilized for rectification with a transformer or transformer-reactor front-end to provide a phase shifted 6-phase input to the drive in both hardware configurations.

A1000 series 6-phase/12-pulse drives can be reconfigured for use in 3-phase input applications by connecting together the main input terminals; R/L1 and R1/L11, S/L2 and S1/L21, and T/L3 and T1/L31, external to the drive. The performance of these reconfigured systems is similar to the standard 3-phase/6-pulse systems with a harmonic distortion higher than the original 6-phase/12-pulse systems.

Applicable Products Yaskawa AC Drive Models

Table 1 Applicable Yaskawa A1000 Series 6-phase/12-pulse Models

Yaskawa AC Drive Series 460 V ModelsA1000 CIMR-AU4T0058 to 4T06754 YASKAWA Application Note AN.A1000.01 Applying Integrated 6-Phase/12-Pulse Drives to 3-Phase Source Applications

2 Important Considerations2 Important ConsiderationsYaskawa A1000 series 6-phase/12-pulse drives are tested and have UL approval for 6-phase/12-pulse applications. When reconfiguring 6-phase/12-pulse drives, it is essential that the guidelines outlined in this document are followed to ensure standards compliance, satisfactory operation, and drive longevity.

Drive Input CurrentLimiting or mitigating the harmonic currents reduces the drive's input RMS current in 12-pulse systems. Hence, the rated input current of a 6-phase/12-pulse drive is lower than the rated current of a standard 3-phase/6-pulse drive of the same power rating. When 6-phase/12-pulse drives are reconfigured to 3-phase/6-pulse drives, the advantage of harmonic mitigation is lost resulting in increased input current. Hence, it is important to ensure that the input currents do not exceed the drive rated input currents at lower voltages (415 V and below) by appropriately derating the output power capacity of the drive. Refer to Table 2 and Table 3 for selecting an appropriate motor capacity based on the input voltage.

DC Bus Capacitor Ripple CurrentDuring the reconfiguration process, the phase-shifting transformer/matching reactor are removed. This decreases the effective impedance of the system. The resulting high DC bus capacitor ripple current can lead to premature drive failure when combined with the absence of the built-in DC link choke in the integrated 12-pulse drive. An appropriately sized AC line reactor must be added to limit DC bus ripple and premature drive failure.

Proper Terminal ConnectionsTo facilitate the use of the 3-phase source, the two sets of input terminals (R/L1, S/L2, T/L3 and R1/L11, S1/L21, T1/L31) should be shorted external to the drive as R/L1 and R1/L11; S/L2 and S1/L21; and T/L3 and T1/L31. A terminal block or the secondary of the line reactor can be used when possible. Shorting directly at the drive terminals is not recommended as the clearance may not be sufficient to meet UL standards. Failure to do so may result in non-compliance and/or damage to the drive.

Conductor LengthTo ensure equal current sharing by the drives two parallel diode modules, it is necessary that the conductors used for shorting have equal lengths. Failure to do so may result in one diode module conducting higher than rated current, leading to diode failure.YASKAWA Application Note AN.A1000.01 Applying Integrated 6-Phase/12-Pulse Drives to 3-Phase Source Applications 5

3 Reconfiguring A1000 Integrated 6-phase/12-pulse Drives3 Reconfiguring A1000 Integrated 6-phase/12-pulse DrivesThe A1000 series integrated 6-phase/12-pulse drive provides a cost effective solution for low harmonics. Figure 1 and Figure 2 depict the typical system configurations when using an A1000 series 6-phase/12-pulse drive for harmonic mitigation. Figure 3 provides an overview for reconfiguration to 6-pulse drives.

The input terminals R/L1, S/L2, T/L3 of the upper diode module can be shorted with the input terminals R1/L11, S1/L21, T1/L31 of the lower diode module by using either the secondary of the line reactor as the common point, as described in Reconfiguration Option 1 (Without Terminal Block) on page 7, or by using a terminal block as the common point, as described in Reconfiguration Option 2 (With Terminal Block) on page 8.

NOTICE: Ensure all wires (shorting conductors) are equal in length for both reconfiguration options. Failure to comply may result in diode failure in the AC drive.Figure 1

Figure 1 Standard 12-pulse System ConfigurationFigure 2

Figure 2 Hybrid 12-pulse System ConfigurationFigure 3

Figure 3 Modified 12-pulse Configuration for 6-pulse Applications6 YASKAWA Application Note AN.A1000.01 Applying Integrated 6-Phase/12-Pulse Drives to 3-Phase Source Applications

3 Reconfiguring A1000 Integrated 6-phase/12-pulse Drives Reconfiguration Option 1 (Without Terminal Block)Reconfiguration Option 1 is configured with drive terminals shorted external to the drive using the secondary of the AC line reactor as the common point as shown in Figure 4. Two separate wires of equal lengths connect the two terminals.

Example: R/L1 and R1/L11 are connected to the secondary or output terminal of the AC line reactor.

The system amperage is given in Table 4, based on the appropriate motor capacity indicated in Table 2 and Table 3. The line side conductor of the line reactor carries full system amperage and the load side conductor, being split, carries half the amperage. Wiring recommendation for 380V-480 V systems are specified in Wiring Recommendations on page 10. The circuit should have branch circuit protection between the AC line and the line reactor as indicated by the fuse in Figure 4. The ratings for branch circuit protection devices are specified in Branch Circuit Protection on page 11. The recommended AC line reactors along with the minimum inductance are specified in AC Line Reactor Recommendation on page 12. Line reactor selection should be based on the system input current and the minimum inductance as indicated.Figure 4

Figure 4 Reconfiguration Option 1

ACYASKAWA Application Note AN.A1000.01 Applying Integrated 6-Phase/12-Pulse Drives to 3-Phase Source Applications 7

3 Reconfiguring A1000 Integrated 6-phase/12-pulse Drives Reconfiguration Option 2 (With Terminal Block)Reconfiguration Option 2 is configured with a terminal block as the common point for shorting the terminals as depicted in Figure 5. This is the case if the line reactor secondary terminal is not able to accommodate two wires due to space constraints. Two separate wires of equal lengths connect the two terminals as shown in Figure 5,

Example: R/L1 and R1/L11, are connected to the output terminal of the terminal block.

The system amperage is given in Table 4, based on the appropriate motor capacity indicated in Table 2 and Table 3. Wiring recommendation for 380V-480 V systems are specified in Wiring Recommendations on page 10. The circuit should have branch circuit protection between the AC line and the line reactor as indicated by the fuse in Figure 5. The ratings for branch circuit protection devices are specified in Branch Circuit Protection on page 11. The recommended AC line reactors along with the minimum inductance are specified in AC Line Reactor Recommendation on page 12. Line reactor selection should be based on the system input current and the minimum inductance as indicated.

The line side conductor of the terminal block carries full system current and the load side conductor, being split, carries half the current. Thus, the terminal blocks should have accommodations for multiple conductors, on the load side.Figure 5

Figure 5 Reconfiguration Option 2

Motor Capacity Maximum Applicable Motor Capacity 460/480 V

Table 2 Maximum Applicable Motor Capacity for 460/480 V Input

ModelNormal Duty (ND) Heavy Duty (HD)

Drive Rated Input Current (A)

MaximumApplicable Motor Capacity (HP)

Motor HP values are based on NEC 2011, Table 430.250 for 460 V motors.

Drive Rated Input Current (A)

MaximumApplicable Motor Capacity (HP)

AU4T0058 54 40 40 30AU4T0072 66 50 54 40AU4T0088 79 60 66 50AU4T0103 97 75 79 60AU4T0139 131 100 97 75AU4T0165 156 125 131 100AU4T0208 190 150 156 125AU4T0250 228 150 190 150AU4T0296 275 200 228 150AU4T0362 317 250 275 200AU4T0414 376 300 317 250AU4T0515 427 350 376 300AU4T0675 603 500 511 400

AC8 YASKAWA Application Note AN.A1000.01 Applying Integrated 6-Phase/12-Pulse Drives to 3-Phase Source Applications

3 Reconfiguring A1000 Integrated 6-phase/12-pulse Drives Maximum Applicable Motor Capacity 380/415 VTable 3 Maximum Applicable Motor Capacity for 380/415 V Input

System AmperageTable 4 Drive Rated Input and Conductor Amperage Ratings in Reconfigured System

ModelNormal Duty (ND) Heavy Duty (HD)

Drive Rated Input Amperage (A)

MaximumApplicable Motor

Capacity (HP)Drive Rated Input

Amperage (A)Maximum

Applicable Motor Capacity (HP)

AU4T0058 54 30 40 25AU4T0072 66 40 54 30AU4T0088 79 50 66 40AU4T0103 97 60 79 50AU4T0139 131 75 97 60AU4T0165 156 100 131 75AU4T0208 190 125 156 100AU4T0250 228 150 190 125AU4T0296 275 150 228 150AU4T0362 317 200 275 150AU4T0414 376 250 317 200AU4T0515 427 300 376 250AU4T0675 603 400 511 350

Model Input Voltage Range (Vac)Drive Rated Input Amperage

(A)Amperage per Conductor (A)

Dual Conductors Single ConductorNormal Duty Heavy Duty Normal Duty Heavy Duty Normal Duty Heavy Duty

AU4T0058

380-480

54 40 27 20 54 40AU4T0072 66 54 33 27 66 54AU4T0088 79 66 40 33 79 66AU4T0103 97 79 49 40 97 79AU4T0139 131 97 66 49 131 97AU4T0165 156 131 78 66 156 131AU4T0208 190 156 95 78 190 156AU4T0250 228 190 114 95 228 190AU4T0296 275 228 138 114 275 228AU4T0362 317 275 159 138 317 275AU4T0414 376 317 188 159 376 317AU4T0515 427 376 214 188 427 376AU4T0675 603 511 302 256 603 511YASKAWA Application Note AN.A1000.01 Applying Integrated 6-Phase/12-Pulse Drives to 3-Phase Source Applications 9

3 Reconfiguring A1000 Integrated 6-phase/12-pulse Drives Wiring Recommendations Wiring Recommendation for Normal Duty (ND) 380-480 V Systems

Table 5 Wiring Recommendation for Reconfigured System for Normal Duty (ND)

Note: Wire selection is based on 75 C copper wire per Table 28.1 of UL508A for currents indicated in Table 4. The wire gauges listed are Yaskawa recommendations. Refer to the NEC and/or local codes for proper wire gauge selections.

Wiring Recommendations for Heavy Duty (HD) 380-480 V SystemsTable 6 Wiring Recommendation for Reconfigured System for Heavy Duty (HD)

Note: Wire selection is based on 75 C copper wire per Table 28.1 of UL508A for currents indicated in Table 4. The wire gauges listed are Yaskawa recommendations. Refer to the NEC and/or local codes for proper wire gauge selections.

Model Input Voltage Range (Vac)Dual

Conductors (AWG/Kcmil)

Requires two conductors per phase. The total number of conductors required per phase will be two times P, where is the number of multiple conductors. (Example: AU4T0675 requires qty 4 4/0 AWG conductors in total)

Single Conductor

(AWG/Kcmil)AU4T0058

380-480

8 4AU4T0072 8 4AU4T0088 6 3AU4T0103 6 1AU4T0139 4 2/0AU4T0165 3 3/0AU4T0208 1 250AU4T0250 1/0 300AU4T0296 2/0 2/0 2P

Indicates multiple conductors.

AU4T0362 3/0 3/0 2P AU4T0414 250 250 2P AU4T0515 300 300 2P AU4T0675 4/0 2P 250 4P

Model Input Voltage Range (Vac)Dual

Conductors (AWG/Kcmil)

Requires two conductors per phase. The total number of conductors required per phase will be two times P, where is the number of multiple conductors. (Example: AU4T0675 requires qty 4 4/0 AWG conductors in total)

Single Conductor

(AWG/Kcmil)AU4T0058

380-480

10 8AU4T0072 8 4AU4T0088 6 4AU4T0103 6 3AU4T0139 6 1AU4T0165 4 2/0AU4T0208 2 3/0AU4T0250 1 250AU4T0296 1/0 300AU4T0362 2/0 2/0 2P AU4T0414 4/0 3/0 2P AU4T0515 250 250 2P AU4T0675 4/0 2P 3/0 4P 10 YASKAWA Application Note AN.A1000.01 Applying Integrated 6-Phase/12-Pulse Drives to 3-Phase Source Applications

3 Reconfiguring A1000 Integrated 6-phase/12-pulse Drives Branch Circuit Protection Branch Circuit Protection Recommendation for Normal Duty (ND)

Table 7 Branch Circuit Protection Recommendation for Reconfigured System for Normal Duty (ND)

Note: Refer to NEC 2011, Article 430 when selecting fuses for branch short circuit protection based on currents indicated in Table 4.

Branch Circuit Protection Recommendation for Heavy Duty (HD)Table 8 Branch Circuit Protection Recommendation for Reconfigured System for Heavy Duty (HD)

Note: Refer to NEC 2011, Article 430 when selecting fuses for branch short circuit protection based on currents indicated in Table 4.

ModelInput

Voltage Range (Vac)

Input Current

(A)

MaximumMCCB Rating

(A)

MaximumTime Delay Fuse Rating

(A)

MaximumNon-Time Delay

Fuse Rating (A)

Bussman Semiconductor

Fuse Rating (A)

AU4T0058

380-480

54 100 100 150

FWH-250A (250)AU4T0072 66 125 110 200AU4T0088 79 150 150 250AU4T0103 97 200 175 300AU4T0139 131 250 225 400 FWH-350A (350)AU4T0165 156 300 250 500 FWH-400A (400)AU4T0208 190 400 350 600 FWH-500A (500)AU4T0250 228 450 400 700 FWH-600A (600)AU4T0296 275 600 500 800 FWH-700A (700)AU4T0362 317 600 600 1000

FWH-800A (800)AU4T0414 376 800 700 1200AU4T0515 427 900 800 1350 FWH-1000A (1000)AU4T0675 603 1200 1100 1800 FWH-1200A (1200)

ModelInput

Voltage Range (Vac)

Input Current

(A)

MaximumMCCB Rating

(A)

MaximumTime Delay Fuse Rating

(A)

MaximumNon-Time Delay

Fuse Rating (A)

Bussman Semiconductor

Fuse Rating (A)

AU4T0058

380-480

40 75 75 125

FWH-250A (250)AU4T0072 54 100 100 150AU4T0088 66 125 110 200AU4T0103 79 150 150 250AU4T0139 97 175 175 300 FWH-350A (350)AU4T0165 131 225 225 400 FWH-400A (400)AU4T0208 156 250 250 500 FWH-500A (500)AU4T0250 190 350 350 600 FWH-600A (600)AU4T0296 228 400 400 700 FWH-700A (700)AU4T0362 275 500 500 800

FWH-800A (800)AU4T0414 317 600 600 1000AU4T0515 376 700 700 1200 FWH-1000A (1000)AU4T0675 511 1000 1000 1600 FWH-1200A (1200)YASKAWA Application Note AN.A1000.01 Applying Integrated 6-Phase/12-Pulse Drives to 3-Phase Source Applications 11

3 Reconfiguring A1000 Integrated 6-phase/12-pulse Drives AC Line Reactor RecommendationNote: 3% line reactors are recommended to maintain the effective impedance in the circuit for lower capacitor ripple currents. 5%

impedance reactors are recommended provided the voltage drop is acceptable for improved THD performance. Please consult factory for further information.

AC Line Reactor Recommendation for Normal Duty (ND)Table 9 AC Line Reactor Recommendation for Reconfigured System for Normal Duty (ND)

AC Line Reactor Recommendation for Heavy Duty (HD)Table 10 AC Line Reactor Recommendation for Reconfigured System for Heavy Duty (HD)

ModelInput Voltage

Range (Vac)

Rated Input ND Current

(A)

Minimum Inductance

(mH)

MTE Line Reactor Part Number

MTE Line Reactor Part Number indicates an open-type reactor. The input reactor can be installed outside the panel provided it is within a suitable enclosure and conductors are appropriately sized for field wiring where necessary as per currents indicated in Table 4.

Yaskawa Line Reactor Part

Number

Standard Inductance

(mH)AU4T0058

380-480

54 0.315 RLW-005503 URX000330 0.48

AU4T0072 66 0.255RLW-008303 URX000336 0.29

AU4T0088 79 0.21

AU4T0103 97 0.18 RLW-010403 URX000339 0.23

AU4T0139 131 0.13RLW-016003 URX000345 0.155

AU4T0165 156 0.11

AU4T0208 190 0.09 RLW-020003 URX000348 0.115

AU4T0250 228 0.075 RLW-025003 URX000351 0.095

AU4T0296 275 0.06RLW-032203 URX000354 0.07

AU4T0362 317 0.05

AU4T0414 376 0.045 RLW-041403 URX000357 0.066

AU4T0515 427 0.035 RLW-051503 URX000360 0.05

AU4T0675 603 0.025 RLW-075003 URX000366 0.035

ModelInput Voltage

Range (Vac)

Rated Input ND Current

(A)

Minimum Inductance

(mH)

MTE Line Reactor Part Number

MTE Line Reactor Part Number indicates open-type reactor. The input reactor can be installed outside the panel provided it is in a suitable enclosure and conductors are appropriately sized for field wiring where necessary as per currents indicated in Table 4.

Yaskawa Line Reactor Part

Number

Standard Inductance

(mH)AU4T0058

380-480

40 0.315 RLW-004603 URX000327 0.55

AU4T0072 54 0.255 RLW-005503 URX000330 0.48

AU4T0088 66 0.21RLW-008303 URX000336 0.29

AU4T0103 79 0.18

AU4T0139 97 0.13 RLW-010403 URX000339 0.23

AU4T0165 131 0.11RLW-016003 URX000345 0.155

AU4T0208 156 0.09

AU4T0250 190 0.075 RLW-020003 URX000348 0.115

AU4T0296 228 0.06 RLW-025003 URX000351 0.095

AU4T0362 275 0.05RLW-032203 URX000354 0.07

AU4T0414 317 0.045

AU4T0515 376 0.035 RLW-041403 URX000357 0.066

AU4T0675 511 0.025 RLW-051503 URX000360 0.0512 YASKAWA Application Note AN.A1000.01 Applying Integrated 6-Phase/12-Pulse Drives to 3-Phase Source Applications

YASKAWA AMERICA, INC.2121 Norman Drive South, Waukegan, IL 60085, U.S.A.Phone: (800) YASKAWA (927-5292) or 1-847-887-7000 Fax: 1-847-887-7310http://www.yaskawa.com

2013 YASKAWA AMERICA, INC. All rights reserved.

Published in U.S.A December 2013 13-12 DOCUMENT NO. AN.A1000.01

YASKAWA AC DrivesApplying Integrated 6-Phase/12-Pulse Drivesto 3-Phase Source ApplicationsApplication Note

YASKAWA AMERICA, INC.

Contents1 OverviewPurpose and Intended AudienceIntroductionApplicable Products

2 Important ConsiderationsDrive Input CurrentDC Bus Capacitor Ripple CurrentProper Terminal ConnectionsConductor Length

3 Reconfiguring A1000 Integrated 6-phase/12-pulse DrivesReconfiguration Option 1 (Without Terminal Block)Reconfiguration Option 2 (With Terminal Block)Motor CapacitySystem AmperageWiring RecommendationsBranch Circuit ProtectionAC Line Reactor Recommendation