Optional add-on cassette Vector-option unit Instruction manual

Transcription

1 E Optional add-on cassette Vector-option unit Instruction manual NOTE 1. Make sure that this instruction manual is delivered to the person who actually uses the vector-option unit. 2. This instruction manual must be referred to before installing and operating the vector-option unit. After reading the manual, make sure to keep it for future reference. (C) TOSHIBA Corporation 1999 All Rights Reserved.

2 Safety Precautions On the inverter and in its instruction manual, important information is contained for preventing injuries to users and damages to assets and for proper use of the device. Read the instruction manual attached to the inverter along with this instruction manual for completely understanding the safety precautions and adhere to the contents of these manuals. Handling in general Never Disassemble Prohibited Mandatory Danger Never disassemble, modify or repair the inverter. Disassembling the inverter could cause electric shocks, fire or injuries. Request your TOSHIBA dealer for repairs. Do not remove connectors when the power is on. It could lead to electric shocks. Do not put or insert foreign objects such as waste cable, bars, or wires into the inverter. It could lead to electric shocks or fire. Do not splash water over the inverter. It could lead to electric shocks or fire. Wiring should be conducted after turning the inverter power off. Turn off the power immediately in case any abnormalities such as smokes, smells or abnormal noise are found. Neglect of these conditions could lead to fire. Ask your TOSHIBA dealer for repairs. Transportation and Installation Prohibited Mandatory Danger Do not install or operate the inverter if it is damaged or any part is missing from it. Operating the inverter in a defective condition could lead to electric shocks or fire. Ask your TOSHIBA dealer for repairs. Do not put any inflammable material near the inverter. It could catch fire if the inverter sparks because of a breakdown and the like. Do not install the inverter where it could be splashed with water and the like. It could lead to electric shocks or fire. Inverter must be used under environmental conditions prescribed in this Instruction manual. Using the inverter under conditions not specified by the instruction manual could lead to breakdown. 1

3 Warning Do not install the inverter in any place subject to vibrations or it could fall. Prohibited Otherwise it can cause injury to people. Wiring Mandatory Danger Be sure to perform the following preparatory work before proceeding to wiring. Turn the power off. Wait 10 minutes or more after turning the power off and confirm that the charge lamp (on the inverter) is extinct. Using a circuit tester that has a D.C. voltage measuring capacity of more than 800V, check to see that the voltage remaining in the D.C. main circuit (between PC and PA) is below 45V. Failure to do this preparation could lead to electric shocks. Tighten the terminal board fixing screws at the specified torque. Failure to do this could lead to fire. About operation Prohibited Danger Do not touch inverter terminals when they are energized even if the motor is halted. Touching terminals while the power is energized could lead to electric shocks. Do not wipe the body with a wet cloth. It could lead to electric shocks. Do not pull on the cable It could cause damage or error. About disposal of Inverter Mandatory Warning Dispose of the inverter as an industrial waste. Unless it is disposed of as an industrial waste, it will become risks for human Injury. 2

4 Introduction Thank you for purchasing the Vector-option unit for industrial inverter TOSVERT VF-A7/P7 and later series. By the use of this unit, vector control with sensor function is possible. This instruction manual describes connecting method and usage of the Vector-option unit. Read this manual carefully before using the unit. Keep this manual near at hand of the operator who uses the Vector-option unit for future reference in the maintenance and inspection. Type of vector-option unit Revision number Without cable Model number of Vector-option Vector-option Confirmation on accessories Following accessory parts are included in the Vector-option unit. Upon unpacking, confirm on the following items. Vector-option unit (1) Instruction manual of vector-option unit (this manual) : one (E ) MANUAL (2) Connector terminal for sensor signal input : one set Connector : MR-16M (made by HONDA TSUSHIN KOGYO CO.,LTD.) x one piece Connector case : MR-16L (made by HONDA TSUSHIN KOGYO CO.,LTD.) x one piece (3) Board for connecting options 3

5 Contents 1. NAME AND FUNCTION OF EACH SECTION Appearance Name of each section (terminal) CONNECTION TO THE INVERTER Connection to the inverter Wiring FUNCTIONAL DESCRIPTION Vector control with sensor PG power supply line Complementary / Open collector method Line driver method Selection of encoder type Vector control setting parameter Speed error detection function Disconnection detection function Monitoring method for feedback amount Accuracy of speed control PGFB open collector output PGFB line driver output Pulse input command Pulse command connection method Pulse input setting parameter Position control command Connecting method of position command Setting method of position command parameter RX2 input Multi-functional output terminals Alarm code output terminals EXTERNAL DIAGRAM SPECIFICATION OPTION CABLE WARRANTY

6 1. Name and function of each section Following figure shows appearance and name of each section of the vector-option unit. 1.1 Appearance Inverter connecting side Connector (left side) View when the cover is removed Bit switch for PG power supply TB1 detachable terminal block Phoenix MC1.5/14-ST V(Default) 6V TB2 detachable terminal block Phoenix MC1.5/15-ST-3.81 Connector for options 12V 15V Terminal block cover SinkSource Bit switch SINK(Default) SOURCE CN8 installation window HONDA TSUSHIN KOGYO CO.,LTD. MR-16RFA Grounding terminal M3 screw terminal 5

7 1.2 Name of each section (terminal) Control signal terminal block (TB1, TB2) Arrangement of PG feedback connector terminals (CN8) VEC001Z Common terminal for control 1 CC signal 2 RX2 10V input terminal P15 power supply (500 3 P15 impedance) N15 power supply (500 4 N15 impedance) 5 CW Reverse pulse train command T CWN Reverse pulse train command 7 CCW Forward pulse train command B 8 CCWN Forward pulse train command Common terminal for control 9 1 CC signal 10 ALM0 Error code 0 11 ALM1 Error code 1 12 ALM2 Error code 2 13 ALM3 Error code 3 14 CC Common terminal for control signal 1 P24 24V power supply 2 OUT3 Programmable output terminal 3 3 OUT4 Programmable output terminal 4 Common terminal for control 4 CC signal 5 PFA Phase A, PG feedback pulse 6 PFB Phase B, PG feedback pulse 7 T PFZ Phase Z, PG feedback pulse 8 B A Phase A, line driver pulse 9 NA Phase A, line driver pulse 2 10 B Phase B, line driver pulse 11 NB Phase B, line driver pulse 12 Z Phase Z, line driver pulse 13 NZ Phase Z, line driver pulse 14 PGVC 15 PGCC Check terminal for PG power supply Common terminal for PG power supply C N 1 PGA1 Phase A, PG insulation input 2 PGA2 Phase A, PG insulation input 3 PGB1 Phase B, PG insulation input 4 PGB2 Phase B, PG insulation input 5 PGZ1 Phase Z, PG insulation input 6 PGZ2 Phase Z, PG insulation input 7 NZ Phase Z, PG line driver input 8 (N.C) Not to be connected 9 VD Detection terminal for PG voltage drop 10 Z Phase Z, PG line driver input 11 NA Phase A, PG line driver input 12 A Phase A, PG line driver input 13 NB Phase B, PG line driver input 14 B Phase B, PG line driver input 15 PGCC Common terminal for PG power supply 16 PGVC PG power supply terminal 6

8 2. Connection to the inverter Connect the vector-option unit to the inverter according to the procedures below. 2.1 Connection to the inverter (1) Confirm that the all power to the inverter are turned off beforehand. Note: Wait 10 minutes or more after turning the power off and confirm that the charge lamp on the inverter is unlit. (2) Fixing the vector-option unit alone by using screws When the vector-option unit is installed alone Tighten M4x25 screws with M4 nuts to an attachment of optional add-on cassette (separately procured) to fix the unit as shown in the figure below. When the unit is installed with another option Read instructions of connection with options on the following page for installation. Same procedures apply when three options are installed together. (When plural options are installed, order of installation from the inverter side is not specified.) (Note) Determine the initial setting of the bit switch for internal signal before connecting options. Mount a board for option connection, then use M4x50 screws and M4 nuts to fix the options as shown below. (When three units of option are installed, use M4x75 screws.) (3) Fixing the unit to the inverter Method for fixing the unit to the inverter differs according to the type of inverter to which the unit is installed. Refer to the instruction manual of Attachment of optional add-on cassette. 7

9 Connection with options When two or more optional add-on cassettes are used, connect them with reference to the following diagram. Mounting of relay board for connecting options Following the diagram below mount the board which is attached to the vector option unit onto the unit for connecting options. Insert a flat head screwdriver into the triangular section at the right side of the option unit and remove the small window cover. Relay board mounting guide Triangular mark on the side face Slide the relay board into the place according to the insertion guide. (Note) Engage the patterned section of the board with the metal pad section of the connector and insert the board in parallel. When the insertion angle inclines, remove the board once and try again. Engage the patterned section of the board with the metal pad section of the connector and insert the board in parallel. When the metallic parts of the relay board is touched with bear fingers, they oxidizes and the contacting failure occurs. Put on gloves for the work. Connecting two options Connect options with reference to the diagram below. Triangular mark on the side face Fit two option s positioning guides on both units and connect two units not to shift the connecting position of the relay board. Hold a triangular section on the side of the unit and engage the relay boards securely. (Connection is satisfactory when the click sound can be heard.) If there is a gap between the units, two boards are misaligned. Carry out the work again from the beginning. Option s positioning guide (two guides on top and bottom) 8

10 2.2 Wiring When conduct wiring, follow the instructions below. Use shield wire for control signal line and ground the unit with shield wire. (Use twisted shield wire for PG connection, output connection of line driver and connection of position command.) Applicable wire size for terminal block is 0.2 to 1.5 mm 2. (Outer sheath diameter of the shield for CN8 connection port should be within 9mm.) Peel off the end of the connection wire for terminal block by about 5mm. For connecting wires, use screwdriver that has a blade tip of 0.4mm thickness and 2.5mm width. Tightening torque of the terminal block should be 0.22 to 0.25 N m. Never bind the signal line and main circuit connection wire together. Use 0.75mm 2 wire for the connection of CC terminal (or PGCC terminal) of the vector-option unit and CC terminal of the inverter. Use 0.75mm 2 wire for the connection of grounding terminal of the vector-option unit and that of the inverter. < Input/output terminal interface > [ TB1 and TB2 terminals] Terminal name RX2 Function Specification Internal circuit Multi-function programmable analog input DC±10V P15 +15VDC power supply +15V output Internal impedance: 500 Output current: 20mA or less 500 Ω +15V N15-15VDC power supply -15V output Internal impedance: 500 Output current: 20mA or less 500 Ω -15V CCW CCWN CW Pulse train position control command input (forward command) Pulse train position control command input (reverse command) Complementary input Open collector input 30VDC 15mA or less Line driver input (equivalent to 26LS31) Maximum input frequency 160kpps Pulse duty 50 ± 10% CCW CW CCWN CWN 100Ω 100Ω Photocoupler V F 1.2~1.7V CWN CC Common terminal for control signal 9

11 Terminal name ALM0 Error code 0 ALM1 Error code 1 ALM2 Error code 2 ALM3 Error code 3 OUT3 Multi-function programmable open OUT4 collector output P24 Function Specification Internal circuit 24V power supply Sink output 30VDC 50mA Source output 24VDC 50mA, total 200mA or less (24VDC: Add-on option, total 200mA or less) 24VDC 200mA (SW1: for SINK setting) (Add-on option, total 200mA or less) PFA PFB PFZ A NA B NB Z NZ PG feedback, open collector output (Phase A output) PG feedback, open collector output (Phase B output) PG feedback, open collector output (Phase Z output) PG line driver output (Phase A output) PG line driver output (Phase B output) PG line driver output (Phase Z output) 30VDC 50mA or less PG line driver output Only when line driver encoder is connected. Line receiver: equivalent to 26LS32 Equivalent to 26LS32 PGVC PG supply voltage, monitor terminal Check terminal for PG power supply voltage Line driver PG PGCC 10

12 < PG interface > [CN8 connector terminal] Terminal name PGA1 PGA2 PGB1 PGB2 PGZ1 PGZ2 A NA B NB Z NZ Function Specification Internal circuit PG feedback input, Pulse train speed command input (Phase A input) PG feedback input, Pulse train speed command input (Phase B input) PG feedback input (Phase Z input) PG feedback input terminal (Phase A input) PG feedback input terminal (Phase B input) PG feedback input terminal (Phase Z input) PG feedback 15V complementary / open collector 12V complementary / open collector Maximum input frequency 120kHz or low (single phase) 60kHz or low (2 phases) Pulse duty 5010 Pulse train speed command 30VDC 15mA Maximum input frequency 120kHz or low (single phase) 60kHz or low (2 phase) Pulse duty 5010 Line driver input Equivalent to 26LS31 Maximum input frequency Single phase: 120kpps 2 phase: 60kpps Pulse duty 5010 With line-disconnection detection function A B Z NA NB NZ +5V Photocoupler V F :1.2~1.7 V Equivalent to 26LS32 Line-disconnection detection circuit Line-disconnection detection is not provided for phase Z. VD Voltage drop detection terminal Voltage drop detection for PG power supply line PGVC Constant voltage power supply circuit +24V PGVC PGCC PG power supply terminal 5,6,12,15 VDC 160mA or less PGCC VD 11

13 3. Functional description In this section, functions added by the installation of this vector-option unit, on top of the standard inverter functions, are described. Vector control with sensor Pulse input speed command Position control command RX2 input Multi-function output terminal Alarm code output terminal 3.1 Vector control with sensor Using the pulse-train feedback signal from the encoder installed on the motor shaft or load rotation shaft, vector control with sensor can be conducted. Speed control operation :150% torque at 0 speed, speed control range 1:1000 (1000 ppr-pg) speed accuracy ±0.02% (50Hz base digital input) Torque control operation :Torque control accuracy: ±10% (torque control range: 100% to 100%) PG power supply line By using this vector-option unit, PG power supply can be selected from 5, 6, 12 and 15V. For changing the output voltage, open the small window on the right side of the unit (use flat head screwdriver or similar) and set the bit switch as follows. When the cover is removed. 5V: All of the bit switches are set to OFF. (Default setting) Bit switch for PG 6V: No. 1 bit switch is set to ON. 12V: No.1 and 2 bit switches are set to ON. 15V: No. 1, 2 and 3 bit switches are set to ON. 5V output: Setting for 5V line driver PG 6V output: Setting for 5V line driver PG (1V for voltage drop of PG power supply line is estimated) 12V output: Setting for 12V complementary or open collector PG 15V output: Setting for 15V complementary or open collector PG Output voltage can be checked by the PG power supply check terminal of TB2 (between PGVC and PGCC). 12

14 Connection for compensation of voltage drop in PG power supply line [special function for 5V power supply] Voltage drop happens to the PG power supply voltage due to the wiring impedance in the circuit. If the voltage drop becomes large, the encoder will not function normally. As for this vector-option unit, voltage drop can be compensated up to 2V at maximum by adding a line to the power supply line (0V side). When the PG voltage setting is selected to 6V, 1V of voltage drop has been already included to it. Thus never add the line for the compensation of voltage drop. (Otherwise 6V voltage will be imposed to the terminals of encoder power supply owing to the voltage drop compensation setting.) Complementary / Open collector method As for the pulse input signals, PGA1 and PGA2 are connected for Phase A, PGB1 and PGB2 are connected for Phase B, and PGZ1 and PGZ2 are connected for Phase Z. (The wiring for Phase Z is done only when using Z-marker is necessary.) The polarity of the pulse input signals should be as follows: + side: PGA1, PGB1, PGZ1 - side: PGA2, PGB2, PGZ2 The signal which is fed back from the encoder should have the waveform of the figure below in terms of the direction of motor rotation. The encoder installation direction and signal wiring should be done accordingly. Forward rotation or reverse rotation is judged from the feedback pulses of Phase A and Phase B (2-phase pulse that have 90 degrees of phase difference). Therefore, it should be noted that, when connections are wrong, there is possibility for abnormal rotation of the motor. Phase A(VA) Forward rotation Phase B(VB) Phase A(VA) Reverse rotation Phase B(VB) PGA1 PGA2 PGB1 PGB2 A A B B V A V B X 1 X 2 X 3 X 4 T Phase difference:xn 0.15T(n=1,2,3,4) Judgement on normal and reverse rotations by the PG feedback of two phases (Phases A and B) <When PG feedback signal is single phase> 1. For PG feedback signal, connect terminals PGA1 and PGA2. 2. The judgement on forward rotation and reverse rotation is impossible. Only the speed control mode is applicable. 13

15 Inverter Free run is stopped when OFF. Forward rotation with ON and reduce speed and stop with OFF Reverse rotation with ON and reduce speed and stop with OFF. When both forward and reverse rotation is ON, reverse rotation. (In case that cmod=0) When single phase, connect terminals PGA1 and PGA2 only. Connect CC of vector-option unit and CC of inverter. Example of complementary encoder connection Inverter Free run is stopped when OFF. Forward rotation with ON and reduce speed and stop with OFF Reverse rotation with ON and reduce speed and stop with OFF. When both forward and reverse rotation is ON, reverse rotation. In case that cmod=0 When single phase, connect terminals PGA1 and PGA2 Connect CC of vector-option unit and CC of inverter. Example of open collector encoder connection 14

16 Caution in case of using open collector encoder connection In case using pulse command oscillator and open collector encoder, the rise time of the voltage when the transistor is OFF tends to be longer than the fall time at the time when the transistor is ON. Therefore, if the maximum input frequency becomes higher, the pulse duty cannot maintain the 50±10% specification. Conduct derating on the maximum input frequency so that the pulse duty will be within the following specification range. <Derating computation formulae of open collector s maximum input pulse frequency > 0.8 / (Maximum input frequency x A) Voltage rise time = 3 x A : (single phase input: 2) (two-phase input: 4) Voltage rise time : Encoder exclusive pulse rise time + R x C Encoder exclusive pulse rise time (s) : Please inquire at the encoder manufacturer. R () (Input resistance) : internal resistance 1000()external resistance value (in case there is external resistance) C(F) (Cable static capacity) : Please inquire at the cable manufacturer. <Example> Encoder Cable : LBJ (SUMTAK), 2-phase input Encoder pulse rise time: 0.35 x 10-6 (s) : ROVV-SB-0.2-5P-10m (Furukawa Electric) Static capacity: 120 x (F/m) x 10 (m) From Formulae 0.8 / (Maximum input frequency x A) Voltage rise time = 3 x 10 6 Voltage rise time = (0.35 x 10 6 ) x (120 x x 10) = 1.55 x 10-6 [Maximum input frequency] (Pulse/s) [Single phase input] (Pulse/s) [Two-phase input] Line driver method As for the PG feedback signals, Terminal A and NA are connected for Phase A, Terminal B and NB are connected for Phase B, and Terminal Z and NZ are connected for Phase Z. (The connection for Phase Z is made only when reading Z-marker is necessary.) The polarity of the pulse input signal should be as follows. Non-inverting input side: A, B, Z Inverting input side: NA, NB, NZ The signal which is fed back from the encoder should have the waveform of chapter in terms of the direction of motor rotation. The encoder installation direction and signal wiring should be done accordingly. Forward rotation or reverse rotation is judged from the feedback pulses of Phase A and Phase B (2-phase pulse that have 90 degrees of phase difference). Therefore, it should be noted that, when connections are wrong, there is possibility for abnormal rotation of the motor. 15

17 Inverter Free run is stopped when OFF. Forward rotation with ON and reduce speed and stop with OFF Torque control with ON and reduce speed and stop with OFF. F115(S1 terminal) : Set to 112. In case that cmod=0 Connect CC of vector-option unit and CC of inverter. Example of wiring for line driver encoder (Speed/Torque switching operation) When using two-phase PG, motor forward and reverse rotation can be judged by PG. When prohibition on reverse rotation is set by the inverter parameter () and when the motor is rotating to reverse direction due to an external force, the inverter starts with reverse operation in accordance with the motor s direction for a time and the motor will be able to shift to the forward rotation and the smooth startup becomes possible Selection of encoder type The encoder type should be selected, following the table below. Encoder Type Characteristics Maximum Wiring Length Complementary Open Collector Line Driver Rated voltage output with emitter/follower combination. High anti-nose characteristics. High-speed response. Long-distance transmission capability. Need to pay attention to waveform irregularity. The collector of the transistor is output directly. Low anti-noise characteristics. Low-cost. Need to pay attention to waveform irregularity and distortion. IC output for high-speed transmission. High anti-noise characteristics. High-speed response. When transmitting over a long-distance, need to pay attention to power voltage drop. 100m 10m 30m (note) (note) Maximum wiring length differs according to the extent of power voltage drop. 16

18 3.1.5 Vector control setting parameter During operation with vector control with sensor, it is necessary to set the following parameters shown in the table below. <Basic parameters> Title Function Name Parameter Setting Setting at Shipment Base frequency Hz 60.0 Motor control mode selection 0: Constant torque 1: Variable torque mode 2: Automatic torque boost 3: Sensorless vector control (speed) 4: Automatic torque boost + automatic energy-saving 5: Sensorless vector control (speed) + automatic energy-saving 6: V/F 5-points setting 7: Sensorless vector control (speed/torque switching) 8: PG feedback vector control (speed/torque switching) 9: PG feedback vector control (speed/position switching) 8 or 9: PG feedback vector control 0 Standard : speed control When conducting vector control with sensor (speed/torque control) with this vector-option unit added, = or =should be set. For torque control operation or position control, it is necessary to allocate control switching (torque/position) to one of the terminal function selection to (input terminal selection 1 to 8) ( =)or to set operation switching by communication system ( = to) in addition to the above parameters. For details of adjustment methods by the speed control command and torque control command, refer to the inverter s instruction manual. Extended Parameter Title Function Name Parameter Setting Setting at Shipment Base frequency voltage # (V) Depends on type. Auto-restart mode 04 0:Speed search #1 Depends on type. Number of PG input pulse Selection of number of PG input phases 1: Single phase input 2: 2-phase input 3: Single phase input(for fmod=11) *1 4: 2-phase input(for fmod=11) *1 1 or 2: Single or 2-phase input Current control proportional gain *2 Depends on type. Current control integral gain *2 Depends on type. Speed loop proportional gain Depends on type. Speed loop integral gain (rad/sec) Depends on type. Auto tuning 02 0 Slip frequency gain Motor constant 1(primary resistance) m Depends on type. Motor constant 2(secondary resistance) m Depends on type. Motor constant 3(exciting inductance) mH Depends on type. Motor constant 4(load inertia moment) Motor constant 5(leak inductance) mH Depends on type. Number of poles of motor 2, 4, 6, 8, 10, 12, 14, 16 4 Rated capacity of motor kW Depends on type. Motor type 04 0 *1 These are not before CPU version V312. *2 These are different before CPU version V312. The motor constant parameter (to ) and requires setting according to the motor used. For details, refer to the inverter manual. 2 17

19 (1) Number of PG input pulse () is the number of encoder output pulses per one motor rotation. (2) For selection of number of PG input phases (), set as follows: If the encoder pulse is single-phase: If the encoder pulse is two-phase: (Phase A and Phase B or Phase A and Pulse B + Z origin signal) When the settings for the above (1) and (2) are wrong, the motor rotation will become abnormal. (3) Adjustment methods for current control proportional gain () and current control integral gain (): These need to be adjusted when it is necessary to fine-tune torque responses. (Normally, standard setting should be used.) For details of adjustment, refer to the inverter manual. (4) Adjustment method for speed loop proportional gain () and speed loop integral gain () The principle of the feedback control is a proportional action. This action produces output in proportion to the speed deviation. It is a simple mechanism but it takes some time until the speed becomes stable. Proportional action merely produces some offset values. (The speed deviation will not be eliminated completely with reference to the command frequency.) In order to eliminate the offset, integration action is effective where the output is calculated by the accumulation of past deviations (from start of operation until now) and added to the proportional action. <Speed loop ratio gain> Adjustments are necessary in accordance with the inverter capacity and load inertia ratio. Set the ratio referring the formulae below as the rule of thumb. Speed loop ratio gain = (50 + A x P w ) x J 0.12 A : Coefficient by number of motor poles (2 poles: poles: poles: 2.2) P w : Inverter capacity (Example: in case of 3.7kW unit P w =3.7) J : Load inertia/toshiba standard motor inertia (Example: In case of inertia ratio being 4, J = 4) <Speed loop integration gain> Standard setting at shipment should be used usually. In case fine-tuning of speed response is necessary, adjust parameters by the following procedure. Measurement device needed for adjustment: Waveform measurement device such as an oscilloscope. Connect the probe of the measurement device to the analog monitor output terminal of the inverter (between the FM terminal and CC terminal). Set FM terminal output to Speed Feedback (real-time value). (Refer to Monitoring method for feedback amount.) Set the acceleration time to minimum, so that there will be no over-current stall.(blinking) Set the operation command mode selection () and speed setting mode selection () to panel input effective. ( = 1 = 5 ) Set the speed setting to about 10Hz and press (RUN) key to measure the speed response waveform at operation start. Press (STOP) key to stop operation. In order to improve the speed response, gradually make the speed ratio gain () greater and repeat above operation and adjust to immediately prior to motor oscillation. Adjust the speed loop integral gain (). Repeat the operation in above and adjust the parameter so that the speed deviation is contained at expected response time. This concludes the speed loop gain setting. 18

20 3.1.6 Speed error detection function Parameter Title Function Adjustment range Default setting Abnormal speed detection filter 0.01 to 100 seconds Over-speed detection frequency range 0.0: Invalid, 0.1 to 30Hz 0.0 Speed drop detection frequency range 0.0: Invalid, 0.1 to 30Hz 0.0 Function When the detected frequency from the encoder is higher than the frequency range of over-speed detection () as compared to the set frequency, or when the detected frequency that is below the frequency range of speed-drop detection () continues until the speed error detection time (), the operation trips by the speed error (). Speed error detection time should be set longer than the acceleration/deceleration time because the detected frequency deviates from the set frequency depending on the acceleration/deceleration time during the speed control. Speed error detection does not function during the unit is not in operation. Speed error detection function is valid only during the speed control. Although this function is invalidated, when the output frequency or detected frequency from encoder exceeds 1.25 times the highest frequency, operation trips by the speed error () Disconnection detection function Parameter Title Function Adjustment range Default setting PG disconnection detection selection 0 : Disable, 1 : Enable 0 Function When the parameter selection is set to [], detection function of disconnection on the line driver signal connection can be selected. Only when the line driver encoder is used for PG, the disconnection of signal line of phase A or phase B can be detected. When PG other than the single-phase input or line driver is used, always select [ ] (default setting). 19

21 3.1.8 Monitoring method for feedback amount Motor rotation speed can be monitored. The motor is equipped with status monitor which is displayed on the panel and analog monitor which used analog output terminals (FM, AM terminals) Set items and for motor speed monitoring. Speed feedback (real-time value) (Unit: Hz/free unit) The real-time display of motor speed can be made (Monitor display setting: ). Speed feedback (one-second filter) (Unit: Hz/free unit) The filtered motor speed (feedback value) is displayed. (Monitor display setting: ). The monitoring for the above and is possible also in cases except for= (PG feedback vector control operation). For example, the monitoring can be used for confirmation of the initial PG feedback amount in open loop (V/F operation and the like). <Setting method for status monitoring> In order to monitor motor rotation speed in condition monitoring, it is necessary to change the setting for extended parameters (to). Refer to <Monitoring Operating Condition) section of the inverter manual. <Setting method for analog monitoring> In order to monitor motor rotation speed by the analog output terminal, it is necessary to change the setting for basic parameter () and extended parameter (. Refer to (Meter Setting and Calibration) section of the inverter manual Accuracy of speed control The accuracy of speed control with the PG feedback can be obtained by the following formulae. Accuracy of speed control = Command frequency accuracy + feedback detection accuracy Command frequency accuracy 0.01(Hz) F(Hz) c (using digital command) Feedback detection accuracy FC ( P 2) PG PH F C P PG : Inverter output frequency : Number of motor poles : Number of PG pulses/rotation PH : Single Phase = 1, Two-Phase = : Response speed of 40ms 20

22 3.2 PGFB open collector output PG feedback signal is converted to the open collector signal and transmitted. In case of an open collector output, because the rise time of the voltage at time of transistor OFF becomes longer than the fall time of the voltage at time of ON, pulse duty cannot be held stable sometimes if the PG input frequency goes higher. In that case, derate PG input frequency. Operate the unit below the ratings listed below. Voltage: 30V or less Current: 50mA or less Wiring length: 1.5m or shorter, use shield wire. 3.3 PGFB line driver output Signal that is input from the line driver encoder is transmitted directly. This method can be used only when the line driver encoder is connected to the PG feedback terminal. Since the output terminal is internally connected to the line driver s PG input terminal, strictly observe the following cautions. Internal circuit CN8 NA NB NZ TB2 R Equivalent to 26LS32 R : 470-1/4W Line driver encoder Use line receiver that is equivalent to AM26LS32, and set the input impedance to 470 1/4W. Use twisted pair and batch shield cable for the pair of wiring and the wiring length should be within 5 meters. Equivalent to 26LS31 21

23 3.4 Pulse input command It is possible to input inverter operation frequency command by pulse signals. This command cannot be used when vector control operation with sensor is effective. Inverter output frequency can be controlled in ratio with the pulse output signal from the pulse oscillator. By inputting two-phase pulse with 90 degrees phase difference, it is possible to input forward and reverse rotation commands Pulse command connection method Two-phase pulse input command 1. Connect pulse input signal to the point between terminals PGA1 and PGA2 on phase A and between terminals PGB1 and PGB2 on phase B 2. The polarity of the pulse input signals should be as follows: + side: PGA1 and PGB1 - side: PGA2 and PGB2 3. Forward and reverse operation can be judged by the pulse from the phase A and B by using a judgement circuit together with the operational frequency command. 4. The judgement on forward and reverse rotation is made as shown in the figure below. Phase A Phase A Forward rotationreverse rotation Phase B Phase B Pulse oscillator Phase difference: Judgement on forward and reverse rotation by the two-phase (Phase A and Phase B) pulse trains <Caution when using open collector method> Refer to the cautions about adopting the open collector method that is described on the chapter of complementary/open collector method, and derate the maximum frequency. The case for single-phase pulse input command For the pulse input signal, connect between PGA1 and PGA2. For switching between forward and reverse rotation, with 0(Terminal input validation), ON and OFF actions between Terminal F-CC and R-CC are used. 22

24 Inverter MCCB IM E With OFF, free run is stopped. Pulse CN8 oscillator With ON, forward rotation PGA1 and with OFF, speed PGA2 reduction and stop. PGB1 (with ON, reverse rotation, PGB1 with OFF, speed reduction E E and stop.) When using in single phase, connect the pulse Connect CC of vector-option unit oscillator between PGA1 and CC of inverter. and PGA2. Example of connection when operating on pulse train command (speed command) Pulse input setting parameter Parameter Title Function Name Adjustment Range Setting at Shipment fmod Speed setting mode selection : Pulse input frequency command 2 f200 Reference priority selection 0: 1: 2: takes precedence. 3: takes precedence. 0 4: / terminal selection (selection of input terminal function: 104) f207 Speed setting mode selection # : Pulse input frequency command 2 f234 Pulse reference point # % 0 f235 Pulse point #1 frequency - 0 f236 Pulse reference point # % 100 f237 Pulse point #2 frequency - 80 f367 Number of PG input pulses f368 Selection of number of PG input phases 1: Single-phase input, 2: 2-phase input 3: Single phase input(for fmod=11) *1 2 4: 2-phase input(for fmod=11) *1 3 or 4: Single or 2-phase input(for fmod=11) f369 PG disconnection detection selection 0: Disable, 1: Enable 0 *1 These are not before CPU version V312. Refer to the instruction manual of inverter for the input selection of frequency (speed) command. For selection of number of PG input phases (), set as follows: If the input pulse is single-phase: If the input pulse is two-phase: 23

25 Computation of frequency command Value of input pulse is converted into the percentage in the range of 100 to 100% by the following calculation. The data of converted percentage is pointed out by two dots in accordance with the point setting ( to ) as shown in the figure on the next page. When the pulse input is carried out with 2-phase operation, forward and reverse operation is possible by the phase difference. When the point conversion setting generates negative frequency command, reverse operation is possible (at time when the forward operation is commanded). input pulse frequency Percent reference data = x 100% PG input pulse x maximum frequency f237 Frequency f234 f236 Percent reference data f235 Monitoring method of pulse input command The pulse input command frequency can be monitored. In order to monitor the pulse input command frequency, set items of the monitor display as shown below. Operation frequency command value [Unit: Hz/free unit] The pulse input command frequency can be confirmed even before the motor is used. Initial value can be confirmed for the combination testing. For setting method of the condition monitor, refer to the inverter instruction manual in the monitoring operation condition section. 24

26 3.5 Position control command Position control operation is possible by the input of external pulse train. For position control operation, line driver method is recommended to PG and pulse train input device. When open collector method is adopted, note that PG feedback signal and pulse command signal is susceptible to noise and deviation of position can occur Connecting method of position command Refer to the circuit diagram below for the connection of position command. < Line driver input > CCW CCWN Equivalent to AM26LS31 < Open collector input > VCC R CCW CCWN 24V 1.3kΩ 12V 510Ω 5V 47Ω 100Ω 100Ω 100Ω 100Ω Photocoupler VF : V Photocoupler VF : V Use line driver that is equivalent to AM26LS31. Output level of open collector should be 30VDC- 15mA or less. Wiring length should be within 1.5 meters and use twisted pair shield cable for each pair of cables to discriminate other main and signal wires. In case of an open collector output, because the rise time of the voltage at time of transistor OFF becomes longer than the fall time of the voltage at time of ON, pulse duty cannot be held stable sometimes if the PG input frequency goes higher. In that case, derate PG input frequency. Inverter Position command Free run when OFF. Run with ON No polarity of forward and reverse direction Position control with ON and speed control with OFF F115(S1 terminal): Set to 112 (In case that cmod=0) In case of complimentary encoder Connect CC of vector-option unit and CC of inverter. Example of position control command 25

27 3.5.2 Setting method of position command parameter Title Function Adjustment Range Operation command mode selection Motor control mode selection 0: Terminal block enabled 1: Operation panel enabled 2: Common serial communication option 3: Serial communication RS485 4: Communication add-on option enabled 09 9: PG feedback vector control (speed/position switching) Default setting Number of PG input pulses pulses / revolution 500 Selection of number of PG input phases 1: Single phase input 2: 2-phase input 3: Single phase input(for fmod=11) *1 4: 2-phase input(for fmod=11) *1 1 or 2: Single or 2-phase input 2 PG disconnection detection selection 0: Disabled, 1: Enabled 0 Electronic gear pulses / revolution 1000 Position loop gain Positioning completion range Frequency limit at position (Hz / second), 8001 disable 800 Motor counter data selection 0: As of encoder 1: 256 counts / revolution 2: 512 counts / revolution 3: 1024 counts / revolution 4: 2048 counts / revolution 5: 4096 counts / revolution Forward speed limit input selection 0: Disabled, 1:VI/II, 2:RR, 3:RX, 4:RX2, 5: 0 Forward speed limit level Reverse speed limit Input selection 0: Disabled, 1:VI/II, 2:RR, 3:RX, 4:RX2, 5: 0 Reverse speed limit level Position deviation limit *1 These are not before CPU version V312. When the V/f control selection (pt) is set to 9 and when the position control is valid at time of control changeover, the position command becomes valid. Position command is set by the forward pulse command or reverse pulse command from the terminal of vector-option unit. Control modes of speed control and position control can be changed by the operation selection parameter (cmod) from the terminal or communication. Once the mode is changed, position information is cleared. As shown in the figure below, position command data is corrected by the parameter of electronic gear (f370) and encoder pulse is corrected by the parameter of number of PG input pulse (f367) for position control Forward pulse command Reverse pulse command 1/f370 Position control Encoder pulse 1/f367 26

28 Shift amount = number of input pulses electronic gear setting ( ) (revolution) Speed = frequency of input pulse electronic gear setting ( ) x 60 (min -1 ) Frequency = speed x number of motor poles ( ) 120 (Hz) Output frequency at time of position control will be restricted by the lowest frequency that is either the speed limit ( to ), maximum frequency or 327.7Hz. Positional loop gain (), the variation limit of positional control frequency () When the over-voltage trip ( or ) occurs during the deceleration of positional control, install the braking resistor or subdue the variation rate of the pulse train input. If the braking resistor has already been installed. Decrease the positional loop gain (). The deceleration time during the positional control depends on the positional loop gain (), not on the deceleration time of the parameter ( etc.). Therefore, reducing this parameter () increases the deceleration time during the positional control and does not set the trip to occur easily. Frequency Acceleration During deceleration Over-voltage trip (op2 or op3) Frequency Acceleration Decrease the positional loop gain (f371). Deceleration If the variation rate of the pulse train input cannot be subdued. Lessen the variation limit of the positional control frequency (). However, there is a possibility to generate the hunting if this parameter is reduced too much. (Output frequency cannot decelerate to stop at the commanded position and will result in overshoot.) If hunting occurs, decrease the positional loop gain () to make the deceleration time longer, and the hunting can be removed. According to the load, adjust the value of positional loop gain () and the variation limit of positional control frequency (). 27

29 Frequency Acceleration During deceleration Over-voltage trip (op2 or 0p3) Frequency Acceleration Decrease the variation limit of positional control frequency. Deceleration Hunting can occur. Frequency Acceleration Decrease the positional loop gain (f371) to prevent hunting. Deceleration Selection of relating monitor function Data relating to the following position command can be displayed on the panel or output to the analog monitor (FM, AM, optional analog output). (Selective parameter:,,,, ) Function number Function Communication number 22 Motor counter dummy PG FE33 23 Location pulse FE34 Motor counter dummy PG By the function of motor counter dummy PG, number of pulses per one revolution is corrected to the count of motor counter data selection () regardless of the number of pulses of encoder, and this count of pulse will be output on the counter indication. Values are shown by the free-run counter in a range from 0 to and if the values go over the limit, the indication returns to 0. Fixed output for meter adjustment (function number = 30) corresponds to the count Motor counter dummy pulse = encoder input pulse PG input pulse ( x motor counted data ) 28

30 Location pulse Location pulse is the monitor output of position command pulse. Values are shown by the free-run counter in a range from 0 to and if the values go over the limit, the indication returns to 0. Fixed output for meter adjustment (function number = 30) corresponds to the count Input function of relating terminals Positive logic Negative logic Function Remark Control switching (torque, position) valid only when = Deviation counter clear valid only when = Position control forward limit switch Position control reverse limit switch Control switching (torque, position) When the operation is controlled (run and stop) by the terminal, this terminal changes the control method from the speed control to the position control to carry out the position control. This function is valid when the operation control is selected to the terminal with the setting of CMOD = 0 (terminal) or input terminal function = 108 (109). When the operation is controlled (run and stop) from the communication, change the control by the communication command. Deviation counter clear While values are being input, the deviation of position pulse is cleared. Position control forward limit switch This limit switch input is for the forward operation side. Even if the forward run pulse is added while this input is set ON, the operation stops halfway in the status of servo-lock. If the forward pulse command is continuously input in this condition, the operation may trip due to the error of extreme location deviation (). Position control reverse limit switch This limit switch input is for the reverse operation side. Even if the reverse run pulse is added while this input is set ON, the operation stops halfway in the status of servo-lock. If the reverse pulse command is continuously input in this condition, the operation can trip due to the error of extreme location deviation (). Note that the motor rotates when the border limit switch is released in the condition when the deviation in the same direction as limit switch that is input to forward operation side or reverse operation side remains. When inputting the command pulse in opposite direction to the limit switch that is input to forward operation side or reverse operation side, the motor rotates in an opposite direction after deviation is cleared. 29

31 Output function of relating terminal Positive logic Negative logic Function Motion Over travel Over travel Activates when the forward or reverse border limit switch is turned on Positioning completion Activates in a range where positioning is completed. This function is set on (positive logic) when the forward or reverse border limit switch activates. Since the deviation is remaining inside, clear the deviation counter if necessary. Positioning completion signal This function is turned on (positive logic) after the positioning completion time () is reached. 30

32 3.6 RX2 input Frequency setting (multi-function programmable setting ) is possible by the voltage input (0 to ± 10Vdc). Connecting method is the same to that of the RX terminal of the inverter. Moreover, the vector-option unit is provided with +15V (internal impedance 500) and 15V (internal impedance 500 ) power supply as a standard for +/- analog command, so the +/- voltage command is possible by the following circuit connection. 0V command with the variable register set to its center +10V command with the positive voltage side -10V command with the negative voltage side Connecting length should be within 1.5 meters and use shield cable. Parameter Title Function Adjustment Range Default setting Speed setting mode selection 11 4: RX2(voltage input (optional)) 2 Reference priority selection 0: 0 1: 2: takes precedence. 3: takes precedence. 4: / terminal selection (selection of input terminal function: 104) Speed setting mode selection # : RX2(voltage input (optional)) 2 Rx2 reference point # % 0 Rx2 point #1 frequency - 0 Rx2 reference point # % 100 Rx2 point #2 frequency - 80 Rx2 reference point #1 % %(For torque control, etc.) 0 Rx2 reference point #2 % %(For torque control, etc.) 100 Torque command selection : RX2 3 Selection of synchronized torque bias : RX2 0 input Selection of tension torque bias input : RX2 0 Load sharing gain input selection : RX2 0 Forward speed limit input selection : RX2 0 Reverse speed limit input selection : RX2 0 Selection of speed limit (torque=0) : RX2 0 reference Power running torque limit 1 selection : RX2 5 Selection of regenerative torque limit # : RX2 5 Override addition input selection : RX2 0 Override multiplication input selection : RX2 0 Refer to the instruction manual of inverter for the input selection of frequency (speed) command. 31

33 Funcetion Command for speed or toque and other functions are possible by the ±10V voltage command. Refer to the instruction manual of the inverter for the function because it is similar to the terminal RX. Select RX2 by using the parameter corresponding to a desirable function. Consider 10V as 100% and +10V as 100% to designate two dots as shown in the figure below. Frequency converted into points Percentage converted into points f225 Frequency f227 Frequency f224 f224 f222 Percent reference data f222 Percent reference data f223 f Multi-functional output terminals Two output terminals can be added. The output is for the open collector. Function is similar to that of the output terminals of the inverter (OUT1 and OUT2), so refer to the inverter s instruction manual. OUT3 terminal: Output terminal 6 OUT4 terminal: Output terminal 7 Parameter Title Function Adjustment Range Default setting Output terminal selection #6(OUT3) (RCH) Output terminal selection #7(OUT4) (OC) Output terminal #6 delayed time(out3) 2200mS (minimum unit 2.5mS) 2 Output terminal #7 delayed time(out4) 2200mS (minimum unit 2.5mS) 2 Output terminal #6 holding time(out3) 2200mS (minimum unit 2.5mS) 2 Output terminal #7 holding time(out4) 2200mS (minimum unit 2.5mS) 2 32