Fuji Electric OPC-E1-PG Operating Manual

Instruction Manual

PG Interface Card "OPC-E1-PG"

Thank you for purchasing our PG interface card.

• Read through this instruction manual and be familiar with the option card before proceeding with installation, connections (wiring), operation, or maintenance and inspection.

• Deliver this manual to the end user of this product. Keep this manual in a safe place until this product is discarded.

• Specifications of this option card are subject to change without prior notice for improvement.

Fuji Electric Systems Co., Ltd. INR-SI47-1118a-EU REV 052010

Copyright © 2006 Fuji Electric FA Components & Systems Co., Ltd. All rights reserved. No part of this publication may be reproduced or copied without prior written permission from Fuji Electric Systems Co., Ltd. All products and company names mentioned in this manual are trademarks or registered trademarks of their respective holders. The information contained herein is subject to change without prior notice for improvement.

Table of Contents

Preface

Thank you for purchasing our PG interface card "OPC-E1-PG." Mounting this optional card into your FRENIC-Multi inverter enables speed control with PG (e.g. V/f control with PG and dynamic torque vector

control with PG), pulse train input and positioning control. Read through this instruction manual in conjunction with the FRENIC-Multi Instruction Manual (INR-SI47-1204-E) and be familiar with proper

handling and operation of this product. Improper handling might result in incorrect operation, a sh ort life, or even a failure of this product. This instruction manual does not contain inverter handling instructions. Refer to the FRENIC-Multi Instruction Manual (INR-SI 47-1204-E), and kee p

this manual in a safe place.

 Safety precautions

Read this manual thoroughly before proceeding with installation, connections (wiring), operation, or maintenance and inspection. Ensure you have sound knowledge of the device and familiarize yourself with all safety information and precautions before proceeding to o perate th e inverter.

Safety precautions are classified into the following two categories in this manual.

Failure to heed the information indicated by this symbol may lead to dangerous conditions, possibly r esulting in death or serious bodily injuries.

Failure to heed the information indicated by this symbol may lead to dangerous conditions, possibly r esulting in minor or light bodily injuries and/or substantial property damage.

Failure to heed the information contained under the CAUTION title can also result in serious consequences. These safety precautions are of utmost importance and must be observed at all times.

Installation and wiring

• Turn the inverter's power OFF and wait for at least five minutes before starting installation and wiring.

• Qualified electricians should carry out wiring.

Otherwise, electric shock could occur.

• Do not use the product that is damaged or lacking parts.

Doing so could cause failure or injuries.

• Prevent lint, paper fibers, sawdust, dust, metallic chips, or other foreign materials from getting into the inverter.

Otherwise, a fire or an accident might result.

• Incorrect handling in installation/removal jobs could cause a failure.

A failure might result.

• Noise may be emitted from the inverter, motor and wires. Implement appropriate measure to prevent the nearby sensors an d devices from

malfunctioning due to such noise.

Otherwise, an accident could occur.

Operation

• Be sure to install the terminal cover before turning the power ON.

Do not remove the cover while the power is on.

Doing so could cause electric shock.

• Confirm and adjust the setting of the function codes before running the inverter.

Otherwise, an accident could occur.

Maintenance and inspection, and parts replacement

• Turn the power OFF and wait for at least five minutes before starting inspection or parts replacement.

Otherwise, electric shock could occur

• Maintenance, inspection, and parts replacement should be made only by qualified persons.

• Take off the watch, rings and other metallic objects before starting work.

• Use insulated tools.

Otherwise, electric shock or injuries could occur.

Disposal

• Treat the PG interface card as an industrial waste when disposing of it.

Otherwise injuries could occur.

Others

• Never attempt to modify the PG interface card or inverter.

Doing so could cause electric shock or injuries.

Icons

The following icons are used throughout this manual.

This icon indicates information which, if not heeded, can result in the inverter not operating to full efficiency, as well as information concerning incorrect operations and settings which can result in accidents.

This icon indicates information that can prove handy when performing certain settings or operations.

This icon indicates a reference to more detailed information.



Table of Contents

Preface................................................i

 Safety precautions ........................... i

Chapter 1 BEFORE USING THE INVERTER ...1-1

1.1 Acceptance Inspection.............1-1

1.2 Mounting the PG Interface Card1-2

1.3 PG Specifications and PG Mounting

Instructions ............................ 1-3

1.3.1 PG specifications.............1-3

1.3.2 Mounting the PG to the

motor ...............................1-3

1.3.3 Wiring between the PG

Interface card and PG...... 1-4

1.3.4 Setting up the power supply for the PG or pulse train

generator......................... 1-5

1.3.5 Connecting to option

terminals..........................1-5

1.3.6 Option terminals...............1-6

Chapter 2

CONNECTION DIAGRAMS .............2-1

2.1 For Frequency Control with Pulse

Rate Input................................2-1

2.2 For Speed and Positioning

Controls .................................2-2

Chapter 3..............................................

PREPARATION FOR OPERATING .. 3-1

Chapter 4..........PG INTERFACE CARD

FUNCTIONS.......................4-1

4.1 Speed Control..........................4-1

4.2 Frequency Control with Pulse

Rate Input................................4-1

4.3 Positioning Control...................4-1

Chapter 5..............................................

FREQUENCY CONTROL WITH

PULSE RATE INPUT.......... 5-1

5.1 Specifications...........................5-1

5.2 T erminal Functions...................5-1

5.3 Function Code List................... 5-1

5.4 Function Code Details..............5-2

5.5 Description of the Control........ 5-3

5.5.1 Input pulse polarity .......... 5-3

5.5.2 Block diagram..................5-3

Chapter 6

SPEED CONTROL ..........................6-1

6.1 Specifications ..........................6-1

6.2 T erminal Functions .................. 6-1

6.3 Function Code List................... 6-2

6.4 Function Code Details ............. 6-2

Chapter 7

POSITIONING CONTROL ............... 7-1

7.1 Specifications ..........................7-1

7.2 T erminal Functions .................. 7-1

7.3 Function Code List................... 7-2

7.4 Description of the Control........ 7-3

7.4.1 Symbols........................... 7-4

7.4.2 Input/output term functions7-5

7.5 Function Code Details ............. 7-6

7.6 Monitoring................................ 7-6

7.6.1 Monitoring items ..............7-6

7.6.2 Displaying system on the LED

monitor ............................7-7

7.6.3 Positioning control status. 7-7

7.7 Serial Pulse Receiving Function7-8

7.8 Assignment of PG Terminals

When Shared ................................7-9

Chapter 8

PROTECTIVE FUNCTIONS ............ 8-1

8.1 Overspeed Alarm (os).............. 8-1

8.2 Excessive Speed Deviation

Alarm (ere).................................... 8-1

8.2.1 Function codes ................8-2

8.2.2 Excessive speed deviation

detection.......................... 8-2

8.3 Positioning Control Alarm (ero )8-3

8.3.1 Function codes ................8-3

Chapter 1 BEFORE USING THE INVERTER

1.1 Acceptance Inspection

Unpack the package and check the following: (1) The PG interface card is the model you ordered. (2) The PG interface card is not damaged during transportation--no defective parts or lacking parts. (3) The model name "OPC-E1-PG" is printed on the PG interface card. (See Figure 1.2.)

If you suspect the product is not working properly or if you have any questions about your product, contact your Fuji Electric representative.

Hooks CN3

Model

name

Figure 1.1 Figure 1.2

1-1

1.2 Mounting the PG Interface Card

• Turn the power OFF and wait for at least five minutes before starting installation.

Otherwise, electric shock could occur.

• Do not use the product that is damaged or lacking parts. Doing so could cause a failure and injuries.

• Prevent lint, paper fibers, sawdust, dust, metallic chips, or other foreign materials from getting into the inverter.

Otherwise, a fire or an accident might result.

• Incorrect handling when mounting or removing the product could cause a failure. A failure might result.

When handling the PG interface card and interface printed circuit board (interface PCB), take any antistatic measure or hold their hooks taking care not to directly touch their circuit boards; otherwise, the static electricity charged in your body may damage them.

(1) Remove the terminal cover.

 For details on how to remove the terminal cover, refer to the FRENIC-Multi Instruction Manual (INR-SI47-1204-E), Chapter 2, Section 2.3

"Wiring."

(2) If the interface PCB is installed on the inverter, push the hooks provided on both ends of the interface PCB and pull it up and out of the inverter with

both hands. (Store the removed interface PCB for future use.) (3) Connect the CN3 connector (shown in Figure 1.2) on the PG interface card to the connector on the inverter until it clicks into place. (4) For inverters of 1 HP or below: Before reinstalling the terminal cover, cut off the barrier (see Figure 1.3) of the te rminal cover using nippers or the

like (5) Reinstall the terminal cover, taking care not to pinch control signal lines.

 When reinstalling the terminal cover, refer to the FRENIC-Multi Instruction Manual (INR-SI47-1204-E), Chapter 2, Section 2.3 "Wiring."

For inverters of 5 HP or below: When performing the wiring for the main circuit terminals, you need to remove the PG interface card beforehand.

Barrier of th

e cable

PG interface card

Figure 1.3

1-2

1.3 PG Specifications and PG Mounting Instructions

• Using the PG whose specifications are not satisfied may cause the inverter and equipment to malfunction. Doing so could cause failure or injuries.

1.3.1 PG specifications

Table 1.2 lists the applicable PG specifications.

Table 1.2 Specifications of Applicable PG and PG Inte rface Card

Item Specifications

Encoder system Incremental system

Applicable PG

PG power supply

Output signal

Pulse resolution 20 to 3000 P/R Input power requirements

5 VDC ±10% / 100 mA

(200 mA, when a single PG is mounted.) Internal power supply +5 VDC ±10% / 200 mA External power supply +5 VDC ±10%, 200 mA or more Open collector (pull-up resistor: 620) Complementary (totem-pole push-pull) voltage output

Note 1: The wiring length between the PG and inverter should not exceed 20 m. Note 2: When the PG power is 200 mA or more, use an external power supply. Note 3: The external power supply should satisfy the voltage specifications of the PG.

1.3.2 Mounting the PG to the motor

The counterclockwise rotation when viewed from the motor output shaft is regarded as "forward rotation" (see Figure 1.4). During rotation in the forward direction, the PG output pulse forms the forward signal as shown in Figure 1.5 (B phase advances 90 degrees from A phase). During rotation in the reverse direction, the PG output pulse forms reverse signal (A phase advances 90 degrees from B phase).

Mount the PG to the motor with a coupling, etc. Table 1.3 lists the correct configurations of commands, rotational directions, and motor wiring. Any other configuration fails to perform speed control

normally.

Table 1.3 Rotational Direction of Encoder and Motor Shafts

Run

command

Rotational direction

Encoder

shaft

Motor shaft

Motor wiring

FWD Forward Forward U V W phases in order

REV Reverse Reverse U V W phases in order

Figure 1.4

Forward direction

Motor

Forward Direction of Motor and

FWD Forward Reverse U V W phases in reverse

REV Reverse Forward U V W phases in reverse

Forward

signal

A phase

B phase

Figure 1.5 Rotational Direction and Output Signal of PG

90°

order order

Reverse

signal

ou can monitor the digital input status of the PG interface card with the inverter keypad. For details, refer to the FRENIC-Multi Instruction Manual

(INR-SI47-1204-E), Chapter 3, Section 3.4.5 "Checking I/O signal status."

1.3.3 Wiring between the PG interface card and PG

• Turn the inverter's power OFF and wait for at least five minutes before starting connection.

• Qualified electricians should carry out wiring.

Otherwise, electric shock could occur.

• Noise may be emitted from the inverter, motor and wires. Implement appropriate measure to prevent the nearby sensors and devices from malfunctioning due to such noise.

Otherwise, an accident could occur.

1-3

Wire the PG to the PG interface card, observing the following precautions and referring to the connection diagrams given in Figures 2.1 to 2.3. (1) Turn the inverter's power OFF.

(2) Use a shielded wire for wiring between the PG and the PG interface card. (3) To prevent malfunction due to noise, keep the wiring a way from the main circuit wiring of the inverter and the power wiring of other d evices as far as

possible (at least 10 cm(3.94 in)). Do not route them in the same duct. (4) Complete the wiring for the PG before turning the inverter's power ON. (5) The wire size applicable to the option connection terminal on the inverter is AWG 18-24(0.82 to 0.2 mm

). When using a wire with its end being stripped, strip its end by 5 to 7 mm(0.2 to 0.28 in). When using a ferrule, use a vinyl-insulated ferrule. Loosen the fixing screw, insert the wire end into the opening of the terminal block, and tighten the screw.

Approx.

6.0 mm(0.24 in)

Figure 1.6 Stripping the Wire End Before Connection to Terminal Board

Recommended wire: AWG 18-24(0.82 to 0.2 mm2) for rated temperature 105°C(221°F) (UL)

1-4

1.3.4 Setting up the power supply for the PG or pulse train generator

The external power supply should match the PG power voltage or pulse train generator voltage. Otherwise, a failure might result.

When using an internal power supply Connect the power supply wire to the terminal [PO] on the PG interface card.

When using an external power supply Connect the power supply wire to the terminal [PI] on the PG interface card.

1.3.5 Connecting to option terminals

Table 1.4 lists terminal symbols, names and functions of the option terminals on the PG interface card.

Table 1.4 Option Terminals and Their Specifications

Classif i-catio n

Termin

symbol

Name Functions

External power supply input

PO Power supply for PG

Power input terminal from the external device External power supply capacity:

5 VDC ±10%, 200 mA or more Power output terminal 5 VDC ±10%, Maximum output 200 mA

CM PG common Common terminal for power supply and PG input

A phase pulse input

X B phase pulse input

PG/ Pulse input

Z phase pulse input

X A phase pulse input

Y B phase pulse input

Z phase pulse input Y

Pulse input terminal for commands To supply speed commands from the pulse train generator or PG, connect an open-collector output signal

or complementary output signal to these terminals. Since [XZ] is not used for train input control, connection to [XZ] is not required if there is no

corresponding output at the PG. In positioning control, however, connection to [XZ] enables positioning correction.

Pulse input terminal for feedback These terminals are for the detection of the inverter-driven motor speed. Connect an open-collector

output signal or complementary output signal to these terminals Since [YZ] is not used for speed control, connection to [YZ] is not required if there is no corresponding

output at the PG. In positioning control, however, connection to [YZ] enables positioning correction.

Note: Incorrect wiring of A/B phase could fail to run the motor normally or cause an inverter trip.

1.3.6 Option terminals

CM XA XB XZ PO CM YA YB YZ PO PI CM

Screw size: M2 Tightening torque: 0.22 to 0.25 N·m(0.16 to 0.18 lbf·ft)

Terminal [PLC] on the PG interface card cannot su pply power to external equipment. Use the terminal onl y for receiving power from external equipment.

Figure 1.8 Option Terminals

1-5

Chapter 2 CONNECTION DIAGRAMS

2.1 For Frequency Control with Pulse Rate Input



Figure 2.1 sh o ws connec tion di agram e xampl es for fr eq uenc y c ont rol wi th puls e r ate input.

Note 1)

Figure 2.1 Connection Diagrams for Frequency Control with Pulse Rate Input

When using inverte r inter nal pow er sup ply

Pulse Train

Generator or PG

(Note 1)

When using exte rnal p o we r s uppl y

For details about applicable PG specifications, refer to Table 1.2 in Chapter 1, Section 1.3.1 "PG specifications."

Pulse Train

Generator or PG

(Note 1)

2.1

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