Fuji Electric OPC-E1-SY Operating Manual

Instruction Manual

Synchronous Operation Card

"OPC-E1-SY"

Thank you for purchasing our synchronous operation card.

• Read through this instruction manual and be familiar with the synchronous operation 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 card are subject to change without prior notice for improvement.

Fuji Electric FA Components & Systems Co., Ltd. INR-SI47-1218-E

No part of this publication may be reproduced or copied without prior written permission from Fuji Electric FA Components & 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.

Preface

Thank you for purchasing our synchronous operation card "OPC-E1-SY."

Mounting this card into your FRENIC-Multi inverter enables the inverter to drive two motors equipped with pulse generators in three synchronous operation modes--speed synchronous operation, standby synchronous operation and simultaneous start synchronous operation modes.

Read through this instruction manual in conjunction with the FRENIC-Multi Instruction Manual (INR-SI47-1094-E) and be familiar with proper handling and operation of this product. Improper handling might result in incorrect operation, a short 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-SI47-1094-E), and keep 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 operate the 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 resulting in death or serious bodily injuries.

Failure to heed the information indicated by this symbol may lead to dangerous conditions, possibly resulting 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 products that are 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 and devices from malfunctioning due to such noise.

Otherwise, an accident could occur.

Operation

• Be sure to mount 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 inverter's 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 product as an industrial waste when disposing of it.

Otherwise injuries could occur.

Others

• Never attempt to modify the product.

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.



iii

Table of Content

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

 Safety precautions .........................................................................................................i

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

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

1.2 Mounting the Synchronous Operation Card..................................................... 1-2

1.3 Pulse Generator (PG) Specifications and PG1-Mounting Instructions............. 1-3

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

1.3.2 Connection between the synchronous operation card and PGs

on reference and slave motors .................................................................. 1-4

1.3.3 Wiring procedure for the PGs and the synchronous operation card ......... 1-5

1.3.4 Setting up the power supply for PGs......................................................... 1-6

1.3.5 Option terminals on the synchronous operation card................................ 1-6

1.3.6 Arrangement of option terminals on the synchronous operation card....... 1-6

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

Chapter 3 PREPARATION FOR OPERATING........................................................... 3-1

Chapter 4 SYNCHRONOUS OPERATION CONTROL ............................................. 4-1

4.1 Specifications of Synchronous Operation ........................................................ 4-1

4.2 Overview of Synchronous Operation ............................................................... 4-2

4.2.1 Standby synchronous operation ................................................................ 4-2

4.2.2 Simultaneous start synchronous operation................................................ 4-3

4.3 Block Diagrams ................................................................................................ 4-4

4.4 List of Function Codes ..................................................................................... 4-6

4.5 Unavailable Function Codes ............................................................................ 4-8

4.6 Configuring Function Codes............................................................................. 4-8

4.6.1 Motor constant data ................................................................................... 4-8

4.6.2 Data setting for synchronous operation ..................................................... 4-8

Chapter 5 CONFIGURATION EXAMPLES AND ADJUSTMENT GUIDE .................. 5-1

5.1 Typical Configuration and Pulse Setting .......................................................... 5-1

5.1.1 Speed reduction ratio setting ..................................................................... 5-1

5.1.2 Wiring of PGs............................................................................................. 5-3

5.2 Key Points on Function Code Configuration and Adjustment Guide................ 5-4

5.3 Function Code Configuration Examples........................................................... 5-6

5.3.1 For position synchronous operation (o60 = 1 or 2), #1.............................. 5-6

5.3.2 For position synchronous operation (o60 = 1 or 2), #2.............................. 5-7

5.3.3 For speed synchronous operation (o60 = 0).............................................. 5-8

5.4 Checking PG Pulse Rate ................................................................................. 5-9

Chapter 6 PROTECTIVE FUNCTIONS ..................................................................... 6-1

6.1 Overspeed Alarm (OS) .................................................................................... 6-1

6.2 Excessive Speed Deviation Alarm (ErE) ......................................................... 6-2

6.2.1 Function codes .......................................................................................... 6-2

6.2.2 Excessive speed deviation detection......................................................... 6-2

6.3 Excessive Deviation Alarm (Ero)..................................................................... 6-3

6.3.1 Function codes .......................................................................................... 6-3

Chapter 1 BEFORE USING THE INVERTER

1.1 Acceptance Inspection

Unpack the package and check the following:

(1) The synchronous operation card is the model you ordered.

(2) The card is not damaged during transportation--no defective parts or lacking parts.

(3) The model name "OPC-E1-SY" is printed on the card. (See Figure 1.3.)

(4) The card is applicable to your inverter.

Applicable inverters have "-2SYZ," "-4SYZ," or "-7SYZ" at the end of the inverter type printed in the TYPE column on the main and sub nameplates labeled on inverters.

FRN5.5E1S-2SYZ

TYPE SER.No.

FRN5.5E1S-2SYZ 5Z3710K1208

Hooks

Model name

OPC-E1-SY

(a) Main nameplate (b) Sub nameplate

Figure 1.1 Nameplates

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

Figure 1.2 Figure 1.3

1-1

1.2 Mounting the Synchronous Operation 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 synchronous operation 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-SI47-1094-E), Chapter 2, Section 2.3 "Wiring."

(2) If the interface PCB is mounted 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 1.3) on the synchronous operation card to the

connector on the inverter until it clicks into place.

(4) For inverters of 0.75 kW or below: Before reinstalling the terminal cover, cut off the barrier (see

Figure 1.4) of the terminal 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-SI47-1094-E), Chapter 2, Section 2.3 "Wiring."

For inverters of 3.7 kW or below: When performing the wiring for the main circuit terminals, you need to remove the synchronous operation card beforehand.

Barrier of the cable outlet

Synchronous operation card

Figure 1.4

1-2

1.3 Pulse Generator (PG) Specifications and PG Mounting Instructions

• Using the pulse generator (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 1.1 lists the specifications of PGs applicable to the synchronous operation card.

Table 1.1 Specifications of Applicable PG and Synchronous Operation Card

Item Specifications

A and B phases (Incremental system), Z phase

20 to 3000 P/R 5 VDC ±10% / 100 mA

(200 mA, when a single PG is mounted.) +5 VDC ±10% / 200 mA +5 VDC ±10%, 200 mA or more

Vcc

Applicable PG

PG power supply

Encoder system

Pulse resolution

Input power requirements

Internal power supply

External power supply

Voltage output

Circuit configured with the grounded-emitter

Output

出力

transistor whose collector outputs voltage

Open collector

Vcc

(pull-up resistor: 620Ω)

Output signal type

Voltage output circuit

出力

Output

configured without resistor between the output terminal and the collector

Complementary

Vcc

(totem-pole push-pull)

Constant voltage output

出力

Output

circuit configured with an emitter follower

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.

Note 4: The reference and slave motors should use pulse generators with the same pulse

resolution.

1-3

Select PGs that match the DC characteristics of the synchronous operation card listed in the table below.

Table 1.2 DC Characteristics of the Synchronous Operation Card

Terminals XA, XB, XZ, YA, YB, YZ Min. Max.

High level input voltage VIH 3.8 V --

Low level input voltage VIL (Input current 9 mA or less)

Low level input current IIL (when an internal power supply is used, VIL=0V)

-- 1.2 V

-- 9 mA

1.3.2 Connection between the synchronous operation card and PGs on reference and slave motors

Connect the PG output signal wires for the reference motor to terminals XA, XB, and XZ on the synchronous operation card and those for the slave motor, to terminals YA, YB, and YZ.

The counterclockwise rotation when viewed from the motor output shaft is regarded as "forward rotation" (see Figure 1.5). The PG output signal wires should be connected so that the PG output pulse during rotation in the forward direction forms the forward signal as shown in Figure 1.6 (B phase advances 90 degrees from A phase).

Forward direction

A phase input

B phase input

Motor

Figure 1.5 Forward Direction of Motor and PG Figure 1.6 Rotational Direction and Output Signal

Table 1.3 lists the relationship between the connection of reference PG output signals, the rotational direction of the reference PG, and the rotational direction of the slave motor that receives

of PG

90°

Forward

signal

Reverse

signal

a run command (FWD or REV).

Table 1.3 Connection of the Reference PG Output Signals and Rotational Direction of the Slave Motor

A and B phase output

signals issued from the

reference PG

If connected to

terminals XA and XB

normally

If connected to

terminals XA and XB

reversely

* If the reference inverter rotates the motor in such a direction that the slave inverter stops, the

pulse count continues so as to cause an Ero excessive deviation alarm. After that, if the reference inverter rotates the motor in the same direction as the slave inverter, the synchronous operation restarts from the position where the deviation becomes zero.

When the rotational

direction of the

reference PG is:

Forward Forward Stop *

Reverse Stop * Reverse

Forward Stop * Reverse

Reverse Forward Stop *

If the slave motor

receives a run forward

command (FWD):

It rotates in the following direction.

Note: Synchronous operation in the direction opposite to the reference PG rotation

If the slave motor

receives a run reverse

command (REV):

To drive the slave PG in the direction opposite to the reference PG rotation in synchronous operation, connect the B and A phase output signals issued from the reference PG to terminals XA and XB, respectively. (See Table 1.3.)

1-4

1.3.3 Wiring procedure for the PGs and the synchronous operation card

• 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.

Wire each PG to the synchronous operation card, observing the following precautions and referring to the connection diagrams given in Figures 2.1 and 2.2.

(1) Turn the inverter's power OFF.

(2) Use a shielded wire for wiring between the PG and the synchronous operation card.

(3) To prevent malfunction due to noise, keep the wiring away from the main circuit wiring of the

inverter and the power wiring of other devices as far as possible (at least 10 cm). 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.

When using a wire with its end being stripped, strip its end by 5 to 7 mm. 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.

5 to 7 (mm)

Figure 1.7 Stripping the Wire End Before Connection to Terminal Block

Recommended wire: AWG 18-24 for rated temperature 105°C (UL)

1-5

1.3.4 Setting up the power supply for PGs

When using an internal power supply

Connect the power supply wire to terminal [PO] on the synchronous operation card.

When using an external power supply

Connect the power supply wire to terminal [PI] on the synchronous operation card.

1.3.5 Option terminals on the synchronous operation card

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

Table 1.4 Option Terminals and Their Specifications

Classification

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

Terminal

symbol

External power supply

input

PO Power supply for PG

CM PG common

XA A phase pulse input X

XB B phase pulse input X

PG/ Pulse input

XZ Z phase pulse input X

YA A phase pulse input Y

YB B phase pulse input Y

YZ Z phase pulse input Y

Name Functions

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

Common terminal for power supply and PG input

Input terminal for A phase signal issued from reference PG

Input terminal for B phase signal issued from reference PG

Input terminal for Z phase signal issued from reference PG

Input terminal for A phase signal issued from slave PG

Input terminal for B phase signal issued from slave PG

Input terminal for Z phase signal issued from slave PG

Input signal status (pulse rate) on terminals [XA], [XB], [XZ], [YA], [YB], and [YZ] can be

checked by using Menu #4 "I/O Checking" (4_15, 4_16, 4_17 and 4_18) on the inverter's keypad. For the operating procedure, refer to the FRENIC-Multi Instruction Manual (INR-SI47-1094-E). (Function code E52 = 2)

1.3.6 Arrangement of option terminals on the synchronous operation card

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

Screw size: M2 Tightening torque: 0.22 to 0.25 N·m

Terminal [PLC] on the synchronous operation card cannot supply power to external equipment. Use the terminal only for receiving power from external equipment.

Figure 1.8 Option Terminals

1-6

+ 28 hidden pages