Mitsubishi FR-A8AP User Manual

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Page 1

INVERTER

Plug-in option

FR-A8AP

INSTRUCTION MANUAL

Orientation control

Encoder feedback control

Vector control

PRE-OPERATION INSTRUCTIONS

INSTALLATION AND WIRING

ENCODER SPECIFICATIONS AND PARAMETER SETTINGS

ORIENTATION CONTROL

ENCODER FEEDBACK CONTROL

VECTOR CONTROL

Page 2

Thank you for choosing this Mitsubishi inverter plug-in option.

Warning

Caution

This Instruction Manual provides handling information and precautions for use of the equipment. Incorrect handling might cause an unexpected fault. Before using this inverter, always read this Instruction Manual carefully to use the equipment to its optimum performance. Please forward this Instruction Manual to the end user.

Safety instructions

Do not attempt to install, operate, maintain or inspect the product until you have read through this Instruction Manual and appended documents carefully and can use the equipment correctly. Do not use this product until you have a full knowledge of the equipment, safety information and instructions. In this Instruction Manual, the safety instruction levels are classified into "WARNING" and "CAUTION".

The level may even lead to a serious consequence according to conditions. Both instruction levels must be followed

because these are important to personal safety.

 Electric Shock Prevention

Incorrect handling may cause hazardous conditions, resulting in death or severe injury.

Incorrect handling may cause hazardous conditions, resulting in medium or slight injury, or may cause only material damage.

Warning

 While the inverter power is ON, do not open the front cover or the wiring cover. Do not run the inverter with the front cover or the wiring cover removed. Otherwise

you may access the exposed high voltage terminals or the charging part of the circuitry and get an electric shock.

 Do not remove the inverter front cover even if the power supply is disconnected. The only exception for this would be when performing wiring and periodic

inspection. You may accidentally touch the charged inverter circuits and get an electric shock.

 Before wiring or inspection, LED indication of the inverter unit operation panel must be switched OFF. Any person who is involved in wiring or inspection shall wait

for at least 10 minutes after the power supply has been switched OFF and check that there is no residual voltage using a tester or the like. For a short time after the power-OFF, a high voltage remains in the smoothing capacitor, and it is dangerous.

 Any person who is involved in wiring or inspection of this equipment shall be fully competent to do the work.  The plug-in option must be installed before wiring. Otherwise you may get an electric shock or be injured.  Do not touch the plug-in option or handle the cables with wet hands. Otherwise you may get an electric shock.  Do not subject the cables to scratches, excessive stress, heavy loads or pinching. Otherwise you may get an electric shock.

 Injury Prevention

Caution

 The voltage applied to each terminal must be the ones specified in the Instruction Manual. Otherwise a burst, damage, etc. may occur.  The cables must be connected to the correct terminals. Otherwise a burst, damage, etc. may occur.  The polarity (+ and -) must be correct. Otherwise a burst or damage may occur.  While power is ON or for some time after power OFF, do not touch the inverter as it will be extremely hot. Touching these devices may cause a burn.

Page 3

 Additional Instructions The following instructions must be also followed. If the product is handled incorrectly, it may cause unexpected fault, an injury, or an electric shock.

Caution

Transportation and mounting

 Do not install or operate the plug-in option if it is damaged or has parts missing.  Do not stand or rest heavy objects on the product.  The mounting orientation must be correct.  Foreign conductive objects must be prevented from entering the inverter. That includes screws and metal fragments or other flammable substance such as oil.  If halogen-based materials (fluorine, chlorine, bromine, iodine, etc.) infiltrate into a Mitsubishi product, the product will be damaged. Halogen-based materials are

often included in fumigant, which is used to sterilize or disinfest wooden packages. When packaging, prevent residual fumigant components from being infiltrated into Mitsubishi products, or use an alternative sterilization or disinfection method (heat disinfection, etc.) for packaging. Sterilization of disinfection of wooden package should also be performed before packaging the product.

Trial run

 Before starting operation, each parameter must be confirmed and adjusted. A failure to do so may cause some machines to make unexpected motions.

Warning

Usage

 Do not modify the equipment.  Do not perform parts removal which is not instructed in this manual. Doing so may lead to fault or damage of the product.

Caution

Usage

 When parameter clear or all parameter clear is performed, the required parameters must be set again before starting operations. Because all parameters return to

their initial values.

 Static electricity in your body must be discharged before you touch the product.

Maintenance, inspection and parts replacement

 Do not carry out a megger (insulation resistance) test.

Disposal

 The inverter must be treated as industrial waste.

 Many of the diagrams and drawings in this Instruction Manual show the inverter without a cover or partially open for explanation. Never operate the inverter in this

manner. The cover must be reinstalled and the instructions in the Instruction Manual must be followed when oper ating the inverter.

General instruction

Page 4

— CONTENTS —

1 PRE-OPERATION INSTRUCTIONS 7

1.1 Unpacking and product confirmation ..............................................................................................7

1.2 Component names.............................................................................................................................8

2 INSTALLATION AND WIRING 9

2.1 Pre-installation instructions .............................................................................................................9

2.2 Installation procedure .......................................................................................................................9

2.3 Encoder specification / terminating resistor switch setting........................................................12

2.4 Wiring ................................................................................................................................................14

2.5 Encoder cables dedicated to Mitsubishi motors ..........................................................................17

2.6 Terminals ..........................................................................................................................................18

3 ENCODER SPECIFICATIONS AND PARAMETER SETTINGS 19

3.1 Encoder.............................................................................................................................................19

3.2 Parameter setting.............................................................................................................................21

3.2.1 Parameter for encoder.................................................................................................................................. 21

3.2.2 Parameter settings for the motor under vector control.................................................................................22

4 ORIENTATION CONTROL 23

4.1 Wiring example ................................................................................................................................23

4.2 Terminals ..........................................................................................................................................25

4.3 Specifications...................................................................................................................................26

Page 5

5 ENCODER FEEDBACK CONTROL 27

5.1 Wiring examples ..............................................................................................................................27

5.2 Specifications...................................................................................................................................28

6 VECTOR CONTROL 29

6.1 Wiring examples ..............................................................................................................................29

6.2 Specifications...................................................................................................................................33

Page 6

1 PRE-OPERATION INSTRUCTIONS

1.1 Unpacking and product confirmation

Take the plug-in option out of the package, check the product name, and confirm that the product is as you ordered and intact. This product is a plug-in option dedicated for the FR-A800 series.

 Product confirmation

Check the enclosed items.

Plug-in option

...............................................1

SW2

123

SW1

SW3

Mounting screw (M3 × 8 mm)

.....................2 (Refer to page 9.)

Spacer

....................2 (Refer to

PRE-OPERATION INSTRUCTIONS

page 9.)

Page 7

1.2 Component names

(g)

Terminal layout

(a)

Front view

(a)

Rear view

(d)

SW2

(b)

SW3

(a)

123

SW1

Symbol

(f)

PZ1

PZ2

PIN and PO are not used.

(a)

PA1

PB1

PA2

PB2

Name Description

a Mounting hole Fixes the option to the inverter with screws, or installs spacers. 9

b Terminal block Connects to the encoder. 14

Encoder type selection switch (SW3)

Switches the encoder type (differential line driver/ complementary). 12

d CON2 connector Not used. ―

Terminating resistor selection switch (SW1)

Switch for manufacturer setting (SW2)

Switches ON or OFF the internal terminating resistor. 12

o not change the initially-set status. (Switches 1 and 2 are OFF .)

g Connector Connects to the option connector of the inverter. 9

(a)

Refer to

page

―

PRE-OPERATION INSTRUCTIONS

Page 8

2 INSTALLATION AND WIRING

2.1 Pre-installation instructions

Check that the inverter's input power and the control circuit power are both OFF.

Caution

 Do not mount or remove the plug-in option while the input power is ON. Doing so may damage the inverter or plug-in option.  To avoid damage due to static electricity, static electricity in your body must be discharged before you touch the product.

2.2 Installation procedure

(1) Remove the inverter front cover. (Refer to Chapter 2 of the

Instruction Manual (Detailed) of the inverter for details on how to remove the front cover.)

(2) For the two mounting holes (as shown in the next page) that will not

be tightened with mounting screws, insert spacers.

(3) Fit the connector of the plug-in option along the guide of the

connector on the inverter, and insert the plug-in option as far as it goes. (Insert it to the inverter option connector 1 or 2.)

(4) Fit the two locations, the left and right, of the plug-in option securely

to the inverter unit by screwing in the supplied mounting screws (tightening torque 0.33 N·m to 0.40 N·m). If the screw holes do not line up, the connector may not be inserted deep enough. Check the connector.

Spacer

INSTALLATION AND WIRING

Inverter side option connector

Spacer

Page 9

Spacer

Mounting screw

Insertion positions for screws and spacers

Connector 3

Do not insert the plug-in option to the connector 3.

Mounting screw

Spacer

Connector 1Connector 2

Spacer

Mounting screw

INSTALLATION AND WIRING

Page 10

NOTE

• Caution must be taken of mounting screws falling off when removing and mounting the plug-in option.

• Only one type of option per inverter may be used. When multiple options are mounted, priority is given to option connectors 1, 2 and 3 on the inverter in this order, and options having a lower priority do not function. (For the positions of the option connectors 1 to 3, refer to page 10.)

• When the inverter cannot recognize that the option unit is mounted due to improper installation, etc., the protective function (E.1 to E.3) is displayed. A different indication will appear according to the mounted position (option connector 1 to 3).

Mounted position Fault indication

Option connector 1

Option connector 2

Option connector 3

• When removing the plug-in option, remove the two screws on the left and right, then pull it straight out. Pressure applied to the connector and to the option board may break the option.

INSTALLATION AND WIRING

Page 11

2.3 Encoder specification / terminating resistor switch setting

Internal terminating resistor-ON (initial status)

Internal terminating resistor-OFF

1 2

O N

SW2

SW3

SW1

123

 Encoder specification selection switch (SW3)

Select either differential line driver or complementary. It is initially set to the differential line driver. Switch its position according to output circuit.

SW2

Differential line driver (initial status)

 Terminating resistor selection switch (SW1)

Select "ON"/"OFF" of the internal terminating resistor. Set the switch to "ON" (initial status) when an encoder output type is differential line driver and set to "OFF" when complementary. ON : with internal terminating resistor (initial setting status) OFF : without internal terminating resistor

NOTE

• Set all switches to the same setting ("ON"/ "OFF").

• If the encoder output type is differential line driver, set the terminating resistor switch to the "OFF" position when sharing the same encoder with other unit (CNC (computerized numerical controller), etc) or a terminating resistor is connected to other unit.

INSTALLATION AND WIRING

123

SW1

SW3

Complementary

Page 12

 Motor used and switch setting

Motor

Mitsubishi standard motor with encoder Mitsubishi high-efficiency motor with encoder

Mitsubishi constant-torque motor with encoder

Vector control dedicated motor SF-V5RU Complementary OFF 12 V

Other manufacturer's motor with encoder

 Set according to the motor encoder used.  Choose a power supply for encoder according to the encoder used (5 V/12 V/15 V/24 V). When the encoder output is the differential line

driver type, only 5 V can be input.

SF-JR Differential ON 5 V

SF-HR Differential ON 5 V

Others

SF-JRCA Differential ON 5 V

SF-HRCA Differential ON 5 V

Others

Encoder specification

selection switch (SW3)

  

Terminating resistor

selection switch (SW1)

specifications

NOTE

• Switch "SW2" is for manufacturer setting. Do not change the setting.

Power

INSTALLATION AND WIRING

Page 13

2.4 Wiring

NOTE

Encoder

2mm

FR-A800

(FR-A8AP)

PZ2

PZ1

PB2

PB1

PA2

PA1

Example of parallel connection

with two cables

(with complementary encoder output)

Encoder cable

Shield

P clip

Earthing (grounding) example using a P clip

(1) Use twisted pair shield cables (0.2 mm2 or larger) to connect the FR-A8AP and position detector. For the wiring to the terminals PG and SD, use several cables in parallel or use a thick cable, according to the wiring length. To protect the cables from noise, run them away from any source of noise (e.g. the main circuit and power voltage).

Wiring length

Within 10 m At least two cables in parallel

Within 20 m At least four cables in parallel

Within 100 m

 At least six cables in parallel

 When differential driver is set and a wiring length is 30 m or more

The wiring length can be extended to 100 m by slightly increasing the 5 V power supply (approx. 5.5 V) and using six or more cables with gauge size of 0.2 mm parallel or a cable with gauge size of 1.25 mm

applied should be within power supply specifications of encoder.

To reduce noise of the encoder cable, earth (ground) the encoder shielded cable to the enclosure (as close as the inverter) with a P clip or U clip made of metal.

• For details of the optional encoder dedicated cable (FR-JCBL/FR-V7CBL), refer to page 17.

• FR-V7CBL is provided with a P clip for earthing (grounding) shielded cable.

INSTALLATION AND WIRING

Parallel connection

(Cable gauge 0.2 mm2)

Larger-size cable

0.4 mm

or larger

0.75 mm

1.25 mm

or larger

or more. Note that the voltage

Page 14

(2) Wire the shielded twisted pair cable after stripping its sheath to make its cables loose.

Sheath

Shield

(perform protective treatment)

Twisted pair shielded cable

5 mm

Wire

Sleeve

0 to 0.5mm

Also, protect the shielded cable of the shielded twisted pair cable to ensure that it will not make contact with the conductive area.

Strip off the sheath for the below length. If the length of the sheath peeled is too long, a short circuit may occur with neighboring wires. If the length is too short, wires might come off. Wire the stripped cable after twisting it to prevent it from becoming loose. In addition, do not solder it.

Cable stripping length

Use a blade terminal as necessary. When using the blade terminal, use care so that the twisted wires do not come

Sleeve

0 to 0.5mm

NOTE

• Blade terminals commercially available (as of February 2012. The product may be changed without notice.)

Ter mina l

Screw Size

Wire Size (mm2)

0.3 to 0.5 Al 0,5-6WH A 0,5-6

0.75 (for two wires) Al-TWIN 2  0,75-10GY ―

Wire

Damaged

Crumpled tip

Wires are not inserted into the sleeve

Blade Terminal Model

with insulation sleeve without insulation sleeve

Unstranded wires

Manufacturer

Phoenix Contact Co.,Ltd.

Blade terminal

crimping tool

CRIMPFOX 6

INSTALLATION AND WIRING

Page 15

(3) Loosen the terminal screw and insert the cable into the terminal.

Screw Size Tightening Torque Cable Size Screwdriver

0.22 N

m to 0.25 Nm

0.3 mm

to 0.75 mm

Small flat-blade screwdriver

(Tip thickness: 0.4 mm/tip width: 2.5 mm )

NOTE

• Undertightening can cause cable disconnection or malfunction. Overtightening can cause a short circuit or malfunction due to damage to the screw or unit.

• When wiring cables to the inverter's RS-485 terminals while a plug-in option is mounted, take caution not to let the cables touch the circuit board of the option or of the inverter. Otherwise, electromagnetic noises may cause malfunctions.

• When one position detector is shared between FR-A8AP and CNC (computerized numerical controller), its output signal should be connected as shown below. In this case, the wiring length between FR-A8AP and CNC should be as short as possible, within 5 m.

Inverter

(FR-A8AP)

Position detector

Encoder

Maximum 5 m

CNC

(two parallel cables)

CAUTION

 Do not use empty terminals as junction terminals because they are used in the option unit. If they are used as the junction terminals, the option unit

may be damaged.

 After wiring, wire offcuts must not be left in the inverter. They may cause a fault, failure or malfunction.

INSTALLATION AND WIRING

Page 16

2.5 Encoder cables dedicated to Mitsubishi motors

F-DPEVSB 12P 0.2mm

Earth cable

Approx. 140 mm

60mm

D/MS3057-12A

D/MS3106B20-29S

11m m

Typ e

Length

L (m)

FR-JCBL5 5

FR-JCBL15 15

FR-JCBL30 30



Earth cable

F-DPEVSB 12P 0.2 mm

D/MS3106B20-29S

D/MS3057-12A

11m m

60mm

Approx. 140 mm

Typ e

Length

L (m)

FR-V7CBL5 5

FR-V7CBL15 15

FR-V7CBL30 30

• A P clip for earthing (grounding) a shielded cable is provided.

Use dedicated encoder cables to connect with Mitsubishi encoder-equipped motors.

FR-JCBL FR-V7CBL

For SF-JR/HR/JRCA/HRCA (with encoder)

For SF-V5RU and SF-THY

FR-A800

(FR-A8AP)

PA1 PA2 PB1 PB2 PZ1 PZ2

PG SD

2mm

 As the terminal block of the FR-A8AP is an insertion type, earth (ground) cables need to be modified. (Refer to page 15.)

Encoder

C R A N B P

H K

Positioning keyway

D/MS3106B20-29S (As viewed from wiring side)

FR-A800

(FR-A8AP)

PA1 PA2 PB1 PB2 PZ1 PZ2

PG SD

Encoder

A B C D F

Positioning keyway

2mm

D/MS3106B20-29S (As viewed from wiring side)

INSTALLATION AND WIRING

Page 17

 Connection terminal compatibility table

Motor SF-JR/HR/JRCA/HRCA (with Encoder) SF-V5RU, SF-THY

Encoder cable FR-JCBL FR-V7CBL

PA1 PA PA

PA2 PAR Keep this open.

PB1 PB PB

FR-A8AP terminal

PB2 PBR Keep this open.

PZ1 PZ PZ

PZ2 PZR Keep this open.

PG 5E PG

SD AG2 SD

2.6 Terminals

Ter mina l

Symbol

PA1 Encoder A-phase signal input terminal

PA2 Encoder A-phase inverse signal input terminal

PB1 Encoder B-phase signal input terminal

PB2 Encoder B-phase inverse signal input terminal

PZ1 Encoder Z-phase signal input terminal

PZ2 Encoder Z-phase inverse signal input terminal

SD Encoder power supply ground terminal

Encoder power supply (positive side) input terminal

INSTALLATION AND WIRING

Ter m ina l Nam e Description

A-phase signal is input from the encoder.

B-phase signal is input from the encoder.

Z-phase signal is input from the encoder. (Not used for the encoder feedback control.)

Input power for the encoder power supply. Connect the external power supply (5 V, 12 V, 15 V, 24 V) and the encoder power cable. When the encoder output is the differential line driver type, only 5 V can be input. Make sure the voltage of the external power supply the same as the encoder output voltage. (Check the encoder specification.)

For details of pulse signal, refer to page 19.

Page 18

3 ENCODER SPECIFICATIONS AND PARAMETER SETTINGS

3.1 Encoder

 Position detection (pulse encoder)

Output pulse specifications

Differential line driver Complementary

A/A signal 1000 P/R to 4096 P/R B/B signal 1000 P/R to 4096 P/R Z/Z signal 1 P/R

A A B B Z Z

abcd

H L

A signal 1000 P/R to 4096 P/R B signal 1000 P/R to 4096 P/R Z signal 1 P/R

abcd

Position detector

Encoder

When rotation is clockwise as viewed from the shaft end (A) of the encoder. a, b, c, d should be (1/4 1/8)P

NOTE

• When orientation control, encoder feedback control, vector control are used together, the encoder is shared between these controls. Use an encoder which has a pulse count of 1000 to 4096 ppr (pulse per revolution).

• The encoder should be coupled with the motor shaft or the spindle oriented with a speed ratio of 1 to 1 without any mechanical looseness.

• To ensure correct operation, the encoder must be set in the proper rotation direction and the A and B phases connected correctly.

ENCODER SPECIFICATIONS AND PARAMETER SETTINGS

Page 19

 Power supply

Choose a power supply for encoder according to the encoder used (5 V/12 V/15 V/24 V). When the encoder output is the differential line driver type, only 5 V can be input. Make sure the voltage of the external power supply the same as the encoder output voltage. (Check the encoder specification.) When an encoder is used under orientation control, encoder feedback control, and vector control, the power supply is shared between the inverter and encoder.

• Specifications of the encoders equipped in the motors with encoders and the vector-control dedicated motors

Item Encoder for SF-JR/HR/JRCA/HRCA Encoder for SF-V5RU, SF-THY

Resolution 1024 pulses/rev 2048 pulses/rev

Power supply voltage 5 VDC±10% 12 VDC±10%

Current consumption 150 mA

Output signal form

Output circuit Differential line driver 74LS113 equivalent Complementary

Output voltage

A, B phases (90° phase shift) Z phase: 1 pulse/rev

H level: 2.4 V or more L level: 0.5 V or less

H level: "Power supply for encoder-3 V" or more L level: 3 V or less

NOTE

• When the input power supply voltage to the encoder and its output voltage differ, the protective function (E.ECT) may be activated.

ENCODER SPECIFICATIONS AND PARAMETER SETTINGS

Page 20

3.2 Parameter setting

NOTE

3.2.1 Parameter for encoder

Parameter

Number

359 C141

369 C140

• If operating at a frequency higher than 120 Hz with Pr.359 = "0 or 1", the motor rotation will be unstable.

Pr.

group

Name

Encoder rotation direction

Number of encoder pulses

Initial Value

1024 0 to 4096

Setting

Range

100

101

Description

Set when using a motor for which forward rotation is clockwise viewed from the motor load shaft.

Set when using a motor for which forward rotation is counterclockwise viewed from the motor load shaft.

Set the number of encoder pulses output. Set the number of pulses before it is multiplied by 4.

ENCODER SPECIFICATIONS AND PARAMETER SETTINGS

Set for the operation at 120 Hz or less.

Set for the operation at a frequency higher than 120 Hz.

Set for the operation at 120 Hz or less.

Set for the operation at a frequency higher than 120 Hz.

Page 21

3.2.2 Parameter settings for the motor under vector control

Motor Name

Mitsubishi standard motor

Mitsubishi constant-torque motor

Mitsubishi vector control dedicated motor

Other manufacturer's standard motor

Other manufacturer's constanttorque motor

 Set this parameter according to the motor (encoder) used.

Pr.359 Encoder rotation

direction

SF-JR 1 (Initial value) 1024 (Initial value)

SF-JR 4P 1.5 kW or less 1 (Initial value) 1024 (Initial value)

SF-HR 1 (Initial value) 1024 (Initial value)

Others

SF-JRCA 4P 1 (Initial value) 1024 (Initial value)

SF-HRCA 4P 1 (Initial value) 1024 (Initial value)

Others

SF-V5RU 1 (Initial value) 2048

SF-THY 1 (Initial value) 2048

—

 

Pr.369 Number of

encoder pulses

ENCODER SPECIFICATIONS AND PARAMETER SETTINGS

Page 22

4 ORIENTATION CONTROL

This function is used with a position detector (encoder) installed to the spindle of a machine tool, etc. to allow a rotary shaft to be stopped at the specified position (oriented). For the details of the parameters used for orientation control, refer to the Instruction Manual (Detailed) of the inverter.

4.1 Wiring example

SF-JR motor with encoder

Earth (Ground)

V W E

∗2

Encoder

∗5

∗6

(-)

(+)

5 VDC power

supply ∗9

For complementary type (SF-V5RU)

MCCB MC OCR

∗1

Three-phase

AC power

supply

Inverter

External thermal relay

∗11

input

FR-A8AP

Differential

Complementary

Terminating resistor ON

OFF

RH(OH)

PA1

PA2

PB1

PB2

PZ1

PZ2

∗7

U V

∗8

Earth (Ground)

2 W1 kΩ

∗6

(+)

U V W E

SF-V5RU

Thermal relay protector

∗2

(-)

12 VDC power

FAN

Encoder

∗5

supply

∗9

Three-phase

AC power

supply

Forward rotation start Reverse rotation start

Orientation command

Contact input common

MCCB

R/L1 S/L2 T/L3

STF

STR

X22∗3

ORA∗4

ORM

∗4

FR-A8AX

∗10

X15

X14

Inverter

FR-A8AP

Differential

Complementary

Terminating resistor ON

OFF

U V

PA1

PA2

PB1

PB2

PZ1

PZ2

∗8

∗7

ORIENTATION CONTROL

Page 23

 For the fan of the 7.5 kW or less dedicated motor, the power supply is single phase (200 V/50 Hz, 200 to 230 V/ 60 Hz).  The pin number differs according to the encoder used.  Use Pr. 178 to Pr. 189 (input terminal function selection) to assign the function to any of terminal.

Refer to the Instruction Manual (Detailed) for details of Pr. 178 to Pr. 189 (input terminal function selection).

 Use Pr. 190 to Pr. 196 (output terminal function selection) to assign the function to any of terminal.

Refer to the Instruction Manual (Detailed) for details of Pr. 190 to Pr. 196 (output terminal function selection).

 Connect the encoder so that there is no looseness between the motor and motor shaft. Speed ratio should be 1:1.  Earth (Ground) the shielded cable of the encoder cable to the enclosure with a P clip, etc. (Refer to pag e 14.)  For the differential line driver, set the terminating resistor selection switch to on position (initial status) to use. (Refer to page 12.)

Note that the terminating resistor switch should be set to off position when sharing the same encoder with other unit (CNC, etc.) and a terminating resistor is connected to other unit. For the complementary, set the switch to off position.

 For terminal compatibility of the FR-JCBL, FR-V7CBL and FR-A8AP, refer to page 1 8.  A separate power supply of 5 V/12 V/15 V/24 V is necessary according to the encoder power specification. When the encoder output is

the differential line driver type, only 5 V can be input. Make the voltage of the external power supply the same as the encoder output voltage, and connect the external power supply between PG and SD. When performing encoder feedback control and vector control together, an encoder and power can be shared.

 When a stop position command is input from outside, a plug-in option FR-A8AX is necessary. Refer to the Instruction Manual (Detailed)

for details of external stop position command.

 Connect the recommended 2W1k resistor between the terminal PC and OH. (Recommended product: MOS2C102J 2W1k by KOA

Corporation) Insert the input line and the resistor to a 2-wire blade terminal, and connect the blade terminal to the terminal OH. (For the recommended 2-wire blade terminals, refer to page 1 5.) Insulate the lead wire of the resistor, for example by applying a contraction tube, and shape the wires so that the resistor and its lead wire will not touch other cables. Caulk the lead wire securely together with the thermal protector input line using a 2-wire blade terminal. (Do not subject the lead wire's bottom area to an excessive pressure.) To use a terminal as the terminal OH, assign the OH (external thermal O/L relay input) signal to an input terminal. (Set "7" in any of Pr.178 to Pr.189. For details, refer to the Instruction Manual (Detailed) of the inverter.)

When OH signal is assigned to terminal RH (Pr.182 = “7”)

RH (OH)

2-wire blade terminal

Resistor (2 W1kΩ)

ORIENTATION CONTROL

Insulate

To thermal protector

Page 24

4.2 Terminals

 Option FR-A8AX terminal

Ter mina l

Symbol

X0 to X15 Digital signal input terminal

Terminal Name Description

Data read timing input signal terminal

 Inverter terminal

Ter mina l

(Signal)

Input X22 Orientation command

ORA Orientation complete

Output

ORM Orientation fault

 Refer to the Instruction Manual (Detailed) for details of Pr.178 to Pr.189 (input terminal function selection) and Pr.190 to Pr.196

Terminal (Signal) Name Application Explanation

(output terminal function selection).

Input the digital signal at the relay contact or open collector terminal. Using Pr. 360, speed or position command is selected as the command signal entered.

Used when a digital signal read timing signal is necessary. Data is read only during the DY signal is on. By switching the DY signal off, the X0 to X15 data before signal-off is retained.

Used to enter an orientation signal for orientation. For the terminal used for X22 signal input, set "22" in any of Pr. 178 to Pr. 189 to assign the function.

Switched LOW if the orientation has stopped within the in-position zone while the start and X22 signals are input. For the terminal used for the ORA signal output, assign the function by setting "27 (positive logic) or 127 (negative logic)" in any of Pr. 190 to Pr. 196.

Switched LOW if the orientation has not completed within the in-position zone while the start and X22 signals are input. For the terminal used for the ORA signal output, assign the function by setting "28 (positive logic) or 128 (negative logic)" in any of Pr. 190 to Pr. 196.



ORIENTATION CONTROL

Page 25

4.3 Specifications

Repeated positioning

accuracy

Permissible speed

Functions

Holding force after

positioning

Input signal

(contact input)

Output signal

(open collector output)

ORIENTATION CONTROL

±1.5° Depends on the load torque, moment of inertia of the load or orientaion, creep speed, position loop switching position, etc.

Encoder-mounted shaft speed (6000 r/min with 1024 pulse encoder). The drive shaft and encoder-mounted shaft must be coupled directly or via a belt without any slip. Gear changing shafts cannot be applied.

Orientation, creep speed setting, stop position command selection, DC injection brake start position setting, creep speed and position loop switch position setting, position shift, orientation in-position, position pulse monitor, etc.

Under V/F control, Advanced magnetic flux vector control...without servo lock function Under vector control...with servo lock function

Orientation command, forward and reverse rotation commands, stop position command (open collector signal input (complementary) is enabled) Binary signal of maximum 16 bit (when used with the FR-A8AX)

Orientation completion signal, orientation fault signal

Page 26

5 ENCODER FEEDBACK CONTROL

Mount FR-A8AP to an FR-A800 series inverter to perform encoder feedback control under V/F control or Advanced magnetic flux vector control. This controls the inverter output frequency so that the motor speed is constant to the load variation by detecting the motor speed with the speed detector (encoder) to feed back to the inverter. For the details of the parameters used for encoder feedback control, refer to the Instruction Manual (Detailed) of the inverter.

5.1 Wiring examples

MCCB MC

Three-phase

C power supply

Forward rotation start

Reverse rotation start

Contact input common

Frequency setting

potentiometer

R/L1 S/L2 T/L3

STF

STR

Inverter

FR-A8AP

Differential

Complementary

Terminating

resistor ON

∗4

OFF

PA1

PA2

PB1

PB2

SF-JR motor with encoder

Earth (Ground)

∗3

(+)

U V

∗1

(-)

Encoder

∗2

5 VDC power

supply

U V

∗5

ENCODER FEEDBACK CONTROL

∗6

Page 27

 The pin number differs according to the encoder used.  Connect the encoder so that there is no looseness between the motor and motor shaft. Speed ratio should be 1:1.  Earth (Ground) the shielded cable of the encoder cable to the enclosure with a P clip, etc. (Refer to pag e 14.)  For the differential line driver, set the terminating resistor selection switch to on position (initial status) to use. (Refer to page 12) Note that

the terminating resistor switch should be set to off position when sharing the same encoder with other unit (CNC, etc) and a terminating resistor is connected to other unit. For the complementary, set the switch to off position.

 For terminal compatibility of the FR-JCBL, FR-V7CBL and FR-A8AP, refer to page 1 8.  A separate power supply of 5 V/12 V/15 V/24 V is necessary according to the encoder power specification. When the encoder output is

the differential line driver type, only 5 V can be input. Make the voltage of the external power supply the same as the encoder output voltage, and connect the external power supply between PG and SD. To perform orientation control together, an encoder and power supply can be shared.

5.2 Specifications

Speed variation ratio

Function

Maximum speed

ENCODER FEEDBACK CONTROL

0.1% (100% means 3600 r/min)

• Setting of speed feedback range

• Setting of feedback gain

• Setting of encoder rotation direction

V/F control: 590 Hz, Advanced magnetic flux vector control: 400 Hz (102400 pulse/s or less encoder pulses)

Page 28

6 VECTOR CONTROL

When FR-A8AP is mounterd on the FR-A800 series, full-scale vector control operation can be performed using a motor with encoder. Speed control, torque control and position control by vector control can be performed. (Refer to the Instruction Manual (Detailed) for details.)

6.1 Wiring examples

 Speed control

Standard motor with encoder (SF-JR), 5 V differential line driver

SF-JR motor with encoder U V W

Earth (Ground)

PA1

PA2

PB1

PB2

PZ1

PZ2

∗3

(+)

∗6

U V W E

∗1

C R

(-)

5 VDC power supply

Three-phase

AC power supply

Forward rotation start

Reverse rotation start

Contact input common

Frequency command

Frequency setting

potentiometer

1/2 W1 kΩ

Torque limit

command

(10 V)

MCCB MC

(+) (-)

R/L1 S/L2 T/L3

STF

STR

Inverter

FR-A8AP

Differential

Complementary

Terminating resistor ON

OFF

∗4

Encoder

∗2

∗5

Vector control dedicated motor

(SF-V5RU, SF-THY), 12 V complementary

∗7

Three-phase

AC power

supply

Inverter

External thermal relay input

FR-A8AP

Differential

Complementary

Terminating

resistor

OFF

MCCB MC

CS(OH)

∗8

PA1

PA2

PB1

PB2

PZ1

PZ2

∗4 ∗6

U V

2W1kΩ

OCR

Earth (Ground)

∗3

(+)

SF-V5RU, SF-THY

A B C

U V

G1 G2

∗1

12VDC power

(-)

supply

FAN

Thermal relay protector

Encoder

∗5

∗2

VECTOR CONTROL

Page 29

 Torque control

Standard motor with encoder (SF-JR), 5 V differential line driver

Vector control dedicated motor

(SF-V5RU, SF-THY), 12 V complementary

Three-phase

AC power

supply

Forward rotation start Reverse rotation start

Contact input common

Speed limit command

Frequency setting

potentiometer

1/2W1kΩ

Torque command

(±10V)

MCCB MC

Inverter

R/L1 S/L2 T/L3

STF

STR

(+) (-)

VECTOR CONTROL

FR-A8AP

Differential

Complementary

Terminating resistor ON

OFF

∗4

PA1

PA2

PB1

PB2

PZ1

PZ2

MCCB MC

SF-JR motor

Earth (Ground)

with encoder

∗1

Encoder

∗2

∗3

(-)

(+)

5VDC power supply

∗5

∗6

∗7

Three-phase

AC power

supply

Inverter

External thermal relay input

FR-A8AP

Differential

Complementary

Terminating

resistor

OFF

∗8

CS(OH)

∗4 ∗6

PA1

PA2

PB1

PB2

PZ1

PZ2

U V

2W1kΩ

OCR

Earth (Ground)

∗3

(+)

SF-V5RU, SF-THY

A B C

U V

G1 G2

∗1

12VDC power

(-)

supply

FAN

Thermal relay protector

Encoder

∗5

∗2

Page 30

 Position control

Positioning unit

MELSEQ-Q QD75P1

STOP

CLEAR

PULSE F

PULSE R

CLEAR COM

PULSE COM

RDY COM

COM

READY

Torque limit command

Vector control dedicated motor (SF-V5RU, SF-THY), 12 V complementary

MCCB MC OCR

∗7

Three-phase

AC power supply

FLS

RLS

DOG

Three-phase

AC power

supply

Forward stroke end

Reverse stroke end

Pre-excitation/servo on

Clear signal

Pulse train

Sign signal

24VDC power supply

Preparation ready signal

(+) (-)

(±10V)

MCCB

R/L1 S/L2 T/L3

External thermal protector relay input

STF

STR

CLR ∗9

JOG

NP ∗9

RDY ∗11

Inverter

∗8

FR-A8AP

∗9

∗10

Differential

line driver

Complementary

Terminating

CS(OH)

resistor

OFF

PA1

PA2

PB1

PB2

PZ1

PZ2

∗4 ∗6

U V

2W1kΩ

Earth (ground)

∗3

SF-V5RU, SF-THY

A B C

FAN

U V

Thermal protector

G1 G2

∗1

Encoder

12VDC

(-)

(+)

power supply

VECTOR CONTROL

∗2

∗5

Page 31

 The pin number differs according to the encoder used.

Speed, control, torque control, and position control by pulse train input are available with or without the Z-phase being connected.

 Connect the encoder so that there is no looseness between the motor and motor shaft. Speed ratio must be 1:1.  Earth (ground) the shield of the encoder cable to the enclosure using a tool such as a P-clip. (Refer to pag e 14.)  For the complementary, set the terminating resistor selection switch to OFF position. (Refer to page 12.)  A separate power supply of 5 V/12 V/15 V/24 V is necessary according to the encoder power specification.

When the encoder output is the differential line driver type, only 5 V can be input. Make the voltage of the external power supply the same as the encoder output voltage, and connect the external power supply across PG and SD. When performing orientation control together, an encoder and power supply can be shared.

 For terminal compatibility of the FR-JCBL, FR-V7CBL, and FR-A8AP, refer to page 1 8.  For the fan of the 7.5 kW or lower dedicated motor, the power supply is single phase. (200 V/50 Hz, 200 to 230 V/60 Hz)  Connect the recommended 2W1k resistor between the terminal PC and OH. (Recommended product: MOS2C102J 2W1k by KOA

When OH signal is assigned to terminal RH (Pr.182 = “7”)

RH (OH)

2-wire blade terminal

Insulate

To thermal protector

Resistor (2 W1kΩ)

Insulate

 Assign the function using Pr.178 to Pr.184, Pr.187 to Pr.189 (input terminal function selection).  When position control is selected, terminal JOG function is invalid and simple position pulse train input terminal becomes valid.  Assign the function using Pr.190 to Pr.194 (output terminal function selection).

VECTOR CONTROL

Page 32

6.2 Specifications

Speed control range 1:1500 (both driving/regeneration )

Speed control

Tor q u e c o n tr o l

Position control

Function

 Regeneration unit (option) is necessary for regeneration  With online auto tuning (adaptive magnetic flux observer), dedicated motor, rated load

Speed variation ratio ±0.01% (100% means 3000 r/min)

Speed response 130 Hz

Maximum speed 120 Hz (102400 pulse/s or less encoder pulses)

Torque control range 1:50

Absolute torque accuracy ±10% 

Repeated torque accuracy ±5% 

Repeated positioning accuracy

Maximum input pulse frequency

Positioning feedback pulse

Electronic gear setting 1/50 to 20

In-position width 0 to 32767 pulses

Error excess 0 to 400k pulses

±1.5° (at motor shaft end)

100 kpps (Terminal JOG)

Number of encoder pulses per motor rotation (Pr.369)  4

• Setting of speed feedback range

• Setting of feedback gain

• Setting of encoder rotation direction

VECTOR CONTROL

Page 33

REVISIONS

*The manual number is given on the bottom left of the back cover.

Print Date *Manual Number Revision

Aug. 2013 IB(NA)-0600505ENG-A First edition

IB(NA)-0600505ENG-A

Page 34

INVERTER

HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN

Printed in Japan Specifications subject to change without notice.IB(NA)-0600505ENG-A(1308) MEE