Mitsubishi FR-A8APA User Manual

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Page 1

INVERTER

Plug-in option

FR-A8APA

INSTRUCTION MANUAL

SinCos encoder interface

Orientation control

Encoder feedback control

Vector control

PRE-OPERATION INSTRUCTIONS

INSTALLATION AND WIRING

INVERTER FUNCTIONS ENABLED WITH FR-A8APA

ORIENTATION CONTROL

ENCODER FEEDBACK CONTROL

VECTOR CONTROL

Page 2

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

WARNING

CAUTION

This Instruction Manual provides handling information and precautions for use of this product. Incorrect handling might cause an unexpected fault. Before using this product, read all relevant instruction manuals carefully to ensure proper use. Please forward this Instruction Manual to the end user.

Safety instructions

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

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.

Note that even the level may lead to a serious consequence depending on conditions. Be sure to follow the

instructions of both levels as they are critical to personnel safety.

 Electric shock prevention

WARNING

 Do not remove the front cover or the wiring cover of the inverter while the inverter power is ON. Do not operate the inverter with any cover or wiring cover removed,

as accidental contact with exposed high-voltage terminals and internal components may occur, resulting in an electrical shock.

 Even if power is OFF, do not remove the front cover of the inverter except for wiring or periodic inspection as the inside of the inverter is charged. Otherwise you

may get an electric shock.

 Before wiring or inspection, check that the display of the inverter operation panel is OFF. Any person who is involved in wiring or inspection shall wait for 10 minutes

or longer after power OFF and check that there are no residual voltage using a tester or the like. The capacitor is charged with high voltage for some time after power OFF, and it is dangerous.

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

 Injury prevention

CAUTION

 The voltage applied to each terminal must be as 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, damage, etc. may occur.  While power is ON or for some time after power OFF, do not touch the inverter as it will be extremely hot. Doing so may cause a burn.

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

CAUTION

Transportation and installation

 Do not stand or place heavy objects on this product.  The installing orientation of this product must be correct.  Do not install or operate this product if it is damaged or has parts missing.  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.), included in fumigants to sterilize or disinfect wooden packages, infiltrate into this product, the

product may be damaged. Prevent residual fumigant components from being infiltrated into the product when packaging, or use an alternative sterilization or disinfection method (heat disinfection, etc.). Note that sterilization or disinfection of wooden package should also be performed before packing the product.

Test operation

 Before starting operation, confirm or adjust the parameter settings. Failure to do so may cause some machines to make unexpected motions.

WARNING

Usage

 Do not modify this product.  Do not remove any part which is not instructed to be removed in the Instruction Manuals. Doing so may lead to a failure or damage of this product.

CAUTION

Usage

 As all parameters return to their initial values after Parameter clear or All parameter clear is performed, the needed parameters for operation of the inverter and this

product must be set again bef ore the operation is started.

 To avoid damage to this product due to static electricity, static electricity in your body must be discharged before you touch this product.

Maintenance, inspection and parts replacement

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

Disposal

 This product must be treated as industrial waste.

 For clarity purpose, illustrations in this Instruction Manual may be drawn with covers or safety guards removed. Ensure all covers and safety guards are properly

General instruction

installed prior to starting operation.

Page 4

─ CONTENTS ─

1 PRE-OPERATION INSTRUCTIONS 6

1.1 Unpacking and product confirmation.......................................................................................................6

1.1.1 Product confirmation.......................................................................................................................................6

1.1.2 SERIAL number check ...................................................................................................................................7

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

2 INSTALLATION AND WIRING 9

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

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

2.3 Wiring ........................................................................................................................................................12

2.4 Terminals...................................................................................................................................................14

2.5 Encoder .....................................................................................................................................................15

3 INVERTER FUNCTIONS ENABLED WITH FR-A8APA 16

4 ORIENTATION CONTROL 17

4.1 Wiring example .........................................................................................................................................17

4.2 Terminals...................................................................................................................................................18

4.3 Specifications ...........................................................................................................................................19

5 ENCODER FEEDBACK CONTROL 20

5.1 Wiring examples .......................................................................................................................................20

5.2 Specifications ...........................................................................................................................................21

6 VECTOR CONTROL 22

Page 5

6.1 Wiring examples .......................................................................................................................................22

6.2 Setting procedure of vector control for motor with encoder ...............................................................25

6.3 Vector control for PM motor with encoder.............................................................................................26

6.4 Offline auto tuning....................................................................................................................................27

6.5 Encoder position tuning ..........................................................................................................................29

6.6 Specifications ...........................................................................................................................................32

APPENDIX 33

Page 6

1 PRE-OPERATION INSTRUCTIONS

NOTE

1.1 Unpacking and product confirmation

Take the product 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 made for the FR-A800 series inverter.

1.1.1 Product confirmation

Check the enclosed items.

Plug-in option

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

• Connection diagrams in this Instruction Manual appear with the control logic of the input terminals as sink logic, unless otherwise specified. (For the control logic, refer to the Instruction Manual of the inverter.)

PRE-OPERATION INSTRUCTIONS

Mounting screw (M3

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



8 mm)

page 9

Spacer

)

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

page 9

)

Page 7

1.1.2 SERIAL number check

SERIAL number

Country of origin

The FR-A8APA can be used with the models of inverters listed below which have the following SERIAL number. Check the SERIAL number indicated on the inverter rating plate or package.

Rating plate example

   

Symbol Year Month Control number

SERIAL

The SERIAL consists of one symbol, two characters indicating the production year and month, and six characters indicating the control number. The last digit of the production year is indicated as the Year, and the Month is indicated by 1 to 9, X (October), Y (November), or Z (December).

FR-A800 series

Model

Country of origin

indication

SERIAL number

FR-A820-00046(0.4K) to 04750(90K) FR-A840-00023(0.4K) to 06830(280K) FR-A842-07700(315K) to 12120(500K) FR-A846-00023(0.4K) to 03610(132K)

MADE in Japan 83 or later

MADE in China 84 or later

PRE-OPERATION INSTRUCTIONS

Page 8

1.2 Component names

Front view Rear view

Terminal layout

EC+ ED+EA+ EB+ ER+

UP UN

EC- ED-EA- EB- ER-

UP UN

(a) (d)

(a)

(c)

(a)

(b)

Symbol Name Description

a Mounting hole Used to fix this product to the inverter by inserting a mounting screw or a spacer. 9

b Terminal block Used to connect the terminals of this product and an encoder. 14

c CON2 connector Pulse output connector. ―

d Board mounted option connector Used to connect this product to the option connector on the inverter. 9

PRE-OPERATION INSTRUCTIONS

Refer

to page

Page 9

Spacer

Option connector on the inverter

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 install or remove this product while the inverter power is ON. Doing so may damage the inverter or this product.  To avoid damage due to static electricity, static electricity in your body must be discharged before you touch this product.

2.2 Installation procedure

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

the Instruction Manual (Detailed) of the inverter for instructions for removing the front cover.)

(2) Insert two spacers into the mounting holes that will not be

filled with mounting screws (see the diagrams on the next page to identify the holes ).

(3) Fit the board mounted option connector on this product to

the guide of the option connector on the inverter, and insert the option as far as it goes.

(4) Fasten this product to the inverter using the two mounting

screws through the holes on either side (tightening torque:

0.33 to 0.40 N·m). If the screw holes do not line up, the connector may not be inserted deep enough. Check the connector.

Example of installation to connector 1

INSTALLATION AND WIRING

Page 10

• Insertion positions for screws and spacers

Connector 3

Connector 2 Connector 1

Spacer

Mounting screw

Spacer

Mounting screw

Spacer

Mounting screw

Connector 1

Connector 3

Ethernet connector

FR-A800

FR-A800-E

Attach the option to connector 1 or 2. (Do not attach the plug-in option to connector 3.)

INSTALLATION AND WIRING

Attach the option to connector 1 or 3.

Page 11

NOTE

• When installing/removing the plug-in option, hold the sides of the option. Do not press on the parts on the option circuit board. Stress applied to the parts by pressing, etc. may cause a failure.

• Be careful not to drop mounting screws during the installation or removal of the plug-in option.

• The priorities of vector control compatible plug-in options are defined as follows: FR-A8AL > FR-A8APS > FR-A8APA > FR-A8APR > FR-A8AP. The vector control compatible plug-in options with lower priority do not function.

• Only one option attached to the option connector with high priority can function at once if more than one option of the same name are installed together on an inverter. Priority is given to option connectors in descending order (1 to 3), and options having a lower priority do not function.

• When the inverter cannot recognize the option unit due to improper installation, etc., or when a fault occurs in the option or encoder, the protective function (E.1 to E.3 or E.OP1 to E.OP3) is activated and the inverter cannot be operated. The indication shown (when a fault occurs) depends on the connector used (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 either side, and then pull it straight out. Pressure applied to the option connectors and to the option board may break the option.

INSTALLATION AND WIRING

Page 12

2.3 Wiring

NOTE

5 mm

Wire

Sleeve

0 to 0.5 mm

(1) Strip the signal wires as shown below. If too much of the wire is stripped, a short circuit may occur with neighboring wires.

If not enough of the wire is stripped, wires may become loose and fall out. Twist the stripped end of wires to prevent them from fraying. Do not solder it.

Wire strip length

Use appropriate crimp terminals (ferrules, blade terminals, etc.) for these terminal blocks as necessary. When using the crimp terminal, make sure that the stranded wire do not come out of the terminal.

Unstranded

Wire

Sleeve

wires

Ter min al

screw size

0 to 0.5 mm

Damaged

Crumpled tip

Wires are not inserted into the sleeve

• Crimp terminals commercially available (as of January 2017. The product may be changed without notice.)

Wire size (mm2)

0.3 AI 0,34-6TQ A 0,34-7

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

Ferrule part No.

Manufacturer

Phoenix Contact Co., Ltd.

INSTALLATION AND WIRING

Crimping tool

model No.With insulation sleeve Without insulation sleeve

CRIMPFOX 6

Page 13

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

NOTE

Screw size Tightening torque Cable size Screwdriver

M2 0.22 to 0.25 Nm

• Under-tightening may cause cable disconnection or malfunction. Over-tightening may cause a short circuit or malfunction due to damage to the screw or unit.

• When wiring the RS-485 terminals on the inverter with the plug-in options installed, be careful not to let RS-485 cables touch the option circuit boards and the inverter circuit board. This is to prevent a malfunction due to electromagnetic noises.

0.3 to 0.75 mm

Small flat-blade screwdriver (Tip thickness: 0.4 mm, tip width: 2.5 mm)

CAUTION

 After wiring, do not leave wire offcuts in the inverter. Doing so may cause a fault, failure, or malfunction.

INSTALLATION AND WIRING

Page 14

2.4 Terminals

Ter minal

symbol

UP Encoder power supply (Up)

UN Encoder earth (ground) (0V)

EA+ Incremental sine signal: phase A (A+)

EA- Incremental sine signal: phase A (A-)

EB+ Incremental cosine signal: phase B (B+) For the incremental cosine signal output from the sinusoidal encoder.

EB- Incremental cosine signal: phase B (B-)

ER+ Home position signal: phase R (R+)

ER- Home position signal: phase R (R-)

EC+

EC-

ED+

ED-

Magnetic pole position detection sine signal: phase C (C+)

Magnetic pole position detection sine signal: phase C (C-)

Magnetic pole position detection cosine signal: phase D (D+)

Magnetic pole position detection cosine signal: phase D (D-)

INSTALLATION AND WIRING

Ter mi na l name Description

For the power supply (5 V) for the encoder

For the incremental sine signal output from the sinusoidal encoder

The cosine signal has a phase difference of 90 degrees with respect to the sine signal (phase A).

For the home position signal output from the sinusoidal encoder

For the sine signal taken from the Z1 track of the sinusoidal encoder (one period per revolution)

For the cosine signal taken from the Z1 track of the sinusoidal encoder (one period per revolution)

Page 15

2.5 Encoder

 Required encoder specifications

Interface

Signal type

Signal period

Permissible speed

The following table shows the supported encoder and cables. (as of January 2018. The product may be changed without notice.)

Applicable encoder

Recommended cable

Maximum wiring length

Manufacturer

FR-A8APA

Sinusoidal voltage signal (1 Vpp)

Incremental signal (sine/cosine) Home position signal Magnetic pole position detection signal (sine/cosine signal taken from the Z1 track, one period per revolution)

2048

Rotation speed of the SinCos encoder interface encoder-mounted shaft: 5800 r/min The drive shaft and encoder-mounted shaft must be coupled directly or via a belt (with the speed ratio of 1:1) without any mechanical looseness or slip. Gear changing shafts cannot be applied.

ERN 1387

Cables compatible with the encoder above (manufactured by HEIDENHAIN)

100 m

HEIDENHAIN

circuit board

Terminals

EA+ UNUPEB+ ER+ EC+ ED+

UNUP

EB- ER- EC- ED-

EA-

SinCos encode

UN: White/Green

UP: Brown/Green

ED-: Violet ED+: Yellow EC-: Pink EC+: Gray ER-: Black ER+: Red EB-: Red/Black EB+: Blue/Black EA-: Yellow/Black EA+: Green/Black

INSTALLATION AND WIRING

Page 16

3 INVERTER FUNCTIONS ENABLED WITH FR-A8APA

NOTE

 Parameter for detector

Setting item Parameters for FR-A8APA

Encoder rotation direction Pr.359

Number of detector pulses (Signal period) Pr.369

Encoder signal loss detection enable/disable selection Pr.376

 Maximum setting speed of the inverter

When the FR-A8APA is installed, operate the inverter so that the encoder pulse frequency is kept at 100 kHz or lower. If a speed higher than the maximum speed is set, the speed is clamped at the maximum speed.

• While the motor stops, signal loss may not be detected depending on the motor shaft position. Before starting the operation, check the wiring.

• The availability of the functions differ according to the specifications of the inverter. Refer to the Instruction Manual of the Inverter.

• When the motor rotation in the low-speed range (60 r/min or lower) is unstable, check if the encoder cables are properly connected.

INVERTER FUNCTIONS ENABLED WITH FR-A8APA

Page 17

4 ORIENTATION CONTROL

V/FV/FV/F

Magnetic fluxMagnetic fluxMagnetic flux

VectorVectorVector

 Use Pr.178 to Pr.189 (input terminal

function selection) to assign the function

to any of terminal. Refer to the Instruction Manual (Detailed) of the inverter 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) of the inverter 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 shield of the encoder

cable to the enclosure using a tool such as a P-clip.

 When a stop position command is input

from outside, a plug-in option FR-A8AX is necessary. Refer to the Instruction Manual (Detailed) of the inverter for details of external stop position command.

This function is used with an 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

Three-phase

MCCB

AC power

supply

Forward rotation start

Reverse rotation start

Orientation command

Contact input common

R/L1 S/L2 T/L3

STF

STR

X22

∗1

ORA

∗2

ORM

∗2

FR-A8AX

∗5

X15

X14

Inverter

FR-A8APA

EA+

EA-

EB+

EB-

ER+

ER-

EC+

EC-

ED+

ED-

EA+

EA-

EB+

EB-

ER+

ER-

EC+

EC-

ED+

ED-

U V W E

Encoder ERN 1387

∗3

ORIENTATION CONTROL

U V W

Earth (Ground)

∗4

Page 18

4.2 Terminals

 FR-A8AX terminal

Ter minal

symbol

X0 to X15 Digital signal input terminal

Terminal name Description

Data read timing input signal terminal

 Inverter terminal

Ter minal

(signal)

Input X22 Orientation command

Output

Terminal (signal) name Application explanation

ORA Orientation complete

ORM Orientation fault

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

Pr.196 (output terminal function selection).

ORIENTATION CONTROL

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 ORM signal output, assign the function by setting "28 (positive logic) or 128 (negative logic)" in any of Pr.190 to Pr.196.



Page 19

4.3 Specifications

Repeated positioning

accuracy

Functions

Holding force after

positioning

Input signal

(contact input)

Output signal

(open collector output)

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

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 Binary signal of maximum 16 bits (when used with the FR-A8AX)

Orientation completion signal, orientation fault signal

ORIENTATION CONTROL

Page 20

5 ENCODER FEEDBACK CONTROL

V/FV/FV/F

Magnetic fluxMagnetic fluxMagnetic flux

Earth (Ground)

Inverter

Three-phase

AC power supply

MCCB

R/L1 S/L2 T/L3

U V W

U V

FR-A8APA

STF

STR

Forward rotation start Reverse rotation start

Contact input common

Frequency setting

potentiometer

∗1

Encoder ERN 1387

∗2

EA+

EA-

EB+

EB-

ER+

ER-

EC+

EC-

ED+

ED-

EA+

EA-

EB+

EB-

ER+

ER-

EC+

EC-

ED+

ED-

EA+

EA-

EB+

EB-

ER+

ER-

EC+

EC-

ED+

ED-

EA+

EA-

EB+

EB-

ER+

ER-

EC+

EC-

ED+

ED-

 Connect the encoder so that there is no

looseness between the motor and motor shaft. Speed ratio should be 1:1.

 Earth (ground) the shield of the

encoder cable to the enclosure using a tool such as a P-clip.

When the FR-A8APA is installed on the FR-A800 series inverter, encoder feedback control can be performed 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 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

ENCODER FEEDBACK CONTROL

Page 21

5.2 Specifications

Speed variation ratio

Function

0.1% (100% means 3600 r/min)

• Setting of speed feedback range

• Setting of feedback gain

• Setting of encoder rotation direction

ENCODER FEEDBACK CONTROL

Page 22

6 VECTOR CONTROL

Three-phase

AC power supply

MCCB

Earth (Ground)

Inverter

Frequency command

Frequency setting

potentiometer

1/2 W1 kΩ

Torque limit

command

( 10 V)

R/L1 S/L2 T/L3

U V

FR-A8APA

STF

STR

(+) (

)

Forward rotation start

Reverse rotation start

Contact input common

∗1

Encoder ERN 1387

∗2

EA+

EA-

EB+

EB-

ER+

ER-

EC+

EC-

ED+

ED-

EA+

EA-

EB+

EB-

ER+

ER-

EC+

EC-

ED+

ED-

When the FR-A8APA is installed on the FR-A800 series inverter, full-scale vector control operation can be performed using a motor with encoder. (For the details of vector control, refer to the Instruction Manual (Detailed) of the inverter.) Speed control, torque control, and position control are enabled under vector control for the induction motor. Speed control and position control are enabled under vector control for the PM motor.

6.1 Wiring examples

 Speed control

VECTOR CONTROL

Page 23

 Torque control (With induction motor only)

R/L1 S/L2 T/L3

STF

STR

Three-phase

AC power supply

Forward rotation start

Reverse rotation start

Contact input common

Speed limit command

Frequency setting

potentiometer

1/2 W1 kΩ

Torque command

( 10 V)

(+) (

)

MCCB

Inverter

FR-A8APA

EA+

EA-

EB+

EB-

ER+

ER-

EC+

EC-

ED+

ED-

EA+

EA-

EB+

EB-

ER+

ER-

EC+

EC-

ED+

ED-

U V

Encoder ERN 1387

∗1

U V

Earth (Ground)

∗2

VECTOR CONTROL

Page 24

 Position control

Positioning unit

MELSEC iQ-R RD75[]

MELSEC-Q QD75P[ ]N/QD75P[ ]

MELSEC-L LD75P[ ]

 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.  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).

Three-phase

FLS

RLS

DOG

STOP

CLEAR

PULSE F

PULSE R

CLRCOM

PULSE COM

RDYCOM

COM

READY

Torque limit command

( 10 V)

MCCB

AC power

supply

Forward stroke end

Reverse stroke end

Pre-excitation/servo on

Clear signal

Pulse train

Sign signal

24 VDC power supply

Preparation ready signal

(+)

)

(

R/L1 S/L2 T/L3

STF

STR

∗3

CLR ∗3

JOG

NP ∗3

RDY ∗5

∗4

Inverter

FR-A8APA

EA+

EA-

EB+

EB-

ER+

ER-

EC+

EC-

ED+

ED-

Earth (ground)

∗2

EA+

EA-

EB+

EB-

ER+

ER-

EC+

EC-

ED+

ED-

U V

Encoder ERN 1387

∗1

U V

VECTOR CONTROL

Page 25

6.2 Setting procedure of vector control for motor with encoder

Test operation

Perform offline auto tuning for induction motors, or perform offline auto tuning and the encoder position tuning for PM motors. (Pr.96) (Refer to page 27.)

Configure the initial parameter setting for the applied motor using Pr.998.

When the setting for the PM motor is selected in Pr.998 PM parameter initialization, the vector control for the motor with an encoder is selected. "8009": Parameter (rotations per minute) settings for an IPM motor other than MM-CF "8109": Parameter (frequency) settings for an IPM motor other than MM-CF "9009": Parameter (rotations per minute) settings for an SPM motor "9109": Parameter (frequency) settings for an SPM motor

Set Pr.96, and perform tuning.

Set the applied encoder. (Pr.359, Pr.369)

Set Pr.359 Encoder rotation direction and Pr.369 Number of encoder pulses according to the encoder to be used.

Under position control

•Set Pr.800 again. (Refer to page 26.)

Set the motor. (Pr.9, Pr.71, Pr.80, Pr.81, Pr.83, Pr.84)

Set Pr.71 Applied motor, Pr.9 Rated motor current, Pr.80 Motor capacity, Pr.81 Number of motor poles, Pr.83 Rated motor voltage, and Pr.84 Rated motor frequency according to the motor specifications. (Setting "9999 (initial value)" in Pr.80 or Pr.81 selects V/F control.) Set Pr.702, Pr.706, Pr.707, Pr.724, or Pr.725 as required for the PM motor.

Select vector control (other than position control). (Refer to page 26.)

PM motor

Induction

motor

Follow the following procedure to change the setting for the vector control for the motor with an encoder.

VECTOR CONTROL

Page 26

NOTE

• For PM motors, after performing offline auto tuning and encoder position tuning, first perform PM parameter initialization. If parameter initialization is performed after setting other parameters, some of those parameters will be initialized too. (For the parameters to be initialized, refer to the Instruction Manual (Detailed) of the inverter.)

6.3 Vector control for PM motor with encoder

• With the FR-A8APA, PM motors with an encoder can be driven under vector control. (For the setting of vector control for an induction motor, refer to the Instruction Manual (Detailed) of the inverter.)

Pr.80

(Pr.453),

Pr.81

Pr.71

(Pr.450)

(Pr.454)

Other than 9999

9999

IPM/SPM motor (other than MM-CF)

 ―― ―

 The setting values of 100 and above are used when the fast-response operation is selected.  The operation for the setting of "0 or 100" is performed when "1, 2, 101, or 102" is set.  The operation for the setting of "4 or 104" is performed when "5 or 105" is set.  Speed control under PM sensorless vector control when the FR-A8APA is not installed.  The operation for the setting of "20 or 110" is performed when "10 to 14, or 111 to 114" is set.  When a PM motor is used, set Pr.80 and Pr.81 according to the motor. Setting "9999" disrupts proper operation.

Pr.800

setting





0, 100

3, 103 Position control ―



4, 104

6, 106

9, 109 ― PM sensorless vector control test operation

20 (initial value), 110

─

Pr.451 settingControl method Control mode Remarks

Speed control ―

Speed control/position control switchover

Torque control by variablecurrent limiter control

Speed control ―

20, 110



9999 (initial value)

Vector control

PM sensorless vector control

The setting value of Pr.800 is used for the second motor. (PM sensorless vector control (speed control) when Pr.800="9 or 109")

MC signal: ON Position control MC signal: OFF Speed control

―

VECTOR CONTROL

Page 27

6.4 Offline auto tuning

VectorVectorVector

• Offline auto tuning enables the optimal operation of a motor with encoder.

Pr. Name

Auto tuning setting/status 0

C110

463

Second motor auto tuning setting/status 0 0, 1, 11, 101

C210

Initial value

POINTPOINT

• Refer to the Instruction Manual (Detailed) of the inverter to perform offline auto tuning.

• This section explains the specific information of the motor with an encoder.

Setting

range

0 Offline auto tuning disabled.

1 Offline auto tuning enabled (without the motor rotating).

101

Offline auto tuning enabled only for motor constant R1 (without the motor rotating).

Encoder position tuning and offline auto tuning enabled (with the motor rotating slightly).

Setting of offline auto tuning for the second motor (refer to Pr.96 for the setting description.)

Description

PM motor Induction motor

Offline auto tuning enabled (with the motor rotating).

VECTOR CONTROL

Page 28

 Parameters to be overwritten with the tuning result data after tuning of PM motor

NOTE

Pr. Name

90 (458) Motor constant (R1) Resistance per phase

92 (460) Motor constant (L1)/d-axis inductance (Ld) ― d-axis inductance

93 (461) Motor constant (L2)/q-axis inductance (Lq) ― q-axis inductance

711 (739) Motor Ld decay ratio ― d-axis inductance decay ratio

712 (740) Motor Lq decay ratio ― q-axis inductance decay ratio

859 (860) Torque current/Rated PM motor current ―

96 (463) Auto tuning setting/status 

373 Encoder position tuning setting/status  ――

1105 Encoder magnetic pole position offset  ――

: Tuned, ―: Not tuned

• If the offline auto tuning is started before the encoder position tuning for a PM motor is finished (Pr.1105 = "9999"), the protective function (E.MP) is activated.

Tuning according to Pr.96 (Pr.463) setting

101 1 11

Description

Encoder position tuning performing status

Turning data of encoder position tuning

VECTOR CONTROL

Page 29

6.5 Encoder position tuning

NOTE

VectorVectorVector

• Encoder position tuning is required when a PM motor with an encoder is driven. The measured offset value between the motor home magnetic pole position and the encoder home position is stored. Only encoder position tuning can be performed when offline auto tuning is not required, such as when the parameters for motor constant are set manually, or when offline auto tuning is already performed.

Pr. Name

373 C142

1105 C143

Encoder position tuning setting/status 0

Encoder magnetic pole position offset 9999

Initial value

 Before performing encoder position tuning

• Check that the FR-A8APA, a motor, and an encoder are properly connected.

• Check that a motor (single, stop status) is connected. (Check that the motor is not rotated by an external force during tuning.)

• Check that the mechanical brake is released.

• Check that the vector control (speed control) for the PM motor with an encoder is selected (refer to page 26).

• Encoder position tuning is required when a PM motor is used. (It is disabled when an induction motor is used.)

• When auto tuning is performed while Pr.96 = "101", offline auto tuning and encoder position tuning can be performed at the same time (refer to page 27).

 Setting

• To perform tuning, set Pr.373 = "1".

Setting

range

0 Encoder position tuning disabled.

1 Encoder position tuning enabled.

0 to 4095 Encoder position tuning data set.

9999 No encoder position tuning data.

Description

VECTOR CONTROL

Page 30

 Performing tuning

NOTE

AutoTune 12:34 TUNE

--- STOP PU

PREV NEXT

AutoTune 12:34 TUNE

STF FWD PU

PREV NEXT

Blinking

AutoTune 12:34 TUNE

Completed

STF STOP PU

PREV NEXT

POINTPOINT

• Before tuning, check the monitor display of the PU if the inverter is in the state ready for tuning. If the start command is turned ON though the inverter is not ready, the motor can start running.

• In the PU operation mode, press / on the operation panel.

In the external operation mode, turn ON the start command (STF signal or STR signal). Tuning will start.

• The motor shaft rotates up to 2 times during tuning.

• The displays/indicator on the operation panel (FR-DU08), the parameter unit (FR-PU07), and the LCD operation panel (FRLU08) will change as shown below while tuning when Pr.373 = "1".

Status Parameter unit (FR-PU07) display

READ:List

TUNE

Setting

STOP PU

Operation panel (FR-DU08)

display/indicator

LCD operation panel (FR-LU08) display

During tuning

Normal completion

VECTOR CONTROL

TUNE

FWD PU

STF

TUNE COMPLETION

STOP PU

STF

Page 31

• When encoder position tuning ends, press on the operation panel during PU operation. In the external operation

NOTE

mode, turn OFF the start signal (STF signal or STR signal). This operation resets encoder position tuning, and the PU's monitor display returns to the normal indication. (Without this operation, next operation cannot be started.)

• The encoder position tuning data is stored in Pr.1105 until encoder position tuning is performed again. However, performing all parameter clear resets the tuning data.

• If encoder position tuning has ended in error (see the table below), tuning data has not been set. Perform an inverter reset and restart tuning.

Pr.373 setting Error cause Corrective actions

8 Forced end Set Pr.373 = "1" and try tuning again.

9 Inverter protective function operation

93 The motor or the encoder is not connected.

• When tuning is ended forcibly by pressing or turning OFF the start signal (STF or STR) during tuning, tuning does

not end properly. (The tuning data have not been set.) Perform an inverter reset and restart tuning.

• When the protective function (Encoder phase fault (E.EP)) is activated during tuning, check the wiring of the motor and the encoder, Pr.359 setting, and then perform tuning again.

• When tuning ends properly, the counter value of the offset between the motor home magnetic pole position and the encoder home position is written in Pr.1105.

Identify and remove the cause of the protective function activation, and make the setting again.

Check the wiring of the motor and the encoder, the brake opening, and make the setting again.

VECTOR CONTROL

Page 32

6.6 Specifications

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

Speed control

Torq ue c ont ro l

Position control

Function

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

Speed response 20 Hz (40 Hz during fast-response operation)

Torque control range 1:50

Absolute torque accuracy 10% 

Repeated torque accuracy 5% 

Repeated positioning accuracy 1.5° (at motor shaft end)

Maximum input pulse frequency 100k pulses/s (Terminal JOG)

Positioning feedback pulse Different depending on the encoder resolution

Electronic gear setting 1/50 to 20

In-position width 0 to 32767 pulses

Error excess 0 to 400k pulses

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

• Setting of speed feedback range

• Setting of feedback gain

VECTOR CONTROL

Page 33

APPENDIX

Restricted Use of Hazardous Substances in Electronic and Electrical Products

The mark of restricted use of hazardous substances in electronic and electrical products is applied to the product as follows based on the “Management Methods for the Restriction of the Use of Hazardous Substances in Electrical and Electronic Products” of the People's Republic of China.

电器电子产品有害物质限制使用标识要求

环境保护使用期限标识

本产品中所含有的有害物质的名称、含量、含有部件如下表所示。

• 产品中所含有害物质的名称及含量

部件名称

电路板组件（如电阻、电容、集成电路、

金属壳体、金属部件

树脂壳体、树脂部件

螺丝、电线

上表依据SJ/T11364的规定编制。 ○：表示该有害物质在该部件所有均质材料中的含量均在GB/T26572规定的限量要求以下。 ×：表示该有害物质在该部件的至少一种均质材料中的含量超出GB/T26572规定的限量要求。

包括印刷电路板及其构成的零部件，

连接器等）、电子部件

 即使表中记载为 ×，根据产品型号，也可能会有有害物质的含量为限制值以下的情况。  根据产品型号，一部分部件可能不包含在产品中。

铅(Pb) 汞(Hg) 镉(Cd) 六价铬(Cr(VI)) 多溴联苯(PBB) 多溴二苯醚(PBDE)

   

    

   

有害物质

APPENDIX

Page 34

MEMO

IB(NA)-0600758ENG-B

Page 35

REVISIONS

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

Print date *Manual number Revision

Jul. 2017 IB(NA)-0600758ENG-A First edition

Feb. 2018 IB(NA)-0600758ENG-B

Addtion

• Compatibility with the FR-A800 series

Page 36

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)-0600758ENG-B(1802) MEE