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VG522P2
Technical Manual
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Saftronics VG520P7, VG522P2, VG527P5, VG52011, VG521P5 Technical Manual

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TECHNICAL MANUAL
VG5
REV2 (9/98) P/N 027-2040 1998
PREFACE
The VG5 Series of general-purpose Inverters provides V/f Control and Vector Control as standard features along with user-friendly operation.
This manual is designed to ensure correct and suitable application of the VG5 Series Inverters. Read this manual before attempting to install, operate, maintain, or inspect an Inverter and keep it in a safe, convenient location for future reference. Make sure you understand all precautions and safety information before attempting any application.
Saftronics, 1998
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of Saftronics. No patent liability is assumed with respect to the use of the information contained herein. Moreover, because Saftronics is constantly striving to improve its high-quality products, the information contained in this manual is subject to change without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, Saftronics assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication.
PREFACE
Safety Information
The following conventions are used to indicate precautions in this manual. Failure to follow the precautions provided in this manual can result in serious or possible even fatal injury or damage to the products or to related equipment and systems.
WARNING
CAUTION
The warning symbols for ISO and JIS standards are different, as shown below.
ISO JIS
The ISO symbol is used in this manual. Both of these symbols appear on warning labels on Saftronics products. Please abide by these warning labels regardless of which symbol is used.
Indicates precautions that, if not followed, could possibly result in loss of life or serious injury.
Indicates precautions that, if not followed, could result in serious injury, damage to the product, or faulty operation.
Visual Aids
The following aids are used to indicate certain types of information for easier reference.
‘‘EXAMPLE•• Indicates application examples.
NOTE: Indicates important information that should be memorized.
General Precautions
• The diagrams in this manual may be indicated without covers or safety shields to show details. Be sure to restore covers or shields
before operating the units and run the units according to the instructions described in this manual.
• Any illustrations, photographs, or examples used in this manual are provided as examples only and may not apply to all products to
which this manual is applicable.
• The products and specifications described in this manual or the content and presentation of the manual may be changed without notice
to improve the product and/or the manual.
• When ordering a new copy of the manual due to damage or loss, contact your Saftronics representatives or the nearest Saftronics sales
office and provide the manual number shown on the front cover.
• If nameplates become warn or damaged, order new ones from your Saftronics representatives or the nearest Saftronics sales office.
Firmware – S1043 Revision: 2 (9/98) ii © Saftronics, Inc.
PREFACE
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Safety Precautions
§ Confirmations upon Delivery
CAUTION
• Never install an Inverter that is damaged or missing components. Doing so can result in injury.
§ Installation
CAUTION
Always hold the case when carrying the Inverter. If the Inverter is held by the front cover, the main body of the Inverter may fall, possibly resulting in injury.
Attach the Inverter to a metal or other noncombustible material. Fire can result in the Inverter if attached to a combustible material.
Install a cooling fan or other cooling device when installing more than one Inverter in the same enclosure so that the temperature of the air entering the Inverters is below 45°C. Overheating can result in fires or other accidents.
§ Wiring
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WARNING
• Always turn OFF the input power supply before wiring terminals. Otherwise, an electric shock or fire can occur.
Wiring must be performed by an authorized person qualified in electrical work. Otherwise, an electric shock or fire can occur.
Be sure to ground the ground terminal. (200 V class: Ground to 100 × or less, 400 V class: Ground to 10 × or less) Otherwise, an electric shock or fire can occur.
Always check the operation of any emergency stop circuits after they are wired. Otherwise, there is the possibility of injury. (Wiring is the responsibility of the user.)
Never touch the output terminals directly with your hands or allow the output lines to come into contact with the Inverter case. Never short the output circuits. Otherwise, electrical shock or grounding can occur.
CAUTION
Check to be sure that the voltage of the main AC power supply satisfies the rated voltage of the Inverter. Injury or fire can occur if the voltage is not correct.
Do not perform voltage withstand tests on the Inverter. Otherwise, semiconductor elements and other devices can be damaged.
Connect braking resistors, Braking Resistor Units, and Braking Units as shown in the I/O wiring examples. Otherwise, a fire can occur.
• Tighten all terminal screws to the specified tightening torque. Otherwise, a fire may occur.
Do not connect AC power to output Terminal T1, T2, and T3 (U, V, and W). The interior parts of the Inverter will be damaged if voltage is applied to the output terminals.
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PREFACE
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CAUTION
Do not connect Power Factor Correction Capacitors or LC/RC noise filters to the output circuits. The Inverter can be damaged or internal parts burnt if these devices are connected.
Do not connect electromagnetic switches or contactors to the output circuits. If a load is connected while the Inverter is operating, surge current will cause the overcurrent protection circuit inside the Inverter to operate.
§ Setting User Constants
CAUTION
Disconnect the load (machine, device) from the motor before Auto-Tuning. The motor may turn, possibly resulting in injury or damage to equipment. Also, motor constants cannot be correctly set with the motor attached to a load.
§ Trial Operation
WARNING
Check to be sure that the front cover is attached before turning ON the power supply. Do not remove the front cover during operation. An electric shock may occur.
Do not come close to the machine when the fault reset function is used. If the alarm is cleared, the machine may start moving suddenly. Also, design the machine so that human safety is ensured even when it is restarted. Injury may occur.
Provide a separate emergency stop switch; the Digital Operator STOP key is valid only when the function is set. Injury may occur.
Reset alarms only after confirming that the RUN signal is OFF. If an alarm is reset with the RUN signal turned ON, the machine may suddenly start. Injury may occur.
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Do not touch the radiation fins (heat sink), braking resistor, or Braking Resistor Unit. These can become very hot. Otherwise, a burn injury may occur.
Be sure that the motor and machine is within the applicable ranges before starting operation. Otherwise, an injury may occur.
• Provide a separate holding brake if necessary. Otherwise, an injury may occur.
• Do not check signals while the Inverter is running. Otherwise, the equipment may be damaged.
Be careful when changing Inverter settings. The Inverter is factory set to suitable settings. Otherwise, the equipment may be damaged. You must, however, you must set the power supply voltage jumper for 400 V class Inverters of 18.5 kW or higher (See Chapter 5, 5.2.4 Setting Input Voltage).
Firmware – S1043 Revision: 2 (9/98) iv © Saftronics, Inc.
CAUTION
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PREFACE
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§ Maintenance and Inspection
WARNING
Do not touch the Inverter terminals. Some of the terminals carry high voltages and are extremely dangerous. Doing so can result in electric shock.
Always have the protective cover in place when power is being supplied to the Inverter. When attaching the cover, always turn OFF power to the Inverter through the MCCB. Doing so can result in electric shock.
After turning OFF the main circuit power supply, wait until the CHARGE indicator light goes out before performance maintenance or inspections. The capacitor will remain charged and is dangerous.
Maintenance, inspection, and replacement of parts must be performed only by authorized personnel. Remove all metal objects, such as watches and rings, before starting work. Always use grounded tools. Failure to heed these warnings can result in electric shock.
CAUTION
A CMOS IC is used in the control board. Handle the control board and CMOS IC carefully. The CMOS IC can be destroyed by static electricity if touched directly.
Do not change the wiring, or remove connectors or the Digital Operator, during operation. Doing so can result in personal injury.
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§ Other
WARNING
• Do not attempt to modify or alter the Inverter. Doing so can result in electrical shock or injury.
PREFACE
How to Change the Digital Operator Display from Japanese to English
If the Digital Operator displays messages in Japanese, change to the English mode using the following steps. (This manual provides descriptions for the English mode.)
Firmware – S1043 Revision: 2 (9/98) vi © Saftronics, Inc.
Table of Contents
1 Introduction .......................................................................................... 1
1.1 Outline and Functions.................................................................................... 2
1.2 Nomenclature ............................................................................................. 6
2 Handling Inverters................................................................................ 9
2.1 Confirmations upon Delivery.......................................................................... 10
2.2 Exterior and Mounting Dimensions................................................................. 12
1.1.1 VG5 Inverter Models ........................................................................................................... 2
1.1.2 Outline of Control Methods................................................................................................. 3
1.1.3 Functions............................................................................................................................. 3
1.2.1 VG5 Components................................................................................................................ 6
1.2.2 Digital Operator Components ............................................................................................. 7
2.1.1 Nameplate Information ........................................................................................................ 10
2.3 Checking and Controlling the Installation Site................................................. 14
2.3.1 Installation on Site............................................................................................................... 14
2.3.2 Controlling the Ambient Temperature................................................................................. 14
2.3.3 Protecting the Inverter from Foreign Matter ....................................................................... 14
2.4 Installation Orientation and Space.................................................................. 15
2.5 Removing/Attaching the Digital Operator and Front Cover.............................. 16
2.5.1 Inverters of 15 kW or Less.................................................................................................. 16
2.5.2 Inverters of 18.5 kW or Higher ............................................................................................ 17
3 Wiring .......................................................................................... 19
3.1 Connections to Peripheral Devices................................................................. 21
3.2 Connection Diagram...................................................................................... 22
3.3 Terminal Block Configuration......................................................................... 23
3.4 Wiring Main Circuit Terminals ........................................................................ 24
3.5 Wiring Control Circuit Terminals..................................................................... 39
3.6 Wiring Check................................................................................................. 42
3.4.1 Applicable Wire Sizes and Closed-Loop Connectors ........................................................ 24
3.4.2 Main Circuit Terminal Functions......................................................................................... 29
3.4.3 Main Circuit Configurations................................................................................................. 30
3.4.4 Standard Connection Diagrams.......................................................................................... 32
3.4.5 Wiring the Main Circuits...................................................................................................... 33
3.5.1 Wire Sizes and Closed-loop Connectors............................................................................ 39
3.5.2 Control Circuit Terminal Functions ..................................................................................... 40
3.5.3 Control Circuit Terminal Connections (All Models)............................................................ 41
3.5.4 Control Circuit Wiring Precautions...................................................................................... 42
3.7 Installing and Wiring PG Speed Option Cards................................................ 43
4 Setting User Constants........................................................................ 53
4.1 Using the Digital Operator.............................................................................. 54
4.2 Modes ......................................................................................................... 56
Firmware – S1043 Revision: 2 (9/98) vii © Saftronics, Inc.
3.7.1 Installing a PG Speed Option Card..................................................................................... 43
3.7.2 PG Speed Option Card Terminal Blocks............................................................................ 44
3.7.3 Wiring a PG Speed Option Card......................................................................................... 45
3.7.4 Wiring PG Speed Option Card Terminal Blocks ................................................................ 49
3.7.5 Selecting the Number of PG Pulses................................................................................... 51
4.2.1 Inverter Modes..................................................................................................................... 56
4.2.2 Switching Modes ................................................................................................................. 57
4.2.3 User Constant Access Levels............................................................................................. 58
4.2.4 Operation Mode................................................................................................................... 63
4.2.5 Initialize Mode...................................................................................................................... 70
4.2.6 Programming Mode ............................................................................................................. 77
4.2.7 Auto-Tuning Mode ............................................................................................................... 81
4.2.8 Modified Constants Mode ................................................................................................... 83
5 Trial Operation....................................................................................... 85
5.1 Procedure...................................................................................................... 57
5.2 Trial Operation Procedures............................................................................. 88
5.2.1 Power ON............................................................................................................................ 88
5.2.2 Checking the Display Status............................................................................................... 88
5.2.3 Initializing Constants........................................................................................................... 88
5.2.4 Setting Input Voltage........................................................................................................... 89
5.2.5 Auto-Tuning......................................................................................................................... 90
5.2.6 No-Load Operation.............................................................................................................. 93
5.2.7 Loaded Operation ............................................................................................................... 94
6 Basic Operation..................................................................................... 95
6.1 Common Settings........................................................................................... 96
6.1.1 Setting the Access Level and Control Method: A1-01, A1-02.......................................... 96
6.1.2 Frequency Reference Settings: b1-01, H3-01, H3-08, H3-09.......................................... 98
6.1.3 Frequency reference from Digital Operator: b1-01, o1-03, d1-01, to d1-09.................... 101
6.1.4 Run Source and Sequence Input Responsiveness: b1-02, b1-06, b1-07 ....................... 103
6.1.5 Acceleration/Deceleration Times: C1-01 through C1-08, C1-09, C1-10 C1-11 .............. 104
6.1.6 Prohibiting Reverse Operation: b1-04................................................................................ 105
6.1.7 Selecting the Stopping Method: b1-03.............................................................................. 106
6.1.8 Multi-Function Input Settings: H1-01 through H1-06........................................................ 107
6.2 Open-Loop Vector Control..............................................................................112
6.3 V/f Control......................................................................................................114
6.4 Flux Vector Control ........................................................................................121
6.5 V/f Control with PG.........................................................................................132
6.2.1 Auto-Tuning......................................................................................................................... 112
6.2.2 Auto-Tuning Faults.............................................................................................................. 113
6.3.1 Setting the Motor Constants: E1-01, E1-02, E2-01.......................................................... 114
6.3.2 V/f Pattern Selection: E1-03.............................................................................................. 115
6.4.1 PG Speed Option Card Settings ........................................................................................ 121
6.4.2 Setting the Zero Speed Operation Constants.................................................................... 124
6.4.3 Auto-Tuning......................................................................................................................... 126
6.4.4 Speed Control (ASR) Structure.......................................................................................... 128
6.4.5 Speed Control (ASR) Gain ................................................................................................. 130
6.5.1 Motor Constants: E1-01, E1-02, E2-01, E2-04................................................................. 132
6.5.2 V/f Pattern Selection: E1-03.............................................................................................. 133
6.5.3 PG Speed Option Card Settings ........................................................................................ 134
6.5.4 Speed Control (ASR) Structure.......................................................................................... 136
6.5.5 Adjusting Speed Control (ASR) Gain................................................................................. 137
7 Advanced Operation.............................................................................139
7.1 Open-Loop Vector Control..............................................................................140
7.2 Normal V/f Control..........................................................................................146
7.3 Flux Vector Control ........................................................................................150
7.4 V/f Control with PG Feedback.........................................................................165
Firmware – S1043 Revision: 2 (9/98) viii © Saftronics, Inc.
7.1.1 Torque Limit Function......................................................................................................... 141
7.1.2 Adjusting Speed Feedback................................................................................................. 143
7.1.3 Setting/Adjusting Motor Constants..................................................................................... 143
7.2.1 Energy Saving Control Function......................................................................................... 147
7.2.2 Hunting Prevention Function .............................................................................................. 148
7.2.3 Setting Motor Constants..................................................................................................... 149
7.3.1 Droop Control Function....................................................................................................... 151
7.3.2 Zero Servo Function ........................................................................................................... 152
7.3.3 Torque Control .................................................................................................................... 153
7.3.4 Speed/Torque Control Switching Function ........................................................................ 159
7.3.5 Torque Limit Function......................................................................................................... 160
7.3.6 Setting/Adjusting Motor Constants..................................................................................... 162
7.4.1 Energy Saving Control Function......................................................................................... 166
7.4.2 Hunting Prevention Function .............................................................................................. 167
7.4.3 Setting Motor Constants..................................................................................................... 168
7.5 Common Functions........................................................................................ 169
7.5.1 Application Constants: b .................................................................................................... 170
7.5.2 Tuning Constants: C........................................................................................................... 178
7.5.3 Reference Constants: d ..................................................................................................... 181
7.5.4 Option Constants: F ........................................................................................................... 183
7.5.5 External Terminal Functions: H ......................................................................................... 187
7.5.6 Protective Functions: L....................................................................................................... 204
7.5.7 Operator Constants: o ........................................................................................................ 215
8 User Constants ............................................................................... 219
8.1 Initialize Mode Constants............................................................................... 221
8.2 Programming Mode Constants....................................................................... 222
8.2.1 Application Constants: b .................................................................................................... 222
8.2.2 Auto-Tuning Constants: C.................................................................................................. 227
8.2.3 Reference Constants: d ..................................................................................................... 233
8.2.4 Motor Constant Constants: E............................................................................................. 236
8.2.5 Options Constants: F.......................................................................................................... 240
8.2.6 Terminal Constants: H ....................................................................................................... 243
8.2.7 Protection Constants: L...................................................................................................... 249
8.2.8 Operator Constants: o ........................................................................................................ 255
8.2.9 Factory Settings that Change with the Control Method (A1-02)........................................ 257
8.2.10 Factory Settings that Change with the Inverter Capacity (o2-04)...................................... 258
9 Troubleshooting ............................................................................... 261
9.1 Protective and Diagnostic Functions .............................................................. 262
9.1.1 Fault Detection .................................................................................................................... 262
9.1.2 Minor Fault Detection.......................................................................................................... 265
9.1.3 Operation Errors.................................................................................................................. 267
9.2 Troubleshooting............................................................................................. 268
9.2.1 If Constant Constants Cannot Be Set................................................................................. 268
9.2.2 If the Motor Does Not Operate............................................................................................ 268
9.2.3 If the Direction of the Motor Rotation is Reversed............................................................. 270
9.2.4 If the Motor Does Not Put Out Torque or If Acceleration is Slow...................................... 270
9.2.5 If the Motor Does Not Operate According to Reference.................................................... 270
9.2.6 If the Slip Compensation Function Has Low Speed Precision .......................................... 270
9.2.7 If There is Low Speed Control Accuracy at High-speed Rotation in Open-
9.2.8 If Motor Deceleration is Slow.............................................................................................. 271
9.2.9 If the Motor Overheats ........................................................................................................ 271
9.2.10 If There is Noise When the Inverter is Started or From an AM Radio............................... 272
9.2.11 If the Ground Fault Interrupter Operates When the Inverter is Run.................................. 272
9.2.12 If There is Mechanical Oscillation....................................................................................... 272
9.2.13 If the Motor Rotates Even When Inverter Output is Stopped ............................................ 273
9.2.14 If 0 V is Detected When the Fan is Started, or Fan Stalls ................................................. 273
9.2.15 If Output Frequency Does Not Rise to Frequency Reference........................................... 273
Loop Vector Control Mode.................................................................................................. 271
10 Maintenance and Inspection ............................................................... 275
10.1 Maintenance and Inspection .......................................................................... 277
11 Specifications....................................................................................... 279
11.1 Standard Inverter Specifications..................................................................... 280
11.2 Specifications of Options and Peripheral Devices........................................... 284
12 Appendix............................................................................................... 287
12.1 Inverter Application Precautions ..................................................................... 288
Firmware – S1043 Revision: 2 (9/98) ix © Saftronics, Inc.
10.1.1 Daily Inspection ................................................................................................................... 277
10.1.2 Periodic Inspection.............................................................................................................. 277
10.1.3 Periodic Maintenance of Parts............................................................................................ 277
12.1.1 Selection ............................................................................................................................. 288
12.1.2 Installation............................................................................................................................ 288
12.1.3 Settings ............................................................................................................................. 288
12.1.4 Handling ............................................................................................................................. 289
12.2 Motor Application Precautions........................................................................289
12.2.1 Using the Inverter for an Existing Standard Motor ............................................................. 289
12.2.2 Using the Inverter for Special Motors................................................................................. 290
12.2.3 Power Transmission Mechanism (Speed Reducers, Belts, and Chains) ......................... 290
12.3 Peripheral Device Application Precautions......................................................291
12.4 Wiring Examples............................................................................................292
12.4.1 Using a Braking Resistor Unit............................................................................................. 292
12.4.2 Using a Braking Unit and a Braking Resistor Unit............................................................. 293
12.4.3 Using Three Braking Units in Parallel ................................................................................ 296
12.4.4 Using a JVOP-95-o, -96-o VS Operator ........................................................................... 299
12.4.5 Using an Open-collector Transistor for Operation Signals................................................ 300
12.4.6 Using Open-collector, contact Outputs .............................................................................. 300
12.5 User Constants .............................................................................................301
INDEX........................................................................................................................305
Firmware – S1043 Revision: 2 (9/98) x © Saftronics, Inc.
1
Introduction
This chapter provides an overview of the VG5 Inverter and describes its functions and components.
1.1 Outline and Functions.................................................... 2
1.1.1 VG5 Inverter Models........................................................................................... 2
1.1.2 Outline of Control Methods................................................................................. 3
1.1.3 Functions ............................................................................................................ 3
1.2 Nomenclature.................................................................. 6
1.2.1 VG5 Components ........................................................................................... 6
1.2.2 Digital Operator Components............................................................................. 7
Chapter 1: Introduction
1.1 Outline and Functions
The VG5 Inverter provides full-current Vector Control based on advanced control logic. An Auto-Tuning function is included for user friendly Vector Control.
The Digital Operator provides a liquid crystal display that is 2 lines by 16 characters in size. User constant settings and monitor items are easily read in interactive operations in either Japanese or English. (The display language can be changed by setting a user constant.)
1.1.1 VG5 Inverter Models
VG5 Inverters are available in 200 and 400 V class models. These are listed in the following table. A total of 37 models are available for motor capacities of 0.4 to 300 kW (0.5 ~ 400HP).
Maximum
Voltage
Class
200 V Class
* Immediate delivery † Available from factory ‡ Manufactured upon order
Applicable
Motor
Output
(HP)
0.75 0.4 1.2 VG520P4 20P41q*
1.5 0.75 2.3 VG520P7 20P71q* 2 1.5 3.0 VG521P5 21P51q* 3 2.2 4.2 VG522P2 22P21q* 5 3.7 6.7 VG523P7 23P71q*
7.5 5.5 9.5 VG525P5 25P51q*
10 7.5 13 VG527P5 27P51q* 15 11 19 VG52011 20111q* 20 15 24 VG52015 25 18.5 30 VG52018 20180q* 20181q‡ 30 22 37 VG52022 20220q* 20221q‡ 40 30 50 VG52030 20300q† 20301q‡ 50 37 61 VG52037 20370q† 20371q‡ 60 45 70 VG52045 20450q† 20451q‡ 75 55 85 VG52055 20550q† 20551q‡
100 75 110 VG52075 20750q‡ 20751q‡
Maximum
Applicable
Motor
Output
(kW)
Table 1.1 VG5 Inverter Models
VG5
Output
Capacity
(kVA)
Model Number
(Specify all required standards when ordering.)
Open Chassis Type
(IEC IP 00)
VG5qqqqqq
Remove the top and
bottom covers from the
models listed at the
Inverter Specifications
Enclosed Wall-Mounted Type
(IEC IP 20, NEMA 1)
VG5qqqqqq
right.
*
20151q*
Maximum
Voltage
Class
400 V Class
* Immediate delivery † Available from factory ‡ Manufactured upon order
Applicable
Motor
Output
(HP)
1 0.4 1.4 VG540P4 40P41q* 2 0.75 2.6 VG540P7 40P71q* 3 1.5 3.7 VG541P5 41P51q* 4 2.2 4.7 VG542P2 42P21q* 5 3.7 6.1 VG543P7 43P71q*
7.5 4 8.4 VG544P0 44P01o*
10 5.5 11 VG545P5 45P51q* 15 7.5 14 VG547P5 47P51q* 20 11 21 VG54011 40111q* 25 15 26 VG54015 30 18.5 31 VG54018 40180q* 40181q‡ 40 22 37 VG54022 40220q* 40221q‡ 50 30 50 VG54030 40300q* 40301q‡ 60 37 61 VG54037 40370q* 40371q‡
75 45 73 VG54045 40450q* 40451q‡ 100 55 98 VG54055 40550q† 40551q‡ 125 75 130 VG54075 40750q† 40751q‡ 150 110 170 VG54110 41100q† 41101q‡ 200 160 230 VG54160 41600q† 41601q‡ 250 185 260 VG54185 41850q‡ — 350 220 340 VG54220 42200q‡ — 500 300 460 VG54300 43000q‡ —
Maximum
Applicable
Motor
Output
(kW)
Output
Capacity
(kVA)
VG5
Model Number
(Specify all required standards when ordering.)
Open Chassis Type
(IEC IP 00)
VG5qqqqqq
Remove the top and
bottom covers from the
models listed at the
Inverter Specifications
Enclosed Wall-Mounted Type
(IEC IP 20, NEMA 1)
VG5qqqqqq
right.
*
40151q*
Firmware – S1043 Revision: 2 (9/98) 2 © Saftronics, Inc.
1.1.2 Outline of Control Methods
The VG5 uses four control methods:
• Open-Loop Vector Control (factory setting)
• Flux Vector Control
• V/f Control without PG
• V/f Control with PG Feedback
Note: PG stands for pulse generator (encoder). Vector Control is a method for removing interference with magnetic flux and torque, and controlling torque according to
references. Current Vector Control independently controls magnetic flux current and torque current by simultaneously controlling the
motor primary current and phases. This ensures smooth rotation, high torque, and accurate speed/Torque Control at low speeds.
Vector Control can be replaced by the conventional V/f Control system. If the motor constants required for Vector Control are not known, the motor constants can be automatically set with Auto-Tuning.
The control methods are effective for the following applications:
• Open-Loop Vector Control: General variable-speed drive.
• Flux Vector Control: Simple servo-drive, high-precision speed control/Torque Control.
• V/f Control without PG: Conventional Inverter control mode. Used for multi-drive operation (connecting
• V/f Control with PG Feedback: Simple speed feedback control. (For applications with the PG connected to the
The control characteristics for each mode are shown in Table 1.2.
Table 1.2 Control Method Characteristics
Characteristic
Speed Control Range 1:100 1:1000 1:40 1:40
Speed Control
Precision
Initial Drive 150% at 1 Hz 150% at 0 r/min 150% at 3 Hz
Open-Loop Flux Vector Without PG With PG Feedback
Chapter 1: Introduction
multiple motors to one Inverter).
machine shaft rather than the motor shaft.)
Vector Control V/f Control
±0.2 % ±0.02 % ±2 to 3 % ±0.03 %
1.1.3 Functions
§ Auto-Tuning
Auto-Tuning is effective for Vector Control. It solves problems in applicable motor restrictions and difficult constant settings. The motor constants are automatically set by entering a value from the motor’s rating nameplate.
Auto-Tuning allows Flux Vector Control to operate accurately with virtually any normal AC induction motor, regardless of the supplier.
§ Torque Control
Torque Control is effective for flux vector control with PG. Torque in controlled by taking multi-function analog input signals as torque references. Torque Control accuracy is ±5%. Switching is possible between Torque Control and speed control.
§ V/f Patter Settings
V/f pattern settings are effective for V/f Control. Select V/f pattern according to the application from among the 15 preset V/f patterns. Custom V/f patterns can also be set.
§ Frequency References
The following five types of frequency references can be used to control the output frequency of the Inverter:
• Numeric input from the Digital Operator
• Voltage input within a range from 0 to 10 V
• Voltage input within a range from 0 to ±10 V (With negative voltages, rotation is in the opposite direction from
the run command.)
• Current input within the range from 4 to 20 mA
• Input from Output Card
Firmware – S1043 Revision: 2 (9/98) 3 © Saftronics, Inc.
Chapter 1: Introduction
Any of the above frequency references can be used by setting a constant. A maximum of nine frequency references can be registered with the Inverter. With remote multi-step speed
reference inputs, the Inverter can operate in multi-step speed operation with a maximum of nine speed steps.
§ PID Control
The Inverter has a PID control loop for easy process control. Process control is an operational method in which the Inverter varies the output frequency to match the feedback value from the sensor to a set target value.
Process control can be applied to a variety of operations, such as those listed below, depending on the variable detected by the sensor.
• Speed Control: With a speed sensor, such as tach generator, the Inverter regulates the rotating speed
of the motor regardless of the load on the motor or synchronizes the rotating speed of the motor with that of another motor.
• Pressure Control: With a pressure sensor, the Inverter performs constant pressure control.
• Flow-Rate Control: By sensing the flow-rate of a fluid, the Inverter performs precise flow-rate control.
• Temperature Control: With a temperature sensor, the Inverter performs temperature control by fan speed.
§ Zero Servo Control
Zero Servo control is effective with flux vector control. Even at a motor speed of zero (0 Hz), a torque of 150% of the motor’s rated torque can be generated and the average servomotor holding power (stopping power) can be obtained.
§ Speed Control by Feedback
Speed control using feedback is effective with a PG. An optional PG Speed Option Card can be used to enable feedback control for speeds, thereby improving speed control accuracy.
§ Dwell Function
By holding the output frequency for a constant time during acceleration and deceleration, acceleration and deceleration can be performed without stepping out even when driving a motor with a large startup load.
§ Low Noise
The output transistor of the Inverter is an IGBT (Insulated Gate Bipolar Transistor). Using sine wave PWM with a high frequency carrier, the motor does not generate metallic noise.
§ Monitor Function
The following items can be monitored with the Digital Operator: frequency reference, output frequency, output current, motor speed, output voltage reference, main-circuit DC voltage, output power, torque reference, status of input terminals, status of output terminals, operating status, total operating time, software number, speed deviation value, PID feedback value, fault status, fault history, etc.
All types of data can be monitored even with multi-function analog output.
§ Bilingual Digital Operator
The Digital Operator can display either English or Japanese. The Digital Operator’s liquid crystal display provides a 16 character by 2-line display area.
Easy-to-read displays allow the advanced functions of the Inverter to be set in interactive operations to input constants, monitoring items, etc. Change the constant setting to select the English display.
§ Harmonic Countermeasures (0.4 to 160 kW Models)
The VG5 Inverters up to 160 kW support DC Reactors to easily handle high frequency control guidelines.
• DC Reactors (optional) can be connected to 0.4 to 15 kW models.
• Models from 18.5 to 160 kW have a built-in DC reactor.
• An optional AC reactor can be connected to Inverters from 185 to 300 kW.
Firmware – S1043 Revision: 2 (9/98) 4 © Saftronics, Inc.
Chapter 1: Introduction
§ User Constant Structure and Three Access Levels
The VG5 has a number of user constants for setting various functions. These user constants are classified into a hierarchy to make them easier to use.
The levels are as follows from top to bottom: Modes, Groups, Functions, and Constants. The access levels for the user constants are shown in Table 1.3.
Table 1.3 Access Levels for User Constants
Level Contents
Classified according to operation Operation: For operating the Inverter. (All kinds of monitoring are possible.) Initialize: For selecting the language displayed at the Digital Operator, setting
Mode
Programming: For setting user constants for operation. Auto-Tuning: For automatic calculation or setting constants. (Only under the Vector
Modified Constants: For referencing or monitoring changed constants after shipment. Groups Classified by application. Functions Classified by function. (See user constants.) Constants Individual user constant settings.
The VG5 allows the following three access levels to be set in order to further simplify setting user constants. (An access level is a range of user constants that can be referenced or set.)
Quick-Start Reads/sets user constants required for trial operation. (factory setting) Basic Reads/sets user constants that are commonly used. Advanced Reads/sets all the user constants that can be used.
In general, press the DATA/ENTER key to move from an upper to a lower level. This varies somewhat, however, according to the access level, as shown in Figure. 1.1. For the Quick-Start access level, which has few user constants that can be set, pressing the DATA/ENTER key jumps directly to the user constant level; whereas for the advanced access level, which has many user constants, pressing the DATA/ENTER key first leads to the Group level.
access levels, initialization, and the control modes.
Control mode.)
Firmware – S1043 Revision: 2 (9/98) 5 © Saftronics, Inc.
Figure 1.1 Access Level Structure
Chapter 1: Introduction
1.2 Nomenclature
This section provides the names of VG5 components, and the components and functions of the Digital Operator.
1.2.1 VG5 Components
The appearance of Inverter and the names of its components are shown in Figure 1.2.
Figure 1.2 Appearance of VG5, Model VG520P4 (200 V, 0.4 kW, 0.5HP)
A 200 V Class Inverter with 0.4 kW Output is shown below with the front cover removed.
Firmware – S1043 Revision: 2 (9/98) 6 © Saftronics, Inc.
Figure 1.3 Terminal Arrangement
1.2.2 Digital Operator Components
This section describes the component names and functions of the Digital Operator. The component names and functions are shown in Figure 1.4 and key functions are described in Table 1.4.
Chapter 1: Introduction
Operation Mode Indicators
DRIVE: Lit when in Operation mode. FWD: Lit when there is a forward run command input. REV: Lit when there is a reverse run command input. SEQ: Lit when the run command from the control circuit terminal is
enabled.
REF: Lit when the frequency reference from control circuit
Terminals 13 and 14 is enabled.
Data Display
Two-line LCD that displays data for monitoring, user constants and set values with 16 characters per line.
Keys
Execute operations such as setting user constants, monitoring, Jog, and Auto-Tuning.
Figure 1.4 Digital Operator Component Names and Functions
Firmware – S1043 Revision: 2 (9/98) 7 © Saftronics, Inc.
Chapter 1: Introduction
Table 1.4 Key Functions
Key Name Function
LOCAL/REMOTE Key
MENU Key Displays menus.
ESC Key Returns to the status before the DATE/ENTER key was pressed.
JOG Key Enables jog operation when the VG5 is being operated from the Digital Operator.
Switches between (LOCAL) operation via the Digital Operator and control circuit terminal (REMOTE) operation. This key can be enabled or disabled by setting a user constant (o2-01).
FWD/REV Key
RESET Key
Increment Key
Decrement Key
Selects the rotation direction of the motor when the VG5 is being operated from the Digital Operator.
Sets the number of digits for user constant settings. Also acts as the reset key when a fault has occurred.
Selects menu items, groups, functions, and user constant names, and decrements set values.
Selects menu items, groups, functions, and user constant names, and decrements set values.
DATA/ENTER Key Enters menu items, functions, constants, and set values after they are set.
RUN Key Starts the VG5 operation when the VG5 is in operation with the Digital Operator.
STOP Key
Stops VG5 operation. This key can be enabled or disabled by setting a user constant (o2-02) when operating from the control circuit terminal.
Note: Except in diagrams, keys are referred to using the key names listed in the above table.
Figure 1.5 RUN and STOP Indicators
Firmware – S1043 Revision: 2 (9/98) 8 © Saftronics, Inc.
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