Yaskawa A1000 User Manual

YASKAWA AC Drive - A1000

Spindle Orientation

Custom Software Supplement

Software Number: VSA91009 Drive Models: 200 V Class, CIMR-AU2A0004□A□-063 to CIMR-AU2A0415□A□-063

400 V Class, CIMR-AU4A0002□A□-063 to CIMR-AU4A0250□A□-063

To properly use the product, read this manual thoroughly and retain for easy reference, inspection, and maintenance. Ensure the end user receives this manual.

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MANUAL NO. TM.A1000SW.063

2 YASK AWA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement

Table of Contents

1 PREFACE AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 SPINDLE ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 REVISION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Refer to the A1000 Technical Manual for content not described in this document.

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 Yaskawa. No patent liability is assumed with respect to the use of the information contained herein. Moreover, because Yaskawa 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. Yaskawa 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.

YASK AWA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement 3

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4 YASK AWA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement

1 Preface and Safety

Yaskawa manufactures products used as components in a wide variety of industrial systems and equipment. The selection and application of Yaskawa products remain the responsibility of the equipment manufacturer or end user. Yaskawa accepts no responsibility for the way its products are incorporated into the final system design. Under no circumstances should any Yaskawa product be incorporated into any product or design as the exclusive or sole safety control. Without exception, all controls should be designed to detect faults dynamically and fail safely under all circumstances. All systems or equipment designed to incorporate a product manufactured by Yaskawa must be supplied to the end user with appropriate warnings and instructions as to the safe use and operation of that part. Any warnings provided by Yaskawa must be promptly provided to the end user. Yaskawa offers an express warranty only as to the quality of its products in conforming to standards and specifications published in the Yaskawa manual. NO OTHER WARRANTY, EXPRESS OR IMPLIED, IS OFFERED. Yaskawa assumes no liability for any personal injury, property damage, losses, or claims arising from misapplication of its products.

 Applicable Documentation

The following manuals are available for the A1000 Drive:

Custom Software Supplement

Yaskawa AC Drive - Spindle Orientation A1000 Custom Software Supplement

SUPPLEMENT

Manual No: TM.A1000SW.063

Read this manual first. This supplement is an addendum to the A1000 Quick Start Guide and Technical Manual. It lists the effects of this custom software on the parameters in the drive and function descriptions in the manual. To obtain the supplement access this site: U.S: http://www.yaskawa.com

Yaskawa Drive

Yaskawa AC Drive A1000 Quick Start Guide

Yaskawa AC Drive A1000 Technical Manual

To obtain instruction manuals for Yaskawa products access these sites: U.S.: http://www.yaskawa.com Europe: http://www.yaskawa.eu.com Japan: http://www.e-mechatronics.com Other areas: contact a Yaskawa representative. For questions, contact the local Yaskawa sales office or the nearest Yaskawa representative.

 Supplemental Safety Information

Read and understand this manual and the A1000 Quick Start Guide before installing, operating, or servicing this option unit. Install the drive according to the A1000 Quick Start Guide and local codes. Observe all cautions and warnings in this document and the standard drive technical manuals.

Refer to the A1000 Quick Start Guide and Technical Manual for safety information and to install and start-up the drive.

This document is a supplement to the standard drive technical manual. It describes the effects on the drive parameters and functions with the software installed.

• Custom software is provided to add functionality to a standard drive to enhance or enable use in a specific application.

• The software is loaded to the flash ROM area of the control board, and replaces the standard drive software.

 Obtaining Support

When seeking support for a drive with custom software, it is imperative to provide the unique part number shown on the drive nameplate. The software is flashed to the control board memory and the operation of parameters, functions, and monitors are different than the standard drive software, as described herein.

Refer to Yaskawa office locations listed on the back cover of this manual.

YAS KA WA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement 5

2 Spindle Orientation

Motor

Encoder

Machine

Motor

Conﬁguration2:IndirectDrivewith

OrientationEncoder

Conﬁguration1:DirectDrive

PG-X3

Orientated

MachinePart

Orientation

Encoder

Orientated

MachinePart

Drivetrain

(GearRatio)

CN5-B

CN5-C

Motor

Encoder

ChA/B/Z

ChA/B

Machine

Motor

Encoder

Machine

Motor

Conﬁguration3:IndirectDrivewith

ProximitySensor

PG-X3

Proximity

Sensor

Orientated

MachinePart

Drivetrain

(GearRatio)

CN5-C

ChZ

ChA/B

2 Spindle Orientation

 Overview

The target applications for this function are on equipment that must stop in specific positions including tool changing for machine tool spindles and die changing for punch/stamping presses. This software also provides for high frequency operation with automatic switchover to closed-loop operation at low speed.

 Applicable Models

This Spindle Orient software is available for the drive models listed in Tab le 1.

Table 1 Applicable Models

Voltage Class Model Software Version

200 V CIMR-AU2A0004A-063 to CIMR-AU2A0415A-063 400 V CIMR-AU4A0002A-063 to CIMR-AU4A0250A-063

 Basic Concepts and Principles

This orientation software allows an A1000 drive to repeatedly stop a machine at a certain point in its rotational cycle. This is accomplished by means of an orientation encoder directly coupled to the machine part to be positioned. A simple example is to think of the hands on a clock. If the orientation encoder is mounted to the motor shaft, this software can stop the motor so that the spindle stops at the 3 o'clock position every time. Application configurations are outlined in

Figure 1. For configurations other than those outlined, contact Yaskawa Application Engineering before applying this

software.

Figure 1

VSA910090

Figure 1 Spindle Orientation Hardware Configurations

6YASKAWA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement

2 Spindle Orientation

 Direct Drive

In the first configuration, the drive motor directly drives the machine part being oriented (positioned). When using this method, the motor encoder is used for both closed loop vector motor control and for orientation. This encoder must have a C or Z channel which provides a “marker” or “index” pulse with every rotation. If the encoder does not have a C/Z channel, an external marker pulse can be implemented as outlined in Encoder (PG) Option Card Configuration and

Wiring on page 29. Additionally, a PG-X3 or PG-B3 encoder (PG) feedback option card is required to connect the

encoder to the drive.

 Indirect Drive with Orientation Encoder

When the motor and the machine part to be oriented (positioned) are connected through a drive train with a constant ratio, two encoders are required. The first encoder is mounted on the driven motor, and the second, an orientation encoder, is mounted on the machine part to be oriented. The orientation encoder must have a C or Z channel which provides a “marker” or “index” pulse with every rotation. If the encoder does not have a C/Z channel, an external marker pulse can be implemented as outlined in Encoder (PG) Option Card Configuration and Wiring on page 29. The motor encoder does not need to have a C/Z channel. Two encoder (PG) feedback option cards are required for this setup.

 Indirect Drive with Proximity Sensor

When the motor and the spindle are connected through a drive train and the spindle does not have its own encoder, a proximity sensor may be used. The proximity sensor is connected as an external marker pulse; therefore this configuration requires only one PG-X3 encoder (PG) feedback option card. In this configuration, the gear ratio of the drive train must be expressed as the number of revolutions of the motor per revolution of the spindle.

 Online Control Mode Switch Function

This software can switch between Closed Loop Vector Control and V/f Control during run. The 1000 Hz software is limited to V/f control mode above 400 Hz, it is possible to change tools without stopping the machine if the inverter switches to Closed Loop Vector Control for Position Control at Low-Speed. At Low-Speed the inverter can be set to operate in Closed Loop Vector Control and automatically switch to V/f Control when the output is above the frequency which is set.

 Changes from the Standard Product

• Second PG Channel Parameters F1-30 through F1-37 are always visible whether or not digital selection H1-0 =16

(Motor 2 Select) is programmed.

• Only two Control Modes can be set in A1-02 and E3-01, 0:V/f and 3:Closed-Loop Vector.

• Only two Auto-Tuning Mode Selections are available, 0:Rotational Auto-Tuning and 2:Stationary Auto-Tuning for Line-to-Line Resistance.

 Deleted Functions

Certain functions in the standard software of A1000 are deleted in this Orientation software. Deleted functions are listed in Tab le 2 .

Table 2 Deleted Functions

Speed Search (all methods) KEB Function Fault Restart High Slip Braking (HSB) Overexcitation Braking Field Weakening Function Energy Savings Droop Control Field Forcing Function Frequency Reference Lower Limit Feed Forward Control DC Injection Braking Current Setting in V/f Torque Detection Stall Prevention Selection during Acceleration Stall Prevention Selection during Run

Function Name

YAS KA WA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement 7

2 Spindle Orientation

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$2/930

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 Limitations

• The multi-function digital input function Motor 2 Select (H1- = 16) and Encoder Option Card Setting F1-30 have

restrictions when used in Closed Loop Vector control mode with an additional orientation encoder. Refer to Tab le 1 5 on page 16 and Tab le 1 7 on page 31.

• Applications using Configuration 2 and Motor 1/Motor 2 switchover must use a motor encoder and an orientation encoder of the same PPR.

• DriveWorks EZ functionality is not fully supported when using this software. If DriveWorks EZ support is required, please contact Yaskawa Application Engineering.

• PG Encoder PPR parameters F1-01 and F1-31 are limited to PPR of 8 to 16384 PPR (32 to 65536 counts per revolution).

• Orient functionality is disabled when the run command comes from the Local Operator (b1-02 = 0).

• Since all forms of speed search are disabled, the stopping method Coast to Stop (b1-03 = 1) causes inconsistent operation of the spindle orient routine if an orient digital input is closed while the drive is coasting. This may include but is not limited to overvoltage trips and faster than expected deceleration.

• Disabling reverse operation by setting Reverse Operation Selection parameter b1-04=1 prohibits the orient function from maintaining position.

• Frequency Upper Limit parameter d2-01 prevents the spindle orient function from operating if the frequency limit is set at or below the P1-02 Creep Speed.

• Orient digital inputs are disabled when Forward or Reverse Jog commands (H1-0 = 12 or 13) are active.

• Orient digital inputs are disabled when Control Mode Switchover Prevention digital input H1-0 = 50 is closed while the drive is not running.

 Related Parameters and Functions

The legend below is used in this section to indicate which parameters are available in which control modes.

The parameter tables in this section are used to set up the drive for operation with the software.

Note: Chinese language support is added to certain parameters and functions. Refer to References on page 31 for the parameters and

functions with Chinese language support.

Table 3 Modified Parameters

MEMOBUS/

No.

F1-01 0380h

F1-30 03AAh

Modbus Address

Digital Operator Display

PG 1 Pulses Per Revolution

PG1 Pulses/Rev

PG Option Card Port for Motor 2 Selection

Mtr2 PG Port Sel

Name

Description Range

Sets the number of encoder pulses per revolution for the encoder on channel 1.

Specifies the drive port for the PG option card used for Motor 2.

0: CN5-C 1: CN5-B

Note: This parameter is available without a digital input H1-0 programmed to 16h (Motor 2 Select).

Default

Value

8 to 16384 PPR 1024 PPR No – – – Y– – N

0 to 1 0 No – – – Y– – N

Change

During

Run

Control Method/

Access Level

8 YASK AWA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement

2 Spindle Orientation

MEMOBUS/

No.

F1-31 03B0h

F1-32 03B1h

F1-35 03BEh

F1-36 03B5h

L3-04 0492h

S1-01 680h

S1-03 682h

S2-01 691h

Modbus Address

Digital Operator Display

PG 2 Pulses Per Revolution

PG2 Pulses/Rev

PG2 Rotation Selection

PG2 Rotation Sel

PG2 Division Rate for Pulse Monitor

PG2 Output Ratio

PG Option Card Disconnect Detection 2

PGCardDisconDet1

Stall Prevention Selection during Deceleration

StallP Decel Sel

On-Delay Compensation Selection

OnDelay Comp Sel

Extended Current Sampling Mode

Extend I Sample

Control Mode Switchover Frequency

HF SwOver Freq

Name

Description Range

Sets the number of encoder pulses per revolution for the encoder on channel 2.

Note: This parameter is available without a digital input H1-0 programmed to 16h (Motor 2 Select).

Determines the direction indicated by the pulses from the PG feedback encoder for motor 2.

0: Pulse A Leads 1: Pulse B Leads

This parameter is available without a digital input H1-0 programmed to 16h (Motor 2 Select).

Sets the ratio between the pulse input and the pulse output of a PG option card. This parameter is available without a digital input H1-0 programmed to 16h (Motor 2 Select).

Sets whether the drive detects a fault when a PG-X3 card is disconnected.

0: Disabled 1: Enabled

This parameter is available without a digital

input H1-0x programmed to 16h (Motor 2 Select).

Determines how Stall Prevention works during Run.

The parameter default is changed to 0: Disabled.

0: Disabled 1: General Purpose 2: Intelligent 3: Stall Prevention w/Braking Resistor 4: Overexcitation Deceleration 5: Overexcitation Deceleration 2

Note: Enabling stall prevention extends the decel time. Other modes such as Intelligent may cause unintended operation during orient, including oscillation and inability to maintain position.

Parameter S1-01 is used to enable and disable On Delay Compensation.

0: Disabled 1: Enabled

Normally there is no need to change S1-03 from its default setting. If there is a problem with output voltage weakening when attempting to compensate for output current distortion as the motor reaches 1000 Hz while decoupled from the load during a test run, then try setting S1-03 = 1.

0: Disabled 1: Enabled

Sets the frequency of switching from Closed Loop Vector Control to V/f Control.

This function is disabled when 0 or 400 Hz is set, the inverter runs as V/f Control when 0 is set and Closed Loop Vector Control when 400 Hz is set. However, OPE21 occurs when the relations among Control Mode Switch Frequency (S2-01) and PG Pulse per Revolution (F1-01) and Numbers of Motor Poles (E2-04) are set higher than the permissible input frequency of PG option.

Default

Value

8 to

16384 PPR

0 to 1 0 No – – – Y– – N

1 to 132 1 No – – – Y– – N

0 to 1 1 No – – – Y– – N

0 to 5 0 No – – – Y– – Y

0 to 1 1 No – – – Y– – Y

0 to 400 Hz 400 No – – – Y– – N

1024 PPR No – – – Y– – N

Change

During

Run

Control Method/

Access Level

S2-02 692h

Control Mode Switchover Bandwidth

HF CtrlMode SwBW

Sets the hysteresis width of Control Mode Switch. Increase if shock occurs during Control Mode switching.

2 to 100 Hz 20 No – – – Y– – N

YAS KA WA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement 9

2 Spindle Orientation

MEMOBUS/

No.

S2-05 695h

S2-06 696h

S2-07 697h

S2-08 698h

S2-11 699h

Modbus Address

Digital Operator Display

High Frequency Slip Compensation Gain

HF SlipComp Gain

High Frequency Slip Compensation Primary Delay Time

HF SlipComp Time

High Frequency Slip Compensation Limit

HF SlipComp Lim

High Frequency Slip Compensation Selection During Regeneration

HF SlipCompRegen

Motor 2 Control Mode Switchover Frequency

HF SwOver Freq 2

Name

Description Range

Sets the gain for the Motor Slip Compensation at Hi-Speed Function. Although this parameter rarely needs to be changed, adjustments might be needed under the following circumstances: If the motor at constant speed is slower than the frequency reference, increase S2-05. If the motor at constant speed is faster than the frequency reference, decrease S2-05.

Sets the filter on the output side of the Slip Compensation at Hi-Speed Function. Although this parameter rarely needs to be changed, adjustments might be needed under the following circumstances:

-Decrease the setting when the slip compensation response is too slow.

-Increase this setting when speed is unstable.

Sets the upper limit for the Slip Compensation at Hi-Speed Function as a percentage of the motor rated slip (E2-02).

When Slip Compensation during Regeneration at Hi-Speed is activated and a regenerative load is applied, it might be necessary to use a dynamic braking option (braking resistor, braking resistor unit, or braking unit).

0: Disabled 1: Enabled (6 Hz and Above) 2: Enabled (Compensation provided wherever possible)

Sets the frequency of switching from Closed Loop Vector Control to V/f Control for Motor 2

This function is disabled when 0 or 400Hz is set, the inverter runs as V/f Control when 0 is set, and Closed Loop Vector Control when 400Hz is set. However, OPE21 occurs when the relations among Control Mode Switch Frequency (S2-11) and PG Pulse per Revolution (F1-31) and Numbers of Motor Poles (E4-04) are set higher than the permissible input frequency of PG option.

Default

Value

0.0 to 2.5 0.0 Yes – – – Y– – N

0 to 10000 ms 2000 Yes – – – Y– – N

0 to 250% 200 No – – – Y– – N

0 to 2 0 No – – – Y– – N

0 to 400 Hz 400 No – – – Y– – N

Change

During

Run

Control Method/

Access Level

S2-12 69Ah

S2-15 69Dh

S2-16 69Eh

S2-17 69Fh

Motor 2 Control Mode Switchover Bandwidth

HF CtrlModeSwBW2

Motor 2 High Frequency Slip Compensation Gain

HF SlipCompGain2

Motor 2 High Frequency Slip Compensation Primary Delay Time HF SlipCompTime2

Motor 2 High Frequency Slip Compensation Limit

HF SlipComp Lim2

Sets the hysteresis width of Control Mode Switch for Motor 2. Increase if shock occurs during Control Mode switching.

Sets the gain for the Motor Slip Compensation at Hi-Speed Function for Motor 2. Although this parameter rarely needs to be changed, adjustments might be needed under the following circumstances:

-If the motor at constant speed is slower than the frequency reference, increase S2-15.

-If the motor at constant speed is faster than the frequency reference, decrease S2-15.

Sets the filter on the output side of the Slip Compensation at Hi-Speed Function for Motor 2. Although this parameter rarely needs to be changed, adjustments might be needed under the following circumstances:

-Decrease the setting when the slip compensation response is too slow.

-Increase this setting when speed is unstable.

Sets the upper limit for the Slip Compensation at Hi-Speed Function for Motor 2 as a percentage of the motor rated slip (E4-02).

2 to 100 Hz 20 No – – – Y– – N

0.0 to 2.5 0.0 Yes – – – Y– – N

0 to 10000 ms 2000 Yes – – – Y– – N

0 to 250% 200 No – – – Y– – N

10 YASK AWA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement

2 Spindle Orientation

MEMOBUS/

No.

S2-18 6A0h

No.

P1-01 0600h

P1-02 0601h

P1-03 0602h

Modbus Address

MEMOBUS/

Modbus Address

Digital Operator Display

Motor 2 High Frequency Slip Compensation During Regeneration Selection

HF SlipCompRgn 2

Digital Operator Display

Orient Speed

Creep Speed

Creep Distance

Name

Description Range

0: Disabled 1: Enabled (6 Hz and Above) 2: Enabled (Compensation provided wherever possible)

Table 4 Additional Parameters

Description Range

This parameter sets the frequency at which the drive switches to the Orient Deceleration Time (P1-12) and Orient ASR settings (P2-10 and P2-

11) when these parameters are enabled.

Note: P1-01 must be set such that it is not greater than the control modes switchover frequency: ((S2-01 – S2-02) > P1-01). P1-01 must also be set lower than the Maximum Output Frequency E1-04.

This parameter sets the speed at which the drive locates the marker pulse. This is also the speed at which s-curves are disabled.

This parameter sets the number of quadrature encoder counts around the orientation position where the frequency reference is allowed to drop below the P1-02 Creep Speed. Within the Creep Distance, the drive accel/decel times are set to 0.

Default

Value

0 to 2 0 No – – – Y– – N

Default

Value

0.00 to 200.00 Hz 20.00 No – – – Y– – N

0.10 to 10.00 Hz 2.00 No – – – Y– – N

0 to 2000 Cnts 200 No – – – Y– – N

Change

During

Run

Change

During

Run

Control Method/

Access Level

Control Method/

Access Level

P1-04 0603h

P1-05 0604h

P1-06 0605h

P1-07 0606h

P1-08 0607h

P1-09 0608h

Approach Speed

Orientation Complete Detection Set Window

ORT Set Window

Orientation Complete Detection Reset Window

ORT Rst Window

Orientation Set Time

ORT Set Time

Positioning Proportional Gain

Pos P Gain

Orientation Compensation Distance

Orient Comp Dist

This parameter sets the minimum speed that the drive operates at until it reaches the P1-05 ORT Set Window.

This parameter sets the initial window around the orientation position that activates the Orient Complete digital output. The Orient Complete

digital output (H2- = 40) closes when the encoder quadrature count is within the P1-05

window of the orientation offset and after the P1-07 delay time has expired.

Note: Counts = Encoder PPR x 4.

This parameterr sets, in quadrature encoder counts, the window around the orient position that keeps the

Orient Complete digital output (H2- = 40) closed.

Note: Counts = Encoder PPR x 4.

This parameter sets the delay time from when the P1-05 Orient Set window is satisfied and the

Orientation Complete digital output (H2- = 40) closes.

This parameter sets the proportional gain used for the position controller.

This parameter sets the minimum orientation distance between the orientation encoder marker pulse at or below P1-02 and the desired orientation offset. This distance is expressed as a percentage of the active encoder PPR (e.g. F1-01 x P1-09).

0.00 to 1.00 Hz 0.10 No – – – Y– – N

0 to 100 Cnts 25 No – – – Y– – N

0 to 100 Cnts 0 No – – – Y– – N

0 to 1000 ms 10 No – – – Y– – N

0.10 to 20.00 1.00 No – – – Y– – N

0 to 100% 50% No – – – Y– – N

YAS KA WA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement 11

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