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.

MANUAL NO. TM.A1000SW.063

2	YASKAWA 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.

Copyright © 2011 YASKAWA AMERICA, INC.

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.

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

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

1 Preface and Safety

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

SUPPLEMENT

Yaskawa AC Drive - Spindle Orientation A1000 Custom Software 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.

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

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2 Spindle Orientation

2Spindle 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 Table 1.

		Table 1 Applicable Models
	Voltage Class	Model	Software Version
	200 V	CIMR-AU2A0004 A -063 to CIMR-AU2A0415 A -063	VSA910090
	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.

	Configuration 1: Direct Drive	Configuration 2: Indirect Drive with	Configuration 3: Indirect Drive with
		Orientation Encoder	Proximity Sensor

PG-X3

CN5-C
Motor Encoder	Machine

Motor

Ch A/B/Z

		PG-X3			PG-X3
CN5-B		PG-X3
	CN5-C			CN5-C
Orientated
Machine Part
Motor	Encoder	Machine	Drivetrain	Motor Encoder	Machine	Drivetrain
		Motor			Motor
			(Gear Ratio)			(Gear Ratio)
Ch A/B				Ch A/B
			Ch A/B/Z
			Orientation Encoder		Proximity
					Sensor
						Ch Z
			Orientated			Orientated
			Machine Part			Machine Part

Figure 1 Spindle Orientation Hardware Configurations

6	YASKAWA 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 Table 2.

Table 2 Deleted Functions

	Function Name
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

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2Spindle Orientation

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 Table 15 on page 16 and Table 17 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.

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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/	Name			Default	Change	Control Method/
	No.	Modbus		Description	Range		During
			Digital Operator Display			Value		Access Level
		Address					Run
	F1-01	0380h	PG 1 Pulses Per Revolution	Sets the number of encoder pulses per revolution	8 to 16384 PPR	1024 PPR	No	– – – Y– – N
			PG1 Pulses/Rev	for the encoder on channel 1.
				Specifies the drive port for the PG option card used
				for Motor 2.
			PG Option Card Port for Motor 2	0: CN5-C
	F1-30	03AAh	Selection		0 to 1	0	No	– – – Y– – N
				1: CN5-B
			Mtr2 PG Port Sel
				Note: This parameter is available without a digital
				input H1-0 programmed to 16h (Motor 2 Select).

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					2	Spindle Orientation
	MEMOBUS/	Name			Default		Change	Control Method/
No.	Modbus		Description	Range			During
		Digital Operator Display			Value			Access Level
	Address						Run
			Sets the number of encoder pulses per revolution
		PG 2 Pulses Per Revolution	for the encoder on channel 2.	8 to
F1-31	03B0h				1024 PPR		No	– – – Y– – N
		PG2 Pulses/Rev	Note: This parameter is available without a digital	16384 PPR
			input H1-0 programmed to 16h
			(Motor 2 Select).
			Determines the direction indicated by the pulses
			from the PG feedback encoder for motor 2.
F1-32	03B1h	PG2 Rotation Selection	0: Pulse A Leads	0 to 1	0		No	– – – Y– – N
		PG2 Rotation Sel	1: Pulse B Leads
			This parameter is available without a digital input
			H1-0 programmed to 16h (Motor 2 Select).
		PG2 Division Rate for Pulse	Sets the ratio between the pulse input and the pulse
			output of a PG option card.
F1-35	03BEh	Monitor		1 to 132	1		No	– – – Y– – N
			This parameter is available without a digital input
		PG2 Output Ratio
			H1-0 programmed to 16h (Motor 2 Select).
			Sets whether the drive detects a fault when a
			PG-X3 card is disconnected.
		PG Option Card Disconnect	0: Disabled
F1-36	03B5h	Detection 2	1: Enabled	0 to 1	1		No	– – – Y– – N
		PGCardDisconDet1	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
		Stall Prevention Selection during	1: General Purpose
			2: Intelligent
L3-04	0492h	Deceleration		0 to 5	0		No	– – – Y– – Y
			3: Stall Prevention w/Braking Resistor
		StallP Decel Sel
			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
S1-01	680h	On-Delay Compensation Selection	Delay Compensation.	0 to 1	1		No	– – – Y– – Y
		OnDelay Comp Sel	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
S1-03	682h	Extended Current Sampling Mode	for output current distortion as the motor reaches	0 to 1	1		No	– – – Y– – Y
			1000 Hz while decoupled from the load during a
		Extend I Sample
			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.
		Control Mode Switchover	This function is disabled when 0 or 400 Hz is set,
			the inverter runs as V/f Control when 0 is set and
S2-01	691h	Frequency	Closed Loop Vector Control when 400 Hz is set.	0 to 400 Hz	400		No	– – – Y– – N
		HF SwOver Freq	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.
		Control Mode Switchover	Sets the hysteresis width of Control Mode Switch.
S2-02	692h	Bandwidth	Increase if shock occurs during Control Mode	2 to 100 Hz	20		No	– – – Y– – N
		HF CtrlMode SwBW	switching.

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2 Spindle Orientation

		MEMOBUS/	Name			Default	Change	Control Method/
	No.	Modbus		Description	Range		During
			Digital Operator Display			Value		Access Level
		Address					Run
				Sets the gain for the Motor Slip Compensation at
				Hi-Speed Function. Although this parameter rarely
			High Frequency Slip	needs to be changed, adjustments might be needed
				under the following circumstances:
	S2-05	695h	Compensation Gain		0.0 to 2.5	0.0	Yes	– – – Y– – N
				If the motor at constant speed is slower than the
			HF SlipComp Gain
				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
			High Frequency Slip	parameter rarely needs to be changed, adjustments
				might be needed under the following
	S2-06	696h	Compensation Primary Delay Time		0 to 10000 ms	2000	Yes	– – – Y– – N
				circumstances:
			HF SlipComp Time	-Decrease the setting when the slip compensation
				response is too slow.
				-Increase this setting when speed is unstable.
			High Frequency Slip	Sets the upper limit for the Slip Compensation at	0 to 250%	200	No	– – – Y– – N
	S2-07	697h	Compensation Limit	Hi-Speed Function as a percentage of the motor
			HF SlipComp Lim	rated slip (E2-02).
				When Slip Compensation during Regeneration at
				Hi-Speed is activated and a regenerative load is
			High Frequency Slip	applied, it might be necessary to use a dynamic
				braking option (braking resistor, braking resistor
	S2-08	698h	Compensation Selection During	unit, or braking unit).	0 to 2	0	No	– – – Y– – N
			Regeneration
			HF SlipCompRegen	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,
			Motor 2 Control Mode Switchover	the inverter runs as V/f Control when 0 is set, and
	S2-11	699h	Frequency	Closed Loop Vector Control when 400Hz is set.	0 to 400 Hz	400	No	– – – Y– – N
			HF SwOver Freq 2	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.
				Sets the hysteresis width of Control Mode Switch
	S2-12	69Ah	Motor 2 Control Mode Switchover	for Motor 2.	2 to 100 Hz	20	No	– – – Y– – N
			Bandwidth	Increase if shock occurs during Control Mode
			HF CtrlModeSwBW2	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
			Motor 2 High Frequency Slip	might be needed under the following	0.0 to 2.5	0.0	Yes	– – – Y– – N
	S2-15	69Dh	Compensation Gain	circumstances:
			HF SlipCompGain2	-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.
			Motor 2 High Frequency Slip	Although this parameter rarely needs to be
				changed, adjustments might be needed under the
	S2-16	69Eh	Compensation Primary Delay Time		0 to 10000 ms	2000	Yes	– – – Y– – N
			HF SlipCompTime2	following circumstances:
				-Decrease the setting when the slip compensation
				response is too slow.
				-Increase this setting when speed is unstable.
			Motor 2 High Frequency Slip	Sets the upper limit for the Slip Compensation at
	S2-17	69Fh	Compensation Limit	Hi-Speed Function for Motor 2 as a percentage of	0 to 250%	200	No	– – – Y– – N
			HF SlipComp Lim2	the motor rated slip (E4-02).

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

					2	Spindle Orientation
	MEMOBUS/	Name			Default		Change	Control Method/
No.	Modbus		Description	Range			During
		Digital Operator Display			Value			Access Level
	Address						Run
			When Slip Compensation during Regeneration at
			Hi-Speed is activated and a regenerative load is
			applied, it might be necessary to use a dynamic
		Motor 2 High Frequency Slip	braking option (braking resistor, braking resistor
S2-18	6A0h	Compensation During	unit, or braking unit).	0 to 2	0		No	– – – Y– – N
		Regeneration Selection
		HF SlipCompRgn 2	0: Disabled
			1: Enabled (6 Hz and Above)
			2: Enabled
			(Compensation provided wherever possible)

Table 4 Additional Parameters

		MEMOBUS/	Name			Default	Change	Control Method/
	No.	Modbus		Description	Range		During
			Digital Operator Display			Value		Access Level
		Address					Run
				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-
	P1-01	0600h	Orient Speed	11) when these parameters are enabled.	0.00 to 200.00 Hz	20.00	No	– – – Y– – N
			Orient Speed	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.
			Creep Speed	This parameter sets the speed at which the drive
	P1-02	0601h		locates the marker pulse. This is also the speed at	0.10 to 10.00 Hz	2.00	No	– – – Y– – N
			Creep Speed
				which s-curves are disabled.
				This parameter sets the number of quadrature
			Creep Distance	encoder counts around the orientation position
	P1-03	0602h		where the frequency reference is allowed to drop	0 to 2000 Cnts	200	No	– – – Y– – N
			Creep Distance
				below the P1-02 Creep Speed. Within the Creep
				Distance, the drive accel/decel times are set to 0.
			Approach Speed	This parameter sets the minimum speed that the
	P1-04	0603h		drive operates at until it reaches the P1-05 ORT Set	0.00 to 1.00 Hz	0.10	No	– – – Y– – N
			Approach Speed
				Window.
				This parameter sets the initial window around the
				orientation position that activates the Orient
				Complete digital output. The Orient Complete
			Orientation Complete Detection Set	digital output (H2- = 40) closes when the
	P1-05	0604h	Window	encoder quadrature count is within the P1-05	0 to 100 Cnts	25	No	– – – Y– – N
			ORT Set Window	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,
			Orientation Complete Detection	the window around the orient position that keeps the
				Orient Complete digital output (H2- = 40)
	P1-06	0605h	Reset Window		0 to 100 Cnts	0	No	– – – Y– – N
				closed.
			ORT Rst Window
				Note: Counts = Encoder PPR x 4.
				This parameter sets the delay time from when the
	P1-07	0606h	Orientation Set Time	P1-05 Orient Set window is satisfied and the	0 to 1000 ms	10	No	– – – Y– – N
			ORT Set Time	Orientation Complete digital output (H2- = 40)
				closes.
	P1-08	0607h	Positioning Proportional Gain	This parameter sets the proportional gain used for	0.10 to 20.00	1.00	No	– – – Y– – N
			Pos P Gain	the position controller.
				This parameter sets the minimum orientation
			Orientation Compensation Distance	distance between the orientation encoder marker
	P1-09	0608h		pulse at or below P1-02 and the desired orientation	0 to 100%	50%	No	– – – Y– – N
			Orient Comp Dist	offset. This distance is expressed as a percentage of
				the active encoder PPR (e.g. F1-01 x P1-09).

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