Yaskawa Drive Simulator User Manual
G7/E7/F7/P7/G5/P5/PS5 Drive Simulator
User Manual
Models: UUX000166 Document Number: TM.AFD.07.Simulator
Figure 1: Simulator unit with no control card installed
1. Introduction:
This control board tester and variable-power-factor load emulator allows the user to test all the basic and advanced
functions of above mentioned control cards without any need for actual drive power supply sections, motor stand, load
stand and power stages.
All of the required signals to operate the cards are simulated through DC and AC voltages and currents, adjustable by
potentiometers and switches. LED’s for digital and VU meters for analog signals monitor all the control and user
outputs. Yet all the signals are provided at test points for external access. PC serial 9-pin connector can be routed to
card’s RS232, RS485 or RS422 ports through on board converters. Two master-slave PG emulators are capable of
emulating wide PPR range of encoders. A true three-phase on-board emulator can simulate induction motors with
adjustable load and power factor for both 2 and 3 level drives. A current-limited pulse reference generator can provide
adjustable amplitude and frequency independently. An automatic power recycling circuit reboots the control card
safely, with feedback. Bipolar I/O references, active current source, external access port, supply voltage monitors, and
capability of supporting a very wide range of control cards are also provided.
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Please note that this equipment is intended for qualified engineering personnel only, familiar with Yaskawa Drives and
technical principles of variable speed AC drives and/or software engineering.
2. Features and Applications:
• CASE development: As this unit provides all the digital and analog I/O available in the control cards with the
monitoring and measurement capabilities, it will be ideal for any level of CASE design and verification.
• Firmware development: In addition to the general I/O, different emulators provide reference, feedback, load
and power factor virtual signals for the firmware designer to test under the most realistic environment, even
for different PWM index implementations.
• Drive application engineering: Versatile communication routers, loading emulators, reference and feedback
encoders and generators capabilities, in addition to I/O handling and easy-access test points, will make it ideal
for application verifications and testing.
• Wizard software and utilities development and testing: In addition to all the above, External Access/PLC
port-EAP opens a gate to automatic repetitive tests, usually required for communication software
verifications. The manual or externally controlled automatic power recycling is another unique feature to help
out the software test and development engineers.
• Hardware Development: The realistic physical environment, access to all ports and signals, easy access test
points, measurement and monitoring features, actual PWM signal outputs, dual encoder emulations and
extensive test points and EAP, will all be the ultimate platform for hardware development.
• Cross Referencing of different drive generations: In order to compare drives performances for an application
or even having all the above features for other old or new drives, their control cards can easily be tested on
this unit through cable adaptors. Therefore it can replace most of the present or even future test units.
• Automatic Test Setup: Almost all the hardware and software platforms, options, extensions, communication
protocols and controls, Wizard tools and Test tools can be either implemented for production or tested during
their development phases.
Figure 2: Simulator with G7 control card installed and running under simulated load
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3. Precautions:
• This unit is designed for office/lab environment and not for harsh industrial conditions. Also as an openchassis electrical system, all the usual precautions for these devices are expected accordingly. Any conductive
liquid spills, tool drops, wiring shortages, heavy physical blo ws or extensive electrostatic discharges can
cause damage to it and/or its connected accessories. However due to the applied precautions in its design,
these damages might be very limited and easily repairable while other modules keep on functioning properly.
• There is no level of electrical isolation in this unit and as soon as any control card gets connected to this unit,
it loses its isolation barriers. This is for ease of operation, probing, lowering the costs, etc. This is done as to
the application and purpose of the unit, which is not definitely industrial control. There are only two
isolated/unregulated IP5/IG5 and IP12/IG12 voltage sources, accessible through test points on J1. Only
mounting I/O terminal cards and providing external 24VDC/AC level commands, will revive this isolation.
• The external access port-EAP pins are all protected against static and dynamic HV/HC/HF interferences but
still applying wrong signals or shorting might interfere with the unit logic and cause invalid reactions and/or
readings. Please refer to this manual for the appropriate probing and signal applications for each pin.
• The power supply pins provided to the user at J1 test points and J8-EAP, are all current-limited to 80mA.
Any loading more than 100mA, may cause damage to the protective current-limiting resistors and the unit.
• There are no high voltages above 24VDC present on this unit anywhere except the components and power
supply module inside the grounded chassis, which carry the Mains voltage. Care should be taken to use the
provided grounded AC-cord and outlets in order to have full ground protection of the unit.
• Control cards G7/E7/F7 and G5/PS5 have their own connector on the unit. Please refer to the labels next to
each connector, before doing any wiring to the control cards (G7/E7/F7 to J9 and G5/PS5 to J10). Depending
on their screw hole positions, you can use the provided spacers to mount them on the unit.
Figure 3: Simulator with E7 I/O card installed
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