Yaskawa E7 Technical Manual

Electronic Lineshaft

With Alignment

F7 Drive Software

Technical Manual

Software Number: VSF11005X, Drive Models: CIMR-F7UXXXXXX-064, CIMR-F7UXXXXXX-065 Document Number: TM.F7SW.064, Date: 02/25/2010, Rev: 10-02

This document is intended to provide proper installation and use of the Yaskawa drive with custom software. 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. Read and understand this document and the standard drive technical manuals before attempting to install, adjust, operate, inspect, or maintain the drive.

warnings in this document and the standard drive technical manuals.

Custom software is written to add

Observe all cautions and

functionality to a standard AC 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. Custom software can add new functions, modify standard functions, or even inhibit standard functions. It can be used to modify display text or parameter names. Custom software is usually loaded to the drive before delivery. The control board and drive nameplate are assigned unique part numbers and the software is registered, archived, and retrievable.

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 has been flashed to the control board memory and the operation of parameters, functions, and monitors are different than the standard drive software, as described herein.

1.0 Overview

The Electronic Lineshaft (ELS) function allows a drive to precisely follow a master encoder (PG) signal in speed, direction, and phase. The follower can match its position (phase angle) to the master within several quadrature encoder counts. The function is used in applications where the machinery being driven requires two mechanically isolated, moving parts to maintain a constant position relationship. The gear ratio between the master and the follower is infinitely adjustable. In addition, a gear ratio adjustment (“draw”) can be added to the speed reference via parameter, analog input, multi-function input, MOP, or network communication. The drive can also be run in a pure speed follower mode for applications that do not require matched position, only velocity following.

Both the master and follower encoder signals are fed into the follower drive’s dual encoder (PG) option card. The master encoder speed is multiplied by the programmed gear ratio to determine the speed reference. The error between the master and follower position is determined. This is fed into a PI controller, which is in turn added to the previously calculated speed reference. When the drive is configured as a speed follower, the position regulator is disabled.

A signed-run mode is also available in ELS. When P1-01 = 5 (Electronic Line Shaft - Sign Run), ELS functions identically to standard ELS (P1-01 = 4), with the following difference:

 When a reverse run command is given through the terminal S2 digital input, the follower will match the

 When a forward run command is present through terminal S1, the follower will run in the same direction is

With revision VSF110052, the software adds an automatic alignment feature to the base electronic line shaft software. This is accomplished by using two proximity switches connected to the trigger inputs on the follower drive. One switch is used to indicate the position of the master, and the other switch is used to indicate the position of the follower. When the alignment feature is activated and the machine is running, the distance between the trigger switches is measured and then compensated for by either advancing or retarding the follower motor.

velocity and phase of the master, but in the opposite direction. If the master runs in the forward direction, the follower will run in reverse direction. If the master runs in the reverse direction, the follower will run in the forward direction.

the master.

Date: 02/25/2010, Rev: 10-02 Page 2 of 34 TM.F7SW.064

Speed Calculation

ELS – Sign Mode Enabled

AND Reverse Run Command

Master Encoder

Pulse Count

Speed

Position Regulator

ELS – Sign Mode Enabled

AND Reverse Run Command

Follower Encoder

Pulse Count

Gear

Calculation

Gear

Calculation

ELS Mode Enabled OR

ELS – Sign Mode

Enabled

Position Error

Accumulator

Controller

Simplified Block Diagram of the Electronic Lineshaft Function

Gear

Follower

Box

Master

Motor

Master Motor

Master Encoder

Master Trigger Switch

Follower Trigger Switch

PG-X2

Motor

Follower Motor

Follower Encoder

F 7

Simplified Application Example of Electronic Lineshaft with Alignment Function

Frequency Reference

PG-W2

F 7

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Input Channel

Monitor Output

Channel 1 Input

Channel 2 Input

Monitor Output

. . .

Channel 1 Input

Channel 2 Input

PG-X2

Pulse

Master Drive

PG-W2

Pulse

Follower Drive 1

PG-W2

Follower Drive n

. . .

Typical Connection Diagram for Electronic Lineshaft

Date: 02/25/2010, Rev: 10-02 Page 4 of 34 TM.F7SW.064

2.0 Changes from Standard Product

a. The Motor 2 Selection (H1-0X = 16) multi-function digital input function is deleted (only Motor 1 can be

used). b. The kWh monitors (U1-29 and U1-30) are deleted. c. Parameter E2-04 (Motor Poles) is available in all control modes (Advanced access level only for V/f and

Open Loop Vector). d. T he follower drive uses acceleration and deceleration times of zero during standard Electronic Line Shaft

(P1-01 = 4, 5). e. All “A2” parameters along with the entire user access level have been deleted from this software.

3.0 Limitations

a. For ELS modes (P1-01 = 4, 5), Flux Vector control mode is highly recommended (A1-02 = 3). b. For ELS modes (P1-01 = 4, 5), the gear ratio must be exactly expressed, including remainder, to prevent

phase drift (error). See section 5.0. c. The proper encoder (PG) option card must be used based on the control mode and follower mode

selection. The table below shows the supported option cards for each configuration. d. If the “Clear Position Error” digital input is activated when an alignment is being performed, the drive could

possibly experience a step-change in frequency reference.

e. Alignment accuracy will be lessened at higher speeds. This is due to latency in the trigger

switches themselves and the drive’s digital inputs and internal scan rate.

Encoder (PG) Option Card Selection

Control Mode P1-01 = 1, 2, 3 (Speed Follower) P1-01 = 4, 5 (ELS)

V/f w/ PG PG-W2, PG-Y2, PG-Z2

Open Loop Vector PG-B2, PG-T2, PG-X2, PG-W2, PG-Y2, PG-Z2

Flux Vector PG-W2, PG-Y2, PG-Z2

V/f PG-B2, PG-T2, PG-X2, PG-W2, PG-Y2, PG-Z2

PG-W2, PG-Y2, PG-Z2

Note: If the PG-W2 option is used, jumper HDR1 must be set to the correct position according to the figure below.

Date: 02/25/2010, Rev: 10-02 Page 5 of 34 TM.F7SW.064

4.0 Related Parameters and Functions

4.1 Parameters

Parameter

Address

Number

Modbus

Parameter Name

Digital Operator

Range

Description

Display

Selects the follower mode.

0: Disabled

Follower mode is disabled and the follower drive runs from the normal frequency reference (B1-01).

1: Speed – Both Dir

The follower drive follows the master encoder speed in both directions.

2: Speed – One Dir

The follower drive follows the master encoder speed in the direction of the run command only.

3: Speed – Abs Val

The follower drive follows the master encoder speed but ignores the master

P1-01 600H

Follower Mode

Selection

Follower Mode

encoder direction (motion is always in the direction of the run command).

4: Elec Line Shaft

0 ~ 5 0 No Q Q Q Q

The follower drive follows the master encoder speed and position (both directions). Terminals S1 or S2 can be used to issue the run command. There is no directional effect.

5: ELS – Sign Run

The follower drive follows the master encoder speed and position (both directions). When a forward run command is present (terminal S1), the drive follows the master in the same direction. When a reverse run command is present (terminal S2), the drive follows in the opposite direction of the master.

*1: Access Level (A1-01): Q = “Quick Start”, A = “Advanced”, F = “Factory”.

Default

Change During

Run

Control Mode *1

Open Loop

V/f w/ PG

V/f

Vector

Flux Vector

Date: 02/25/2010, Rev: 10-02 Page 6 of 34 TM.F7SW.064

4.1 Parameters (continued)

Parameter

Address

Number

Modbus

Parameter Name

Digital Operator

Display

Description

Range

Default

Change During

Run

Control Mode *1

Open Loop

V/f w/ PG

V/f

Vector

Flux Vector

P1-02 601H

P1-03 602H

Master Encoder

PPR

Master PG PPR

Ratio Numerator

(Upper 4 Digits)

Ratio Num High

Sets the pulses per revolution (PPR) of the master encoder (PG).

Sets the upper 4 digits of the primary gear ratio numerator. See section 5.1.

20 ~ 60,000 Pulses

0 ~

9999

Ratio

P1-04 603H

Denominator

(Upper 4 Digits)

Sets the upper 4 digits of the primary gear ratio denominator. See section 5.1.

0 ~

9999

Ratio Den High

P1-05 604H

Ratio Numerator

(Lower 4 Digits)

Ratio Num Low

Sets the lower 4 digits of the primary gear ratio numerator. See section 5.1.

0 ~

9999

Ratio

Sets the lower 4 digits of the primary gear ratio denominator. See section 5.1.

0 ~

9999

P1-06 605H

Denominator

(Lower 4 Digits)

Ratio Den Low

Sets the numerator of the secondary gear ratio. Active when a multi-function digital input is set to 81 (Ratio 2 Select) and the input is closed.

Sets the denominator of the secondary gear ratio. Active when a multi-function digital input is set to 81 (Ratio 2 Select) and the input is closed.

1 ~

65,535

1 ~

65,535

P1-07 606H

P1-08 607H

Ratio 2

Numerator

Ratio 2 Num

Ratio 2

Denominator

Ratio 2 Den

Sets when the position error accumulator is enabled in the follower drive.

0: Only During Run

Position error is only calculated when the follower drive is running

during High Slip Braking)

1: Always

Position error is calculated

0 ~ 1 0 No A A A A

(not

P1-09 608H

Position Error Accumulation

Selection

Pos Accum

Select

whenever power is applied to the follower drive.

Note: ELS modes only.

*1: Access Level (A1-01): Q = “Quick Start”, A = “Advanced”, F = “Factory”.

1024 No Q Q Q Q

1000 Yes Q Q Q Q

0 Yes A A A A

1 Yes A A A A

Date: 02/25/2010, Rev: 10-02 Page 7 of 34 TM.F7SW.064

4.1 Parameters (continued)

Parameter

Address

Number

Modbus

Parameter Name

Digital Operator

Range

Description

Display

Selects the units used for the follower drive Position Error Monitor (U1-96).

0: Encoder Counts

Position error is displayed in quadrature follower encoder counts (cts).

1: Motor Revs

P1-10 609H

Position Units

Selection

Position Units

Position error is displayed in follower motor revolutions (0.001rev).

2: Motor Degrees

0 ~ 3 0 Yes A A A A

Position error is displayed in follower motor degrees (0.1°).

3: Motor Radians

Position error is displayed in follower motor radians (0.001rad).

Note: ELS modes only.

Sets the digital gear ratio adjustment of the follower drive. The gear ratio adjustment is also influenced by the analog, MOP and communication gear ratio

-99.99 ~

+99.99

P2-01 60AH

Digital Ratio

Adjustment

Digital RatioAdj

adjustments.

Sets the time for the MOP ratio

P2-02 60BH

MOP Adjust Time

MOP Adjust

Time

adjustment to change by

100.00% when the MOP Adjust Increase or MOP Adjust Decrease multi-function input

0.0 ~

6000.0 sec

is closed.

P2-03 60CH

Gear Ratio

Adjustment Ramp

Time

Ratio Adj Ramp

Sets the time for the composite gear ratio adjustment of the follower drive to change by

100.00%.

0.0 ~

6000.0 sec

*1: Access Level (A1-01): Q = “Quick Start”, A = “Advanced”, F = “Factory”.

Change During

Control Mode *1

Default

Run

V/f

V/f w/ PG

Open Loop

Flux Vector

Vector

0.00 Yes A A A A

50.0 Yes A A A A

10.0 Yes A A A A

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4.1 Parameters (continued)

Parameter

Address

Number

Modbus

Parameter Name

Digital Operator

Range

Description

Display

Selects the advance/retard functionality of the follower drive.

0: Continuous

The follower will advance or retard continuously while the Advance Follower or Retard Follower multifunction input is closed. P205 sets amount of advance/retard encoder counts per second.

1: Step

0 ~ 1 0 No A A A A

P2-04 60DH

Advance/Retard

Mode Selection

Adv/Ret Mode

Sel

The follower will advance or retard by the amount set in parameter P2-05 each time the Advance Follower or Retard Follower multifunction input is closed.

Note: ELS modes only.

Sets the number of quadrature follower encoder counts the follower will advance/retard per second when P2-04 = 0. Sets the step amount of the advance/retard function when P2-04 = 1.

0 ~

65,535 Counts

P2-05 60EH

Advance/Retard

Amount

Adv/Ret Amount

Note: ELS modes only.

Sets the amount of position error in quadrature follower encoder counts that will

P2-06 60FH

Follower

Deviation Level

Follower Dev Lvl

activate the follower deviation detection. Also sets the scaling for the Position Error analog output selection (H3-

0 ~

65,535 Counts

05, H3-09 = 94).

Note: ELS modes only.

*1: Access Level (A1-01): Q = “Quick Start”, A = “Advanced”, F = “Factory”.

Change During

Control Mode *1

Default

Run

V/f

V/f w/ PG

Open Loop

Flux Vector

Vector

2048 Yes A A A A

4096 No A A A A

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4.1 Parameters (continued)

Parameter

Address

Number

Modbus

Parameter Name

Digital Operator

Range

Description

Display

Selects the follower drive action when the position error exceeds the P2-06 setting.

0: No Detection

P2-07 610H

Follower

Deviation

Selection

Follower Dev Sel

The drive continues to run.

1: Alarm

The drive continues to run and an FDEV alarm flashes on the digital operator.

0 ~ 2 2 No A A A A

2: Fault (Coast to Stop)

The FDEV fault is displayed, the drive fault contact is activated, and the motor coasts to a stop.

Selects which input encoder signal is sent to the PG monitor output when using a

P2-08 611H

Encoder (PG)

Monitor Channel

Selection

PG Mon Ch

Select

dual channel PG option card (PG-W2, PG-Y2, or PG-Z2).

0: Channel 1

Encoder 1 is sent to the monitor output.

0 ~ 1 1 Yes A A A A

1: Channel 2

Encoder 2 is sent to the monitor output.

Determines if the MOP gear adjustment is memorized when

P2-09 612H

MOP Adjustment

Memorization at

Power Off

MOP Mem @Pwr

Off

the drive loses power.

0: Disabled

MOP adjustment is not memorized at power down.

1: Enabled

0 ~ 1 0 No A A A A

MOP adjustment is memorized at power down.

Sets the proportional gain of the position regulator PI loop.

Note: ELS modes only.

Sets the integral time of the position regulator PI loop.

Note: ELS modes only.

0.00 ~

100.00

0.00 ~

50.00 sec

P3-01 614H

P3-02 615H

Position P Gain

Position I Time

*1: Access Level (A1-01): Q = “Quick Start”, A = “Advanced”, F = “Factory”.

Change During

Control Mode *1

Default

Run

V/f

V/f w/ PG

Open Loop

Flux Vector

Vector

5.00 Yes A A A A

0.00 Yes A A A A

Date: 02/25/2010, Rev: 10-02 Page 10 of 34 TM.F7SW.064

4.1 Parameters (continued)

Parameter

Address

Number

Modbus

Parameter Name

Digital Operator

Display

Description

Range

Default

Change During

Run

Control Mode *1

Open Loop

V/f w/ PG

V/f

Vector

Flux Vector

P3-03 616H

Position

Regulator Filter

Time

Pos Filter Time

Sets the filter time of the position regulator output. This is a first order lag filter.

Note: ELS modes only.

0.00 ~

1.50 sec

Sets the limit (+/-) of the position regulator output. Set

P3-04 617H

Position PI Limit

Pos PI Limit

as a percentage of the maximum output frequency E1-04.

0.00 ~

10.00 %

Note: ELS modes only.

Selects how the position regulator output is used to trim the follower drive speed reference (master encoder frequency).

0: Constant

The position regulator output is independent of the master encoder speed reference.

1: Speed Prop

0 ~ 1 0 Yes A A A A

P3-05 618H

Position

Regulator Trim

Mode

Pos Trim Mode

The position regulator output is proportional to the master encoder speed reference.

Note: ELS modes only.

Speed

Proportional

P3-06 619H

Position Trim

Lower Limit

Sets the lower limit of the position regulator trim when P3-05 = 1.

0.00 ~

100.00% 10.00 Yes A A A A

SpdProp

LowerLim

Sets the frequency width used to determine “Speed Agree” when the drive is accelerating

P3-07 61AH

Ratio Change

Speed Agree

Width

RatioChg

SpdAgrF

or decelerating due to one of the following:

 Gear ratio change  Change in state of the

Follower Disable multi-

0.0 ~

20.0 Hz

function input

 Change in state of the run

command

*1: Access Level (A1-01): Q = “Quick Start”, A = “Advanced”, F = “Factory”.

0.00 Yes A A A A

8.00 Yes A A A A

0.5 Yes A A A A

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