Yaskawa G5 User Manual

Electronic Lineshaft with Alignment

GPD515/G5 Software Option (VSG114713E)

Part Number: CIMR-G5MXXXXXF-046

(1)

A Yaskawa GPD515/G5 flashed with this software has the ability to electronically emulate a lineshaft connection between 2 or more independently driven devices. In this system there will be a master device and one or more slave drives. The slaves will follow the master device and can be automatically aligned to it by using the alignment feature. Once aligned the relationship between the leading master device and the following slave drives will be maintained. The gearing feature allows the slaves drives to follow the master device at a definable ratio.

This system requires supplying the slave drive with a line driver quadrature feedback from the device to be followed. Any electronic device that is capable of supplying the following drive with the proper signal can be used as the master signal. The following drive will follow the master signal pulse for pulse after applying the ratio in either direction. The following drive must be operated using closed loop or flux vector control and therefore must have an encoder coupled to the motor.

The typical application will have a master drive and a slave drive. The equipment being driven requires two mechanically isolated and motor driven moving parts to maintain a constant position relationship to within a few encoder counts. The position of the moving part driven by the slave motor requires alignment to the position of the master device.

The master drive can be operated in any control mode but master device feedback connected to the slave drive is required. The feedback or master signal controls the follower drive. The follower drive monitors the master signal and compares it to the feedback from the slave motor’s encoder. The follower will then compensate for any position errors resulting by adjusting the output frequency of the slave drive. This results in near perfect alignment between the master device and slave device. There is no accumulation of position error, so alignment will always be maintained within a few pulses.

The slave drive has an automatic alignment feature with this software. This feature provides a means of aligning the follower encoder to the master signal. This is accomplished by using two switches connected to the trigger inputs of the slave drive. One switch is used to indicate the position of the master. The other switch is used to indicate the position of the follower. When the alignment feature is active, advancing or retarding the slave motor corrects the difference between when these switches are activated. When both encoders are activated at the same time the master and follower are aligned. An offset feature is provided enabling fine adjustment for switch misalignment.

This software provides a trim advance and retard input to adjust the following drive in respect to the to the master. Adjustments can be made while running. This adjustment will change the position or phase relationship between the drives.

When the master signal is from another GPD515/G5 it is not necessary for it to be running lineshaft software. All follower or slave GPD515/G5 drives must be running lineshaft software.

Date: 07-01-04, Rev: 04-07 Page 1 of 15 TM.G5SW.046

Electronic Lineshaft with Alignment

Features:

Disable Lineshaft Input – Disables the lineshaft software placing the drive back into standard control Advance (Trim) Input – Advances the alignment position of the slave drive at a settable rate Retard (Trim) Input – Retards the alignment position of the slave drive at a settable rate Slave Trigger Input – Indicates the position of the slave drive when activated Master Trigger Input – Indicates the position of the master drive when activated Align Slave Input – Enables the automatic alignment feature Aligned Output – Indicates the alignment procedure was performed and the following drive did align Alignment Checking – Monitors the difference between the trigger inputs with the result controlling an output Alignment Fault – Monitors the travel during alignment and faults the drive when the limit is exceeded Following Alarm – Monitors the following error and provides a selectable result when it exceeds the limit Gear Ratio – Adjust the ratio of the following drive in respect to the master Monitors – Displays useful information to indicate how close the follower is following

The disable lineshaft input provides a means to operate the drive independent from the master drive. This feature can be selected at any time and disables all lineshaft features when active. The position relationship between the master and the slave drive will be lost when this input is activated. The slave drive will maintain the current position with the master when the lineshaft disable input is deactivated.

The trim controls provide a means to adjust the position relationship between the master and the slave drives. The trim rate is settable. The slave position can be advanced or retarded in relation to the master drive when the slave’s run input is on. The trim can function if the run input is on.

The align slave, master and slave trigger inputs are required to perform an alignment. The alignment procedure can be used to align the slave to the master using fixed trigger positions. This process does not control the master drive. All correction is made by the slave drive. The amount of the correction is controlled by the quadrature counts that are accumulated from the time when the first or leading trigger starts the process and continues until the trailing trigger stops it. The correction will be made as soon as the trailing trigger input becomes active. This process was intended to be performed at lower frequencies but will function if the triggers provide a minimum of a 5 millisecond signal.

The alignment check is provided to indicate whether the trigger inputs are activated within a settable quadrature count range. An alignment check output will be on when the triggers are within the defined range and will go off when the range is exceeded. This output will only change after the trailing trigger has activated. This check is always active in lineshaft mode.

The following alarm monitors the quadrature error count that exists between the master and the slave drive. If the count exceeds the settable range a selectable action will occur.

The gear ratio provides a means to apply a ratio between the master device and the slave drive. This may be used to correct for errors in drivetrain ratios or to apply a required ratio between the drives.

The monitors provided allow monitoring of how well the slave drive is following the master signal. The master signal can also be monitored.

Date: 07-01-04, Rev: 04-07 Page 2 of 15 TM.G5SW.046

1.1 Sample Application

Electronic Lineshaft with Alignment

Gear

Slave

Box

Master

Motor

Slave Trigger Switch

Motor

Slave Motor

Slave Encoder

PG-W2

GPD

515

Master Motor

Master Encoder

Master Trigger Switch

PG-X2

GPD

515

This example shows two pusher chains. Each chain is mechanically isolated from the other. The master and slave trigger switches are placed in line providing an alignment position for the pushers. The pusher’s leading edge will activate the switches as they pass.

When this line starts alignment is necessary. The “Align Slave” input must be activated and maintained to cause the alignment feature to operate. The slave drive will align itself after the trailing pusher has triggered. The “Aligned” output indicates that the alignment procedure was successful and that the “Align Slave” input may be removed. If this input is not removed alignment will occur each time a pusher passes a trigger switch. The pushers will be aligned to the associated trigger switch position.

The lineshaft software will maintain the follower’s position in respect to the master. The follower position is monitored and if it exceeds the users set value a following fault or alarm will result. The alignment check will also monitor the quadrature counts between the triggers. An “Alignment Check” output will remain on if the check was within the set range.

Date: 07-01-04, Rev: 04-07 Page 3 of 15 TM.G5SW.046

Electronic Lineshaft with Alignment

1.2 Example Configuration Diagram

to the 1

Master Source Signal

Slave GPD515 Drive

Master Source Signal

Slave GPD515 Drive

to the 2

Master Source Signal

to the 3rd Slave GPD515 Drive

Master Source Option 1

Pulse

Generator

+A Pulse

-A Pulse

+B Pulse

-B Pulse

Master Source Option 2

Encoder

Master Source Option 3

Motor

Encoder

1.2 Example Wiring Diagram

Master Drive

T1 T2 T3

MGL

Red 5-15VDC

Black Common

2 3

Blue +A

Gray -A

Green +B

Yellow -B

7 8 9

Blue +A

Gray -A

Green +B

Yellow -B

TA2 TA1

PG-X2 PCB Option

5 6

TA3

Run

Speed Ref

L1 L2

GPD515

1 FWD Run 2 REV Run 3 EXT Fault 4 Fault Reset 5 Definable 6 Definable 7 Definable 8 Definable 11 Common

12 GND 13 Input 0-10V 14 Input 4-20mA 15 Supply +15V@20mA 16 Input 0-10V 17 Supply Common 33 Supply -15V@20mA

9 10

18 19 20

25 26 27

23 Analog Output +/- 10 VDC 24 Analog Output +/- 10 VDC 25 Analog Output Common

Motor

Shield

Master Source Option 4

Encoder

encoder

PG-X2

GPD

515

Any Software

Master

Motor

Encoder

Enable / Run

Disable S Align Switch M Align Switch Alignment Sw

PG-W2

GPD

515

G114712 Software

Slave 1

Motor

Slave Drive

GPD515

G11471x

1 FWD Run 2 REV Run 3 EXT Fault 4 Fault Reset 5 DisableLineshaft 6 Slave Trigger 7 Master Trigger 8 Align Slave 11 Common

12 GND 13 Input 0-10V 14 Input 4-20mA 15 Supply +15V@20mA 16 Input 0-10V 17 Supply Common 33 Supply -15V@20mA

9 10

18 19 20

25 26 27

23 Analog Output +/- 10 VDC 24 Analog Output +/- 10 VDC 25 Analog Output Common

PG-W2

GPD

515

G114712 Software

Slave 2

Motor

Encoder

T1 T2 T3

MGL

Red 5-15VDC

Black Common

Blue +A

Gray -A

Green +B

Yellow -B

6 7 8 9

Blue +A

Gray -A

Green +B

Yellow -B

13 14 15 16

PG-W2 PCB Option

-A

-B

20 21 22

Shield

23 24

To Next Drive

Motor

encoder

Date: 07-01-04, Rev: 04-07 Page 4 of 15 TM.G5SW.046

Electronic Lineshaft with Alignment

1.3 PG-W2 Terminal Description and Wiring Notes

Refer to the GPD515/G5 User’s Manual for additional information regarding encoder feedback option cards.

PG-W2

Terminal #

1 IP12 +12V supply to power encoder 2 IG12 3 +A 4 -A 5 +B

6 -B 10 +A 11 -A 12 +B 13 -B 17 +A 18 -A 19 +B 20 -B

For proper lineshaft operation the following conditions must be met:

1) A PG-W2 encoder feedback card must be installed in the follower VFD(s).

2) The pulse reference from the master device must be quadrature, differential line driver type.

3) Encoder feedback from the follower motor must be quadrature, differential line driver type.

4) When the master operates in its normal, forward direction, monitor U1-50 of the follower should display a positive value. If it does not, it may be necessary to reverse the channel 2 pulse input A wires at terminals 10 and 11 of the follower’s PG-W2.

5) If the follower’s U1-50 display is positive, when the drive is commanded to run via input to terminal #1, the motor should rotate in the proper direction and the follower’s U1-05 monitor should display a positive value. If the motor direction is incorrect, it may be necessary to reverse any two of the motor leads on the VFD output. If the motor fails to rotate, or is unstable, it may be necessary to reverse the channel 1 pulse input A wires at terminals 3 and 4 of the PG-W2.

6) Do not use parameter F1-05 to change encoder phasing in this software. Please swap encoder signals A+ and A- instead.

1.4 Alignment Operation Description

The alignment operation performed by the follower drive requires three external inputs. The “Align Slave” input enables and disables the alignment feature. The “Master Trigger” input indicates the master drive is at the aligned position. The “Slave Trigger” input indicates that the slave drive is at the aligned position. The aligned position is where both trigger switches are activated at the same time.

When the “Align Slave” input is activated the slave drive will monitor the trigger inputs. The slave drive will accumulate the error count that separates the leading edges of the trigger inputs. When aligned both triggers are simultaneous. When not aligned the leading trigger will start an error count. The following trigger will stop the error count and the error will be corrected by advancing or retarding the slave drive at a maximum frequency of 4 Hz. The correction will occur when the leading edge of the following trigger is activated.

The recommended speed range for alignment is between 6 to 12Hz. Alignment can be performed at higher speeds. The trigger inputs require a minimum signal of 5 milliseconds. If the alignment speed is below 4 Hz the slave drive may run in the reverse direction to retard.

Parameter P1-02: “Align Offset” has been provided to adjust for misalignment of the trigger switches. The adjustment allows for + / - 9999 quadrature encoder counts or approximately 2.5 motor revolutions when using a

Designation Function Remarks

Power Supply

Follower Motor

Feedback

Master Device

Signal

Pulse Output

(Mirrors Channel 2)

0V, Common for 12V power supply Channel 1, Pulse Input A

Channel 1, Pulse Input B Channel 2, Pulse Input A Channel 2, Pulse Input B Encoder 2, Pulse Output, Channel A (5V pk) Encoder 2, Pulse Output, Channel B (5V pk)

Date: 07-01-04, Rev: 04-07 Page 5 of 15 TM.G5SW.046

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