Yaskawa G5 User Manual

Eliminator

GPD515/G5 Software Option (VSG114676)

Part Number: CIMR-G5MXXXXXF-015

With this factory-installed FLASH software, the GPD515 / G5 becomes a configurable drive.

User Configurable software enhances the standard drive software with embedded functions. The drive may be operated as a standard off the shelf drive or may be configured to utilize the embedded functions. The functions can be configured to create the necessary control logic for many speed or torque control applications. It is possible to reduce the need for external control modules and PLC’s. Whole control systems may be integrated into a stand-alone GPD515 / G5 drive.

With this software, it is possible to read in information and output it into other functions from the following sources;

! All analog inputs ! All PG options ! Drive speed output ! Drive torque output ! Drive Hertz output ! Internal MOP ! Parameters

These sources can be input into the following functions that perform operations to change and control them. The following operations are available;

! Add, subtract, multiply and divide ! Change polarity

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XXXXX refers to the base Model Number of the drive in which the software is installed.

! Compare sources ! Absolute value ! PID ! Diameter calculator ! Scale information ! Switch between sources

The outputs from these functions can be connected to other functions or used to control the drive. The drive functions can be used to write information directly to the following drive controls;

! Analog outputs ! Speed reference ! Torque reference ! Multi-function outputs ! Digital Operator Monitors

This software provides the user the flexibility to configure their own logic and to change it when needed. It is one software flash that could replace many.

To better understand what this software can do it is necessary to understand the functions. It is also necessary to understand how to enter the configuration into the drive. The following sections of this manual will explain how to use and setup the functions.

This document is an addendum to Technical Manual TM4515, listing the effect of this software on the parameters in the drive and function descriptions in the manual.

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Date: 07/01/04, Rev: 04-07 Page 1 of 27 TM.G5SW.015

Function Blocks - Quick Reference

Source

Term 13

Analog

Input

Figure 2.1.1 Figure 2.1.2

P1-01

Number

Input

Figure 2.1.3 Figure 2.1.4

Figure 2.1.5 Figure 2.1.6 Figure 2.1.7 Figure 2.1.8 Figure 2.1.9

Read

Memory 1

Figure 2.1.A

Term 14

Analog

Input

P1-02

Number

Input

0 18

Read

Memory 2

Term 16

Analog

Input

P1-03

Number

Input

Drive

Output

16 MOP 25

P1-04

Number

Input

Drive

Torque

Output

1110000 12

Step

MOP

P1-05

Number

Input

Motor

Speed

Pulse

Input 1

Pulse

Input 2

Operation

Absolute

Value

PID

2423

Figure 2.2.5

Figure 2.2.1

Compare

70 <= 71

71 72

Figure 2.2.2

Center

Winder

Figure 2.2.6

False

True

3230

Compare

70 = 71

False

72 73

True

H1-0? = 80

Switch 1

Figure 2.2.7 Figure 2.2.8

3c3a

70 71

72 73

Compare 70 >= 71

False

True

H1-0? = 81

Switch 2

5250

Figure 2.2.3 Figure 2.2.4

Space

H1-0? = 85

Hold

Number

5c5a

Change

Sign

Scale

6160

Drive

Speed

Figure 2.3.1 Figure 2.3.2 Figure 2.3.3

U1-55

Monitor

Drive

Analog

Output 50

U1-50

Monitor

Figure 2.3.5

Torque

U1-51

Monitor

Drive

Max

U1-56

Drive

Analog

Output 51

Accel/

Decel

Figure 2.3.4

U1-52

Monitor

U1-57

Monitor

Drive

Output 40

U1-53

Monitor

U1-58

Monitor

Drive

Output 41

U1-54

Monitor

U1-59

Monitor

Figure 2.3.6

Drive

Output 42

Write

Memory 1

Write

Memory 2

Date: 07/01/04, Rev: 04-07 Page 2 of 27 TM.G5SW.015

Function Block Setup - Quick Reference

Sheet 1 of 2

2.1 Sources

Figure Description Information Input Output Setup

2.1.1

Analog

Inputs

2.1.2

MOP /

Step MOP

2.1.3

Number

Inputs

2.1.4

Pulse

Inputs

2.1.5

10000

2.1.6 0

2.1.7

Drive

Output

2.1.8

Torque Output

2.1.9

Motor

Speed

2.1.A Read

Memory

Analog Input 13 Terminal 13 13 Terminal 13 can not be reassigned Analog Input 14 Terminal 14 14 Terminal 14 – H3-09 = 20: Eliminator T-14 Analog Input 16 Terminal 16 16 Terminal 16 – H3-05 = 21: Eliminator T-16

P2-02 = MOP Rate / second

MOP 25

Step MOP P1-01 Range 0 to 65535 9A

P1-02 Range 0 to 65535 9B P1-03 Range 0 to 65535 9C P1-04 Range 0 to 65535 9D P1-05 Range 0 to 65535 9E

PG Channel 1

PG Channel 2

100 % Reference 10000 output value 12

0 % Reference 0 output value 18

Output Reference

Torque Reference

Motor Speed Percentage

Read Memory 1 46 Reads Write Memory1 Read Memory 2

P2-03 = MOP Max Percent P2-04 = MOP Min Percent P2-05 = MOP Rst Percent

P2-06 = MOP Step Rate

F1-01 = Pulses Per Rev.

P2-01 = Pulses input at 100 % inverter speed ( Range 0 to 65535)

Percentage of Maximum Frequency 0-10000 output value

Percentage of 100.00 Percent Torque 0-40000 output value

Available in PG and Vector modes only

Reads the value written into memory with the associated write memory.

2.2 Operations

Figure Description Information Input Output Information / Equation

Input Value 30 Input Value to add 31 Input Value 3a Input Value to subtract 3b Input Value 50 Input Value to multiply by 51 Input Value 5a Input Value to divide by 5b

2.2.1

Math

Addition

Subtraction

Multiplication

Division Absolute Value Same Input / Output Connector 40 Absolute Value of X

Change Sign Same Input / Output Connector 41 X times -1

Connections

H1-xx = 82: MOP UP H1-xx = 83: MOP DOWN H1-xx = 84: MOP RESET

0E PG Option Card Required (PG-X2 or PG-W2)

OF PG-W2 Option Card Required

47 Reads Write Memory 2

Connections

32 30 + 31 = 32

3c 3a - 3b = 3c

52 (50 x 51) / 10000 = 52

5c (5a x 10000) / 5b = 5c

Date: 07/01/04, Rev: 04-07 Page 3 of 27 TM.G5SW.015

Function Block Setup - Quick Reference

Sheet 2 of 2

Connections

23 24 B5-01 PID Mode = Disabled

60 61 ((60 X P1-08) / P1-09) + P1-10 = 61

42 43 Terminal ? - H1-01 to 06 = 85: Number Hold

70 <= 71 (True: 74 = 73) (False: 74 = 72) 70 = 71 (True: 75 = 73) (False: 75 = 72) 70 >= 71 (True: 76 = 73) (False: 76 = 72)

P1-06 = Diameter Filter Time

P1-07 = Diameter Build Ratio

03 Terminal ? - H1-01 to 06 = 80: Switch 1 DI

06 Terminal ? - H1-01 to 06 = 81: Switch 2 DI

Connections

94 44 Number Write 1

E1-04: Max Frequency Limits the drive output

P2-10 = Max Torque Ref (limit) Sets Max torque limit L7-01: Fwd = L7-02: Rev

Accel Time = (19 x C1-01) / 10000 Decel Time = (19 x C1-02) / 10000

H2-03 = 42: CONNECTION 82

H4-01 or H4-04 = 51: Case Monitor 2

Monitor Value = Input Value / 10

Number Write 2

2.2 Operations

Figure Description Information Input Output Information / Equation

1st Value 70 Compared to 1st Value 71

2.2.2

Compare

2.2.3

Space

2.2.4 PID

2.2.5

Scale

2.2.6

Center

Winder

2.2.7

Internal

Switches

2.2.8

Number

Hold

Compare input 70 to input 71

Enter Spaces

PID 23 = Error input

Scale

Calculate Diameter with ratio output

Switch 1

Switch 2

Hold last input value

Value if True 73 Value if False 72 Output less or equal 74 Output equal 75 Output greater or equal

Used to enter spaces into a configuration

B5-02 PID Gain = P Gain B5-03 PID I Time = I Bld Rate B5-04 PID I Limit = I Limit B5-05 PID D Time = D Rate B5-06 PID Limit = Output Limit P1-08 = Scale Multiplier P1-09 = Scale Divisor P1-10 = Scale Bias Line Speed Ref input 20 Diameter Filter Output Motor Speed Ref input 21 Normally Open 01 Normally Closed 02 Normally Open 04 Normally Closed 05

Outputs input value until the Hold is activated causing it to hold the last value read..

2.3 Drive

Figure Description Information Input Output Information / Equation

2.3.1

Drive

Speed

2.3.2

Drive Max

Torque

2.3.3

Accel /

Decel

2.3.4

Drive

Outputs

2.3.5

Analog /

Monitor

Outputs

2.3.6

Write

Memory

Frequency Reference to Drive

Torque Reference

Accel / Decel

Contact Output 9 Connects terminal 9 to 10 80 H2-01 = 40: CONNECTION 80 Trans Output 25 Sinks terminal 25 to 27 81 H2-02 = 41: CONNECTION 81 Trans Output 26 Sinks terminal 26 to 27 82 Monitor 1 (U1-50) 90 H4-01 or H4-04 = 50: Case Monitor 1 Monitor 2 (U1-51) Monitor 3 (U1-52) 92 Monitor 4 (U1-53) 93 Monitor 5 (U1-54)

Write a value into the Number Read registers

Controls the drives output frequency Range 0 to +/- 10000

Controls the Max output torque from the drive. Flux vector control only. Same as changing L7-01 and L7-02.

Changes the acceleration and deceleration time. Accel = Decel

Information can be passed to analog output terminals 21 and 23

Store numerical data into running memory. Two registers provided.

Date: 07/01/04, Rev: 04-07 Page 4 of 27 TM.G5SW.015

1.0 Configuring The Function Blocks

User Configurable software allows the GPD515/G5 drive to be configured to a specific application. This is accomplished by internal drive functions that may be connected to provide the logic required. For the purposes of understanding and developing logic the internal functions have been reduced to function blocks. The function block diagrams indicate how they can be connected.

Some functions have required setup as multi-function selections to operate. Many functions have associated parameters to provide control. Developing a configuration involves choosing the functions required, connecting them for the required logic and setting the parameters that control the functions.

1.1 Developing a Configuration

Function blocks are simple block diagrams that indicate their function and how they are connected. The arrow like icons used for the input and output connectors indicate the direction information is moving. A connector number is shown within these icons. Figure 1.1 shows the anatomy of the three categories of functions as function blocks.

Source Operation

Source

Input

Function

Convert

Source

Function

Drive

Output

Function

Figure 1.1

Output

Connector

Input

Connector

Output

Connector

Input

Connector

Using function blocks provides a way to develop configurations so they may be understood. From Figure 1.1 it is possible to see how the function blocks may be connected. Figure 1.2 demonstrates how the function blocks are connected.

Input

Connector

Drive

Output

Function

Source Operation

Source

Input

Function

Figure 1.2

Connection Connection

Output

Connector

Input

Connector

Convert

Source

Function

0302

Output

Connector

In figure 1.2 a source input function sends information to the output connector 01. The information is passed through the connection to the input connector 02 of the operation. The operation reads this information and converts it sending the result to the output connector 03. The information is passed through the connection to the input connector 04. The drive output function directs the information to control the drive. All configurations follow this example. There can be more complex configurations with more operations but the basics are the same. The information starts at a source. It is connected to the operations necessary to convert and control it. The information is then passed to the drive.

Developing a configuration for a drive requires selecting a data source and directing it through operations changing it to information that will provide the proper drive control and then

Date: 07/01/04, Rev: 04-07 Page 5 of 27 TM.G5SW.015

connecting it to the drive function. Configurations can be complex with many sources and operations or as simple as selecting a source reference and connecting it to the drive function.

Once a configuration has been developed using the function blocks to convert source information, it is necessary to enter the configuration into the drive. Entering the configuration into the drive requires generating a configuration list. This list is a record of all connections starting with the beginning information and following the operations in the manner that they must be executed until the information is connected to the drive functions required.

1.2 Configuring The GPD515

Using figure 1.2 a configuration list can be generated by starting at the source output connector 01 and recording the number within it. Next record the number within the input connector 02 that it connects. Follow the information path in the manner that it must be executed. This will yield – 01,02,03,04. The configuration list of connector numbers must be entered into the drive in this sequence.

This software reserves twenty-two User Parameters for the purpose of configuring the GPD515 / G5 drive. The User Parameters are located under the Initialize menu option. Parameters A2-01 through A2-10 remain unchanged serving their standard function. Parameters A2-11 through A2-32 are used for configuring the drive. Configuring the drive requires entering the configuration list into these parameters.

To enter the configuration list into the drive start at A2-11 and enter the first two-connector numbers or the first connection. Enter the next two-connector numbers or the second connection in the next parameter A2-12 and continue this until the complete configuration list has been entered.

Using the configuration list developed for figure 1.2, User Parameter A2-11 will be set to 0102, which are the numbers of the first connection. A2-12 will be set to 0304, which are the numbers of the second connection. When the drive is returned to operation the configuration list will be executed in the sequence that it was entered. The sequence ends at the first 00 connector number, which is the default number for the user parameters. The User Parameter connector numbers are read in the sequence that they are entered. Each connector number results in an operation. Input connectors store the information that is connected to them. Output connectors execute a function to read the stored input connector information or to read information from the drive then the associated function is executed converting the information sending it to the output connector.

1.3 Setup of Functions

Some functions require being selected in the standard drive parameters before they will function. Many functions have parameters and multi-function inputs associated with them. Sections 2 explains the functions, their setup and controls. This information can also be found in the quick reference information. The parameters used for these purposes should be set when the configuration is entered into the GPD515 / G5. Only the parameters required for the current configuration need to be setup.

Date: 07/01/04, Rev: 04-07 Page 6 of 27 TM.G5SW.015

1.4 Configuring Examples

This software may be configured just using the quick references. The following examples will demonstrate that it is just a matter of selecting the needed functions and connecting them together. Once the configuration is finished just record the connector numbers in the sequence that starts at the source information and follows it through the operations in the manner that it must be converted util it is sent to the drive. Then input the connector numbers into the drive.

Example 1.4.1:

This configuration will provide a speed reference to the drive and a scaled display monitor for the machine operator.

Figure 1.4.1

Terminal 13

Analog

Input

Terminal 13

Analog

Input

Scale

Drive

Speed

Control

6160

U1-54

Monitor

Configuration List 13,60,61,94,13,ff, 00

Configure the Drive

A2-11 = 1360 A2-12 = 6194 A2-13 = 13ff A2-14 = 00XX

XX = Don’t Care

The scaling parameters must be set to control the value displayed by the monitor.

Example 1.4.2:

This configuration uses 2 multi-function inputs to select between the 3 analog inputs to be used as the speed reference.

Configuration List 16,04,14,05,06,01,13,02,03, ff, 00

Configure the Drive

A2-11 = 1604 A2-12 = 1405 A2-13 = 0601 A2-14 = 1302 A2-15 = 03ff A2-16 = 00XX

XX = Don’t Care

Terminal 16

Analog

Terminal 14

Analog

Terminal 13

Analog

Figure 1.4.2

Input

16 14

06 13

H1- 0x : 81

04 05

Switch 2 DI

H1- 0x : 80

01 02

Switch 1 DI

Drive

Speed

Control

The multi-function and analog inputs must be setup. The drive will use terminal 13 as a reference with both switches off. When switch 1 is on via the multi-function input, terminal 14 becomes the reference. When both switches are on via the multi-function inputs, terminal 16 becomes the reference.

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1.5 Advanced Topics / Examples

The configuration entered in the A2 User Parameters is a sequence of numbers that are read back and executed by connector numbers. Each A2 parameter can contains one connection point or two connector numbers. Each connector number must be two digits. When the connector number is a single digit a 0 must be added to make it two. The leading zeros must be entered.

When a connector is read into the drive the function it represents is executed. Upon completion the next connector or two digit number is read and executed. This continues until a 00 is read or until all 22 A2 parameters or all 44 connector numbers have been executed.

The connectors are always read in sequence starting at the beginning and finishing at the end. The complete sequence is read each scan. The process starts over again on the next scan.

All operation input connectors store the connected input value without changing it. Because of this it is possible to connect values to all operation inputs before entering the output connector number into the sequence. When an operation output connector is read and executed the current stored input or last read values will be used and a new value is calculated and output. This must be considered when using an operation more than one time. Each time it is used all the inputs must only be in the sequence one time before the output is entered. After the output is entered it is possible to reuse the operation inputs but the output must be entered again before the end of the configuration sequence.

It is also possible to reduce the numbers required in the sequence by only entering an output one time when it is connected to several inputs. Once the output has been executed, the current value that will be passed to all input connectors is unchanged until the next output is executed. Therefore all input connectors that connect to an output may be entered into the configuration sequence after the output and before the next output. Outputs change the current value that will be passed. Inputs do not change the current or last output value.

Despite the flexibility provided with this software there are some configurations that may not be possible. The following examples demonstrate what has been covered in this section.

Date: 07/01/04, Rev: 04-07 Page 8 of 27 TM.G5SW.015

Example 1.5.1: This will function properly

Term 13

Analog

Input

Term 16

Analog

Input

Term 14

Analog

Input

Figure 1.5.1

Drive

3230

3c3a

3230

Speed

Configuration List 13,30,16,31,16,3a,14,3b,32,30,3c,31,32,ff

Configure the Drive

2-11 = 1330 A2-15 = 3230 2-12 = 1631 A2-16 = 3c31 2-13 = 163a A2-17 = 32ff 2-14 = 143b A2-18 = 00XX

XX = Don’t Care

Example 1.5.2: This w ill not function as intended

Term 13

Analog

Input

Term 16

Analog

Input

Term 14

Analog

Input

Figure 1.5.2

Drive

3230

Speed

Configuration List 13,30,16,31,16,30,14,31,

Configure the Drive

2-11 = 1330 A2-15 = 3230 2-12 = 1631 A2-16 = 3231 2-13 = 1630 A2-17 = 32ff 2-14 = 1431 A2-18 = 00XX

XX = Don’t Care

In this example output 32 will provide the value from the last execution to both connected inputs.

Example 1.5.3 This will function properly

Term 13

Analog

Input

Term 16

Analog

Input

Term 14

Analog

Input

Figure 1.5.3

Drive

3230

3c3a

Speed

Configuration List 13,30,16,31,32, 3a,16,30,14,31,32,3b,3c,ff

Configure the Drive

2-11 = 1330 A2-15 = 1431 2-12 = 1631 A2-16 = 323b 2-13 = 323a A2-17 = 3cff 2-14 = 1630 A2-18 = 00XX

XX = Don’t Care

Example 1.5.4 Figure 1.5.1 above can be reduced as shown

Reduced List Figure 1.5.1 13,30,16,31,3a, 14,3b, 32, 30, 3c, 31, 32, ff

Configure the Drive

2-11 = 1330 A2-15 = 303c 2-12 = 1631 A2-16 = 3132 2-13 = 3a14 A2-17 = ff00 2-14 = 3b32 A2-18 = XX

Figures 1.5.2 and 1.5.3 cannot be reduced. The common output 16 must be input to the addition function for each execution since a function will use the last value input for each execution. If output 16 was connected to input 31 on both addition functions it could be reduced since input 31 would remain the same for both executions.

32,30,32,31,32,ff

Date: 07/01/04, Rev: 04-07 Page 9 of 27 TM.G5SW.015

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