Yaskawa PG-E3 User Manual

YASKAWA AC Drive 1000-Series Option

Motor Encoder Feedback HEIDENHAIN ERN1387 Interface

Installation Manual

Type PG-E3

To properly use the product, read this manual thoroughly and retain for easy reference, inspection, and maintenance. Ensure the end user receives this manual.

安川インバータ1000シリーズオプション

エンコーダインタフェース（ERN1387用）

取扱説明書

形式

PG-E 3

製品を安全にお使い頂くために，本書を必ずお読みください。また，本書をお手元に保管していただくとともに，最終的に本製品をご使用になるユーザー様のお手元に確実に届けられるよう，お取り計らい願います。

MANUAL N O. TOBP C730600 52C

1 Preface and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2 Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

3 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

4 Option Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

5 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

6 Related Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

7 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

8 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

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.

YAS KAWA ELE CTR IC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 1

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 option:

Option

Yaskawa AC Drive 1000-Series Option Motor Encoder Feedback HEIDENHAIN ERN1387 Interface PG-E3 Installation Manual (This book) Manual No: TOBPC73060052

Yaskawa Drive

Yaskawa AC Drive 1000-Series Quick Start Guide

Yaskawa AC Drive 1000-Series Technical Manual

2 YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual

The drive manuals cover basic installation, wiring, operation procedures, functions, troubleshooting, and maintenance information. The manuals also include important information about parameter settings and drive tuning. Access these sites to obtain Yaskawa instruction manuals: U.S.: http://www.yaskawa.com Europe: http://www.yaskawa.eu.com Japan: http://www.e-mechatronics.com Other areas: contact a Yaskawa representative.

Read this manual first. The installation manual is packaged with the option and contains information required to install the option and set up related drive parameters.

1 Preface and Safety

DANGER

W ARNING

CAUTION

◆ Terms

Note: Indicates supplemental information that is not related to safety messages

Drive: Yaskawa AC Drive 1000-Series

Yaskawa AC Drive 1000-Series Option Motor Encoder Feedback HEIDENHAIN ERN1387

Option:

Interface: Type PG-E3

PG: Pulse Generator or Encoder mounted on the motor

◆ Registered Trademarks

Trademarks are the property of their respective owners.

◆ Supplemental Safety Information

Read and understand this manual before installing, operating, or servicing this option. Install the option according to this manual and local codes.

The following conventions indicate safety messages in this manual. Failure to heed these messages could cause fatal injury or damage products and related equipment and systems.

Indicates a hazardous situation, which, if not avoided, will result in death or serious injury.

Indicates a hazardous situation, which, if not avoided, could result in death or serious injury.

Indicates a hazardous situation, which, if not avoided, could result in minor or moderate injury.

YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 3

1 Preface and Safety

NOTICE

DANGER

NOTICE

Indicates an equipment damage message.

■ General Safety

General Precautions

• The diagrams in this book may include options and drives without covers or safety shields to illustrate details. Be sure to reinstall covers or shields before operating any devices. Use the option according to the instructions described in this manual.

• Any illustrations, photographs, or examples used in this manual are provided as examples only and may not apply to all products to which this manual is applicable.

• The products and specifications described in this manual or the content and presentation of the manual may be changed without notice to improve the product and/or the manual.

• When ordering new copies of the manual, contact a Yaskawa representative or the nearest Yaskawa sales office and provide the manual number shown on the front cover.

Heed the safety messages in this manual.

Failure to comply will result in death or serious injury.

The operating company is responsible for any injuries or equipment damage resulting from failure to heed the warnings in this manual.

Do not modify the drive or option circuitry.

Failure to comply could result in damage to the drive or option and will void warranty.

Yaskawa is not responsible for any modification of the product made by the user. This product must not be modified.

Do not expose the drive or option to halogen group disinfectants.

Failure to comply may cause damage to the electrical components in the option.

Do not pack the drive in wooden materials that have been fumigated or sterilized.

Do not sterilize the entire package after the product is packed.

4 YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual

2 Product Overview

◆ About This Product

The PG-E3 Option allows the user to connect an ERN1387 rotary encoder for motor speed feedback to the drive and take advantage of the "Closed Loop Vector for PM Motors" control mode. The option helps increase the control accuracy and performance.

This encoder signal allows the drive to compensate for subtle variations in the load, while providing the drive with the necessary data to control the output frequency and maintain an accurate constant speed.

The PG-E3 Option reads a maximum frequency of 20 kHz. Be sure to select an encoder with an output of maximum 20kHz when operating at maximum speed.

When using the PG-E3 Option, the drive must be in the "Closed Loop Vector Control for PM Motors" control mode. Refer to the Technical Manual of the drive for details.

◆ Applicable Models

The option can be used with the drive models in Table 1.

Table 1 Applicable Models

Drive Series Drive Model Number

L1000A All models

YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 5

3 Receiving

Please perform the following tasks upon receipt of the option:

• Inspect the option for damage. Contact the shipper immediately if the option appears damaged.

• Verify receipt of the correct model by checking the model number printed on the name plate of the option. (Refer to Figure 1 on page 7 for more information)

• Contact your supplier if you have received the wrong model or the option does not function properly.

◆ Option Package Contents

Description: Option Ground Wires Screws (M3) Installation Manual

MANUAL

–

Quantity: 1131

◆ Tools Required for Installation

• A Phillips screwdriver (M3 metric / #1, #2 U.S. standard size) is required to install the option.

• A straight-edge screwdriver (blade depth: 0.6 mm (1/32”), width: 3.5 mm (1/8”)) is required to wire the option terminal block.

• A pair of diagonal cutting pliers.

• A small file or medium-grit sandpaper.

Note: Tools required to prepare option cables for wiring are not listed in this manual.

6 YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual

4 Option Components

Underside

PG-E3

◆ PG -E3 Option

Figure 1

4 Option Components

A – Terminal block TB1 B – Model number E – Installation hole C – Terminal block TB2 F – Ground terminal (installation

<1> Terminal for ground wire packaged with the option card

Figure 1 PG-E3 Option Components

D – Connector (CN5)

<1>

hole)

◆ Terminal Blocks TB1 and TB2

IP A+ A– C+ C– R+ R– a+ a–

TB1

Refer to Ta bl e 5 on page 19 for details on TB1 and TB2 terminal functions and signal levels.

YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 7

IG FEb

D–b+D+B–B+

–

TB2

5 Installation Procedure

W ARNING

5 Installation Procedure

◆ Section Safety

DANGER

Electric Shock Hazard

Do not connect or disconnect wiring while the power is on.

Failure to comply will result in death or serious injury.

Disconnect all power to the drive, wait at least the amount of time specified on the drive front cover safety label. After all indicators are off, measure the DC bus voltage to confirm safe level, and check for unsafe voltages before servicing. The internal capacitor remains charged after the power supply is turned off.

Electrical Shock Hazard

Do not remove the front cover of the drive while the power is on.

Failure to comply could result in death or serious injury.

The diagrams in this section may include options and drives without covers or safety shields to show details. Be sure to reinstall covers or shields before operating any devices. Use the option according to the instructions described in this manual.

Do not allow unqualified personnel to use equipment.

Failure to comply could result in death or serious injury.

Maintenance, inspection, and replacement of parts must be performed only by authorized personnel familiar with installation, adjustment, and maintenance of this product.

Do not touch circuit boards while the power to the drive is on.

Failure to comply could result in death or serious injury.

8 YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual

5 Installation Procedure

NOTICE

W ARNING

Do not use damaged wires, stress the wiring, or damage the wire insulation.

Failure to comply could result in death or serious injury.

Fire Hazard

Tighten all terminal screws to the specified tightening torque.

Loose electrical connections could result in death or serious injury by fire due to overheating of electrical connections.

Damage to Equipment

Observe proper electrostatic discharge (ESD) procedures when handling the option, drive, and circuit boards.

Failure to comply may result in ESD damage to circuitry.

Never shut the power off while the drive is running or outputting voltage.

Failure to comply may cause the application to operate incorrectly or damage the drive.

Do not operate damaged equipment.

Failure to comply may cause further damage to the equipment.

Do not connect or operate any equipment with visible damage or missing parts.

Do not use unshielded cable for control wiring.

Failure to comply may cause electrical interference resulting in poor system performance.

Use shielded twisted-pair wires and ground the shield to the ground terminal of the drive.

Properly connect all pins and connectors.

Failure to comply may prevent proper operation and possibly damage equipment.

Check wiring to ensure that all connections are correct after installing the option and connecting any other devices.

Failure to comply may result in damage to the option.

YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 9

5 Installation Procedure

◆ Prior to Installing the Option

Prior to installing the option, wire the drive, make the necessary connections to the drive terminals, and verify that the drive functions normally. Refer to the Quick Start Guide packaged with the drive for information on wiring and connecting the drive.

Figure 2 shows an exploded view of the drive with the option and related components for

reference.

Figure 2

A – Insertion point for CN5 G – Removable tabs for wire routing B – Option card H – Ground wire C – Included screws I – Drive grounding terminal (FE) D – Front cover J – Connector CN5-A E – Digital operator K – Connector CN5-B F – Terminal cover L – Connector CN5-C

Figure 2 Drive Components with Option

10 YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual

5 Installation Procedure

◆ Installing the Option

Remove the front covers of the drive before installing the option. Refer to the drive manual for directions on removing the front covers. Cover removal varies depending on drive size.

1. Shut off power to the drive, wait the appropriate amount of time specified on the

drive for voltage to dissipate, then remove the digital operator (E) and front covers (D, F).

DANGER! Electrical Shock Hazard. Do not connect or disconnect wiring while the power is on. Before wiring terminals, disconnect all power to the equipment. The internal capacitor remains charged even after the power supply is turned off. After shutting off the power, wait at least the amount of time specified on the drive before touching any components.

Figure 3

Figure 3 Remove the Front Covers and Digital Operator

YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 11

5 Installation Procedure

2. Insert the option (B) into the CN5-C (L) connector located on the drive and fasten it

into place using one of the included screws (C). Connect the ground wire (H) to the ground terminal (I) using one of the remaining screws (C). Connect the other end of the ground wire (H) to the remaining ground terminal and installation hole on the option using the last remaining provided screw

Figure 4

(C).

Figure 4 Insert the Option and Connect the Ground Wire

Note: There are two screw holes on the drive for use as ground terminals. When connecting three

options, two ground wires will need to share the same drive ground terminal.

12 YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual

3. Route the option wiring.

Depending on the drive model, some drives may require routing the wiring through the side of the front cover to the outside. In these cases, cut out the perforated openings on the left side of the drive front cover as shown in Figure 5 (A) and leave no sharp edges to damage wiring. Route the wiring inside the enclosure as shown in Figure 5 (B) for drives that do not require routing through the front cover. For more information, refer to the Peripheral Devices & Options section of Yaskawa

Figure 5

AC Drive Technical Manual in your application.

5 Installation Procedure

A – Route wires through the openings

provided on the left side of the front cover.

<1> The drive will not meet NEMA Type 1 requirements if wiring is exposed outside the enclosure.

YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 13

<1>

Figure 5 Wire Routing Examples

B – Use the open space provided

inside the drive to route option wiring.

5 Installation Procedure

4. Prepare wire ends as shown in Figure 6. Refer to Wire Gauges and Tightening

Torques on page 18 to confirm that the proper tightening torque is applied to each

terminal. Take particular precaution to ensure that each wire is properly connected and wire insulation is not accidentally pinched into electrical terminals.

WARNING! Fire Hazard. Tighten terminal screws to the specified tightening torque. Loose electrical connections could result in death or serious injury by fire due to overheating. Tightening screws beyond the specified tightening torque may cause erroneous operation, damage the terminal block, or cause a fire.

NOTICE: Heat shrink tubing or electrical tape may be required to ensure that cable shielding does not contact other wiring. Insufficient insulation may cause a short circuit that can damage the option or drive.

Figure 6

Shield

PG option terminal

FE/SD

Figure 6 Preparing Ends of Shielded Cable

Insulation

PG at moto

Shield sheath (Insulate with electrical tape or shrink tubing)

Ground Terminal

5. Wire the motor PG encoder to the terminal block on the option using a

HEIDENHAIN 17-pin cable. Refer to Figure 7 for wiring instructions. Limit the length of all motor output power cables to less than 10 m.

Refer to Option Terminal Functions on page 19 for a detailed description of the

option board terminal functions.

Tab l e 2

Option Terminal

IP Brown/Green Up

IG White/Green 0V

A+ Green/Black A+

A– Yellow/Black A–

B+ Blue/Black B+

B– Red/Black B–

C+ Gray C+

C– Pink C–

D+ Yellow D+

D– Purple D–

R+ Red R+

R– Black R–

PG Encoder Cable Specification

PG Encoder Cable

Color PG Encoder Side

14 YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual

5 Installation Procedure

a–

0 V

5 V

IP IG

A+

B+

C+ C– D+

R+

D–

R–

B–

A–

CN5-C

YASKAWA

Drive

PG-E3 Option

U/T1 V/T1

W/T1

R/L1 S/L2 T/L3

TB1,TB2

b–

Cable

(by HEIDENHAIN)

Shield in cable <1>

Encoder

A pulse monitor signal

B pulse monitor signal

main circuit terminal control circuit terminal

<2>

Ground wire

Figure 7

Figure 7 PG-E3 Option and PG Encoder Connection Diagram

<1> Properly connect the shield in cable to terminal IG on the option Terminal Block

TB2 or remove the ground connection on both ends.

<2> Ground the shield on the PG encoder side and the drive side. If noise problems

arise in the PG encoder signal, remove the shield ground from one end of the

Figure 8

YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 15

signal line or remove the shield ground connection on both ends.

5 Installation Procedure

6. Replace and secure the front covers of the drive (D, F) and replace the digital

Figure 9

operator (E).

Figure 8 Replace the Front Covers and Digital Operator

Note: Take proper precautions when wiring the option so that the front covers will easily fit back onto

the drive. Make sure cables are not pinched between the front covers and the drive when replacing the covers.

16 YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual

7. Set drive parameters for proper motor rotation.

The leading pulse determines the motor rotation direction. A PG encoder signal with leading A pulse is considered to be rotating forward (counter-clockwise when

Figure 10

viewing rotation from motor load side).

Pulse

Figure 9 Displacement of A and B Pulses

After connecting the PG encoder outputs to the option, apply power to the drive and manually rotate the motor and check the rotation direction by viewing monitor U1-05 on the digital operator. Reverse motor rotation is indicated by a negative value for U1-05; forward motor rotation is indicated by a positive value. If monitor U1-05 indicates that the forward direction is opposite of what is intended, set drive parameter F1-05 to 1 to switch the direction of how the option reads pulses from the PG encoder output. Please note that when the drive is initialized using A1-03 =1110, 2220, 3330, the value for F1-05 will reset to factory default and the parameter will need to be adjusted again to switch the direction.

5 Installation Procedure

The A pulse leads, followed by the B pulse displaced at 90 degrees

Time

→

YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 17

5 Installation Procedure

6 mm

◆ Wire Gauges, Tightening Torque, and Crimp Terminals

Wire gauge and torque specifications are listed in Tab le 3 .Yaskawa recommends using crimp terminals with the specifications listed in Table 4 to facilitate wiring and ensure proper connection.

Table 3 Wire Gauges and Tightening Torques

Ter min al

Signal

a+, a–, b+, b–, FE

IP, IG, A+, A–, B+, B–, C+, C–, D+, D–, R+, R–

<1> Use HEIDENHAIN 17-pin Cable. Refer to PG Encoder Cable Specification on page 14 to for detail.

■

Crimp Terminals

Screw

Size

Tightening

Torque

Nxm

(inxlb)

0.22 to 0.25

(1.95 to 2.21)

Yaskawa recommends using CRIMPFOX 6 by Phoenix Contact or equivalent to crimp the terminal ends.

Note: Properly trim wire ends so loose wire ends do not extend from the crimp terminals.

Bare Cable Crimp Terminals

Applicable

Gauges

(AWG)

Stranded wire:

0.25 to 1.0 (24 to 17)

Solid wire:

0.25 to 1.5 (24 to16)

<1>

Recomm.

Gauge

(AWG)

0.75 (18)

Applicable

Gauges

0.25 to 0.5 (24 to 20)

Recomm.

Gauge

(AWG)

–––

(AWG)

0.5

(20)

Wire Typ e

Shielded

twisted

pair, etc.

Tab le 4 Crimp Terminal Sizes

Wire Gauge

(AWG)

0.25 (24) AI 0.25 - 6YE 10.5 (13/32) 0.8 (1/32) 2 (5/64)

0.34 (22) AI 0.34 - 6TQ 10.5 (13/32) 0.8 (1/32) 2 (5/64)

0.5 (20) AI 0.5 - 6WH 14 (9/16) 1.1 (3/64) 2.5 (3/32)

18 YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual

Phoenix Contact

Model

mm (in)

mm (in)d2mm (in)

◆ Terminal Functions

0.6 V to 1.2 V

Ter mi nal

Block

Terminal Function Description

PG encoder Power Supply

Common

B+ B Pulse Signal Input Input for the B pulse sine-wave from the PG encoder.

B– Inverse B Pulse Signal Input

5 Installation Procedure

Tab le 5 Option Terminal Functions

Supplies power to the PG encoder.

• Max. input frequency: 20 kHz

• Input signal differential: B+ – B–

0.6 V to 1.2 V

TB1

D+ D Pulse Signal Input Input for the D pulse sine-wave from the PG encoder.

D– Inverse D Pulse Signal Input

b+ B Pulse Monitor Signal Output Outputs a ratio of the B pulse frequency.

Inverse B Pulse Monitor Signal

b–

Output

FE Ground Ground terminal for shielded cable.

Input signal differential: D+ – D–

• Output method: Line driver

• Output voltage: RS-422 level

• Possible resolution:1/n Set F1-06 to monitor the pulse signal. Varies by drive model.

YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 19

5 Installation Procedure

0.6 V to 1.2 V

0.2 V to 2.38 V

Ter min al

Block

TB2

Ter min al Function Description

IP PG encoder Power Supply

A+ A Pulse Signal Input Input for the A pulse sine-wave from the PG encoder.

A– Inverse A Pulse Signal Input

C+ C Pulse Signal Input Input for the C pulse sine-wave from the PG encoder.

C– Inverse C Pulse Signal Input

R+ R Pulse Signal Input Input for the R pulse (PG encoder home pulse) from

R– Inverse R Pulse Signal Input

a+ A Pulse Monitor Signal Output Outputs a ratio of the A pulse frequency.

Inverse A Pulse Monitor Signal

a–

Output

Supplies power to the PG encoder. Voltage range: 5 V ± 5%, 200 mA

• Max. input frequency: 20 kHz

• Input signal differential: A+ – A–

Input signal differential: C+ – C–

0.6 V to 1.2 V

the PG encoder. Input signal differential: R+ – R–

• Output method: Line driver

• Output voltage: RS-422 level

• Possible resolution:1/n Set F1-06 to monitor the pulse signal. Varies by drive model.

20 YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual

6 Related Parameters

The following parameters are used to set up the drive for operation with the option. Set parameters as needed. Parameter setting methods can be found in the drive Quick Start Guide or Technical Manual.

Tab le 6 Related Parameters

No.

(Addr. Hex)

A1-02

(102)

F1-01 (380)

<2>

F1-02 (381)

F1-03 (382)

Name Description

0: V/f Control 1: V/f Control with PG

Control Method Selection

PG 1 Pulses per Revolution

PG Feedback Loss Operation Selection

PG Overspeed Operation Selection

2: Open Loop Vector Control 3: Closed Loop Vector Control 5: Open Loop Vector Control for PM 6: Advanced Open Loop Vector Control for PM 7: Closed Loop Vector Control for PM Set to 7 when using PG-E3.

Sets the signal periods per revolution to be read from the pulse generator.

Sets the stopping method when the PG encoder becomes disconnected (PGo). 0: Ramp to stop (decelerates at time set to C1-02) 1: Coast to stop 2: Fast Stop (decelerates at the time set to C1-09) 3: Continue running 4: No alarm display NOTICE: Due to potential damage to the motor and machinery, do not use the "Continue running" and "No alarm display" settings except under special circumstances.

Sets the stopping method when overspeed is detected. 0: Ramp to stop (decelerates at time set to C1-02) 1: Coast to stop 2: Fast Stop (decelerates at the time set to C1-09) 3: Continue running NOTICE: Due to potential damage to the motor and machinery, do not use the "Continue running" setting except under special circumstances.

Available

Control

Mode

All Modes

CLV CLV/PM

Values

Default: Range: <1>

Default: Min: <1> Max: <1>

Default: 1 Range:

Default: 1 Range: 0 to 3

<1>

YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 21

6 Related Parameters

No.

(Addr. Hex)

F1-04 (383)

F1-05 (384)

F1-06 (385)

F1-08 (387)

F1-09 (388)

F1-10 (389)

F1-11 (38A)

F1-14 (38D)

F1-18

(3AD)

F1-19

(3AE)

F1-20 (3B4)

Name Description

0: Ramp to stop (decelerates at time set to C1-02)

PG Deviation Operation Selection

PG 1 Rotation

PG 1 Ratio for PG Pulse Monitor

PG Overspeed Level

Overspeed Det. Time

Excessive Speed Deviation Det. Level

Excessive Speed Deviation Det. Time

PG Disconnect Det. Time

Reverse Rotation Det. for PG 1

PG 1 Hardware Disconnect

1: Coast to stop 2: Fast Stop (decelerates at the time set to C1-09) 3: Continue running NOTICE: Due to potential damage to the motor and machinery, do not use the "Continue running" setting except under special circumstances.

0: Forward = A pulse leads 1: Forward = B pulse leads

Sets the division ratio for pulses output from the PG encoder. Set as a three-digit number: x is the first digit, y is the second digit, and z is the third digit: When using the PG-E3 option card, the drive disregards the value set for "x", and uses the formula 1/yz to determine the division rate for the pulse generator. The setting range is consequently 1/32 to

Sets the level for detecting overspeed as a percentage of the maximum output frequency.

Sets the time required for the motor to exceed the level set in F1-08 to trigger a fault.

Sets the degree of speed deviation to trigger a dEv fault. Set as a percentage of the maximum output frequency.

Sets the time required a speed deviation situation to trigger a fault.

Sets the time in seconds for PG encoder disconnect to be detected.

0: Disabled n: Number of times a dv3 situation must be detected to trigger a fault.

0: Disabled n: Number of times a dv4 situation must be detected to trigger a fault.

0: Disabled. No fault if the connection is lost. 1: Enabled. Fault if connection is lost.

Available

Control

Mode

CLV CLV/PM

CLV/PM

CLV CLV/PM

Values

<1>

Default: Range: 0 to 3

Default: <1> Range: 0, 1

Default: 1 Min: 1 Max: 132

Default: 115 Min: 0 Max: 120

Default: 0.0 Min: 0.0 Max: 2.0

Default: 10 Min: 0 Max: 50

Default: 0.5 Min: 0.0 Max: 10.0

Default: 2.0 Min: 0.0 Max: 10.0

Default: 10 Min: 0 Max: 10

Default: 128 Min: 0 Max: 5000

Default: 1 Range: 0, 1

22 YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual

6 Related Parameters

Sinθ2 + Cosθ

No.

(Addr. Hex)

F1-51 (3D3)

<1> Varies by drive models. <2> The output frequency of the PG encoder can be calculated as follows:

Operation at max.

output frequency

Name Description

PGoH Detection Level

Set the level for detecting PG Hardware Fault (PGoH). Set as a percentage of .

Motor speed at maximum frequency output (r/min)

＝

Available

Control

Mode

CLV/PM

PG rating (p/rev)

Values

Default: 80 Min: 1 Max: 100

YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 23

7 Troubleshooting

◆ Preventing Noise Interference

Take the following steps to prevent erroneous operation caused by noise interference:

• Use shielded wire for the PG encoder signal lines.

• Limit the length of all motor output power cables to less than 10 m.

• Separate the control wiring to the option, main circuit input power wiring, and motor output power cables.

• Ground the shield on the PG encoder side and the drive side. If noise problems arise in the PG encoder signal, verify that the shield is properly grounded and ground one end of the signal line or remove the ground connection on both ends.

• Properly connect the shield in cable to the IG on the option terminal or remove the ground connection on both ends.

■ Interface Circuit

Figure11

2.5 V

PG-E3

120 Ω

1 kΩ

A–,B–,R–

A+,B+,R+

C–,D–

C+,D+

PG Encoder

2.5 V

26LS31 Level

Figure 10 Interface Circuit

24 YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual

a–

b–

Monitor Signal

7 Troubleshooting

◆ Drive-Side Error Codes

Ta bl e 7 lists the various fault codes related to the option and pulse generator. Refer to the

drive Technical Manual for further details on fault codes.

Check the following items first when an error code occurs on the drive:

• Make sure the PG encoder cable is properly connected.

• Check the cables between the PG encoder and the option.

• Make sure the option is properly installed to the drive.

Table 7 Fault Displays, Causes, and Possible Solutions

Digital Operator Display Fault Name

dEv

Cause Possible Solution

The load is too heavy. Reduce the load.

The acceleration and deceleration times are set too short. / Acceleration and deceleration ramps are set too large.

The load is locked up. Check the machine.

Parameters are set inappropriately.

Motor brake is engaged. Ensure the motor brake releases properly.

Brake control sequence is incorrect.

Digital Operator Display Fault Name

dv1

Cause Possible Solution

The PG encoder is disconnected or is not wired properly, or the PG option or PG encoder are damaged.

Speed Deviation (for Control Mode with PG)

The deviation between the speed reference and speed feedback is greater than the setting in F1-10 for longer than the time set to F1-11.

Increase the acceleration and deceleration times (C1-01 through C1-08)./ Decrease the acceleration and deceleration ramps (C1-01 through C1-08)

Check the settings of parameters F1-10 and F1-11.

Correct the brake control sequence and then verify that the brake has been released.

Z Channel Pulse Fault Detection

The motor turned one full rotation while failing to detect the Z channel pulse.

• Rewire the PG encoder and make sure all wiring including shielded wiring is properly connected

• If the problem continues after cycling power, replace the PG option or the PG encoder.

YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 25

7 Troubleshooting

Digital Operator Display Fault Name

dv2

Cause Possible Solution

PG encoder cable noise interference.

The PG encoder is disconnected or is not wired properly, or the PG option or PG encoder are damaged.

Digital Operator Display Fault Name

dv3

Cause Possible Solution

E5-11 is not set properly. Set the value for Δθ to E5-11 as specified on the motor nameplate.

An external force on the load side caused the motor to move.

Noise interference along the PG encoder cable is affecting the A channel or B channel.

The PG encoder is disconnected or is not wired properly, or the PG option or PG encoder are damaged.

The PG encoder rotational direction set to F1-05 is in the opposite direction of the motor wiring.

Digital Operator Display Fault Name

dv4

Cause Possible Solution

E5-11 is not set properly.

Z Channel Pulse Noise Fault Detection

The Z channel pulse is out of phase by more than 5 degrees for the number of times specified in parameter F1-17.

Separate the PG encoder cable wiring from the source of the noise (e.g., drive output wiring).

• Rewire the PG encoder and make sure all wiring including shielded wiring is properly connected

• If the problem continues after cycling power, replace the PG option or the PG encoder.

Inversion Detection

• Torque reference and acceleration are in opposite directions.

• The speed reference and actual motor speed differ by over 30% for the number of pulses set to parameter F1-18.

• Make sure the motor is rotating in the proper direction.

• Investigate problems on the load side causing motor rotation in the opposite direction.

• Rewire the PG encoder and make sure all wiring including shielded wiring is properly connected

• If the problem continues after cycling power, replace the PG option or the PG encoder.

Make sure motor wiring for each phase (U, V, W) is connected properly.

Inversion Prevention Detection

Pulses indicate that the motor is rotating in the opposite direction of the speed reference. Set the number of pulses to trigger inverse detection to F1-19. Note: To avoid nuisance faults, be sure to disable inverse detection in applications where the motor may rotate in the opposite direction of the speed reference. Set F1-19 to 0 to disable this feature.

• Set the value for Δθ to E5-11 as specified on the motor nameplate.

• If the problem continues after cycling power, replace the PG option or the PG encoder.

26 YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual

7 Troubleshooting

Noise interference along the PG encoder cable is affecting the A or B pulse.

PG encoder is disconnected or is not wired properly, or the PG option or PG encoder are damaged.

Digital Operator Display Fault Name

oFA00 Non-Compatible Option connected to drive port CN5-A

Cause Possible Solution

Non-compatible option connected to drive port CN5-A.

Digital Operator Display Fault Name

oFb00 Non-Compatible Option connected to drive port CN5-B

Cause Possible Solution

Non-compatible option connected to drive port CN5-B.

Digital Operator Display Fault Name

oFC01 Option Connection Error at drive port CN5-C

Cause Possible Solution

Option at drive port CN5-C was changed during run.

Digital Operator Display Fault Name

oFC50

Cause Possible Solution

The option card is damaged. Replace the option card

Digital Operator Display Fault Name

oFC51

Cause Possible Solution

The option card is damaged. Replace the option card

Digital Operator Display Fault Name

Cause Possible Solution

Overshoot is occurring.

• Make sure the motor is rotating in the proper direction.

• Investigate problems on the load-side that may be causing the motor to rotate in the opposite direction.

• Rewire the PG encoder and make sure all wiring including shielded wiring is properly connected

• If the problem continues after cycling power, replace the PG option or the PG encoder.

Use only compatible options. Connect PG-E3 to CN5-C. For other option cards, refer to the Installation Manual for that option card.

Switch the power off and reconnect the option.

PG Encoder Option A/D Conversion Error

Error with the A/D conversion level (VCC level), or A/D conversion timed out.

PG Encoder Option Analog Circuit Error

Incorrect signal level (+2.5 V signal)

Overspeed

The motor speed feedback exceeded the F1-08 setting.

Increase the settings for C5-01 (Speed Control Proportional Gain 1) and reduce C5-02 (Speed Control Integral Time 1).

YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 27

7 Troubleshooting

Incorrect speed feedback scaling when terminal RP is used as speed feedback input in V/f control.

Incorrect PG encoder pulse number set.

Inappropriate parameter settings.

Digital Operator Display Fault Name

PGo

Cause Possible Solution

PG encoder cable is disconnected.

PG encoder cable wiring is wrong.

PG encoder does not have enough power.

Brake control sequence is incorrect.

Digital Operator Display Fault Name

PGoH

Cause Possible Solution

PG encoder cable is disconnected.

• Set H6-02 to the value of the speed feedback signal frequency when the motor runs at the maximum speed.

• Adjust the input signal using parameters H6-03 through H6-05.

Check and correct parameter F1-01.

Check the setting for the overspeed detection level and the overspeed detection time (F1-08 and F1-09).

PG Encoder Disconnected

Detected when no PG encoder pulses received for a time longer than setting in F1-14.

Reconnect the cable.

Correct the wiring.

Make sure the correct power supply is properly connected to the PG encoder.

Correct the brake control sequence and then verify that the brake has been released.

PG Encoder Hardware Fault

PG encoder cable is disconnected.

Reconnect the cable.

28 YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual

Table 8 Operation Error Displays, Causes, and Possible Solutions

Digital Operator Display Fault Name

oPE02

Cause Possible Solution

Parameters were set outside the possible range.

Digital Operator Display Fault Name

oPE06

Cause Possible Solution

Control mode requires installing a PG option, but no PG option is installed (A1-02 = 7).

Parameter Range Setting Error

Use U1-18 to find parameters set outside range.

Set parameters to the proper values.

Note: When multiple errors occur at the same time, other errors

are given precedence over oPE02.

Control Method Selection Error

Correct the setting for the control method.

• Connect a PG option.

• Correct the value set to A1-02.

7 Troubleshooting

YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 29

8 Specifications

Table 9 Option Specifications

Items Specifications

Model PG-E3

Compatible PG Encoder Type

Multi-turn Not available

PG Encoder Wiring Length

PG Encoder Power Supply

Compatible Control Modes

Maximum Input Frequency

Pulse Monitor Output

PG Encoder Disconnect Detection

Ambient Temperature

Humidity 95% RH or lower with no condensation

Storage Temperature

Area of Use Indoor (free of corrosive gas, airborne particles, etc.)

Altitude 1000 m (3280 ft.) or lower

ERN1387 (HEIDENHAIN)

10 m (32 ft.) maximum

Output voltage: 5 V ± 5% Max. Output Current: 200 mA

Closed Loop Vector for PM motors

20 kHz

Monitor for A and B pulse output Matches RS-422 Level

Software detection

–10°C to 50°C (14 °F to 122 °F)

–20°C to 60°C (-4 °F to 140 °F) allowed for short-term transport of the product

30 YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual

◆ Revision History

Revision dates and manual numbers appear on the bottom of the back cover.

MANUAL NO. TOBP C730600 52B

Published in Japan November 2009 09-7

Date of publication

Revision number

Date of original publication

Date of

Publication

March 2010 Entire Document Edited for clarity.

November 2009 Entire Document Edited for clarity.

July 2009 −−First edition

Rev. No Section Revised Content

YASKAWA ELECTRIC TOBP C730600 52C 1000-Series Option PG-E3 Installation Manual 31

YASKAWA AC Drive 1000-Series Option

Motor Encoder Feedback HEIDENHAIN ERN1387 Interface

Installation Manual

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YASKAWA ELECTRIC CORPORATION

YASKAWA

In th e event that th e end u ser of this pr oduct i s to be the mi litary and sa id prod uct is to be e mployed in any weapons system s or th e manufa cture there of, the export will fa ll unde r the r elevant regulat ions as stipul ated in the For eign Ex change and For eign Trade R egulati ons. Ther efore, b e sure to fo llow all proced ures an d submi t all r elevant documen tation accordi ng to a ny and all rul es, reg ulation s and l aws tha t may ap ply.

Speci ficatio ns are subject to cha nge wi thout n otice fo r ongoi ng prod uct mod ificati ons and improve ments.

MANUAL NO.

Published in Japan March 2010 09-7 10-3-3

TOBP C730600 52C

2 -0

Yaskawa PG-E3 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

1 Preface and Safety

◆ Applicable Documentation

◆ Terms

◆ Registered Trademarks

◆ Supplemental Safety Information

2 Product Overview

◆ About This Product

◆ Applicable Models

3 Receiving

◆ Option Package Contents

◆ Tools Required for Installation

◆ PG -E3 Option

4 Option Components

◆ Terminal Blocks TB1 and TB2

5 Installation Procedure

◆ Section Safety

◆ Prior to Installing the Option

◆ Installing the Option

◆ Wire Gauges, Tightening Torque, and Crimp Terminals

◆ Terminal Functions

6 Related Parameters

7 Troubleshooting

◆ Preventing Noise Interference

◆ Drive-Side Error Codes

8 Specifications

◆ Revision History