Yaskawa PG-X3 User Manual

YASKAWA AC Drive 1000-Series Option

Motor PG Feedback Line Driver Interface

Installation Manual

Type: PG-X3

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

ラインドライバタイプPG インタフェース

取扱説明書

形式 PG-X3

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 NO. TOBP C730600 37B

1 Preface and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2 Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

4 Option Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6 Related Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

7 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

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 37B 1000-Series Option PG-X3 Installation Manual 3

1 Preface and Safety

PG-X3

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 PG-X3 Installation Manual (This book) Manual No: TOBPC73060037

Yaskawa Drive

Yaskawa AC Drive 1000-Series Quick Start Guide

Yaskawa AC Drive 1000-Series Technical 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.

4 YASKAWA ELECTRIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual

1 Preface and Safety

W ARNING

CAUTION

◆ Terms

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

Drive: Yaskawa AC Drive 1000-Series

Option: Yaskawa AC Drive 1000-Series Option Motor PG Feedback Line Driver Interface: Type PG-X3

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.

DANGER

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 ELECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual 5

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.

6 YAS KA WA E LE CTR IC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual

2 Product Overview

◆ About This Product

The PG-X3 Option allows the user to connect an incremental line driver encoder (PG) for motor speed feedback to the drive and take advantage of the V/f with PG, Closed Loop Vector, and Closed Loop Vector for PM motors control modes. The option helps increase the control accuracy and performance.

This PG 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-X3 Option reads a maximum input frequency from the PG of 300 kHz. Be sure to select a PG with an output of maximum 300 kHz when operating at maximum speed.

Note: This option cannot be used with an open collector encoder. Use option PG-B3 with open

collector encoders.

◆ Applicable Models

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

Table 1 Applicable Models

Drive Series Drive Model Number

A1000 All models

L1000A All models

YASKAWA ELECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual 7

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 9 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

–

Quantity: 1231

PG-X3

◆ 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.

8 YASKAWA ELECTRIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual

MANUAL

4 Option Components

PG-X3

CN3

Underside

IP IG

a+ z+

z−a− b−

A+ B+A− B− Z+ SD FEZ−

TB1

TB2

4 Option Components

◆ PG-X3 Option

Figure 1

A – Terminal block TB1 E – Installation hole B – Jumper for PG power supply

voltage (CN3)

C – Model number G – Ground terminal (installation

D – Connector (CN5)

<1> Refer to Tab le 2 on page 18 for detail. <2> Terminal for ground wire packaged with the option card

<1>

Figure 1 PG-X3 Option Components

F – Terminal block TB2

hole)

<2>

◆ Terminal Blocks TB1 and TB2

Refer to Ta bl e 5 on page 21 for details on TB1 and TB2 terminal functions and signal levels.

YASKAWA ELECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual 9

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.

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.

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.

10 YASKAWA ELECTRIC TOBP C730600 37B 1000-Series Option PG-X3 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 ELECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual 11

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

12 YASK AWA E LEC TRI C TOBP C730600 37B 1000-Series Option PG-X3 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 ELECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual 13

5 Installation Procedure

2. Insert the option (B) into the CN5-B (K) or CN5-C (L) connectors located on the

drive and fasten it into place using one of the included screws (C). Use the CN5-C connector (L) when connecting only one option to the drive; use both CN5-B and CN5-C when connecting two options. Connect one of the ground wires (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

Figure 4

remaining provided screw (C).

Figure 4 Insert the Option and Connect the Ground Wire

Note: 1. The option package includes two ground wires. Use the longer wire when plugging the option into

connector CN5-C on the drive side. Use the shorter wire when plugging the option into connector CN5-B. Refer to Option Package Contents on page 8 for more information.

2. 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.

14 YA SKA WA EL ECT RIC TOBP C730600 37B 1000-Series Option PG-X3 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 ELECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual 15

<1>

Figure 5 Wire Routing Examples

B – Use the open space provided

inside the drive to route option wiring.

5 Installation Procedure

Insulation

Shield sheath

Shield

PG option terminal

PG at motor

FE/SD

Ground Terminal

(Insulate with electrical tape or shrink tubing)

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

Torques on page 20 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

Figure 6 Preparing Ends of Shielded Cable

5. Wire the motor PG encoder to the terminal block on the option. Refer to Figure 8 for

wiring instructions.

Refer to Option Terminal Functions on page 21 for a detailed description of the

option board terminal functions.

Parameter Settings and Connections for Different Encoder Types

• Connecting a Single-Channel Encoder When using a single-channel encoder in V/f with PG control mode, connect the

pulse output from the PG to the option and set drive parameter F1-21 to 0.

• Connecting a Two-Channel Encoder When using a two-channel encoder, connect the A and B pulse outputs on the PG

to the option and set F1-21 to 1. When using a two-channel encoder in Closed Loop Vector control mode, connect pulse outputs A and B from the encoder to the corresponding terminals on the option.

• Connecting a Two-Channel Encoder with Z Marker Pulse When using a two-channel encoder with Z marker pulse, connect the A channel,

B channel, and Z pulse outputs to the corresponding terminals on the option.

Control Method V/f with PG Closed Loop Vector

No. of Encoders 1 CN5-C 2 CN5-B 1 CN5-C 2 CN5-B

Single Channel (A) F1-21 = 0 F1-37 = 0 N/A N/A

Two Channel (AB Quadrature) F1-21 = 1 F1-37 = 1 No setting required No setting required

Two Channel with Marker (ABZ) F1-21 = 1 F1-37 = 1 No setting required No setting required

16 YA SKA WA EL ECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual

Figure 7

U/T1 V/T1

W/T1

R/L1 S/L2 T/L3

A+ A

B

Z

B+

Z+

a+ a

b

z

IP IG

IP12

IP5

TB1

TB2

CN5-B

CN5-C

A channel monitor signal

Ground wire

B channel monitor signal

Z pulse monitor signal

YASKAWA

Drive

PGX3

Option

CN3

twisted-pair shielded line

main circuit terminal control circuit terminal

<1>

5 Installation Procedure

YASKAWA ELECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual 17

Figure 7 PG-X3 Option and PG Connection Diagram

<1> Ground the shield on the PG side and the drive side. If noise problems arise in the

PG signal, remove the shield ground from one end of the signal line or remove the shield ground connection on both ends.

5 Installation Procedure

CN3

5.5 V 12 V

6. Set the voltage for the PG power supply using jumper CN3 located on the option.

Position the jumper as shown in Table 2 to select the voltage level.

NOTICE: The positioning of jumper CN3 selects the PG power supply voltage (5.5 V or 12 V). Select the voltage level for the PG connected to the option and motor. If the wrong voltage is selected, the PG may not operate properly or may become damaged as a result.

Table 2 Setting PG Power Supply Voltage (IP) with Jumper CN3

Voltage Level 5.5 V ± 5% (default) 12.0 V ± 5%

5.5 V 12 V

Jumper CN3

CN3

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

Figure 8

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.

18 YA SKA WA EL ECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual

8. Set drive parameters for proper motor rotation.

A pulse

B pulse

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

Time

→

With a two-channel or three-channel encoder, the leading pulse determines the motor rotation direction. A PG signal with leading A pulse is considered to be

Figure 9

Figure 10

rotating forward (counter-clockwise when viewing rotation from motor load side).

Figure 9 Displacement of A and B Pulses

After connecting the PG 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, reverse the two A channel wires with the two B channel wires on option terminal TB1 as shown in Figure 10.

A+ B+A− B− Z+ SD FEZ− A+ B+A− B− Z+ SD FEZ−

Figure 10 A Channel and B Channel Wire Switching

If switching the wires is inconvenient, set drive parameter F1-05/F1-32 to 1 to switch the direction of how the option reads pulses from the PG output. Please note that when the drive is initialized using A1-03 =1110, 2220, 3330, the value for F1-05/F1-32 will reset to factory default and the parameter will need to be

adjusted again to switch the direction.

5 Installation Procedure

YASKAWA ELECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual 19

5 Installation Procedure

6 mm

◆ Wire Gauges, Tightening Torque, and Crimp Terminals

Wire gauge and torque specifications are listed in Ta bl e 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–, Z+, Z–, SD, FE, IP, IG

a+, a–, b+, b–, z+, z–, SG

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.

Table 4 Crimp Terminal Sizes

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 to 16)

Recomm.

Gauge

(AWG)

0.75 (18)

Applicable

Gauges

0.25 to 0.5 (24 to 20)

(AWG)

Recomm.

Gauge

(AWG)

0.5

(20)

Wire Typ e

Shielded twisted pair, etc.

Shielded cable, etc.

Wire Gauge mm2 (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)

20 YA SKA WA EL ECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual

Phoenix Contact

Model

mm (in)

mm (in)d2mm (in)

5 Installation Procedure

◆ Terminal Functions

Table 5 Option Terminal Functions

Ter mi nal

Block

TB1

TB2

<1> A separate power supply is needed if the PG requires more than 200 mA to operate. Select a UL-listed class 2

Terminal Function Description

A+ A pulse signal input

A– A inverse pulse signal input

B+ B pulse signal input

B– B inverse pulse signal input

Z+ Z pulse signal input

Z– Z inverse pulse signal input

SD NC pin (open)

FE Ground Used as the shield ground termination point.

IP PG power supply

IG PG power supply common

SG Monitor signal common

a+ A pulse monitor signal

a– A pulse inverse monitor signal

b+ B pulse monitor signal

b– B pulse inverse monitor signal

z+ Z pulse monitor signal

z– Z pulse inverse monitor signal

power supply.

• Inputs for the A channel, B channel, and Z pulses from the PG

• Signal level matches RS-422

Open connection port for use when cable shields should not be grounded

• Output voltage: 12.0 V ± 5% or 5.5 V ± 5%

• Max. output current: 200 mA

• Output signal for monitoring A channel, B channel, and Z pulses from the PG

• Signal level matches RS-422

<1>

YASKAWA ELECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual 21

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.

Table 6 Related Parameters

No.

(Addr. Hex)

A1-02

(102)

F1-01

(380)

<2> <3>

F1-02

(381)

F1-03

(382)

F1-04

(383)

Name Description

0: V/f Control

Control Method Selection

PG 1 Pulses per Revolution

PG Feedback Loss Operation Selection

PG Overspeed Operation Selection

PG Deviation Operation Selection

1: V/f Control with PG 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

Sets the pulses to be read from the pulse generator.

Sets the stopping method when the PG 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 Note: Due to potential damage to the motor and machinery, only use the “Continue running” and “No alarm display” settings 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 Note: Due to potential damage to the motor and machinery, only use the “Continue running” setting under special circumstances.

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 Note: Due to potential damage to the motor and machinery, only use the “Continue running” setting under special circumstances.

Control Method

All Modes

V/f w/ PG CLV CLV/PM

V/f w/ PG CLV CLV/PM AOLV/PM

Value s

Default: Range: <1>

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

Default: 1 Range:

Default: 1 Range: 0 to 3

Default: Range: 0 to 3

<1>

22 YASKAWA ELECTRIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual

6 Related Parameters

Pulses × 60

F1-01

F1-13 (load side)

F1-12 (motor side)

No.

(Addr. Hex)

F1-05

(384)

<3>

F1-06

(385)

<3>

F1-08

(387)

F1-09

(388)

F1-10

(389)

F1-11 (38A)

F1-12 (38B)

<3> <5>

F1-13 (38C)

<3> <5>

F1-14 (38D)

F1-18

(3AD)

<3>

F1-19 (3AE)

<3>

F1-20 (3B4)

<3>

Name Description

PG 1 Rotation

PG 1 Ratio for PG Pulse Monitor

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:

(1 + x)

Ratio =

When only the A pulse is read, this ratio is disabled and pulses are set as 1/32 to 1.

PG Overspeed Level

Overspeed Det. Time

Excessive Speed Deviation Det. Level

Excessive Speed Deviation Det. Time

PG 1 Gear Teeth 1

PG 1 Gear Teeth 2

PG Disconnect Det. Time

Reverse Rotation Det. for PG 1

PG 1 Hardware Disconnect

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

Sets the time required for the motor to exceed the 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.

Number of gear teeth between the PG and motor.

A gear ratio of 1 will be used if any of these parameters is set to 0.

Sets the time in seconds for PG 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.

Control Method

V/f w/ PG CLV CLV/PM

V/f w/ PG CLV CLV/PM AOLV/PM

V/f w/ PG

V/f w/ PG CLV CLV/PM

CLV/PM

V/f w/ PG CLV CLV/PM

Value s

<1>

Default: Range: 0, 1

Default: 1 Min: 1 Max: 132

Default: 115 Min: 0 Max: 120

<4>

Default: Min: 0.0 Max: 2.0

Default: 10 Min: 0 Max: 50

Default: 0.5 Min: 0.0 Max: 10.0

Default: 0 Min: 0 Max: 1000

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

YASKAWA ELECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual 23

6 Related Parameters

fPG(Hz)

Motor speed at maximum frequency output (min

-1

)

PG rating (p/rev)

＝

No.

(Addr. Hex)

F1-21

(3BC)

<3>

F1-30

(3AA)

<6>

F1-31 (3B0)

<2> <7>

F1-32 (3B1)

<7>

F1-33 (3B2)

<5> <7>

F1-34 (3B3)

<5> <7>

Name Description

PG 1 Option Function

Motor 2 PG Connector

PG 2 Pulse Setting

PG 2 Rotation

PG 2 Gear Teeth 1

PG 2 Gear Teeth 2

0: A pulse detection 1: AB pulse detection

Selects the connector for the PG option connected to motor 2. 0: CN5-C 1: CN5-B

Sets the pulses to be read from the pulse generator.

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

Number of gear teeth between the PG and motor.

Pulses × 60

F1-31

A gear ratio of 1 will be used if any of these parameters is set to 0.

F1-33 (load side)

F1-34 (motor side)

Sets the division ratio for the pulses output from the PG encoder. Set as a three-digit number where x is

F1-35 (3BE)

<7>

F1-36 (3B5)

<7>

F1-37

(3BD)

<7>

<1> Veries by drive models. <2> The number of output pulses for the PG can be calculated as follows:

PG 2 Division Ratio for Pulse Monitor

PG 2 Hardware Disconnect

PG 2 Option Function

the first digit, y is the second digit, and z is the third digit:

(1 + x)

Ratio =

When only the A pulse is read, this ratio is disabled and pulses are set as 1/32 to 1.

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

0: A pulse detection 1: AB pulse detection

Control Method

V/f w/ PG

V/f w/ PG CLV

V/f w/ PG

V/f w/ PG CLV

V/f w/ PG

Value s

Default: 0 Range: 0, 1

Default: 1 Range: 0, 1

Default: 1024 Min: 0 Max: 60000

Default: 0 Range: 0, 1

Default: 0 Min: 0 Max: 1000

Default: 1 Min: 1 Max: 132

Default: 1 Range: 0, 1

Default: 0 Range: 0, 1

<3> The parameter is available only for the drive connector CN5-C. <4> Value changes according to the control mode selection in A1-02. <5> Enabled only when using the V/f with PG control mode. <6> Depending on the drive series, a second PG (PG 2) may not be possible. Refer to the Yaskawa AC Drive Technical

Manual for the drive in your application

<7> The parameter is available only for the drive connector CN5-B.

24 YA SKA WA EL ECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual

7 Troubleshooting

26LS32 level

26LS31level

PGX3

A,B,Z

A+,B+,Z+

600 Ω

a,b,z

a+,b+,z+

Monitor Signal

A,B,Z

26LS31 level

7 Troubleshooting

◆ Preventing Noise Interference

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

• Use shielded wire for the PG signal lines.

• Limit the length of all motor output power cables to less than 100 m.

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

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

■ Interface Circuit

Figure 11

Figure 11 Interface Circuit

YASKAWA ELECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual 25

7 Troubleshooting

◆ Drive-Side Error Codes

Table 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 cable is properly connected.

• Check the cables between the PG 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.

The load is locked up. Check the machine.

Parameters are set inappropriately.

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

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 are damaged.

Digital Operator Display Fault Name

dv2

Cause Possible Solution

PG cable noise interference.

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).

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

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.

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

26 YA SKA WA EL ECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual

7 Troubleshooting

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

Digital Operator Display Fault Name

dv3

Cause Possible Solution

The Z channel pulse offset is not set properly to E5-11.

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

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

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

The Z channel pulse offset is not set properly to E5-11.

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

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.

Set the value for Δθ to E5-11 as specified on the motor nameplate. Replacing the PG encoder or changing the application so the motor rotates in reverse requires readjustment of the Z channel pulse offset.

• 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. Replacing the PG encoder or changing the application so the motor rotates in reverse requires readjustment of the Z channel pulse offset.

• 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.

YASKAWA ELECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual 27

7 Troubleshooting

PG encoder is disconnected or is not wired properly, or the PG option or PG 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

oFb01 Option Connection Error at drive port CN5-B

Cause Possible Solution

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

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

oPE06

Cause Possible Solution

Control mode requires installing a PG option, but no PG encoder is installed (A1-02 = 1, 3, or 7).

Digital Operator Display Fault Name

Cause Possible Solution

Overshoot is occurring.

• 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-X3 to CN5-B or CN5-C. For other option cards, refer to the Installation Manual for that option card.

Switch the power off and reconnect the option.

Control Method Selection Error

Correct the setting for the control method.

• Connect a PG option.

• Correct the value set to A1-02.

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).

• Enable Feed Forward Control and perform Inertia Auto-Tuning in CLV.

28 YA SKA WA EL ECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual

7 Troubleshooting

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

Incorrect PG pulse number set. Check and correct parameter F1-01.

Inappropriate parameter settings.

Digital Operator Display Fault Name

PGo

Cause Possible Solution

PG cable is disconnected. Reconnect the cable.

PG cable wiring is wrong. Correct the wiring.

PG encoder does not have enough power.

Brake is holding the PG. Ensure the brake releases properly.

Digital Operator Display Fault Name

PGoH

Cause Possible Solution

PG cable is disconnected. Reconnect the cable.

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

PG Disconnected

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

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

PG Hardware Fault

PG cable is disconnected.

YASKAWA ELECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual 29

8 Specifications

Table 8 Option Specifications

Items Specifications

Model PG-X3

Compatible

Pulse Generators

PG Wiring Length 100 m (328 ft.) maximum

PG Power Supply

Compatible Control

Modes

Maximum Input

Frequency

Pulse Monitor Output

PG Disconnect

Detection

Ambient Temperature -10 °C to +50 °C (14 °F to 122 °F)

Humidity 95% RH or lower with no condensation

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

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

Altitude 1000 m (3280 ft.) or lower

Line driver Single-channel (A pulse), two-channel (A, B pulse) or three-channel (A, B, Z (R) pulse)

Output voltage: 12 V ± 5% or 5.5 V ± 5% Max. Output Current: 200 mA

V/f with PG, Closed Loop Vector, Closed Loop Vector for PM motors

300 kHz

Monitor for A channel, B channel, and Z pulse output Matches RS-422 level

Software and hardware detection

30 YASKAWA ELECTRIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual

◆ Revision History

MANUAL NO. TOBP C730600 37A

Published in Japan April 2009 08-7

Date of publication

Date of original publication

Revision number

54321

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

Date of

Publication

February 2014 − Japanese version only.

October 2013 Back cover Revision: Address

March 2013 Back cover Revision: Address

July 2012 Back cover Revision: Address

June 2011

August 2010 Back cover Revision: Address

April 2010 Back cover Revision: Address

November 2009 Entire Document Edited for procedural clarity and readability.

April 2009 Chapter 4

July 2008 −−First edition

Rev. No Section Revised Content

Front cover,

Back cover

Revision: Format

Addition: Connection Diagram Instruction to counteract noise by grounding shielded lines.

YASKAWA ELECT RIC TOBP C730600 37B 1000-Series Option PG-X3 Installation Manual 31

YASKAWA AC Drive 1000-Series Option

Motor PG Feedback Line Driver Interface

Installation Manual

DRIVE CENTER (INVERTER PLANT)

2-13-1, Nishimiyaichi, Yukuhashi, Fukuoka, 824-8511, Japan Phone: 81-930-25-3844 Fax: 81-930-25-4369 http://www.yaskawa.co.jp

YASKAWA ELECTRIC CORPORATION

New Pier Takeshiba South Tower, 1-16-1, Kaigan, Minatoku, Tokyo, 105-6891, Japan Phone: 81-3-5402-4502 Fax: 81-3-5402-4580 http://www.yaskawa.co.jp

YASKAWA AMERICA, INC.

2121 Norman Drive South, Waukegan, IL 60085, U.S.A. Phone: 1-800-YASKAWA (927-5292) or 1-847-887-7000 Fax: 1-847-887-7310 http://www.yaskawa.com

YASKAWA ELÉTRICO DO BRASIL LTDA.

Avenida Piraporinha 777, Diadema, São Paulo, 09950-000, Brasil Phone: 55-11-3585-1100 http://www.yaskawa.com.br

YASKAWA EUROPE GmbH

Hauptstrasse 185, 65760 Eschborn, Germany Phone: 49-6196-569-300 Fax: 49-6196-569-398 http://www.yaskawa.eu.com

YASKAWA ELECTRIC KOREA CORPORATION

9F, Kyobo Securities Bldg., 26-4, Yeouido-dong, Yeongdeungpo-gu, Seoul, 150-737, Korea Phone: 82-2-784-7844 http://www.yaskawa.co.kr

YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.

151 Lorong Chuan, #04-02A, New Tech Park, 556741, Singapore Phone: 65-6282-3003 http://www.yaskawa.com.sg

YASKAWA ELECTRIC (CHINA) CO., LTD.

12F, Carlton Bld., No.21 HuangHe Road, HuangPu Distr ict, Shanghai 200003, China Phone: 86-21-5385-2200 http://www.yaskawa.com.cn

YASKAWA ELECTRIC (CHINA) CO., LTD. BEIJING OFFICE

Room 1011, Tower W3 Oriental Plaza, No. 1 East Chang An Ave., Dong Cheng District, Beijing, 100738, China Phone: 86-10-8518-4086

YASKAWA ELECTRIC TAIWAN CORPORATION

9F, 16, Nanking E. Rd., Sec. 3, Taipei, 104, Taiwan Phone: 886-2-2502-5003

YASKAWA INDIA PRIVATE LIMITED

#17/A Electronics City, Hosur Road Bangalore 560 100 (Karnataka), India Phone: 91-80-4244-1900 http://www.yaskawaindia.in

Fax: 55-11-3585-1187

Fax: 82-2-784-8495

Fax: 65-6289-3003

Fax: 86-21-5385-3299

Fax: 86-10-8518-4082

Fax: 886-2-2505-1280

Fax: 91-80-4244-1901

YASKAWA ELECTRIC CORPORATION

In the event that the end user of this product is to be the military and said product is to be employed in any weapons systems or the manufacture thereof, the export will fall under the relevant regulations as stipulated in the Foreign Exchange and Foreign Trade Regulations. Therefore, be sure to follow all procedures and submit all relevant documentation according to any and all rules, regulations and laws that may apply.

Specifications are subject to change without notice for ongoing product modifications and improvements.

MANUAL NO. TOBP C730600 37B

Published in Japan February 2014 08-7 13-7-11

9 -0

Yaskawa PG-X3 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

4 Option Components

◆ PG-X3 Option

◆ 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