Toshiba G7 User guide

1
G7/H7 Applications
Workbook
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2
G7 Applications Workbook
©2006 Toshiba International Corporation
Industrial Division
13131 West Little York Road
Houston Texas 77041
Phone [phone] • Fax [phone]
www.toshiba.com/ind
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TABLE OF CONTENTS
Application Page
Configuring Local / Remote 4
PID Control 9
Three Wire Control 17
Motor Operated Pot (MOP) 19
Configuring Analog Inputs 21
Configuring Analog Outputs 23
Acc/Dec Time Switching Frequency 26
Frequency Priority Switching 28
Trim Pot 30
Customizing Display Units 32
Cyclic Overhauling Loads 34
Sensorless Vector Control (Speed) 35
Sensorless Vector Control (Torque) 39
Feedback Vector Control (Speed) 41
Feedback Vector Control (Torque) 43
Encoder Recommendations 46
G7 Master/Follower Via Communications 48
Master/Follower Using Analog Terminals 53
Basic Drooping 54
Remote Mount EOI 57
Preset Speeds 58
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1
Configuring Local / Remote operations
Introduction
Local/Remote Key – Toggles between the Local and Remote modes. The LED is on when the
system is in the Local mode.
The Local mode allows the Command and Frequency control functions to be carried out via the
EOI.
The Remote mode enables the Command and Frequency control functions to be carried out via the
Control Terminal Strip, LED Keypad, RS232/485, Communication card or Pulse Input.
The availablity of the Local mode of operation may be disabled via Program ⇒ EOI Option Setup ⇒
Local/Remote Key. Here you have the option of selecting Command Mode or Frequency Mode.
The availability of the Local mode of operation may be reinstated by changing this setting, performing
a Reset, or powering down.
EOI
Command Mode Selection Program ⇒ Fundamental Parameters ⇒ Standard Mode Set
Direct Access Number – F003
Parameter Type – Selection List
Factory Default – Use Control Terminal Strip
Changeable During Run – No
The Command Mode selection establishes the source of the command inputs. Command inputs
include Run, Stop, Forward, etc.
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If the LCD or LED keypad is selected, the Local / Remote key is enabled to select either the
Keypad (local) or the Control Terminal Strip (remote) as the command source.
If the Control Terminal Strip (remote) is selected, it may be programmed to select any of the following
as a source of the command signal:
•Use RR (Factory Default)
•Use LED Keypad (option)
•Use Common (TTL)
•Use RS232/485
•Use Communication Card (option)
Frequency Mode #1 Program ⇒ Fundamental Parameters ⇒ Standard Mode Set
Direct Access Number – F004
Parameter Type – Selection List
Factory Default – Use RR
Changeable During Run – No
The Frequency Mode #1 determines the source of the frequency command or the torque command
(when operating in the torque control mode) of the G7.
If the LCD or LED keypad is selected, the Local / Remote key is enabled to select either the
Keypad (local) or the Control Terminal Strip (remote) as the command source.
Selections are
•Use Vi/II
•Use RR
•Use RX
•Use RX2 (Option Card)
•Use LED Keypad (option)
•Use Binary/BCD Input
•Use LCD Keypad
•Use RS232/485
•Use Communication Card (Option)
•Use MOP Function Simulation
•Use Pulse Input Option
Frequency Mode #2 Program ⇒ Fundamental Parameters ⇒ Standard Mode Set
Direct Access Number – F207
Parameter Type – Selection List
Factory Default – VI/II
Changeable During Run – Yes
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This parameter selects the source of the frequency command signal to be used as Frequency Mode
#2 in the event that Frequency Mode#1 is disabled or Frequency Mode #2 is set up as the primary
control parameter.
Selections are
•Use Vi/II
•Use RR
•Use RX
•Use RX2 (Option Card)
•Use LED Keypad (option)
•Use Binary/BCD Input
•Use LCD Keypad
•Use RS232/485
•Use Communication Card (Option)
•Use MOP Function Simulation
•Use Pulse Input Option
Lockout of Local/Remote
Lockout of the Local/Remote can be done by Program ⇒ EOI Setup ⇒ Lockout ⇒ Lockout
Local/Remote.
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Operating the G7 with two installed EOIs
Required Equipment
One 120V G7 Demo with simulator terminal strip and two EOIs
Connections
Connect one EOI using the TTL port on the EOI and on the G7
Connect the second EOI using the RS485 port on the EOI and the RS232/485 port on the G7
EOI #2
EOI #1
Programming
EOI Number One (Functionality Start/Stop, Frequency Control, No Programming, No monitoring)
Direct
Access Path Parameter Name Comments
NA EOI Setup Options/Local Remote
Key Command Selection Selected (default)
NA EOI Setup Options/Local Remote
Key Frequency Selection Selected (default)
NA EOI Setup Options/Lockout Lockout Reset Selected
NA EOI Setup Options/Lockout Lockout Monitor Selected
NA EOI Setup Options/Lockout Lockout Parameter
Access Selected
NA EOI Setup
Options/Lockout/Password Enable Password Select Enable Password and
set password to
999
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EOI Number Two (Functionality: Run/Stop, No Frequency Control, Full Programming and Monitoring)
Direct
Access Path Parameter Name Comments
NA EOI Setup Options/Local Remote
Key Command Selection Selected (default)
NA EOI Setup Options/Local Remote
Key Frequency Selection NOT Selected
Instructions
This demonstration makes obvious the ability to use multiple EOIs with one G7 drive. Each EOI may
have different functionality and privileges. This is often desirable when an EOI is mounted at the
drive to facilitate programming, troubleshooting, and monitoring while an additional EOI may be
mounted remotely for use by an operator.
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2
PID Control
Introduction
The built-in PID of the G7 can be used to maintain a constant process variable such as flow,
pressure, temperature, and level. In the example below, the drive is used to vary the speed of the
motor/pump to maintain a constant pressure at the output of the pump. As the valves on the output of
the pump are opened, the pressure goes low. The drive senses this via a 4-20 mA feedback signal
and speeds up to increase pressure up to the desired level. The drive will slow the motor/pump down
as the valves close. The rate at which the drive responds to changes is adjustable via three
parameters (Proportional Gain, Integral Time, and Differential Time) and will have to be field-tuned.
Later in this guideline, PID applications will be discussed in general.
Connections
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Check your transducer’s schematic for connection information. The above diagram is typical for a loop-powered transducer.
Separately powered isolated transducers feed into the ‘II’ and “CC” terminals. If your transducer is not isolated, order an isolated
input board. The inputs to the standard G7 are not isolated; do not connect the ‘CC’ terminal to ground.
Output Flow
VALVES
//
//
MOTOR
D/A
4
-
20 mA feedback
Transduce
Area in which constant
pressure is desired
II
CC
P24
G7
PUMP
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Programming
Direct
Access Parameter Path Parameter Name Comments
F012 ProgramÎFundamental
ParametersÎFrequency Setting Upper Limit Set to 60
F011 ProgramÎFundamental
ParametersÎFrequency Setting Maximum Frequency Set to 60
F009 ProgramÎFundamental
ParametersÎStandard Mode Selection Accel #1 Set to 5
F010 ProgramÎFundamental
ParametersÎStandard Mode Selection Decel #1 Set to 5
F201 ProgramÎFrequency Setting
ParametersÎSpeed Reference
Setpoints
VI/II Set 0 hz at 20%
Set 60 hz at 100%
F360 ProgramÎFeedback
ParametersÎFeedback Settings Input Selection Set to VI/II for the PID feedback signal
The above programming assumes a system in which an increase in 4-20 mA feedback signal causes
the drive to reduce output frequency. If the system is such that increasing feedback should cause an
increase in output frequency, the ‘II’ terminal should be reversed by programming the following:
Direct
Access Parameter Path Parameter Name Comments
F201 ProgramÎFrequency Setting
ParametersÎSpeed Reference
Setpoints
VI/II Set 60 hz at 20%
Set 0 hz at 100%
Setting the Setpoint
In general, the setpoint is set by adjusting the setpoint to whatever level (frequency) is necessary to
yield the desired process variable setting. The commanded frequency and actual output frequency
will most likely not be the same; it is only the process variable’s (pressure, temperature, etc.) value
that is of concern. It is the ratio of Frequency Command to Maximum Output Frequency that the drive
uses to determine the feedback value it is trying to maintain (the setpoint).
Setpoint via keypad (Local Mode)
Press LOCAL/REMOTE button to illuminate the panel’s green LED. Hit RUN and adjust the keypad
pot to whatever value it takes to develop the desired process variable value. If you still need to setup
the setpoing via the keypad but need to Start/Stop from terminal, then set the F004 Frequency Mode
#1 to Use Common (TTL).
Setpoint via pot on RR terminal (Remote Mode)
Press LOCAL/REMOTE button to turn green LED off. Make F-CC OR R-CC. Adjust RR pot to
whatever setting it takes to generate the desired process variable value.
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How to find your set point in Local Mode:
You need to know what the range of your transducer is in order to solve for the set point in the drive.
Here is an example:
Transducer range: 4 to 20mA
Pressure range of transducer: 0 to 5 inches
Range of Drive: 0 to 60 (Maximum Frequency set at 60 hz)
Desired set point: 1.5 inches
Set point entered in the drive 60
)420( __ × −mApressureatmApressureat pressuresetpiontdesired
= inchesinches
inches
05 5.1 −×60 = 18
So for this example you would enter 18 as your set point in the drive.
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Tuning the PID
The idea when tuning this PID is to get fast enough response from the drive that the pressure doesn’t drop or increase very much. One
problem with this is that if the response is too quick, the drive can actually overshoot (put out a higher frequency than necessary), and
in extreme cases, oscillations can occur. The object then when tuning a PID loop is to minimize the rise and settling times.
Time
Settling
Ti
PID Drive Output Hz vs. Time
(
in res
p
onse to
p
ressure dro
p)
Rise Time
40
Hz
30
The above figure illustrates what is meant by the rise and settling times. Suppose that a G7 is running at 30 Hz. At Time 0, all of the
valves in the example system open. Suppose also that the drive now needs to speed up to 40 Hz to maintain the desired pressure. The
rise time, is the time it takes to go from Time 0 (pressure change) to the needed Hz (for the first time). As seen in the above graph,
there can be some oscillations that (hopefully) settle out after a time called the Settling Time. Remember that as the output frequency
changes, so does the pressure. THE USER MUST DECIDE WHAT ARE ACCEPTABLE RISE AND SETTLING TIMES.
Time 0
The rise time, settling time, and overshoot are dependent on the system and can be adjusted by changing three of the parameters in the
table programming above: Proportional Gain, Integral Time, and Differential Time.
Some recommended PID values based on application type:
Process Variable Proportional Gain Integral Gain
(seconds/repeat) Differential Gain (seconds)
Flow 0.3 0.6 0.0
Levels: fast 1.0 8.0 0.0
Levels: slow 0.25 16.0 0.0
Pressure: fast 2.0 0.5 0.0
Pressure: slow 1.0 2.0 0.0
Temperature: fast 1.0 2.0 0.0
Temperature: slow 1.0 16.0 0.25
Temperature: furnace 0.8 8.0 0.125
Compressor speed 1.0 2.0 0.0
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Simplified PID flowchart
Verror = Vsetpoint - Vfeedback
(
+
)
Setpoint
(frequency
command that
develops
desired
process
condition)
Feedback (indicates actual process
condition)
Integral
Differential
+
+new frequency reference to
drive main circuit
Proportional
erro
r
(-) +
PROPORTIONAL GAIN
Note that PIDs for quickly-changing process variables have higher proportional gains than do their counterparts for slowly-changing
process variables. The higher the proportional gain, the smaller the rise time. With increased proportional gain usually comes
increased overshoot and increased chance of oscillation.
INTEGRAL GAIN
Also known as reset,integral gain is not really a gain at all, but a time. The integral time (units seconds per repeat) defines how long it
takes the integral circuit output to go from zero to the level set by the output of the proportional circuit. The integral action is
therefore influenced by the proportional action. The output of the integral circuit represents the area under the Verror vs. time graph. In
the below example, if Verror were to remain at the level shown, the output of the integral circuit would continue to increase linearly
with time (integral output is proportional to area of the rectangle = Proportional gain times Verror times time). The shorter the
integral time, the stronger the effect of the integral action. If you have a system that never quite gets to the setpoint (there is
steady-state error), decrease the integral time.
Output from Integral Circuit
Input to Proportional Circuit
Time
Time
Verror
Output of Proportional Circuit
Proportional Gain times Verror
In
p
ut to Inte
g
ral Circui
t
Time
Verro
r
Integral
Time
Time
Proportional Gain times
DIFFERENTIAL GAIN
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Also known as anti-hunting gain or rate, differential gain is really not a gain, but a time. Differential gain is seldom used, but it helps
to stop oscillations on slowly changing variables (temperature). Any high frequency changes in the system variable (including noise,
if present) are picked up by the differential circuit and could lead to instability. The longer the differential time, the stronger the
differential action.
Output from Differential Circuit
Input to Differential Circuit
Derivative
Time
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Time
Time
Time
Time
Improve by decreasing
Integral Time
Desired Res
p
onse
PID Drive Output Hz vs. Time
(
in res
p
onse to
p
ressure dro
p)
40
Hz
30
40
Hz
30
Improve by decreasing
Proportional Gain,
decreasing Integral Time
40
Hz
30
40
Improve by increasing
Proportional Gain
Hz
30
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More PID parameters:
¾Feedback Source Delay Filter determines the drive reaction time. Decrease Filter Constant to improve drive reaction to
process variable change. Too long of a filter time can result in under/overshoot.
¾When PID is turned on, Lower Limit and Upper Limit frequency are both effective in setting the setpoing and the output
frequency in Local Mode, but in Remote mode it only affects the output frequency.
¾Use PID Deviation Limits to limit the amplitude of the error signal. The values entered here are in percent of Maximum Output
Frequency. Use on systems that change quickly and drastically. Feedback Settings Lower Deviation Limits applies to the error
when the feedback is less than the setpoint. Feedback Settings Upper Deviation Limits applies to the error when the feedback is
greater than the setpoint. Discrete output 1 or 2 can be programmed to be function 19 so that when the deviation is exceeded, the
output will be closed for indication.
PID can be turned ON/OFF remotely by programming one of the input terminal’s functions to “18” and opening/closing it to ‘CC’
respectively. Feedback source selection must still be set with a feedback source. The drive’s stop/start command must be coming
from the terminal strip for the remote PID ON/OFF to work (a frequency reference can come from keypad if desired). PID can be
turned ON/OFF in this way while the motor is turning.
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3
Three Wire Control
Introduction
The G7 can be programmed to allow three-wire start/stop functionality without the use of an external
relay. Note that the pushbuttons utilized are momentary. The switch “S3” determines direction.
When S3 is closed, it is in reverse direction, when opened, forward direction.
The following programming example will demonstrate how to set up a G7 to function as a three-wire
control operator.
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Programming
Direct
Access Parameter Path Parameter Name Comments
F115 ProgramÎTerminal Selection
ParametersÎInput Terminal Function S1 Set S1 function to 47 as when S1 is closed to CC, the drive will start
F116 ProgramÎTerminal Selection
ParametersÎInput Terminal Function S2 Set S2 function to 48 as when S2 is closed to CC, the drive will stop
F117 ProgramÎTerminal Selection
ParametersÎInput Terminal Function S3 Set S3 function to 49 as when S3 is closed to CC, the drive will be in reverse direction
(1) Place G7 in remote control mode
(2) Push Start button to close S1 to CC terminal momentarily
(3) Use speed pot to adjust frequency
(4) The drive will ramp up to the set speed from the pot in forward direction
(5) Close S3 to CC terminal
(6) The drive will ramp down speed and pass zero hertz and speed up to set speed from the pot in reverse direction
(7) Push Stop button to close S2 to CC terminal momentarily
(8) The drive will ramp down to stop
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4
Motor Operated Pot (MOP)
Introduction
Connections
TERMINAL STRIP
ST CC F CC
S1 CC S2 CC S3 CC
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Increase Decrease Reset
Frequently used for pendant stations on cranes, MOP control generates a speed reference for the G7
based on how long a momentary contact is made. When the “increase” contact is made, the drive
increases its output frequency until the contact is released, at which point it maintains the current
frequency. When the “decrease” contact is made, the drive decreases its output frequency until the
contact is released, at which point it maintains the current frequency. A closure of the momentary
“reset” contact ramps the drive down to zero hertz. Do not use this control scenario with ACCEL
and/or DECEL time greater than 10 seconds.
The following programming example will demonstrate how to set up a G7 to function as a MOP
operator.
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Programming
Direct
Access Parameter Path Parameter Name Comments
F115 ProgramÎTerminal Selection
ParametersÎInput Terminal Function S1 Set S1 function to 44 as when S1 is closed to CC, the drive will increase the frequency
until the contact is opened
F116 ProgramÎTerminal Selection
ParametersÎInput Terminal Function S2 Set S2 function to 45 as when S2 is closed to CC, the drive will decrease the frequency
until the contact is opened
F117 ProgramÎTerminal Selection
ParametersÎInput Terminal Function S3 Set S3 function to 46 as when S3 is closed to CC, the drive will clear the frequency setting
and stop
F004 ProgramÎFundamental
ParametersÎStandard Mode Selection Frequency Mode #1 Set to Use Motorized Pot Simulation
(9) Place G7 in remote control mode
(10)Close F to CC terminal
(11)Close S1 to CC terminal
(12)The drive will ramp up speed until either the S1 contact is opened or upper limit is reached
(13)Close S2 to CC terminal
(14)The drive will ramp down speed until either the S2 contact is opened or lower limit is reached
(15)Close S3 to CC terminal
(16)The drive will ramp down to zero and the frequency setting will be zero
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