YASKAWA PG-Z2 User manual

YASKAWA
DUAL ENCODER (PG) FEEDBACK CARD (PG-Z2)
INSTRUCTIONS
Upon receipt of the product and prior to initial operation, read these
instructions thoroughly, and retain for future reference.
Package Contents:
Name Part No. (Code No.)
Dual Encoder (PG) Feedback
Card (PG-Z2) PG-Z2 (73600-A0251)
Spacer SRNT41028-9
Instructions EZZ009533
YASKAWA
AUDIN - 7 bis rue de Tinqueux - 51100 Reims - France
Tel : [phone] - Fax : [phone] - Web : http: www.audin.fr - Email : [email protected]

AUDIN - 7 bis rue de Tinqueux - 51100 Reims - France
Tel : [phone] - Fax : [phone] - Web : http: www.audin.fr - Email : [email protected]

NOTES FOR SAFE OPERATION
Before installation, operation, maintenance or inspection of this option, a technically
qualified individual who is familiar with this type of equipment and the hazards involved
should read this entire manual thoroughly. In this manual, the NOTES FOR SAFE
OPERATION are classified as “CAUTION”.
CAUTION
Indicates a potentially hazardous situation that, if not avoided, may result in minor or
moderate injury to personnel and damage equipment. Lock all power sources feeding
the drive in the “Off” position.
It may also be used to alert against unsafe practices.
Failure to heed notices labeled with may result in dangerous
situations or equipment damage.
Steps to be taken to insure proper operation and
to avoid malfunctions.
Caution
•The option card uses a CMOS IC chip. Be careful when handling.
•When removing the option card from the drive for transportation or storage, the
card should be placed in the anti-static package it was received in.
•DO NOT alter wiring or connect or disconnect connectors while equipment power
is ON.
Failure to observe these cautions may result in injury or equipment damage!
Before use,
(1) Before installing the PG-Z2 card, read this manual and the manual for the
installation of the drive.
(2) Before connecting the PG-Z2 or external terminals, turn OFF the main
power to the drive and verify that the CHARGE indicator lamp of the
Drive is OFF.
(3) When ordering the PG-Z2 card, specify the part number and code
number.
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CAUTION
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1. Inspection after Delivery
Caution
•Verify that the products received are the products ordered.
Installation of incorrect product may lead to injury or damage.
Prior to shipment, all Yaskawa products undergo rigorous inspection procedures to
ensure accuracy and reliability. We recommend checking the following items upon
receipt.
1. Check that the product code (73600-A0251) and part number (PG-Z2)
labeled on the actual card correspond to product ordered.
2. Check for damage caused during transportation.
3. Report any damages or shortages to the commercial carrier who
transported the products.
Report any material or manufacturing defects on the c ard to your Yaskawa
representative.
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2. Introduction
The Dual Encoder (PG) Feedback Card (PG-Z2) (Figure 1) is mounted on the drive’s
control board to provide speed and direction feedback from two encoders. The drive’s
control logic can use this information for purposes such as correcting for speed
fluctuation caused by motor slip, maintaining the velocity and phase relationship
between two machine (motor) shafts, and aligning a spindle at stop for tool changing.
Using standard software, the PG-Z2 can be used for closed loop control (Flux Vector or
V/F with PG) of one or two motors. The second motor is selected by using a multi-
function digital input programmed for “Motor 2 Select”. Standard software does not
utilize the marker (C or Z) pulse from the encoder.
Custom software titles such as Electronic Line Shaft, and others utilize the PG-Z2 card.
The configuration varies so please consult the specific software technical manual. The
marker pulse may be needed depending on the software.
The PG-Z2 option card is compatible with the F7 and G7 Yaskawa drives. The G5 is
not compatible and uses the PG-W2 option card instead.
- Z Pulse
+ Z Pulse
- B Pulse
+ B Pulse
- A Pulse
+ A Pulse 0 Volt
+ 5 or +12 Volt
1
2
3
4
5
6
7
8
9
7
3
6
5
4
2
1
5
6
7
1
2
4
3
- B Pulse
- Z Pulse
+ Z Pulse
- A Pulse
+ B Pulse
+ A Pulse
0 Volt
- B Pulse
- Z Pulse
+ Z Pulse
- A Pulse
+ B Pulse
+ A Pulse
Common
Secondary
Encoder (PG)
Input
Encoder (PG)
Input
Primary
Encoder (PG)
Output CN4
CN5
CN6
CN3
CN2
CN1
PA1
PB1
PZ1
PA2
PB2
PZ2
Common
Line Driver Open
Jumper Settings
(Default) Collector
" "
" "
"
"
"
"
" "
Test Point
Connections
Shield Connection
Spacer Mounting Hole
0.157 in. (4.0 mm) dia.
0.126 in. (3.2 mm) dia.
Spacer Mounting Holes
Code No.
Part No.
Grounding Lead
0 Volt
Voltage Supply for
Encoder (PG) Operation
(Set at Switch S9)
Voltage
Switch (S9)
+5 (Default)
for Encoder (PG)
Selection
+12
K 471
*681
(Line Driver ONLY)
Figure 1. Dual Encoder (PG) Feedback Card (PG-Z2)
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3. Configuring the PG-Z2
The PG-Z2 option card was designed to combine several older option
cards and has user and software programmable features. These features
must be set correctly for your application in order to operate properly.
3.1 PG-Z2 Configuration
(1) Carefully remove the option card from the static bag following procedures for
safe handling of static sensitive devices.
(2) Verify that the correct option card has been received by matching the code and
part numbers on the card with your order.
(3) Use Figure 1 to locate the following components.
(4) Set jumpers CN1 thru CN3 to either line driver (default) or open collector
depending on your encoder requirements. This sets the input type to the PG-Z2
on terminal TA1. The second encoder input, TA2, is fixed to a line driver type
encoder.
(5) Set voltage supply switch (S9) to the voltage required to operate your encoder
(PG). Default is 5 volts. Maximum current available for encoder (PG) operation
is 200mA. Check your encoder (PG) manual for your encoder’s (PG)
requirements. When supplying power to two encoders using the PG-Z2, ensure
that the total current is less than 200mA.
3.2 Terminal block TA3 is the encoder output, which passes through one of the two
encoder inputs with no delay (less than 1 microsecond). Using standard software,
the output is fixed to pass through the primary encoder input. When using custom
software, there may be a software parameter to select which encoder to output.
Check the specific custom software manual for details.
(1) Set jumpers CN4 thru CN6 to either line driver (default) or open collector
depending on your system requirements. This sets the output type from the
PG-Z2 on terminal TA3.
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4Installation Procedure
It is necessary to install and wire option cards to positions C and D
(See Figure 3), prior to installing the PG-Z2 option.
4.1 Drive Installation Procedure
(1) Remove contents from package and verify that a mounting spacer (code
number SRNT41028-9) is included with the card (see Figure 2).
Drive End Option Card End
0.197 in. [5 mm] 1.32 in. [33.5 mm] 0.22 in. [5.6 mm]
0.57 in. [14.5 mm]
Figure 2. Spacer
(2) Turn OFF the main power and wait for the time specified on the cover of the
Drive for voltage to bleed off the DC bus capacitors. Remove the cover and
verify that the CHARGE indicator lamp is OFF.
(3) Insert the spacer (SRNT41028-9) into the spacer mounting hole in the mounting
base of the Drive, just above the top edge of the control board (see Figure 3).
Some Drive models have two closely spaced mounting holes. Insert the spacer
into the hole closest to the 7CN connector on the control board. Insertion of the
spacer into the incorrect hole WILL NOT provide proper alignment with the
option card’s mounting hole.
(4) Position the bottom edge of the option card into the mounting bracket on the
control board’s terminal block. Align the two (2) mounting holes in the card with
the pins on the bracket.
(5) Rotate the top edge of the card down into place, carefully aligning connector
4CN on the back of the card with connector 4CN on the control board.
(6) Gently press the card into place until 4CN and the spacer clickinto place.
(7) Connect the green ground wire to the grounding terminal on the control board.
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AUDIN - 7 bis rue de Tinqueux - 51100 Reims - France
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4Installation Procedure (cont’d)
Option
Card
C
Option
Card
D
Grounding
Terminals
PG-Z2
Option
Card
* Option Clip Prevents Option
Boards C and D from Rising
Mounting
Spacer
Grounding
Lead
Option
Clip *
4CN Connector
7CN Connector
Figure 3. Installation of Dual Encoder (PG) Card (PG-Z2)
CAUTION
Be sure the PG wiring is clear of the enclosure when reinstalling the cover.
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5Interconnection
Figure 4 shows interconnection between the Drive, PG-Z2, and peripheral equipment,
using standard Drive software.
1
2
3
4
5
6
7
8
9
3
7
6
5
4
2
1
3
6
7
4
5
1
2
TA1
TA2
TA3
TA4
8
2
7
3
6
1
OC CN1
CN1
IP12 (+5 or +12V)
OC CN2
CN2
CN3
OC CN3
Pulse A
4CN4CN
L1 (R)
L2 (S)
L3 (T) T3 (W)
T2 (V)
T1 (U)
MCCB
Ground Terminal
Drive
IM PG (Encoder)
Encoder (PG)
Connector
Example Shows
SLIM Tach SL56
Terminal ID
Consult Encoder (PG)
Manufacture's manual
for correct terminal ID
Select" function in standard software. Custom
TA2 terminal can be used with the "2 Motor
Motor
Pulse A
Pulse B
Forward Direction
Default output voltage set to 5 volts.
TA1 Terminals 1 & 2: +5 or +12V 200mA max.
Set Output Voltage at Switch S9.
Verify voltage required for your Encoder (PG).
E
E
Ground Lead CASE software may alter this function. Consult
standard software. Output can be adjusted
TA3 terminal output defaults to TA1 with
with some Custom CASE software, consult
0V
0V
Common
Pulse B
Pulse Z
0V
P
P
P= Twisted Pair
software manual for complete instructions.
PG-Z2
Encoder (PG) Speed Control Card (PG-Z2)
P
the CASE software manual for details.
Basic Encoder PG Feedback Card (PG-Z2) Interconnection Diagram
For Dual Encoder Connections Consult Software Manual
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6Wiring
Important: Check the power supply requirements of your encoder (PG) and
set the S9 switch on the PG-Z2 card accordingly. Default setting is 5 volts.
See Table 1.
Terminal block
symbol Pin No. Functions
1+ 5 or +12V
20V
Power supply for Encoder (PG). Set at Switch S9
200mA maximum
+5V (Default)
3+
4-A Pulse
5+
6-B Pulse
7+
8-Z Pulse*
TA1
90V
Encoder (Pulse generator, PG)
signal input. Signal type
determined by CN1-3.
1+
2-A Pulse
3+
4-B Pulse
5+
6-Z Pulse*
TA2
70V
Secondary encoder (pulse
generator, PG) input. Line
driver only.
Signal input RS-422 Level.
1+
2-A Pulse
3+
4-B Pulse
5+
6-Z Pulse*
TA3
7Common
Encoder (Pulse generator, PG)
signal output. Signal type
determined by CN-4-6.
Default signal is Primary
Encoder (TA1).
TA4 Shielded sheath connection terminal
* Not required for standard software. May be required for custom software.
Table 1. Terminal Functions of PG-Z2
Terminal Symbol Terminal Screw Clamping Torque
Lb-in(N-m) Wire Range AWG (mm2)
TA1, TA2, TA3 M2 1.8 to 2.2
(0.22 to 0.25)
26 to 16
(Stranded: 0.14 to 1)
(Solid: 0.14 to 1.5)
Table 2. Terminal and Wire Specification
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6Wiring (Cont’d)
Make sure of the following when wiring:
•Separate the control signal wires (terminals TA1, TA2, and TA3) of the PG-Z2 from
the main circuit wires and other power cables.
•A separate metallic grounded conduit with the PG wiring ONLY is preferred to
prevent the introduction of noise on encoder (PG) signals.
•Use a shielded wire to connect the encoder (PG). Connect the wires as shown in
Figure 5 to prevent noise interference. The wire distance must be 164 ft. (50m) or
less.
•Be sure the PG wiring is clear of the enclosure when reinstalling thecover.
Outer Jacket
Shielded Sheath
Connect to terminal
TA4 on PG-Z2 card
Do not connect
or ground sheild at
this end
Insulate these parts
with insulting tape
Encoder (PG) End
PG-Z2 Connection
Figure 5. Shielded wire termination
(mm2)
AWG I (amps) VAC
Thin 116 12 125
Solid Wire 1.5 16 12 125
UL -22-16 10 300
CSA -28-16 10 300
CSA -28-16 10 150
(Terminal: MKDS1 series manufactured by Phoenix Contact GmbH & Co.)
Table 3. Wire specification
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6Wiring (Cont’d)
0.22 in. (5.5mm)
Insulation Stripping Length
for Terminals TA1, TA2, TA3
of PG-Z2 Option Card
•Strip back insulation for a distance of 0.22 inches (5.5mm) on wire leads
connected to the PG-Z2
Notes on selecting cables
Cable that is too thick will apply pressure to the option card and may lead to
failure.
Cable that is too thin will produce poor electrical contact and conductor may
break.
-11 -
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7Application of Encoder (PG)
The maximum frequency of the encoder (PG) output pulses that can be detected in Line
Drivermode is 300kHz. In Open Collector mode the pulse limit is 32kHz. To find the output
frequency of your encoder (PG), use the following formula.
Motor rotation speed (r/min) at max. frequency output
60 X Encoder (PG) constant (pulses/rev)
fPG (Hz) =
To convert to kHz divide the result in Hz by 1000.
Maximum power available to drive the encoder (PG) with the PG-Z2 is 200mA. Should your
encoder (PG) require more than 200mA, it will be necessary to provide a separate power
supply. See Figure 6.
TA4
9
8
7
4
6
5
3
2
TA1
1
Encoder
(PG)
IP12 (+5 or +12V)
IG (0V)
A (+)
A (-)
B (-)
B (+)
Z (+)
Z (-)
PG-Z2 0V 12V
Auxiliary Encoder (PG)
Power Supply
AC
IG (0V)
Figure 6. Connection example with encoder (PG) when using separate power supply
The PG-Z2 card requires a “quadrature” with “compliments” type signals from the encoder
(PG).
Quadrature Signal
A quadrature signal is one that lags the primary signal by 90 electrical degrees (½a pulse).
This gives the Drive the capability to detect the rotational direction of the motor shaft. As
shown in Figure 7, for “forward” rotation (C.C.W.),the rise of signal A+ will lead the rise of
signal B+ by 90°.
-12 -
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7Application of Encoder (PG), (cont’d)
All signals shown are taken in relation to power supply common, Pin 2 of
the PG-Z2 card.
Complimentary Signal
A complimentary signal includes both a primary signal (A+) and it’s inverse (A-). See
Figure 7. This scheme improves the noise immunity of the feedback because the two
signals are combined in the PG-Z2 providing double the voltage level difference from
low to high signal levels. For example, a +12V encoder has a low voltage level of 0V
and a high voltage level of +24V as measured by the PG-Z2.
The A and B quadrature signals each have their own compliment and if any one of the
four signals is missing, the drive cannot accurately detect encoder (PG) speed or
direction.
+3 to
+12V
Signal A+
Pin 3
0V
Primary Signal
Complement
Quadrature Signal
90°
Complement
0V
Signal A-
Pin 4
+3 to
+12V
0V
Signal B+
Pin 5
+3 to
+12V
0V
Signal B-
Pin 6
+3 to
+12V
Figure 7. Encoder (PG) Signals –Forward Direction (C.C.W.)
-13 -
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8Encoder (PG) Speed Control (PG-Z2) Parameter List
Encoder (PG) Speed Control (PG-Z2) Parameter List
Control Method (3)
Digital
Operator
Function
Group
Digital Operator
Display
Parameter
No. Parameter Name Setting Range Factory Setting
Change
During
Operation
(2)
Data Selection
V/f Control
V/f w/PG
Fdbk
Open loop
Vector
Flux Vector
Open loop
Vector 2
PG Pulse/Rev F1 -01 PG Constant 0 to 60000 1024 XXOXOX
PG Fdbk Loss
Sel F1 -02 Operation at PG open circuit 0 to 3 1X0: Ramp to Stop
XOXOX
PG Overspeed
Sel F1 -03 Operation
selection at
overspeed 0 to 3 1X
1: Coast to Stop
2: Fast-
Stop
3: Alarm Only
XOXOX
PG Deviation Sel F1 -04 Operation selection at
deviation 0 to 3 3XXOXOX
PG Rotation Sel F1 -05 PG rotation 0,1 0X
0: Fwd=CCW
1: Fwd=CW XOXOX
PG Ramp PI/I
Sel F1 -07 Integral value
during accel/decel
enable/disable 0,1 0X
0: Disabled
1: Enable XOXXX
PG Overspeed
Level F1 -08 PG overspeed detection level 0 to 120% 115% XXOXOX
PG Overspeed
Time F1 -09 PG overspeed detection delay 0 to 2.0s 1.0s XXOXOX
PG Deviation
Level F1 -10 Excessive speed
deviation detection
level 0 to 50% 10% XXOXOX
PG Deviation
Time F1 -11 Excessive speed
deviation detection
delay time 0 to 10s 0.5s XXOXOX
P
G# Gear Teeth
1F1 -12 No. of gear teeth 1
0 to 1000 0XXOXXX
PG# Gear Teeth
2F1 -13 No. of gear teeth 2
0 to 1000 0XXOXXX
PGO Detect
Time F1 -14 PGO detection time 0 to 10s 2sec XXOXOX
PG
Option
Setup
Speed Detection
Filter Selection
(F7 only) F1-15 Speed detection
filter selection 0,1 1X0: No moving
AVG 1: 2
moving AVG XOXOX
ASR P Gain 1 C5-01 ASR proportional
gain 1 0 to 300.00
0.00 OXOXOX
ASR I Time 1 C5-02
ASR integral
time 1 0 to 10.000s
0.00s OXOXOX
ASR P Time 2 C5-03 ASR proportional
gain 2 0 to 300.00
0.00 OXOXOX
ASR I Time 2 C5-04
ASR integral
time 2 0 to 10.000s
0.00s OXOXOX
ASR Limit C5-05 ASR Limit 0.0 to 20% 0.0% XXOXXX
ASR Delay Time C5-06 ASR primary
delay time 0.000 to 0.500s 0.000s
XXXXOX
ASR Gain SW
Freq C5-07 ASR switching freq
00 to
400.00Hz 0.0Hz XXXXOX
ASR
Tuning
(1)
ASR Integral
Limit C5-08
ASR Integral
limit 0 to 400% 400% XXXXOX
(1) ASR -Automatic Speed Regulator
(2) O = Enable, X = Disable
(3) O = Setting enable, X = Setting disable, open loop vector 2 is only available in G7.
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