YASKAWA Varispeed G7 User manual

Software Number: VSG13306X, Drive Models: CIMR-G7UXXXXX-117
Document Number: TM.G7SW.117, Date: 05/16/08, Rev: 08-05
Motion Control
G7 Drive Software
Technical Manual

Date: 05/16/08, Rev: 08-05 Page 2 of 38 TM.G7SW.117
Contents:
1.0 Overview ................................................................................ 3
2.0 Changes from Standard Product ............................................ 4
3.0 Limitations .............................................................................. 4
4.0 Related Parameters and Functions ........................................ 5
5.0 Function Descriptions ........................................................... 14
6.0 Appendices .......................................................................... 35
This document is intended to provide proper installation and use of the Yaskawa drive with custom software. This
document is a supplement to the standard drive technical manual. It describes the effects on the drive parameters
and functions with the software installed. Read and understand this document and the standard drive technical
manuals before attempting to install, adjust, operate, inspect or maintain the drive. Observe all cautions and
warnings in this document and the standard drive technical manuals. Custom software is written to add
functionality to a standard AC drive to enhance or enable use in a specific application. The software is loaded to
the flash ROM area of the control board, and replaces the standard drive software. Custom software can add new
functions, modify standard functions, or even inhibit standard functions. It can be used to modify display text or
parameter names. Custom software is usually loaded to the drive before delivery. The control board and drive
nameplate are assigned unique part numbers and the software is registered, archived, and retrievable.
When seeking support for a drive with custom software, it is imperative to provide the unique part number shown
on the drive nameplate. The software has been flashed to the control board memory and the operation of
parameters, functions, and monitors is different from the standard drive software, as described herein.

Date: 05/16/08, Rev: 08-05 Page 3 of 38 TM.G7SW.117
The drive becomes a simple position regulator. The software does this by internally taking control of the drive’s
frequency reference. All time-critical calculations are completed in a scan that is 2.5 ms or faster.
This software gives the G7 simple position control capability.
•Linear Absolute Motion
•Rotary Absolute Motion
•Relative Motion w/o Memory
•Relative Motion with Memory
•All position commands and position feedback monitors are displayed in engineering units. A parameter
selects from the following list of engineering units: “inches,” “feet,” “centimeters,” “meters,” “degrees,”
“revolutions,” or none.
•Position command via modbus registers.
•Absolute Incremental Encoder Support “TR ISI style Absolute Encoder”
•Momentary or Maintained Move Command
•Several different homing sequences to choose from.
•Serial Communications Compatible
•Incremental Encoder
•Dual Incremental Encoders
•Absolute Gray-Code Encoder Support (18 bit)
•16 Preset Positions Plus Home
•Distance Command via High-speed Frequency Reference Register (in engineering units)
•“Pre-Activation” Digital Output (settable in engineering units)
•Ability to monitor and command a 32 bit (31 bits + sign) bi-polar position over network communication.
•An additional “Distance Select” selection is added, which when selected, re-purposes two existing
Modbus registers to be combined into one 32 bit (31 bits + sign) position register.
•Two read-only 16 bit Modbus registers are added to monitor position with offset (distance from home)
in encoder quadrature counts, for a total of 32 bits (31 bits + sign).
•A read-only 16 bit Modbus motion control status register is added sequentially after the 32 bit position
registers so that the position and the status of the drive can be read with one Modbus “Read Multiple”
command.
1.0 Overview

Date: 05/16/08, Rev: 08-05 Page 4 of 38 TM.G7SW.117
•Due to parameter limitations, the “User” access level and all of the associated “A2” parameters are
deleted.
•3-Wire control is not allowed when the motion software is enabled.
•Parameter b1-01 (Reference Source) is only effective when motion control is disabled (P1-01 = 0).
When motion control is enabled, parameter b1-01 is ignored, and the frequency reference originates
from the motion control routine.
•Parameters d2-02 and d2-03 are disabled, which fixes the minimum output speed at 0%.
•Accel and Decel ramp switching via multifunction digital input or via speed sensing is disabled when a
move is in progress. Accel and Decel ramp switch is controlled by the motion software during a move.
•Encoder direction selection F1-05 is not available when encoder type is “Serial Abs Ch1” (P3-01 = 3).
•PG Channel 2 parameters F1-21 and F1-22 have no effect when motion control is enabled.
•All 230V units will have a default carrier frequency of 2.0 kHz. The maximum carrier frequency setting
on models G7U2075 and smaller is limited to 4.0 kHz.
•The Motion Control algorithm is only available when the drive is in the Flux Vector control method
(A1-02 = 3).
•The distance from home cannot exceed 109encoder counts.
•The 32 bit position monitor registers should be read using a “Read Multiple” Modbus command (03h)
to ensure that the data from high and low words are read together for an accurate reporting of position.
•Using the 32 bit position command, the drive can now operate in a position beyond what the digital
operator can display.
•The drive must be re-homed after a PG Open (PGo) fault occurs.
2.0 Changes from Standard Product
3.0 Limitations

Date: 05/16/08, Rev: 08-05 Page 5 of 38 TM.G7SW.117
Function P1 – Motion Setup
Function P2 – Homing Setup
Function P3 – Advanced Motion Setup
Function P4 – Preset Position Setup
4.0 Related Parameters and Functions
4.1 Parameters
Parameter
Number
Modbus
Address
Parameter
Name
Digital
Operator
Display
Description
Range
Default
Change
During Run
Control Mode
V/f
V/f w/ PG
O.L.V.
Flux
Vector
O.L.V. 2
P1-01 600h
Motion Type
Motion Type
0: Disabled
1: Linear Absolute
2: Rotary Absolute
3: Relative Mem Off
4: Relative Mem On
0 ~ 4 0 N - - - A -
P1-02 601h
Distance Select
Distance Select
0: Preset P4-XX
1: Modbus (061Ch and 061Dh) (1)
2: Hi-Speed Option Card
Frequency Reference Register
(2)
A multifunction input selection
of “Distance Select” will
override this parameter.
3: Modbus 32-Bit (061Ch and
061Dh) (3)
0 ~ 3 0 N - - - A -
P1-03 602h
Move Command
Type
Move Cmd. Type
0: Maintained – Move command
must be maintained for the
entire move.
1: Rising Edge – Move command
is edge-triggered.
2: Falling Edge – Move command
is edge-triggered.
0 ~ 2 0 N - - - A -
P1-04 603h
Positioning
Proportional Gain
Pos P Gain
Proportional gain used for the
position controller. 1.0 ~ 20.0 1.0 Y - - - A -
P1-05 604h
Decel Start
Compensation
Distance
Decel Comp Dist
Starts the deceleration ramp early.
Increase if there is overshoot,
decrease if there is undershoot.
0 ~ 65535
cts 0Y---A-
P1-06 605h
Positioning Speed
Compensation
Pos Spd Comp
Provides fine adjustment for the
automatically calculated
positioning speed.
10.0 ~
200.0 % 100.0 Y - - - A -
P1-07 606h
Triangle Move
Compensation
Trig Mov Comp
Determines response for a
triangular move. Increase if
overshooting, decrease if
undershooting when performing a
“Triangle” move instead of a
“Trapezoid” move.
0.0 – 10.0 1.0 Y - - - A -

Date: 05/16/08, Rev: 08-05 Page 6 of 38 TM.G7SW.117
P1-08 607h
In Position Window
In Posit. Window
Controls when the “Move
Complete” digital output turns on.
Also determines when another
edge-triggered move will be
accepted.
0 ~ 65,535
cts 200.0 Y - - - A -
P1-09 608h
Counts Per Unit
Counts Per Unit
This parameter is multiplied by the
distance command, in order to
determine move length in counts.
1 ~ 65,535
cts 4096 N - - - A -
P1-10 609h
Distance Display
Units
Distance Units
0: none
1: in (inches)
2: ft (feet)
3: cm (centimeters)
4: m (meters)
5: o(degrees)
6: rev (revolutions)
0 ~ 6 0 N - - - A -
P2-01 60Ah
Homing Type
Homing Type(5)
0: Home Negative
1: Home Neg with Backup
2: Home Positive
3: Home Pos with Backup
4: Negative with Marker Pulse
5: Positive with Marker Pulse
6: Manual
0 ~ 6 1 N - - - A -
P2-02 60Bh
Homing Speed
Homing Speed
Speed reference used during
course homing.
0.0 ~
400.0 Hz 10.0 Y - - - A -
P2-03 60Ch
Homing Back-Up
Speed
Homing BU Speed
Speed reference used during the
back-up portion of the homing
routine.
0.00 ~
20.00 Hz 2.00 Y - - - A -
P2-04 60Dh
Homing Final Speed
Homing Final Spd
Speed referenced used during the
final portion of the homing routine.
0.00 ~
20.00 Hz 1.00 Y - - - A -
P2-05 60Eh
Switch Type
Switch Type
Sets the normal (not activated)
state of the home and over-travel
limit switches.
0: Both NO
1: OT NO Home NC
2: OT NC Home NO
3: Both NC
0 ~ 3 0 N - - - A -
P2-06 60Fh
Home Offset
Distance
Home Offset Dist
Distance from the home limit
switch that is considered home.
-99.99 ~
99.99
Units (4)
0.00 N - - - A -
P2-08 611h
Pre-Action Distance
Pre Act Dist
During a move, when the machine
is this distance from the
destination, a digital output
(H2-0X = 46) will activate until the
“In Position” window is reached.
0.00 ~
500.00
Units (4)
0.00 Y - - - A -
P3-01 614h
Position Encoder
Source
Encoder Source
0: PG-X2, PG-B2, or
PG-W2 Channel 1
1: PG-W2 Channel 2
2: Absolute Gray Code
(connected via DI-16H2)
3: TR Encoder Channel 1
4: TR Encoder Channel 2
0 ~ 4 0 N - - - A -
4.1 Parameters (Continued)
Parameter
Number
Modbus
Address
Parameter
Name
Digital
Operator
Display
Description
Range
Default
Change
During Run
Control Mode
V/f
V/f w/ PG
O.L.V.
Flux
Vector
O.L.V. 2

Date: 05/16/08, Rev: 08-05 Page 7 of 38 TM.G7SW.117
P3-02 615h
Positioning Encoder
Pulses Per
Revolution
Second Encoder
PPR
Encoder pulses per revolution
when P3-01 = 1, encoder counts
per revolution when P1-01 = 2.
60 ~
10,000
PPR
1024 N - - - A -
P3-03 616h
Positioning Encoder
Numerator
Second Encoder
NUM
Machine mounted encoder ratio
numerator. Used in conjunction
with P3-04. Effective only when a
second machine-mounted
encoder is used.
1 ~ 65,535 1 N - - - A -
P3-04 617h
Positioning Encoder
Denominator
Second Encoder
DEN
Machine mounted encoder ratio
denominator. Used in conjunction
with P3-03. Effective only when a
second machine-mounted
encoder is used.
1 ~ 65,535 1 N - - - A -
P3-07
(6) 61Ah
Length Of One
Rotation (Encoder
Revolutions)
Len 1 Rotate REV
Sets the distance of one complete
revolution of the rotary machine.
Effective only when P1-01 = 2.
One Rotation (counts) =
(P3-07 * F1-01* 4) + P3-08
0 ~ 9999
Rev 0N---A-
P3-08
(6) 61Bh
Length Of One
Rotation (Encoder
Counts)
Len 1 Rotate CTS
Sets the distance of one complete
revolution of the rotary machine.
Effective only when P1-01 = 2.
One Rotation (counts) =
(P3-07 * F1-01* 4) + P3-08
0 ~ 40,000
cts 0N---A-
P4-01 106h
Position 1
Position 1
Position Reference in units.
Position Ref. (counts) = P4-01 *
P1-09.
0.00 –
655.35
Units (4)
0.00 Y - - - A -
P4-02 107h
Position 2
Position 2
Position Reference in units.
Position Ref. (counts) = P4-02 *
P1-09.
0.00 –
655.35
Units(4)
0.00 Y - - - A -
P4-03 108h
Position 3
Position 3
Position Reference in units.
Position Ref. (counts) = P4-03 *
P1-09.
0.00 –
655.35
Units (4)
0.00 Y - - - A -
P4-04 109h
Position 4
Position 4
Position Reference in units.
Position Ref. (counts) = P4-04 *
P1-09.
0.00 –
655.35
Units (4)
0.00 Y - - - A -
P4-05 10Ah
Position 5
Position 5
Position Reference in units.
Position Ref. (counts) = P4-05 *
P1-09.
0.00 –
655.35
Units (4)
0.00 Y - - - A -
P4-06 10Bh
Position 6
Position 6
Position Reference in units.
Position Ref. (counts) = P4-06 *
P1-09.
0.00 –
655.35
Units (4)
0.00 Y - - - A -
P4-07 10Ch
Position 7
Position 7
Position Reference in units.
Position Ref. (counts) = P4-07 *
P1-09.
0.00 –
655.35
Units (4)
0.00 Y - - - A -
P4-08 10Dh
Position 8
Position 8
Position Reference in units.
Position Ref. (counts) = P4-08 *
P1-09.
0.00 –
655.35
Units (4)
0.00 Y - - - A -
P4-09 10Eh
Position 9
Position 9
Position Reference in units.
Position Ref. (counts) = P4-09 *
P1-09.
0.00 –
655.35
Units (4)
0.00 Y - - - A -
4.1 Parameters (Continued)
Parameter
Number
Modbus
Address
Parameter
Name
Digital
Operator
Display
Description
Range
Default
Change
During Run
Control Mode
V/f
V/f w/ PG
O.L.V.
Flux
Vector
O.L.V. 2

Date: 05/16/08, Rev: 08-05 Page 8 of 38 TM.G7SW.117
(1) When P1-02 = 1, the actual commanded destination is calculated as follows:
Destination = modbus register 61CH * P1-09 / 100
(2) Actual destination (in encoder quadrature counts) is calculated as follows:
(3) When P1-02 = 3, the actual commanded destination is the combined value of Modbus registers 61Ch (low word)
and 61Dh (high word). Parameter P1-09 has no effect as this is strictly a command in encoder quadrature counts.
Speed for this profile is set by d1-01, the acceleration time is set by C1-01, and the deceleration time is set by
C1-02.
(4) The units text displayed in the digital operator is determined by parameter P1-10. Actual destination in encoder
counts is calculated by multiplying the preset position reference by P1-09.
(5) When parameter P3-01 = 3 or 4 (encoder type = TR Encoder), the Homing Type (P2-01) parameter has no
effect. Instead, when a home command is issued, the drive is base-blocked and then the position is read from the
encoder via channel 2 on the PG-W2 option board. This will only happen if the drive does not have a run
command.
(6) If P3-01 = 1, then parameter P3-02 is used in place of parameter F1-01 when determining actual distance.
P4-10 10Fh
Position 10
Position 10
Position Reference in units.
Position Ref. (counts) = P4-10 *
P1-09.
0.00 –
655.35
Units (4)
0.00 Y - - - A -
P4-11 110h
Position 11
Position 11
Position Reference in units.
Position Ref. (counts) = P4-11 *
P1-09.
0.00 –
655.35
Units (4)
0.00 Y - - - A -
P4-12 111h
Position 12
Position 12
Position Reference in units.
Position Ref. (counts) = P4-12 *
P1-09.
0.00 –
655.35
Units (4)
0.00 Y - - - A -
P4-13 112h
Position 13
Position 13
Position Reference in units.
Position Ref. (counts) = P4-13 *
P1-09.
0.00 –
655.35
Units (4)
0.00 Y - - - A -
P4-14 113h
Position 14
Position 14
Position Reference in units.
Position Ref. (counts) = P4-14 *
P1-09.
0.00 –
655.35
Units (4)
0.00 Y - - - A -
P4-15 114h
Position 15
Position 15
Position Reference in units.
Position Ref. (counts) = P4-15 *
P1-09.
0.00 –
655.35
Units (4)
0.00 Y - - - A -
P4-16 115h
Position 16
Position 16
Position Reference in units.
Position Ref. (counts) = P4-16 *
P1-09.
0.00 –
655.35
Units (4)
0.00 Y - - - A -
4.1 Parameters (Continued)
Parameter
Number
Modbus
Address
Parameter
Name
Digital
Operator
Display
Description
Range
Default
Change
During Run
Control Mode
V/f
V/f w/ PG
O.L.V.
Flux
Vector
O.L.V. 2
Destination Frequency Reference (Hi-speed register)
100
------------------------------------------------------------------------------------------------------------------- P1 - 09×=

Date: 05/16/08, Rev: 08-05 Page 9 of 38 TM.G7SW.117
Note: Stall prevention during decel increases the deceleration distance even when the bus voltage remains at
the nominal level. For this reason, it is important to leave L3-04 set to “Disabled” (0).
Note: The ENTER command is not required when writing to these registers.
4.2 Modified Existing Parameters
Parameter
Number
Modbus
Address
Parameter
Name Description
Range
Default
Change
During Run
Control Mode
V/f
V/f w/ PG
O.L.V.
Flux
Vector
O.L.V. 2
C1-01
~
C1-08
200h
~
207h
Accel Time 1
~
Decel Time 8
Acceleration and Deceleration
Times
0.0 ~
6000.0
Sec.
2.0 Y---A-
C2-01
~
C2-03
20bh
~
20dh
S-Crv @ Acc Start
S-Crv @ Acc End
S-Crv @ Dec Start
S-curve Times
0.00 ~
2.50
Sec.
0.00 N---A-
d1-09
~
d1-16
280h
~
291h
Frequency Ref. 9
~
Frequency Ref. 16
Digital Preset Speeds
0.00 ~
400.00
Hz
6.09
~
6.16
Y---A-
L3-04 492h Stall Prevention
During Decel
0: Disabled
1: General Purpose
2: Intelligent
0 ~ 2 0N---A-
4.3 Modbus Registers
Modbus
Address Description Scaling
061Ch Modbus Communication Speed Reference during a Move. Effective only when P1-02 = 2. 0.01 Hz
100 = 1.00 Hz
061Dh
Modbus Communication Position Reference (Engineering Units)
Actual position reference in encoder counts = 61Dh * P1-09.
Range is: 0.00 ~ 655.35 units. Effective only when P1-02 = 2.
0.01 Units
100 = 1.00 Units
061Ch Modbus 32-bit Communication Position Reference (low word). Effective only when P1-02 = 3. Quadrature
Encoder Counts
061Dh Modbus 32-bit Communication Position Reference (high word). Effective only when P1-02 = 3.
0734h
32 Bit Distance From Home (low word)
Distance from home (+ home offset) for absolute applications, or distance from start of previous
move for relative applications. Read only. Quadrature
Encoder Counts
0735h
32 Bit Distance From Home (high word)
Distance from home (+ home offset) for absolute applications, or distance from start of previous
move for relative applications. Read only.
0736h
Motion Control Modbus Status Register
Bits 0 ~ 5 are a copy of the information in monitor U1-11. Bits 6 ~ C behave the same as the
motion control digital outputs (H2-0X = 40 ~ 46). Read only.
Bit 0: Digital Output Status – M1-M2
Bit 1: Digital Output Status – M3-M4
Bit 2: Digital Output Status – M5-M6
Bit 3: Digital Output Status – P3-C3
Bit 4: Digital Output Status – P4-C4
Bit 5: Not Used
Bit 6: Not Used
Bit 7: Digital Output Status – MA-MB-MC (fault)
Bit 8: Move In Progress
Bit 9: Move Complete
Bit A: Homing Complete
Bit B: Homing Needed
Bit C: At Home
Bit D: Learn Successful
Bit E: Pre-Action Output
Bit F: Not Used
(N/A)

Date: 05/16/08, Rev: 08-05 Page 10 of 38 TM.G7SW.117
(7) The actual units text displayed in the digital operator is determined by parameter P1-10. Actual distance in
encoder counts is calculated by multiplying the monitor output by P1-09. If the monitor is in excess of 327.67 units,
the display will be clamped at 327.67 units. If the monitor is less than -99.99 units, the display will be clamped at
-99.99 units.
(8) The actual units text displayed in the digital operator is determined by parameter P1-10. Actual distance in
encoder counts is calculated by multiplying the monitor output by P1-09. If the monitor is in excess of 32,767 units,
the display will be clamped at 32,767 units. If the monitor is less than -9999 units, the display will be clamped at
-9999 units.
4.4 Monitors
Parameter
Number
Modbus
Address
Parameter
Name
Digital
Operator
Display
Description
Analog
Monitor
Scaling
Units
Control Mode
V/f
V/f w/ PG
O.L.V.
Flux
Vector
O.L.V. 2
U1-90 720h
Distance From
Home (Fine)
Dist From Home f
Distance from home (+ home offset) for
absolute applications, or distance from
start of previous move for relative
applications. Displayed with fine
resolution (0.01 units).
N/A 0.01 Units
(7) --- A -
U1-91 721h
Distance To Go
(Fine)
Dist To Go f
Distance from the destination. Displayed
with fine resolution (0.01 units). N/A 0.01 Units
(7) --- A -
U1-92 722h
Commanded
Destination (Fine)
Commanded Dest f
Commanded destination. Displayed with
fine resolution (0.01 units). N/A 0.01 Units
(7) --- A -
U1-93 723h
Distance From
Home (Coarse)
Dist From Home c
Distance from home (+ home offset) for
absolute applications, or distance from
start of previous move for relative
applications. Displayed with coarse
resolution (1 unit).
N/A 1 Unit
(8) --- A -
U1-94 724h
Distance To Go
(Coarse)
Dist To Go c
Distance from the destination. Displayed
with coarse resolution (1 unit). N/A 1 Unit
(8) --- A -
U1-95 725h
Commanded
Destination (Coarse)
Commanded Dest c
Commanded destination. Displayed with
coarse resolution (1 unit). N/A 1 Unit
(8) --- A -
U1-96 726h
Commanded Speed
Reference
Cmd Speed Ref
Commanded speed for the selected
destination. N/A 0.01 Hz - - - A -
U1-97 727h
Raw Gray Code
Encoder Position
Raw Gray Pos.
Position of the gray code absolute
encoder in “tens” of counts. N/A
1 dct
(deka-
count)
--- A -
U1-99 729h
TR Absolute
Incremental Encoder
Position Request.
Ser Enc Pos Req
TR Absolute Incremental Encoder
Position Request.
Used by the drive to request absolute
position information from the encoder.
(Analog output only, no display)
10V =
Request
Position
- -----