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
- -----

Date: 05/16/08, Rev: 08-05 Page 11 of 38 TM.G7SW.117
(9) When using either of the over-travel switches/inputs, it is STRONGLY recommended that the switch be
maintained beyond the trigger point of the switch, all the way to the end of the mechanical limit. If this cannot be
accomplished, an External Fault input is a better choice. If either of the over-travel inputs is used, it is
recommended that additional digital inputs be programmed to Jog Fwd or Jog Rev in order to jog the machine back
out of the over-travel condition.
Note: See Section 2 of the G7 technical manual for a complete description of how to interface with the digital
input terminals. Be aware of different types of proximity switches (sinking or sourcing).
4.5 Multifunction Digital Input Settings (H1-XX)
Setting Description
80 Move – Move to commanded position.
(For absolute rotary motion (P1-01 = 2), direction will always be forward.)
81 Move (Invert) – Move to commanded position * (-1).
(For absolute rotary motion (P1-01 = 2), direction will always be reverse.)
82 Home Command – Starts the homing sequence, must be maintained until “Home Complete” output comes on.
83 Home Switch – Indicates a “Home” or fixed position of the machine. Also used to indicate “Home” when using the “Manual”
homing routine (P2-01 = 6).
84 (9) Positive Over-travel Limit Switch – Drive will ramp to zero speed and display “POSOT - Pos Ovr Travel.” Drive can be jogged but
no moves can be commanded. Re-homing is required (if applicable).
85 (9) Negative Over-travel Limit Switch – Drive will ramp to zero speed and display “NEGOT - Neg Ovr Travel.” Drive can be jogged
but no moves can be commanded. Re-homing is required (if applicable).
86 Learn Position – Allows the storage of the current position. Must be maintained for 1 second.
87 Distance Select A – Used to select the commanded distance / move profile.
88 Distance Select B – Used to select the commanded distance / move profile.
89 Distance Select C – Used to select the commanded distance / move profile.
8A Distance Select D – Used to select the commanded distance / move profile.
8B Disable Motion Control NOTE: All position information is cleared, requiring another homing routine once re-enabled.
4.6 Multifunction Digital Output Settings (H2-XX)
Setting Description
40 Move In Progress - Closed: Drive is completing the specified move profile. Deactivates at the end of a move when machine is
within the specified “in position” window AND the motor speed is below the DC Injection at start frequency (B2-01).
41
Move Complete - Closed: Move routine is complete and is within the specified “in position” window AND motor speed is below
the DC Injection start frequency. Deactivates when the move command is removed. If a momentary move command is utilized
(P1-03 = 1 or 2), this output deactivates when another “move” command is given.
42 Homing Complete - Closed: A homing routine has been completed. Drive knows its position relative to the home switch, and has
moved to the home + home offset position (P2-06).
43 Homing Needed – Closed: A successful homing routine has NOT been completed.
44 At Home – Closed: The drive is within +/- the “in position” of home (home + home offset).
45 Learn Successful – Closes when the drive has successfully learned the present position. Opens when the learn command is
removed.
46 Pre-Action – Closes when distance from commanded destination is less than parameter P2-08. Opens when distance from
commanded destination is less than P1-08.

Date: 05/16/08, Rev: 08-05 Page 12 of 38 TM.G7SW.117
(10) An OPE03 error can be caused by many other conditions as well. These conditions are listed in Section 7 of the
G7 technical manual (TM.G7.01).
4.7 Multifunction Analog Input Settings (H3-05/H3-09)
Setting
Description
Digital Operator Display
20
Absolute Incremental Encoder Drive Disable. Used by the absolute incremental encoder to disable the drive when transferring
position information.
Ser Enc Drv Dis
4.8 Faults
Fault Display Description Cause Countermeasures
OPE03
Terminal
Multifunction Input
Selection Error (10)
Motion control is enabled (P1-01 > 0) AND
3-wire control is enabled. (One of the H1
parameters is set to “0 – 3-Wire Control.”
Disable the motion control by setting
P1-01 = 0, or reprogram the H1
parameter that is set to “0.”
Motion control is enabled (P1-01 > 0) AND
Motor 2 Select is programmed into an H1
parameter.
Disable the motion control by setting
P1-01 = 0, or reprogram the H1
parameter that is set to “16.”
OPE05
Sequence Select Option Card Selection Error
Distance Select is programmed for Option
Card Fref (P1-02 = 2) and no
communications option is installed at
connector 2CN.
Re-program parameter P1-02 or
install communications option board.
OPE12
Motion Ctrl Stup Motion control setup error
Absolute Encoder is selected (P3-01 = 2)
and motion type is not “Linear Absolute”
(P1-01 ≥2).
Adjust motion type or encoder type.
Absolute Encoder is selected (P3-01 = 2)
and a DI-16H2 option board is not installed.
Adjust motion type or encoder type,
or install a DI-16H2 option board.
The numerator (P3-03) is set more than 100
times greater than the denominator (P3-04).
Adjust the numerator and the
denominator.
Encoder type is set to “Serial Abs Ch1” and
encoder rotation is set to CW. (P3-01 = 3
and F1-05 = 1)
Adjust parameter F1-05 back to zero
and change PG Ch.1 feedback
wiring.
2ENFL
Second Enc. Fault
There is a problem with the
encoder connected to either
the second channel of the
PG-W2 (Terminals 10
– 15) or with the absolute
encoder connected to the
DI-16H2.
Incremental encoder connected to the
second channel of the PG-W2 (Terminals 10
– 15) has opposite rotation from the motor
encoder.
Switch the polarity of the incremental
encoder connected to the second
channel by swapping terminals 10
and 11 on the PG-W2 card.
Absolute encoder has either “rolled over”
and no longer contains valid position data,
or has opposite rotation from the motor
encoder.
Mechanically reset the absolute
encoder, or force the encoder to
count in the opposite direction.
POSOF
Position Ovrflow
The internal register that
tracks position has
exceeded its limits during a
motion-control move.
The distance from home (or home + home
offset) has exceeded 109encoder counts.
Re-home and verify position of
moving equipment.
SENCF
Ser Enc Fault
Absolute Incremental
Encoder Fault
The drive did not receive valid data / control
signals from the absolute incremental
encoder within 35 seconds after power up or
home command.
Check encoder and wiring. Check
that an analog input and output are
programmed and wired properly for
a absolute incremental encoder.

Date: 05/16/08, Rev: 08-05 Page 13 of 38 TM.G7SW.117
4.9 Alarms
Alarm Display Description Cause Countermeasures
RHS
Run Homing Seq Run homing sequence
A move or learn command was
given before the drive has been
homed. This will only occur when
P1-01 = 1 or 2.
Perform a homing routine.
POSOT
Pos Ovr Travel Positive Over-travel The machine has moved past the
positive over-travel switch.
Drive can be moved out of positive
over-travel using the “Jog Reverse”
input.
NEGOT
Neg Ovr Travel Negative Over-travel The machine has moved past the
negative over-travel switch.
Drive can be moved out of negative
over-travel using the “Jog Forward”
input.
SENCR
Serial Encoder Reading
The drive is receiving position
information from the absolute
incremental encoder. All run
commands are ignored during
this time.
Absolute incremental encoder is
reporting its position by bringing a
multifunction input (A2 or A3) above
9V.
Wait for the absolute incremental
encoder to finish homing (35 sec.
max), or troubleshoot analog input
wiring.

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5.1 Types of Motion:
LINEAR ABSOLUTE MOTION: Linear absolute motion is used in applications such as: ball screws, linear slides,
and transfer stations. With this type of motion, a home switch and a homing sequence or an absolute encoder are
required. All position references are with relation to the actual home position + home offset.
Figure 1: Linear Absolute Motion Example – Ball Screw
ROTARY ABSOLUTE MOTION: Rotary absolute motion would be used in applications such as: index turntables,
turret winders and dial tables. With this type of motion, a home switch and a homing sequence are required. All
position references are with relation to the actual home position + home offset.
Figure 2: Rotary Absolute Motion Example – Turret Winder
5.0 Function Descriptions

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RELATIVE MOTION: Relative motion is used in applications such as cut-to-length and metering pumps. This type
of motion can be used with or without a homing sequence. When the motion type is “Relative Mem Off”
(P1-01 = 3), the move distance is measured from the position at the time of the move command. When the motion
type is “Relative Mem On” (P1-01 = 4), the distance is measured from the destination of the previous move. If a
conveyor with pockets or “flights” is being indexed, “Relative Mem On” is the appropriate motion type.
Figure 3: Relative Motion Example – Cut To Length
5.2 Commanded Position:
DIGITAL PRESET: Up to 16 different digital preset positions can be programmed. Each position is set in user
selectable units, set up by parameters P1-09 and P1-10. Distance in encoder counts can be calculated by
multiplying the digital preset value by parameter P1-09 (counts per rev). Encoder counts refer to the counts after
quadrature. The counts after quadrature are four times that of the “Pulses Per Revolution” rating of all compatible
encoders except the absolute gray code type. For the gray code type, encoder counts are NOT multiplied by 4.
Move velocity is determined by a different parameter for each digital preset position. Accel and Decel rates will be
one of 4 different sets as shown in Table 1 on the next page.
MODBUS DISTANCE: One 16 bit modbus register is used to command a speed during a move, and one 16 bit
modbus register is used to command a position. Modbus register 061Ch holds the speed reference (in 0.01 Hz),
and register 061Dh holds the position reference in engineering units (061Dh * P1-09). These registers can be
written by using the drive’s built-in modbus communications, or by other optional protocols such as DeviceNet,
Ethernet, Profibus or Modbus Plus. Accel and Decel rates are determined by parameters C1-01 and C1-02.
HIGH SPEED OPTION CARD REGISTER (Frequency Reference): In this mode, the option card’s frequency
reference is redefined and used as the commanded distance. The commanded position originates from the
“Frequency Reference” channel of the option card. The position reference is scaled as follows: Commanded
Position (in encoder counts) = Frequency Reference * P1-09. Move velocity is determined by parameter d1-09 and
Accel and Decel rates are determined by parameters C1-01 and C1-02.
For example: If P1-09 = 4096 counts / unit, and the frequency reference over the option PCB is 15.00 Hz, the result
is a move that is exactly 61,440 encoder counts (4096 * 15.00 = 61,440). When motion control is disabled, the
high-speed frequency reference channel returns to normal operation as an actual frequency reference.

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(11) Programmable using the multifunction digital input parameters H1-01 ~ H1-10.
(12) When P1-02 = 1, the actual commanded destination is calculated as follows:
Destination = modbus register 61CH * P1-09 / 100
(13) Actual destination (in encoder quadrature counts) is calculated as follows when b1-01 = 3:
(14) When motion control is disabled, the option card frequency reference register returns to its normal function.
Table 1: Profile Selection Information
Distance
Select
D (11)
Distance
Select
C (11)
Distance
Select
B (11)
Distance
Select
A (11)
Parameter
P1-02
Setting
Position Reference
Source
Accel /
Decel
Parameters
Maximum
Speed
Used
Open Open Open Open
0 Parameter P4-01
C1-01 and
C1-02
d1-09
1Modbus Address 061Dh
100 = 1.00 Units (12)
Modbus
Addr. 061Ch
2
High Speed Option PCB
(Profibus) Frequency
Reference Register (13) (14)
(in XXX.XX Units) d1-09
3
Modbus Addresses
061Ch (Low Word)
061Dh (High Word)
Open Open Open Closed N/A P4-02 C1-03 and
C1-04 d1-10
Open Open Closed Open N/A P4-03 C1-05 and
C1-06 d1-11
Open Open Closed Closed N/A P4-04 C1-07 and
C1-08 d1-12
Open Closed Open Open N/A P4-05 C1-01 and
C1-02 d1-13
Open Closed Open Closed N/A P4-06 C1-03 and
C1-04 d1-14
Open Closed Closed Open N/A P4-07 C1-05 and
C1-06 d1-15
Open Closed Closed Closed N/A P4-08 C1-07 and
C1-08 d1-16
Closed Open Open Open N/A P4-09 C1-01 and
C1-02 d1-09
Closed Open Open Closed N/A P4-10 C1-03 and
C1-04 d1-10
Closed Open Closed Open N/A P4-11 C1-05 and
C1-06 d1-11
Closed Open Closed Closed N/A P4-12 C1-07 and
C1-08 d1-12
Closed Closed Open Open N/A P4-13 C1-01 and
C1-02 d1-13
Closed Closed Open Closed N/A P4-14 C1-03 and
C1-04 d1-14
Closed Closed Closed Open N/A P4-15 C1-05 and
C1-06 d1-15
Closed Closed Closed Closed N/A P4-16 C1-07 and
C1-08 d1-16
Destination Frequency Reference (Hi-speed register)
100
------------------------------------------------------------------------------------------------------------------- P1 - 10×=

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5.3 Encoders:
SINGLE INCREMENTAL ENCODER: The encoder used for positioning is mounted to the motor and serves two
purposes. One is to provide velocity feedback for the Flux Vector control method and the other is to provide
position information to the motion control software. In order for this to work, there needs to be a “positive drive”
setup, such as a direct-coupled gear box or a cogged timing belt between the motor and the load. When this
scheme is employed, there is no compensation for backlash or slack in the mechanical system. The drive requires
one of the following encoder feedback cards: PG-X2, PG-B2 or PG-W2.
Note: Wiring for the encoder marker pulse (Z+ and Z-) is only required if using a “Homing w/marker” homing
routine (P2-01 = 4 or 5).
Figure 4: Single Incremental Encoder Wiring (P3-01 = 0)

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DUAL INCREMENTAL ENCODERS: The encoder used for positioning is mounted elsewhere on the machine.
Using this scheme, the need for a “positive drive” setup is somewhat reduced. A second motor-mounted encoder is
required. The ratio between the motor and the machine-mounted encoder must be entered into parameters P3-03
and P3-04, and the PPR of the encoder must be entered into P3-02. The drive requires a PG-W2 encoder
feedback card.
Note: Wiring for the encoder marker pulse (Z+ and Z-) is only required if using a “Homing w/marker” homing
routine (P2-01 = 4 or 5).
Figure 5: Dual Incremental Encoder Wiring (P3-01 = 1)

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ABSOLUTE (GRAY CODE): The encoder can be either machine-mounted or motor-mounted. The motion type has
to be “Linear Absolute” with this style of encoder. If the absolute encoder is machine-mounted, the ratio between
the motor and the encoder must be entered into parameters P3-03 and P3-04, and the encoder counts per
revolution must be entered into P3-02. The encoder requires a DI-16H2 digital input option card and an external
power supply for the encoder. Encoder outputs must be 24VDC and capable of “sinking” current when a logic “low”
is present on the output. This software was tested with a Danaher / Dynapar brand 12-bit by 12-bit gray code
encoder, part number: ai2512122b121.
Figure 6: Gray Code Absolute Encoder Wiring (P3-01 = 2)

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ABSOLUTE INCREMENTAL ENCODER: For use with a TR-electronic, series “CE-65” serial (ISI) encoder. Upon
power-up, the drive must read the actual position of the absolute incremental encoder. This process usually is
completed within a few seconds. As an option, the encoder can be monitored and configured directly using a PC,
an RS-232 to RS-485 converter, and the TR Electronic EPROGW32 program.
Note: The wiring below is for a “TR Electronic” brand encoder model #: CD65M-G/S-4096/4096-D23BB-R10NR/
N7 4096 counts / rev, +/-2048 revolutions (multi-turn).
Figure 7a: Absolute Incremental Encoder Wiring (P3-01 = 3)