YASKAWA A1000 Series User manual

Custom Software Supplement
MANUAL NO. TM.A1000SW.063
To properly use the product, read this manual thoroughly and retain
for easy reference, inspection, and maintenance. Ensure the end user
receives this manual.
Software Number: VSA91009□
Drive Models: 200 V Class, CIMR-AU2A0004□A□-063 to CIMR-AU2A0415□A□-063
400 V Class, CIMR-AU4A0002□A□-063 to CIMR-AU4A0250□A□-063
Spindle Orientation
YASKAWA AC Drive - A1000

2YASKAWA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement

YASKAWA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement 3
Table of Contents
1 PREFACE AND SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 SPINDLE ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 REVISION HISTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Refer to the A1000 Technical Manual for content not described in this document.
Copyright © 2011 YASKAWA AMERICA, INC.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or
by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written permission of
Yaskawa. No patent liability is assumed with respect to the use of the information contained herein. Moreover, because
Yaskawa is constantly striving to improve its high-quality products, the information contained in this manual is subject to
change without notice. Every precaution has been taken in the preparation of this manual. Yaskawa assumes no
responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information
contained in this publication.

4YASKAWA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement
This Page Intentionally Blank

1 Preface and Safety
YASKAWA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement 5
1 Preface and Safety
Yaskawa manufactures products used as components in a wide variety of industrial systems and equipment. The selection
and application of Yaskawa products remain the responsibility of the equipment manufacturer or end user. Yaskawa
accepts no responsibility for the way its products are incorporated into the final system design. Under no circumstances
should any Yaskawa product be incorporated into any product or design as the exclusive or sole safety control. Without
exception, all controls should be designed to detect faults dynamically and fail safely under all circumstances. All systems
or equipment designed to incorporate a product manufactured by Yaskawa must be supplied to the end user with
appropriate warnings and instructions as to the safe use and operation of that part. Any warnings provided by Yaskawa
must be promptly provided to the end user. Yaskawa offers an express warranty only as to the quality of its products in
conforming to standards and specifications published in the Yaskawa manual. NO OTHER WARRANTY, EXPRESS OR
IMPLIED, IS OFFERED. Yaskawa assumes no liability for any personal injury, property damage, losses, or claims
arising from misapplication of its products.
Applicable Documentation
The following manuals are available for the A1000 Drive:
Supplemental Safety Information
Read and understand this manual and the A1000 Quick Start Guide before installing, operating, or servicing this option
unit. Install the drive according to the A1000 Quick Start Guide and local codes. Observe all cautions and warnings in this
document and the standard drive technical manuals.
Refer to the A1000 Quick Start Guide and Technical Manual for safety information and to install and start-up the drive.
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.
• Custom software is provided to add functionality to a standard 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.
Obtaining Support
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 is flashed to the control board memory and the operation of parameters, functions, and
monitors are different than the standard drive software, as described herein.
Refer to Yaskawa office locations listed on the back cover of this manual.
Custom Software Supplement
Yaskawa AC Drive - Spindle Orientation A1000 Custom Software Supplement
Manual No: TM.A1000SW.063
Read this manual first. This supplement is an addendum to the A1000 Quick Start Guide and Technical Manual. It lists the effects of this custom software on
the parameters in the drive and function descriptions in the manual.
To obtain the supplement access this site: U.S: http://www.yaskawa.com
Yaskawa Drive
Yaskawa AC Drive -
A1000 Quick Start Guide To obtain instruction manuals for Yaskawa products access these sites:
U.S.: http://www.yaskawa.com
Europe: http://www.yaskawa.eu.com
Japan: http://www.e-mechatronics.com
Other areas: contact a Yaskawa representative.
For questions, contact the local Yaskawa sales office or the nearest Yaskawa representative.
Yaskawa AC Drive -
A1000 Technical Manual
SUPPLEMENT

6 YASKAWA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement
2 Spindle Orientation
2 Spindle Orientation
Overview
The target applications for this function are on equipment that must stop in specific positions including tool changing for
machine tool spindles and die changing for punch/stamping presses. This software also provides automatic switchover to
closed-loop operation at low speed.
Applicable Models
This Spindle Orient software is available for the drive models listed in Table 1.
Table 1 Applicable Models
Basic Concepts and Principles
This orientation software allows an A1000 drive to repeatedly stop a machine at a certain point in its rotational cycle. This
is accomplished by means of an orientation encoder directly coupled to the machine part to be positioned. A simple
example is to think of the hands on a clock. If the orientation encoder is mounted to the motor shaft, this software can stop
the motor so that the spindle stops at the 3 o'clock position every time. Application configurations are outlined in
Figure 1. For configurations other than those outlined, contact Yaskawa Application Engineering before applying this
software.
Figure 1
Figure 1 Spindle Orientation Hardware Configurations
Voltage Class Model Software Version
200 V CIMR-AU2A0004A-063 to CIMR-AU2A0415A-063 VSA91009x
400 V CIMR-AU4A0002A-063 to CIMR-AU4A0250A-063
Motor
Encoder
Machine
Motor
Configuration2:IndirectDrivewith
OrientationEncoder
Configuration1:DirectDrive
PG-X3 PG-X3
PG-X3
Orientated
MachinePart
Orientation
Encoder
Orientated
MachinePart
Drivetrain
(GearRatio)
CN5-B
CN5-C
CN5-C
Motor
Encoder
ChA/B/Z
ChA/B/Z
ChA/B
Machine
Motor
Motor
Encoder
Machine
Motor
Configuration3:IndirectDrivewith
ProximitySensor
PG-X3
Proximity
Sensor
Orientated
MachinePart
Drivetrain
(GearRatio)
CN5-C
ChZ
ChA/B

2 Spindle Orientation
YASKAWA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement 7
Direct Drive
In the first configuration, the drive motor directly drives the machine part being oriented (positioned). When using this
method, the motor encoder is used for both closed loop vector motor control and for orientation. This encoder must have
a C or Z channel which provides a “marker” or “index” pulse with every rotation. If the encoder does not have a C/Z
channel, an external marker pulse can be implemented as outlined in Encoder (PG) Option Card Configuration and
Wiring on page 29. Additionally, a PG-X3 or PG-B3 encoder (PG) feedback option card is required to connect the
encoder to the drive.
Indirect Drive with Orientation Encoder
When the motor and the machine part to be oriented (positioned) are connected through a drive train with a constant ratio,
two encoders are required. The first encoder is mounted on the driven motor, and the second, an orientation encoder, is
mounted on the machine part to be oriented. The orientation encoder must have a C or Z channel which provides a
“marker” or “index” pulse with every rotation. If the encoder does not have a C/Z channel, an external marker pulse can
be implemented as outlined in Encoder (PG) Option Card Configuration and Wiring on page 29. The motor encoder
does not need to have a C/Z channel. Two encoder (PG) feedback option cards are required for this setup.
Indirect Drive with Proximity Sensor
When the motor and the spindle are connected through a drive train and the spindle does not have its own encoder, a
proximity sensor may be used. The proximity sensor is connected as an external marker pulse; therefore this
configuration requires only one PG-X3 encoder (PG) feedback option card. In this configuration, the gear ratio of the
drive train must be expressed as the number of revolutions of the motor per revolution of the spindle.
Online Control Mode Switch Function
This software can switch between Closed Loop Vector Control and V/f Control during run. The 590 Hz software is
limited to V/f control mode above 400 Hz, it is possible to change tools without stopping the machine if the inverter
switches to Closed Loop Vector Control for Position Control at Low-Speed. At Low-Speed the inverter can be set to
operate in Closed Loop Vector Control and automatically switch to V/f Control when the output is above the frequency
which is set.
Changes from the Standard Product
• Second PG Channel Parameters F1-30 through F1-37 are always visible whether or not digital selection H1-0=16
(Motor 2 Select) is programmed.
• Only two Control Modes can be set in A1-02 and E3-01, 0:V/f and 3:Closed-Loop Vector.
• Only two Auto-Tuning Mode Selections are available, 0:Rotational Auto-Tuning and 2:Stationary Auto-Tuning for
Line-to-Line Resistance.
Deleted Functions
Certain functions in the standard software of A1000 are deleted in this Orientation software. Deleted functions are listed
in Table 2.
Table 2 Deleted Functions
Function Name
Speed Search (all methods) KEB Function Fault Restart
High Slip Braking (HSB) Overexcitation Braking Field Weakening Function
Energy Savings Droop Control Field Forcing Function
Frequency Reference Lower Limit Feed Forward Control DC Injection Braking Current Setting in V/f
Torque Detection Stall Prevention Selection during Acceleration Stall Prevention Selection during Run

2 Spindle Orientation
8YASKAWA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement
Limitations
• The multi-function digital input function Motor 2 Select (H1- = 16) and Encoder Option Card Setting F1-30 have
restrictions when used in Closed Loop Vector control mode with an additional orientation encoder. Refer to Table 15 on
page 16 and Table 17 on page 31.
• Applications using Configuration 2 and Motor 1/Motor 2 switchover must use a motor encoder and an orientation
encoder of the same PPR.
• DriveWorks EZ functionality is not fully supported when using this software. If DriveWorks EZ support is required,
please contact Yaskawa Application Engineering.
• PG Encoder PPR parameters F1-01 and F1-31 are limited to PPR of 8 to 16384 PPR
(32 to 65536 counts per revolution).
• Orient functionality is disabled when the run command comes from the Local Operator (b1-02 = 0).
• Since all forms of speed search are disabled, the stopping method Coast to Stop (b1-03 = 1) causes inconsistent
operation of the spindle orient routine if an orient digital input is closed while the drive is coasting. This may include
but is not limited to overvoltage trips and faster than expected deceleration.
• Disabling reverse operation by setting Reverse Operation Selection parameter b1-04=1 prohibits the orient function
from maintaining position.
• Frequency Upper Limit parameter d2-01 prevents the spindle orient function from operating if the frequency limit is set
at or below the P1-02 Creep Speed.
• Orient digital inputs are disabled when Forward or Reverse Jog commands (H1-0= 12 or 13) are active.
• Orient digital inputs are disabled when Control Mode Switchover Prevention digital input H1-0= 50 is closed while
the drive is not running.
Related Parameters and Functions
The legend below is used in this section to indicate which parameters are available in which control modes.
The parameter tables in this section are used to set up the drive for operation with the software.
Note: Chinese language support is added to certain parameters and functions. Refer to References on page 31 for the parameters and
functions with Chinese language support.
Table 3 Modified Parameters
No.
MEMOBUS/
Modbus
Address
Name
Digital Operator Display Description Range Default Value
Change
During
Run
Control Method/
Access Level
F1-01 0380h PG 1 Pulses Per Revolution
PG1 Pulses/Rev
Sets the number of encoder pulses per revolution
for the encoder on channel 1. 8 to 16384 PPR 1024 PPR No – – – Y– – N
F1-30 03AAh
PG Option Card Port for Motor 2
Selection
Mtr2 PG Port Sel
Specifies the drive port for the PG option card used
for Motor 2.
0: CN5-C
1: CN5-B
Note: This parameter is available without a digital
input H1-0programmed to 16h (Motor 2 Select).
0 to 1 0 No – – – Y– – N
–––Y ––Y
CLV/PM
OLV/PM
AOLV/PM
CLV
OLV
V/F w PG
V/f
N = Not Viewable
Y = Viewable/Available
– = Not Available
Control Method / Access Level Decoding

2 Spindle Orientation
YASKAWA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement 9
F1-31 03B0h PG 2 Pulses Per Revolution
PG2 Pulses/Rev
Sets the number of encoder pulses per revolution
for the encoder on channel 2.
Note: This parameter is available without a digital
input H1-0programmed to 16h
(Motor 2 Select).
8 to
16384 PPR 1024 PPR No – – – Y– – N
F1-32 03B1h PG2 Rotation Selection
PG2 Rotation Sel
Determines the direction indicated by the pulses
from the PG feedback encoder for motor 2.
0: Pulse A Leads
1: Pulse B Leads
This parameter is available without a digital input
H1-0programmed to 16h (Motor 2 Select).
0 to 1 0 No – – – Y– – N
F1-35 03BEh
PG2 Division Rate for Pulse
Monitor
PG2 Output Ratio
Sets the ratio between the pulse input and the pulse
output of a PG option card.
This parameter is available without a digital input
H1-0programmed to 16h (Motor 2 Select).
1 to 132 1 No – – – Y– – N
F1-36 03B5h
PG Option Card Disconnect
Detection 2
PGCardDisconDet1
Sets whether the drive detects a fault when a
PG-X3 card is disconnected.
0: Disabled
1: Enabled
This parameter is available without a digital
input H1-0x programmed to 16h
(Motor 2 Select).
0 to 1 1 No – – – Y– – N
L3-04 0492h
Stall Prevention Selection during
Deceleration
StallP Decel Sel
Determines how Stall Prevention works during
Run.
The parameter default is changed to 0: Disabled.
0: Disabled
1: General Purpose
2: Intelligent
3: Stall Prevention w/Braking Resistor
4: Overexcitation Deceleration
5: Overexcitation Deceleration 2
Note: Enabling stall prevention extends the decel
time. Other modes such as Intelligent may cause
unintended operation during orient, including
oscillation and inability to maintain position.
0 to 5 0 No – – – Y– – Y
S1-01 680h On-Delay Compensation Selection
OnDelay Comp Sel
Parameter S1-01 is used to enable and disable On
Delay Compensation.
0: Disabled
1: Enabled
0 to 1 1 No – – – Y– – Y
S1-03 682h Extended Current Sampling Mode
Extend I Sample
Normally there is no need to change S1-03 from its
default setting. If there is a problem with output
voltage weakening when attempting to compensate
for output current distortion as the motor reaches
590 Hz while decoupled from the load during a test
run, then try setting S1-03 = 1.
0: Disabled
1: Enabled
0 to 1 1 No – – – Y– – Y
S2-01 691h
Control Mode Switchover
Frequency
HF SwOver Freq
Sets the frequency of switching from Closed Loop
Vector Control to V/f Control.
This function is disabled when 0 or 400 Hz is set,
the inverter runs as V/f Control when 0 is set and
Closed Loop Vector Control when 400 Hz is set.
However, OPE21 occurs when the relations among
Control Mode Switch Frequency (S2-01) and PG
Pulse per Revolution (F1-01) and Numbers of
Motor Poles (E2-04) are set higher than the
permissible input frequency of PG option.
0 to 400 Hz 400 No – – – Y– – N
S2-02 692h
Control Mode Switchover
Bandwidth
HF CtrlMode SwBW
Sets the hysteresis width of Control Mode Switch.
Increase if shock occurs during Control Mode
switching.
2 to 100 Hz 20 No – – – Y– – N
No.
MEMOBUS/
Modbus
Address
Name
Digital Operator Display Description Range Default Value
Change
During
Run
Control Method/
Access Level

2 Spindle Orientation
10 YASKAWA TM.A1000SW.063 Spindle Orientation A1000 Custom Software Supplement
S2-05 695h
High Frequency Slip
Compensation Gain
HF SlipComp Gain
Sets the gain for the Motor Slip Compensation at
Hi-Speed Function. Although this parameter rarely
needs to be changed, adjustments might be needed
under the following circumstances:
If the motor at constant speed is slower than the
frequency reference, increase S2-05.
If the motor at constant speed is faster than the
frequency reference, decrease S2-05.
0.0 to 2.5 0.0 Yes – – – Y– – N
S2-06 696h
High Frequency Slip
Compensation Primary Delay Time
HF SlipComp Time
Sets the filter on the output side of the Slip
Compensation at Hi-Speed Function. Although this
parameter rarely needs to be changed, adjustments
might be needed under the following
circumstances:
-Decrease the setting when the slip compensation
response is too slow.
-Increase this setting when speed is unstable.
0 to 10000 ms 2000 Yes – – – Y– – N
S2-07 697h
High Frequency Slip
Compensation Limit
HF SlipComp Lim
Sets the upper limit for the Slip Compensation at
Hi-Speed Function as a percentage of the motor
rated slip (E2-02).
0 to 250% 200 No – – – Y– – N
S2-08 698h
High Frequency Slip
Compensation Selection During
Regeneration
HF SlipCompRegen
When Slip Compensation during Regeneration at
Hi-Speed is activated and a regenerative load is
applied, it might be necessary to use a dynamic
braking option (braking resistor, braking resistor
unit, or braking unit).
0: Disabled
1: Enabled (6 Hz and Above)
2: Enabled
(Compensation provided wherever possible)
0 to 2 0 No – – – Y– – N
S2-11 699h
Motor 2 Control Mode Switchover
Frequency
HF SwOver Freq 2
Sets the frequency of switching from Closed Loop
Vector Control to V/f Control for Motor 2
This function is disabled when 0 or 400Hz is set,
the inverter runs as V/f Control when 0 is set, and
Closed Loop Vector Control when 400Hz is set.
However, OPE21 occurs when the relations among
Control Mode Switch Frequency (S2-11) and PG
Pulse per Revolution (F1-31) and Numbers of
Motor Poles (E4-04) are set higher than the
permissible input frequency of PG option.
0 to 400 Hz 400 No – – – Y– – N
S2-12 69Ah Motor 2 Control Mode Switchover
Bandwidth
HF CtrlModeSwBW2
Sets the hysteresis width of Control Mode Switch
for Motor 2.
Increase if shock occurs during Control Mode
switching.
2 to 100 Hz 20 No – – – Y– – N
S2-15 69Dh
Motor 2 High Frequency Slip
Compensation Gain
HF SlipCompGain2
Sets the gain for the Motor Slip Compensation at
Hi-Speed Function for Motor 2. Although this
parameter rarely needs to be changed, adjustments
might be needed under the following
circumstances:
-If the motor at constant speed is slower than the
frequency reference, increase S2-15.
-If the motor at constant speed is faster than the
frequency reference, decrease S2-15.
0.0 to 2.5 0.0 Yes – – – Y– – N
S2-16 69Eh
Motor 2 High Frequency Slip
Compensation Primary Delay Time
HF SlipCompTime2
Sets the filter on the output side of the Slip
Compensation at Hi-Speed Function for Motor 2.
Although this parameter rarely needs to be
changed, adjustments might be needed under the
following circumstances:
-Decrease the setting when the slip compensation
response is too slow.
-Increase this setting when speed is unstable.
0 to 10000 ms 2000 Yes – – – Y– – N
S2-17 69Fh
Motor 2 High Frequency Slip
Compensation Limit
HF SlipComp Lim2
Sets the upper limit for the Slip Compensation at
Hi-Speed Function for Motor 2 as a percentage of
the motor rated slip (E4-02).
0 to 250% 200 No – – – Y– – N
No.
MEMOBUS/
Modbus
Address
Name
Digital Operator Display Description Range Default Value
Change
During
Run
Control Method/
Access Level