YASKAWA PG-F3 User manual

MANUAL NO. TOBP C730600 51A
エンコーダタイプ（EnDat用）
安川インバータオプションカード
取扱説明書
形式 PG-F3
製品を安全にお使い頂くために，本書を必ずお読みください。
また，本書をお手元に保管していただくとともに，最終的に本製品をご使用になる
ユーザー様のお手元に確実に届けられるよう，お取り計らい願います。
Encoder Type (EnDat)
YASKAWA AC Drive-Option Card
Installation Manual
Type PG-F3
To properly use the product, read this manual thoroughly and retain
for easy reference, inspection, and maintenance. Ensure the end user
receives this manual.

This Page Intentionally Blank

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 3
Table of Contents
1 PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 PRODUCT OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 OPTION CARD COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 8
4 ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 9
5 RELATED PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
7 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Copyright © 2009 YASKAWA ELECTRIC CORPORATION
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.

4 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual
1 Preface
1 Preface
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
This instruction manual has been written for the items listed below. Use this option card for
its intended purpose only.
Option Card
YASKAWA AC Drive-Option Card
Encoder Type (EnDat) : PG-F3 Installation Manual (this book)
Document Number: TOBP C730600 51
Read this manual first.
It contains information required to install the option card and set up related drive
parameters.
Drive
Refer to the manual of the drive this option card is being used with.
The manual for the drive covers basic installation, wiring, operation procedures,
functions, troubleshooting, and maintenance information.
It also includes important information on parameter settings and how to tune the drive.
To obtain instruction manuals for Yaskawa products access these sites:
Europe: http://www.yaskawa.eu.com
Japan: http://www.e-mechatronics.com
Other areas: contact a Yaskawa representative.

1 Preface
YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 5
◆Registered Trademarks
• Company names and product names listed in this manual are the registered trademarks of
those companies.
◆Supplemental Safety Information
Read and understand this manual before installing, operating or servicing this option unit.
The option unit must be installed according to this manual and local codes.
The following conventions are used to indicate safety messages in this manual. Failure to
heed these messages could result in serious or possibly even fatal injury or damage to the
products or to related equipment and systems.
DANGER
Indicates a hazardous situation, which, if not avoided, will result in death or serious
injury.
WARNING
Indicates a hazardous situation, which, if not avoided, could result in death or serious
injury.
CAUTION
Indicates a hazardous situation, which, if not avoided, could result in minor or moderate
injury.
NOTICE
Indicates an equipment damage message.

1 Preface
6YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual
■General Safety
General Precautions
• The diagrams in this section may include option units and drives without covers or safety shields to
illustrate details. Be sure to reinstall covers or shields before operating any devices. The option
board should be used according to the instructions described in this manual.
• Any illustrations, photographs, or examples used in this manual are provided as examples only and
may not apply to all products to which this manual is applicable.
• The products and specifications described in this manual or the content and presentation of the
manual may be changed without notice to improve the product and/or the manual.
•When ordering a new copy of the manual due to damage or loss, contact your Yaskawa
representative or the nearest Yaskawa sales office and provide the manual number shown on the
front cover.
DANGER
Heed the safety messages in this manual.
Failure to comply will result in death or serious injury.
The operating company is responsible for any injuries or equipment damage resulting
from failure to heed the warnings in this manual.
NOTICE
Do not expose the option unit to halogen group disinfectants or DOP gas.
Failure to comply may cause damage to the electrical components in the option unit.
Do not pack the option unit in wooden materials that have been fumigated or sterilized.
Do not sterilize the entire package after the product is packed.

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 7
2 Product Overview
2 Product Overview
◆Regarding this Product
The pulse generator option card PG-F3 uses rotary encoder EnDat2.1/01 and EnDat2.2/01
by HEIDENHAIN.
When installed to the control board, the drive uses the feedback signal from the encoder to
detect motor speed. PG-F3 allows the drive to maintain constant motor speed by adjusting
the output frequency in response to any changes to the load.
PG-F3 has a maximum input frequency of 50 kHz. Do not allow the input frequency for PG-
F3 to exceed 50 kHz when operating the drive.
PG-F3 requires that the drive use Closed Loop Vector Control for PM to operate the motor.
For detail, refer to the manual of the drive this option card is being used with.
◆Checking Package Contents
Table 1 Items Included with this Option Card
• Inspect the Option Card for damage. If the Option Card appears damaged upon receipt,
contact the shipper immediately.
• Verify receipt of the correct model by checking the model number printed on the Name
plate of the Option Card. (see Figure 1)
• If you have received the wrong model or the Option Card does not function properly,
contact your supplier.
◆Tools Required for Installation
A Phillips screwdriver PH1 (#1) is needed to install this option card.
Additionally a straight-edge screwdriver (blade depth: 0.4 mm, width: 2.5 mm) will be
needed to wire the terminal block.
Package
Contents Option Card Lead Line (for grounding) Screws (M3) Manual (this book)
–
Number of
Items 1 131
MANUAL

8 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual
3 Option Card Components
3 Option Card Components
◆Option Card
Figure 1
Figure 1 Option Card
◆Terminal Block
Figure 2
Figure 2 Terminal Block
A – Terminal block TB1 E – Model number
B – Terminal block TB2 F – Installation hole
C – Jumper for encoder power supply
voltage (CN3)
G – Connector (CN5)
D – Ground terminal (installation hole)
Underside
D
F
ABC
E
G
PG-F3
IP b–b+B+ B–DTDTIG
TB1
TB2
IP IG CK CK A+ A– a+ a– FE

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 9
4 Electrical Installation
4 Electrical Installation
◆Safety Messages
DANGER
Electric Shock Hazard
Power to the drive must be shut off when installing this option card.
Even though the power has been shut off, voltage still remains in the drive’s DC bus. Wait
before removing the front cover once the drive has been turned off.
The CHARGE light on the drive will go out after voltage in the DC bus drops below 50 V,
at which point it is safe to remove the front cover.
Due to the risk of electric shock, be sure that all LEDs have gone out and that the DC bus
voltage has reached a safe level prior to performing any work on the drive.
WARNING
Electrical Shock Hazard
Do not allow unqualified personnel to perform work on the drive.
Failure to comply could result in death or serious injury.
Maintenance, inspection, and replacement of parts must be performed only by authorized
personnel familiar with installation, adjustment and maintenance of AC drives and Option
Cards.

4 Electrical Installation
10 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual
NOTICE
Damage to Equipment
Observe proper electrostatic discharge procedures (ESD) when handling the option
unit, drive, and circuit boards
Failure to comply may result in ESD damage to circuitry.
Never shut the power off while the drive is outputting voltage.
Failure to comply may cause the application to operate incorrectly or damage the drive.
Do not operate damaged equipment.
Failure to comply may cause further damage to the equipment.
Do not connect or operate any equipment with visible damage or missing parts.
Properly connect all pins and connectors.
Failure to comply may prevent proper operation and possibly damage equipment.

4 Electrical Installation
YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 11
◆Installing the Option Card
Insert the option card into the CN5-C connectors located on the drive’s control board.
See the drive manual for directions on removing the front cover.
1. Shut off power to the drive, wait the appropriate amount of time for voltage to
dissipate, then remove the operator and front cover.
2. Insert the CN5 connector on the option card into the matching CN5 connector on
the drive, then fasten it into place using one of the screws included with the option
card.
Figure 3
Figure 3 Installing an Option Card
A – Connector CN5-C G – Mounting screw
B – Connector CN5-B H – Lead line
C – Connector CN5-A I – Use wire cutters to create an opening
for cable lines
D – Drive grounding terminal (FE) J – Front cover
E – Insert connector CN5 here K – Digital operator
F – Option card L – Terminal cover
A
I
E
L
B
C
D
F
G
G
H
K
J

4 Electrical Installation
12 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual
3. Connect the lead line using one of the screws to the ground terminal.
Note: There are only two screw holes on the drive for ground terminals. If three option cards are
connected, two of the lead lines will need to share the same ground terminal.
Figure 4
Figure 4 Connecting the Ground Terminal

4 Electrical Installation
YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 13
4. Wire the option card to the terminal block on the option card.
For wiring instructions, see Interface Circuit on page 15.
If the wiring does not fit easily into the drive, cut an opening through the left side of
the front cover and allow the wires to protrude of the drive. Any sharp edges along
the opening should be filed down to minimize damage to encoder wiring.
There is no need to cut an opening in the front cover if the wires fit inside the drive.
Figure 5
Figure 5 Wiring space
5. Place the front cover back onto the drive as it was before.
Note: 1. Take care when wiring the option card so that the front cover easily fits back onto the drive. Make sure
a cable is not caught between the front cover and the drive when putting the cover back on.
2. The drive will not be used as NEMA Type1 if there is any exposed wiring outside the enclosure.
A – Wires should pass through the
access hold provided on the left
side of the front cover.
B – Use the open space provided
inside the drive to route option
card wiring.
B
A

4 Electrical Installation
14 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual
◆Connection Diagram
Refer to Figure 6 when wiring the terminal block on the option card.
• Connect the encoder and PG-F3 using the HEIDENHAIN 17-pin cable.
• Wiring length over 10 m requires two connections to both IP and IG.
A detailed description of the option board terminals can be found in Terminal Functions on
page 16.
Figure 6
Figure 6 Wiring the Option Card and PG
a–
M
CN5
Drive PG-F3
U/T1
V/T1
W/T1
R/L1
S/L2
T/L3
FE
0V
B+
B–
A–
A+
DT
DT
CK
CK
IP
IP
IG
IG
TB1,TB2
CN3
8V
5V
FE
a+
b+
b–
Cable
(by HEIDENHAIN)
EnDat encoder
A pulse monitor signal
B pulse monitor signal
Lead line
main circuit terminal control circuit terminal

4 Electrical Installation
YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 15
Take the following steps to prevent erroneous operation caused by noise interference:
• Use shielded wire for the signal lines.
• Make sure that control lines to the option card, main circuit wiring, and power lines are
separated from one another.
• The shield should be grounded on both the encoder side as well as the drive side. If noise
problems arise in the encoder signal, try grounding only one end of the signal line, or
removing the ground connection on both ends.
■Interface Circuit
Figure 7
Figure 7 The Interface Circuit
120 Ω
120 Ω
PG-F3
CK
CK
DT
DT
a+
a
–
b+
b
–
2.5 V
Encoder
26LS31 Level
Clock
Data output
Data input
Monitor Signal
A
– , B –
A+, B+

4 Electrical Installation
16 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual
◆Terminal Functions
Table 2 Terminal Functions
Terminal
Block Terminal Function Description Specifications
TB1
IP Encoder power
supply
Supplies power to the
encoder.
• Jumper with terminal CN3 to select the
power supply voltage, 8 V or 5 V.
• Voltage range:
5 V ±5%, 330 mA
8 V ±10%, 150 mA
Note: Number of connections to terminals
IP and IG differs by wiring length when the
power supply is set for +5 V ±5%.
• Up to 10 m: One or two connections to
both IP and IG.
• 10 to 20 m: Two connections to both IP
and IG.
IG Encoder power
supply common
DT Comm. data
signal I/O Reads and processes
encoder data. Signal level: RS-485 protocol
DT Inverse comm.
data signal I/O
B+ B pulse signal
input Input for the B pulse sine-
wave from the encoder.
• Max. input frequency: 50 kHz
• Input signal differential: B+ - B–
B– Inverse B pulse
signal input
b+ B pulse monitor
signal output Outputs a ratio of the B
pulse frequency.
• Output method: Line driver
• Output voltage: RS-422 level
• Possible resolution: 1/n
Set F1-06 to monitor the pulse signal.
Varies by drive models.
b–
Inverse B pulse
monitor signal
output
0.6 V to 1.2 V

4 Electrical Installation
YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 17
TB2
IP Encoder power
supply Supplies power to the
encoder.
Connects to terminal IP on the option card.
IG Encoder power
supply common Connects to terminal IG on the option card.
CK Comm. clock
signal output Outputs the comm. clock
signal to the encoder. Signal level: RS-485 protocol
CK
Inverse comm.
clock signal
output
A+ A pulse signal
input Input for the A pulse sine-
wave from the encoder.
• Max. input frequency: 50 kHz
• Input signal differential: A+ - A–
A– Inverse A pulse
signal input
a+
A pulse
monitor signal
output Outputs a ratio of the A
pulse frequency.
• Output method: Line driver
• Output voltage: RS-422 level
• Possible resolution ratio: 1/n
Set F1-06 to monitor the pulse signal.
Varies by drive models.
a–
Inverse A pulse
monitor signal
output
FE Ground Ground terminal for
shielded cable. Used for grounding shielded line.
Terminal
Block Terminal Function Description Specifications
0.6 V to 1.2 V

4 Electrical Installation
18 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual
◆Setting the Voltage for the Encoder Power Supply
Jumper CN3 determines the voltage for the encoder power supply. The voltage level is set by
the positioning the jumper as shown below.
NOTICE: Setting the incorrect voltage can damage the encoder. Make sure the jumper is positioned
properly to supply the correct voltage for the encoder being used.
Table 3 Encoder Power Supply Voltage (IP)
◆Encoder Signal Output and Option Card Settings
The motor rotation direction is determined by the pulse that leads. A signal with leading A
pulse is considered as rotation in Forward direction (counter-clockwise when from the load
side).
NOTICE: Make sure that the option card and encoder have been set correctly to ensure that the motor
operates as expected.
Figure 8
Figure 8 Displacement of A and B Pulses
Connect the encoder outputs to the option card, then manually rotate the motor shaft a bit
while monitoring the speed feedback with U1-50.
If U1-50 shows the forward direction as being the opposite of what is desired, then set
parameter F1-05 to 1 to switch the direction of how the option card reads pulses from the
encoder output.
Voltage Level 5.0 V ± 5% (default) 8.0 V ±5%
Jumper
8 V
5 V
8 V
5 V
A
B
The A pulse leads, followed
by the B pulse displaced at 90 degrees
Time→
Pulse
Pulse

4 Electrical Installation
YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 19
◆Encoder Cables
Connect PG-F3 and the encoder using a HEIDENHAIN 17-pin cable.
For cables longer than 10 m, the signal “Sensor Up” must be connected to terminal IP on the
PG-F3 option card, and “Sensor 0 V” must be connected to terminal IG.
Table 4 Encoder Cable Specification
Option Card Encoder Cable
Terminal Color Encoder Side
IP Brown/Green Up
Blue Sensor Up
IG White/Green 0V
White Sensor 0V
CK Purple CLOCK
CK Yellow CLOCK
DT Gray DATA
DT Pink DATA
A+ Green/Black A+
A– Yellow/Black A–
B+ Blue/Black B+
B– Red/Black B–

4 Electrical Installation
20 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual
◆Wire Gauges and Tightening Torque
Wire gauge specifications are listed below in Table 5.
Yaskawa recommends using crimp terminals for easy of wiring and to ensure proper
connection. Crimp terminal specifications can be found in Table 6.
Table 5 Wire Gauges and Tightening Torque
■Crimp Terminals
Yaskawa recommends using CRIMPFOX ZA-3 by Phoenix Contact to crimp the terminal
ends.
NOTICE: Wire ends should be properly trimmed so no wire extends out from the crimp terminals.
Table 6 Crimp Terminal Sizes
Terminal
SignallNo.l
<1> Use HEIDENHAIN 17-pin Cable. Refer to Encoder Cables on page 19 to for detail.
Screw
Size
Tightening
Torque
(Nxm)
Bare Cable Wiring Gauges with
Crimp Terminals
Wire Type
Possible
Gauges
mm2
(AWG)
Recom
mended
Gauges
mm2
(AWG)
Possible
Gauges
mm2
(AWG)
Recom
mended
Gauges
mm2
(AWG)
a+, a–, b+, b–,
FE
M2 0.22 to 0.25
Stranded wire:
0.25 to 1.0
(24 to 17)
Single line:0.25 to
1.5
(24 to16)
0.75
(18)
0.25 to 0.5
(24 to 20)
0.5
(20)
Shielded
twisted pair,
etc.
IP, IG, DT
DT, B+, B–
CK, CK,
A+, A–
<1> –––
Wire Gauge
mm2
(AWG)
Model L
(mm)
d1
(mm)
d2
(mm) Manufacturer
0.25 (24) AI 0.25 - 6YE 10.5 0.8 2
Phoenix Contact0.34 (22) AI 0.34 - 6TQ 10.5 0.8 2
0.5 (20) AI 0.5 - 6WH 14 1.1 2.5
d1 d2
6 mm
L