Synchronous Operation Manual - Fuji Electric Corp. of America
Contents
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4. Z 3 1 3 2 2 d41 3 Z Z 1 1 d76 Z 0 A B
5. SYoutput OFF ON Correct the integrated values so that the Z phase difference becomes the same as the first applied one when d41 4 RM p DIELA br edn ey ee ee Sec Reference PG Z phase Reference PG phase angle Slave PG phase angle Figure 3 1 Simultaneous Start Synchronous Operation 9 ENGLISH 3 2 2 Standby synchronous operation In standby synchronous operation d41 3 the inverter controls the slave motor to synchronize its Z phase with the reference motor s Z phase based on the first detected Z phases positions of those two motors after the start of synchronous operation The slave motor could cause a single cycle delay at a maximum on standby at the start of operation Once the slave motor starts running after standby it will never go standby unless the synchronous operation is cancelled see Note 1 below The Z phase synchronization angles of the reference and slave motors can be adjusted with d76 The inverter integrates the position pulses for each of the reference and slave motors and controls the slave motor s rotation speed and position to keep the deviation between those two motors at zero If any incorrect count due to electrical noise or other factors is found in the integrated count of A B phases the inver
6. EU s EN 4 4 3 4 4 2 9 999 999 9 999 999 LED 4 1 HSM 4 3 1 4 3 4 13 LED 0 0 o 9 f 39 Kr 9 599 999 3999999 99 2 159 s 4 4 3
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9. No part of this publication may be reproduced or copied without prior written permission from Fuji Electric Systems Co Ltd All products and company names mentioned in this manual are trademarks or registered trademarks of their respective holders The information contained herein is subject to change without prior notice for improvement ABIL FRENIC MEGA PG 2 PG PG IE
10. B m FRENIC M
11. en DP BY WE cnl ENYE a ZYRE xu Gx ora 9 MdL NE e et Tora eq b fevd 9yV GbV d Tpop Teop 1 E EHER EIGA P era er a GL V 1od Rysy d sugie 01 x 8ZP TA T SHARHI N Ng 913 fori x HT 191P AMT IZH ZZH 8773 H eee op4 9 LLP E f BE ova Tara Ej Em LEEN 9bV ebV N lg mu 2 RESAS E v V E1 1 Z1 0 P LoP oi 9P a ERE z ix 80 0d zur 9P Ekel Or K EE RH BETY E TY FY 18 lg e y U 4 le u le e fo ip 4 amp a SA SUED O O Q7 BrufddVv e F 54 N f T o dliBalAe eT GCSE ERE HATTE 1 b B l ig E E nn KM SHRI p VLP ELP en Tri piv zon zv LLP L9P P 09P e EE fI INT ELE i 29 YBUzHOvZ WEA EL RUEDA CH o REA G SBUEEEXDI Jr EX 38 c2 3H CO VLE KLEM oe j fich KI CD 2 D IA NR He 2 3 p ub er Lod Se ee x OEC SOS MA SCS ORCI 09 c e 10 040 04 81 Ista er v 37HzoXXC E3082 WT GASER 09 E3E FL HERL REL CO X CR STERNE 61 04 proa prov 04 2 38 e AG Y RG C0 22 L 3626298 DAR 1L2H 22H 09 lt 2 Z 3 3 dH 1 0
12. P LET Ek P B P d03 d04 PI P P 1 0 100 100 100 P P
13. PG 4 2 PG 4 2 PG T RT d41 gnus und E PG g gt XAXB ax ood ul MEN PG gat OL WO N gt YA YB SS FRENIC MEGA zn DER bes pr gt XA XB 6 PG d YA YB I3 Oo s s Bet PG gt XA XB PG gt YA YB En Fi PG uf en gt XAXB core PG PG x YA YB PG y gt XA XB Id 00 d Piet i n FR 5 PG d l YA YB FRENIC MEGA PG id NU HR gt XA XB PG E gt YA YB 24 4 2 4 2 1 Z 941 2
14. a b FRENIC MEGA gt L1 R L2 S L3 T 3 5 OF 2 d17 TOSMER 1d16 ER 2 d17 b er d 1 d16 u a C 1 d16 a x C 2 d17 b x d 1 d16 2 d17 1 d59 d60 BR d62 d63 1 2
15. d14 d17 4 d61 z 4197s d41 3 5 d41 Dmm gmmes zmms EINEN E mmm Z Z LL 13 2 FRENIC MEGA 5 TE 4 d71
16. 24 4 1 2 Wiring of PGs and slave s run forward reverse command 25 4 2 Function Code Configuration Examples pp 26 4 2 1 For synchronous operation without Z phase compensation d41 2 26 4 2 2 For synchronous operation with Z phase compensation d41 3 or 4 28 4 2 Checking PG Pulse Rate 2 ton tiii dieat nad eed a Foto xoa basis SiG 30 4 4 Monitoring the Running Status during Synchronous Operation 31 4 41 Monitor liest ar N PR Oe CO EF iac ne E THEE EI 31 422 MOhItOr display sc sea 31 4 4 3 Synchronous operation control status pp 32 Chapter5 PROTECTIVE EUNCTIONS Sara aan ea aa 33 5 1 Excessive Deviation Alarm EnO an ea 34 ST Function codes re EE 34 5 2 PGiwire break alarm AO Menara ea EE EK 34 Chapter 1 BEFORE USE 1 1 Applicable Inverters Synchronous operation using this interface card is available on the inverter type having the ROM version as listed in Table 1 1 Table 1 1 Applicable Inverters and ROM Version Inverter Type Inverter Capacity ROM Version FRENIC MEGA FRNLILIEIG1LI LILILI Any capacity 3000 or later Boxes replace alphanumeric letters that represent inverter capacity enclosure power supply voltage etc To check the inverters ROM version use Menu 5 Maintenance Information 5 14 in Programming mode For details refer to the FRENIC MEGA Instruction
17. 4 6 4 14 Hz xz M N N N N YZ FWD ON d41 0 3 SS1 ON SY ON 22 WAZ 231N M IF are 0 STOP X 20 SCANI 21 SOFF 25 SY X 26 SY C 21 SOFF 4 6 14 gs dus d41 2 4 F01orC30 7 dus 12 21 PID x Ban n a be ON T Z 22 Z 8 n E E is i i Z 26 TIIERBLEFT Z Kir Z
18. B d06 1 P d70 V f PI PI x PI PI zu
19. gt repp 40 gt m Puis T 2000P R Ts uso 2000P R l 6 tX us DIREA 04 SAS BER FRENIC MEGA ANAA Fspa 80 PG UVW XA XB XZ YA YB YZ U V W 4 4 Z 4 7 d41 3 4 4 1 ua Im 150 5 Pas AO d 9 ass 580 2 d16 di7 d17 1 1 10 d16 SmxSp 1 1 1 5 2 2 1 2 d15 d16 d17 4 8
20. F07 E10 E12 E14 F08 E11 E13 E15 Cyr F42 6 0 0s F23 F24 F25 F39 0 0s Cyr F42 6
21. PG Z PG aca UVW XA XB XZ 8 YA YB YZ 4 1 d41 3 4 4 1 d41 3 4 E RE PG mm gt Sp Cp gt x P01 x 42 228 PG FRENI C MEGA d17 d16 SmxSp d62 d16 d63 d17 4 1 2
22. 1 2 F42 3 4 6 4 d59 d60 d62 d63 B dum d14 d59 d14 d17 gt OFF ON gt E L gt gt A A B48 oeae BEAJ T L 90 B B B d15 d60 B 1 d16 2 di7 d62 d63
23. 2 3 4 2 3 4 14 3 6 2 F01 1 C30 2 12 Hz2 Hz1 Bd 3 3 3 4 X1 ON F01 12 030 0 E01 11 X1 sm Hz2 Hz1
24. 2 x GUEEEWETA T 00 135 HT OO PR P 0 020000 f amp 0 0 999 9997 2 60 1650 riolol 0 359 ejo O 0 10 1 degl 15 O 0765535 x3 er none 3 10000 A 100 E 100 x10LED LI FRENIC MEGA 5 EE ae 3 5 F16 C01 C04 F42 6 F07 F08
25. Z aS L Z nz te gt ErE lt 8 8 mar ee festosa I Sm PO PG 1 2 OPC G1 PG22 Z SW1 1 SW1 4 ON OPC G1 PG22 E De ee en UR ROTEN wes OFF ON CA 3 2 5 1 Ero 5 2 PG PG d78
26. APR 3 3 3 4 3 7 999 3 7 APR d75 Z APR 10 1 0 d76 Z d77 E20 E21 E22 E23 E24 E27 29 d77 SY
27. 1 4 0PC G1 PG22 1 5 1 3 1 0OPC G1 PG 1 4 OPC G1 PG a 12Vdc 10 15Vdc 10 PG 150mA PG 12Vdc 10 120mA E A X XO AR ERAT SAT B X B Z X Z A Y A B Y B Z Y Z 1 3 2 0PC G1 PG22 1 5 0PC G1 PG22 5Vdc 10 PG P6 GR isis 5Vdc 10 300mA PG PG CM A
28. 1 2 ROM 4 1 2 PG PG PG PG T0PC 61 PGI Er OPC G1 PG22 XA XB XZ YA YB YZ 1 1 1 2 B A 90 gt gt ane 2 AA B i 1 1 PG 1 2 PG ANE D 1 3 Z
29. P P P O
30. 14 3 PG 3 2 3 2 3 2 2 3 2 2 2 3 2 1 d41 2 4 TODE 0 d77 SY d78 10 d41 4 A B Z ON
31. ON 100ms sy 3 i d 7 d _ lt gt lt gt ON OFF T 3 8 SY d78 ro d78 10 ra d78 d78 x10 d78x 10 0 3 9 mu 4 4 1 4 1 1 4 1 d41 3 4 1 2 4 1 EI
32. Z EA e Z mr e UE Z mr w sm A METER ECOLE SY LCD 2 LCD 3 20 I 5 LED mL 5 1 6 5 1
33. 4 11 PG PG FWD REV DUST LL 1 2 28 4 3 PG P01 d15 1 2 d16 d17 PG 4 0 4 15 PG 1 4 17 PG 2 FRENIC MEGA 3 4 5 4P P01 4 1000P R d15 1000 1 2 1 30 d16 1 d17 30 20Hz r min 120x 120 x20 4 600 r min 10 r s
34. Z Z Z 1 3 PG PG PG IH es 2 T H REV REV XA XB XA XB a 0 X1 co Z Z 3 T Z PG XA PG B XB PG A 1 3 1 3 OPC GI PG
35. PG PG FWD REV DUST O 1 2 27 4 2 4 Z d41 3 4 2 Sm f T L Cp 206 FRENIC MEGA ME di 4 Pen er PG UVW XA XB XZ YA YB YZ 1000P R RST 1000P R 4 5 Z 4 9 PG 4 2 PG 1 Hi Hisl dou d16 SmxSp 11 2 3 2 1 d15 d16 d17 2
36. 0 0s F42 3 A 6 V f F42 3 235 5 d01 d04 P d06 d01 d06 Pl P d03 d04 d02 B d01 1 B d02 1
37. 0 000 5 00 0000 lt 5000 0007 5 000 0 020 0 00 100 00 4 100 00 0 1 2 A B 8 90 cx 0014 EA60 16 0400 x2 20 60000 1024 1 AERIS 2 19999 O 1 x 0 i i 1 x j 2 A B 90 ate 0014 0E10 16 EOE AES x2 20 3600 1024 0 000 5 000 s 0 085 O 1 ic999 a x 2 p 7 93 1 X7 PG X2 d41 2 3 4 20 3000P R PG 242 3 4 esp ge u 0 _ 2 Z 3 m 4
38. 4 13 Starzen Shinagawa Bldg 2 4 13 Konan Minato ku Tokyo 108 0075 Japan URL www fujielectric co jp fes Phone 81 3 6717 0617 Fax 81 36717 0585 URL http www fujielectric com fes 513 8633 5520 TEL 0120 128 220 FAX 0120 128 230
39. 2s 3 Z E Z 3 PG PG XA XB XZ PG YA YB YZ 3 1 3 1 3 1 180 3600 r min MA 4P 1024P R 4A i E T 1 1 1 3600 r min 2 100m X1 10 p s 100 kp s X1 AB 1 PG 30kp s 20m E gt EE PG
40. p s r s x P r x 1 2 10x 1000 x 1 30 333 3333 333 p s 4 17 0 33 p s 1000 x PG 30 kp s 3 100 kp s 29 4 4 EK GE ROM 6400 CS ROM 6 KP 4 4 1 4 12
41. 10 5 1 5 1 1 5 3 amp Eee ks 10 65535 10000 4 100 100 x10LED 5 2 Z 5 4 PG Z 2 5 1 3 3 c MEMO 34 English Version Preface Thank you for purchasing our PG interface card OPC G1 PG OPC G1 PG22 Mounting the interface card in your FRENIC MEGA inverter enables synchronous operation of two motors equipped with pulse generators PG This manual sets forth the simultaneous start s
42. X AG A X A BG X BG BC X B Z X Z SW1 4 ZC X Z ON A Y AG AC Y A B Y BG BC Y B Z Y SW1 1 ZC Y Z ON B XA XB XZ VA YB YZ Er 4 0 4 15 4_1
43. 2 Sm ane L BR Cp 4 3 FRENIC MEGA 4 4 PG UVW XA XB YAYB RST 2000P R 4 3 Z 2000P R 4 5 d41 2 d17 1 1 _20 d16 SmxSp 1 1 1 2 5 4 d15 1 d63 1 1 _15 i 1 1 2 d62 SmxCp A 1 4 6 PG PG FWD REV TE LU 1 2 286 4 2 3 Z d41 3 4 1
44. Maximum wiring length 100 m requirements PEE pulse tate 1O PS TQUE KDIS A B phase encoders in use For PGs with an open collector output the input pulse rate is 30 kp s or below and the maximum wiring length is 20 m Control Speed control range CTp For the procedure on how to calculate the PG input pulse rate based on the inverter output frequency refer to Section 4 3 Checking PG Pulse Rate 3 2 Details of Synchronous Operation Table 3 1 lists the synchronous operation modes Table 3 1 Synchronous Operation Modes Synchronous operation mode Z phase signal Simultaneous start synchronous operation Not required Section 3 2 1 without or oo Z phase Standby synchronous operation synchronous operation Section 3 2 2 3 2 2 Required Simultaneous start synchronous operation q Section 3 2 1 using Z phase 3 2 1 Simultaneous start Synchronous operation In simultaneous start synchronous operation d41 2 or 4 the inverter controls the rotation speed and position of the slave motor to maintain the difference between the reference and slave motors hereafter called deviation at the time when the single motor drive operation is switched to the synchronous operation That is it keeps the deviation between the integrated position pulses of the reference and slave motors at zero If the deviation falls below the synchronization completion detection angle specified by d77 the inverter issues an SY synchr
45. 1 Sm FRENIC MEGA 4 4 sch PG Cp E Esci won U VW XAXB c YA YB RST 1000P R 1000P R 4 2 Z 4 3 d41 2 BEI ar m 4 N x 1000 1 di7 1 1 10 d16 SmxSp 1 2 5 2 1000 d15 1 d63 1 1 15 1A 2 d62 SmxCp 3 1 4 4 PG PG FWD REV DUST e O 1 2 25 4 2 2 Z 41 2
46. 1 1 E10 E11 2 2 E13 E14 3 3 E15 E16 4 4 F24 F39 H18 0 J01 0 H18 J01 PID 3 6 F42 3 4or6 4 3 6 1 FRENIC MEGA 5 F03 F04 F05 F42 PO1 PO2 P03 PO6 PO7 PO8 PO9 P10 P11 P12 P99 2 3 4 A01 A02 A03 A14 A15 A16 A17 A20 A21 A22 A23 A24 A25 A26 A39 b01 b02 b03 b14 b15 b16 b17 b20 b21 b22 b23 b24 b25 b26 b39 r01 r02 r03 r14 r15 r16 r17 r20 r21 r22 r23 r24 r25 r26 r39
47. Function Terminal X5 X6 Function Terminal X7 1 X8 Function Terminal X9 Function Terminal FWD REV Function Terminal Y1 Y2 Function Relay output Terminal Y3 Y4 Function Terminal Y5 Function Terminal 30A B C Function Function Speed Control 1 Speed command filter Speed detection filter P Gain Integral time Output filter Speed control limiter Feedback Input Pulse input format Encoder pulse resolution 2 17 Positional deviation in synchronous operation In the case of voltage output 0 to 5 to 10 VDC 180 to 0 to 180 deg 0to6 Set F42 to 3 4 or 6 for selecting control with speed sensor 11 1011 Hz2 Hz1 Select frequency command 2 1 Only the related items indicated 29 1029 SY Synchronization completed Only the related items indicated 0 Pulse train sign Pulse train input 1 Forward rotation pulse Reverse rotation pulse 2 A B phase with 90 degree phase shift 0 020 0 005 10 00 0 100 e o gt 00 00 0400 0014 to EA60 hex 20 to 60000 pulses 1 to 9999 1 to 9999 1 Mounting the PG interface card disables the pulse train input function assigned to the inverter s X7 terminal 2 When synchronous operation is selected d41 2 3 or 4 the reference and slave sides should use a PG 20 to 3000 P R of the same pulse resolution Pulse count factor 1 En ERE Pulse c
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49. d17 to 1 d59 d60 d62 d63 Command Pulse Rate Input Pulse count factor 2 Pulse input format Encoder pulse resolution Pulse count factor 1 These function codes specify the command frequency to apply to the inverter The setting items are the same as for feedback input d14 to d17 For application samples in the actual machinery refer to Chapter 4 Configuration Examples of Synchronous Operation d61 Command Filter time Pulse Rate Input constant d61 specifies a filter time constant for pulse train input Choose an appropriate value for the time constant taking into account the response speed of the machinery system since a large time constant slows down the response When the reference frequency fluctuates due to small number of pulses specify a larger time constant 20 d41 Application defined Control d41 selects the desired synchronous operation mode Table 3 4 Setting of d41 Data for d41 Synchronization system Z phase signal o0 Ordinary control Disable Not required Constant peripheral speed control Simultaneous start synchronization Enable 2 without Z phase Standby synchronization Required Simultaneous start synchronization with Z phase LL For details about synchronous operation modes refer to Section 3 2 For details about the constant peripheral speed control refer to the FRENIC MEGA User s manual Chapter 5 CTp For the configuration procedures of sync
50. e uonei ep Pur E ae A3uH OMJ Za uonisogd i zop i s1n220 UUJBIB 5 7 ue ZH OpZ speeoxe v LN pl L9p cop ogpl peeds peloelep y JI Josues peeds YIM IOJJUO9 JoloeA Jepun Sx ct 4 i om Jou 1 Seop 10sseooJd JojeJ9 e29p Jo3eJojoooe se Josues peeds le JolgIn6e JeleAuoo UUM OJUOO JoloeA Jepun uoneuedo snouoAyaufs Buung vx x peeds urey peedS ouenbeJ e2u919J8J OU SPW Mo Jelluull AOuenbe ayl Ex 9H F a SN elBAJOS 9JBADJBH ouenbe goueJgj9 eu SW UBIH Jellull AOuenbe oyl z N 089 10 104 Aq Lod Uonegedo eAup Jolou el6uls i a i pue uonejedo snouoJuou s ueewjeq DulU21IAS 104 pesn eq pueuuulo ouenbei4 er Ista ey us 089 Z puewwoo Aousnbaa pue L03 L DIM ouenbg US9AN9d seuojs SIBUIUUJ91 Indul IB1IBID eur 4 JO euo oj poubisse J ZH zZH Puewwos leuluuel 94 Duis 1x pie ro Troad tow 04 2 d41 ion thout Z Phase Compensati ion WI Figure 3 3 Block Diagram for Synchronous Operat 11 3 Or 4 d41 ion th Z Phase Compensat ION WI 12
51. 4 digit LED monitor that displays the upper four digits of the setting values For 10000 pulses or more it displays the value in units of 100 pulses with the x10 LED ON For function codes not listed above see the FRENIC MEGA Instruction Manual Chapter 5 Function Codes For codes that are listed above and also in the FRENIC MEGA Instruction Manual descriptions in this manual precede 14 3 5 Unavailable Function Codes During synchronous operation the following functions are not available F16 Frequency Limiter Low C01 to C04 Jump Frequency Selecting Vector control with speed sensor F42 6 disables the settings of the following functions during synchronous operation as well as making the above functions unavailable F07 F08 Acceleration Time 1 Deceleration Time 1 E10 E11 Acceleration Time 2 Deceleration Time 2 E13 E14 Acceleration Time 3 Deceleration Time 3 E15 E16 Acceleration Time 4 Deceleration Time 4 F24 Starting Frequency Holding time F39 Stop Frequency Holding time During synchronous operation the following control should be disabled H18 0 J01 0 H18 Torque Control J01 PID Control 3 6 Configuring Function Codes To perform synchronous operation be sure to select the control with speed sensor F42 3 4 or 6 and configure the function codes given in this section In conjunction with this section refer to Chapter 4 Configuration Examples of Synchronous Operation ENGLISH 3 6
52. N PER E tox dec TAR SNE EI AKAs Ee i Tiq Telv z9P ct 19P E9P 09P 3E IIT C451 OL BRAGA AY FILAN RHA 89 ex J u PENAI EON BE EU 914 1 fat CSI CO D UD BACH rv E 72 EE P HIRE ODMIVIGVEHACARE 1 ar ag Cheated LTG oe PEVWGCEN SBME DBD ML OOS BME ex SO P2 0E940 104 PLLENIKTHNZEHELEN T GASNA E O9 EN PERLE ZHAO AE ET EEE Iena EH ood Tovi Teo 2 38 n Y REA OST SMD EU LZH ZZH 1 en 3 4 d41 3 4 Z 1 1 3 4 3 3 PETER smi mm 0 1 2 3 5 7 8 11 12 F01 C30 12 17 DC OV 5V 10V 180 0 180deg 0 6 3 4 6 X1 X2 X3 X4 11 1011 Hz2 Hz1 X5 X6 2 1 X7xi X8 X9 FWD REV Yl Y2 29 1029 SY Y3 Y4 Y5 30ABC Dom 995r 9 1 0 007010 s 995 O P 0 01 200 0 10 O 1 5
53. Option Terminals on the PG Interface Card When connecting the PG interface card OPC G1 PG or OPC G1 PG22 refer to Table 1 4 or 1 5 respectively 1 3 1 OPC G1 PG Table 1 4 Option Terminals on OPC G1 PG and Their Specifications Power input terminal from the external device External power supply capacity External power supply 12 Vdc 10 or input 15 Vdc 10 An external power supply to be connected should assure at least PG power consumption 150 mA Power output terminal Power supply for PG 12 Vdc 10 120 mA or below or 15 Vdc 10 120 mA or below Common terminal for power supply and PG input Input terminal for A phase signal issued from reference PG Input terminal for B phase signal issued from reference PG Input terminal for Z phase signal issued from reference PG A phase pulse input Y Input terminal for A phase signal issued from slave PG A phase pulse input X B phase pulse input X Z phase pulse input X B phase pulse input Y Input terminal for B phase signal issued from slave PG Z phase pulse input Y Input terminal for Z phase signal issued from slave PG For details about switching between the internal and external power supplies refer to the PG Interface Card instruction manual ENGLISH 1 3 2 OPC G1 PG22 Table 1 5 Option Terminals on OPC G1 PG22 and Their Specifications Terminal Name Functions Remarks Symbol Power input terminal from the external device External power supply cap
54. d16 Cm x Cp Sm x Sp p conveyer speed _ a Available J63 d17 Cp Sp Slave conveyer speed Cp Available The equations in the above table are for cases where the reference and slave motors have the same number of poles Set the number of poles of the slave motor to P01 For configuration examples refer to Section 4 2 24 4 1 2 Wiring of PGs and slave s run forward reverse command Table 4 2 shows three wiring patterns of reference and slave PGs and the slave s run forward reverse commands according to the rotational directions of those PGs in relation to that of the slave motor Reference conveyer Reference conveyer Reverse Reference conveyer Forward XA XB XZ YA YB YZ supply R S T Table 4 2 System Configuration and Wiring of PGs System configuration examples Slave conveyer Slave conveyer Slave conveyer Reference PG Reverse Forward FRENIC MEGA T OPC G1 PG OPC G1 PG22 FRENIC MEGA OPC G1 PG OPC G1 PG22 FRENIC MEGA T OPC G1 PG OPC G1 PG22 d41 Wiring of PGs Reference PG Normal connection to terminals XA and XB Slave PG Normal connection to terminals YA and YB Reference PG Normal connection to terminals XA and XB Slave PG Normal connection to terminals YA and YB Reference PG gt Reverse connection to terminals XA and XB Slave PG Normal connection to t
55. reverse REV Forward FWD Reverse REV For details about the run commands and rotational direction refer to Section 1 2 26 Configuration example 2 Reference conveyer Slave conveyer Reduction ratio Sm Reference motor 1 Bened Reduction ratio Cp BEER purpose RTT RENTA No of poles 4 inverter 2 Reference Slave PG OPC G1 PG PG OPC G1 PG22 U V W XA XB YA YB Power supply R S T 2000 P R 2000 P R Figure 4 3 Configuration Example of Synchronous Operation System without Z phase compensation Table 4 5 For Synchronous Operation d41 2 Function Code Seting Motor No of poles Set the number of poles of the slave motor d15 Slave Pulse In synchronous operation be sure to set the Encoder pulse resolution 2000 same value for both the reference and slave PGs Pulse count factor 1 d17 _ 1 M d16 SmxSp 1 1 5 Pulse count factor 2 5 4 Reference Pulse Set the same value as d15 2000 Encoder pulse resolution 1 1 15 Pulse count factor 1 d63 _ Pulse count factor 2 d62 SmxCp 1 1 x ENGLISH Table 4 6 Rotational Direction Rotational direction of Run command at slave inverter Reference PG Slave PG Run forward FWD Run reverse REV Forward FWD Reverse REV For details about the run commands and rotational direction refer to Section 1 2 2T 4 2 2 Forsynchronous operation w
56. synchronization completion detection angle specified by d77 the inverter issues a synchronization completion signal SY provided that the E20 E21 E22 E23 E24 or E27 data Terminal function is set to 29 Synchronization completed Once turned ON the synchronization completion signal SY is kept ON for 100 ms Synchronization completion detection signal 0 Position deviation Figure 3 8 Synchronization Completion Detection Signal SY d78 Synchronous Operation Excessive deviation detection range d78 specifies the detection range for excessive deviation alarm 7 If the absolute value of the phase angle deviation position deviation between the reference and slave PGs exceeds 10 times the d78 setting the inverter issues an alarm and shuts down its output L During synchronous operation the inverter always monitors an excessive deviation The d78 177 setting should be made taking into account that the deviation temporarily increases immediately after the start of running ENG Excessive deviation alarm Era d78 x 10 d78 x 10 ON OFF Position deviation Figure 3 9 Excessive Deviation Alarm 23 Chapter 4 CONFIGURATION EXAMPLES OF SYNCHRONOUS OPERATION 4 1 Typical Configuration and Pulse Setting 4 1 1 Speed reduction ratio setting Figure 4 1 shows the system configuration applicable to the synchronous operation taking a conveyer system as an example Table 4 1 li
57. the alarm Note that if the alarm is reset when any run command is set to on the inverter may supply the power to the motor which may cause the motor to rotate Injury may occur 33 ENGLISH 5 1 Excessive Deviation Alarm Table 5 2 Excessive Deviation Alarm Specifications This alarm occurs when the position deviation absolute value between the reference and slave PGs exceeds 10 times the d78 setting during synchronous operation This alarm is contained in alarm category Y in Table 5 1 so it cannot be disabled by any function code 5 1 1 Function codes Table 5 3 lists function codes related to an excessive deviation alarm Table 5 3 Related Function Codes Default Can96 Code Name Data setting range when setting running Synchronous Operation 0 to 65535 d78 i Hysteresis width To be set in units of 10 pulses The standard keypad has a 4 digit LED monitor that displays the upper four digits of the setting values For 10000 pulses or more it displays the value in units of 100 pulses with the x10 LED ON 5 2 PG wire break alarm Table 5 4 PG Wire Break Alarm Specifications This alarm occurs when the inverter has not detected the Z phase of the slave PG at least twice after the last detection during synchronous operation This alarm is contained in alarm category Y in Table 5 1 so it cannot be disabled by any function code 34 MEMO LHSIION3 35
58. 1 Motor parameters Configure function codes F03 to F05 F42 P01 to P03 P06 to P12 and P99 referring to the FRENIC MEGA Instruction Manual Chapter 5 Function Codes When using motors 2 3 and 4 configure the following function codes For motor 2 A01 A02 A03 A14 A15 A16 A17 A20 A21 A22 A23 A24 A25 A26 A39 For motor 3 b01 b02 b03 b14 b15 b16 b17 b20 b21 b22 b23 b24 b25 b26 b39 For motor 4 r01 r02 r03 r14 r15 r16 r17 r20 r21 r22 r23 r24 r25 r26 r39 In the descriptions given later function codes for motors 2 3 and 4 are omitted 15 3 6 2 F01 C30 Data setting for synchronous operation Frequency Command 1 Frequency Command 2 Select the pulse train input F01 C30 12 as a reference command source Switching between synchronous operation and single motor operation is possible using the Hz2 Hz1 terminal command see Figures 3 3 and 3 4 The switching example is given below Example Turning terminal X1 ON for single motor operation during which a digital frequency command drives the inverter Set F01 and C30 data to 12 and 0 respectively And set E01 data to 11 to assign the Hz2 Hz1 command to terminal X1 It is recommended to perform switching between synchronous operation and single motor operation when the inverter is stopped Switching when the inverter is running may activate the protective function To avoid it decrease the difference between the output f
59. 36 Supplement to FRENIC MEGA Instruction Manual OPC G1 PG OPC G1 PG22 Synchronous Operation Manual First Edition September 2010 Fuji Electric Systems Co Ltd e The purpose of this supplement is to provide accurate information in handling setting up and operating of the PG interface card Please feel free to send your comments regarding any errors or omissions you may have found or any suggestions you may have for generally improving the manual In no event will Fuji Electric Systems Co Ltd be liable for any direct or indirect damages resulting from the application of the information in this supplement Ge Fuji Electric Systems Co Ltd 108 0075
60. 5 PROTECTIVE FUNCTIONS If any inverter protective function is activated to issue an alarm the inverter displays the corresponding alarm code on the LED monitor of the keypad and shuts down its output Accordingly the motor coasts to a stop Table 5 1 lists alarm codes related to the PG interface card For other alarm codes refer to the FRENIC MEGA Instruction Manual Chapter 6 TROUBLESHOOTING Table 5 1 Related Alarm Codes A eda Alarms ame Synchronous Synchionbis Refer to operation control operation control Section NEM 4 Z phase nn mn Z ee Overspeed alarm ee Speed mismatch or excessive speeds deviation alarm 1 For details refer to the FRENIC MEGA Instruction Manual 2 The inverter connected with the OPC G1 PG22 issues this alarm if a PG wire break occurs When not using the Z phase in line driver input turn ON selectors 1 and 4 on SW1 on the PG interface card For details refer to the OPC G1 P22 Instruction Manual Y Always active The protective function for the alarm is always active when the control is enabled C Conditionally active The protective function for the alarm is active when the control is enabled and the protective function is enabled with the function code The factory default is enabled NA Not available when the control is enabled A WARNING If any of the protective functions has been activated first remove the cause Then after checking that the all run commands are set to off reset
61. 6 4_17 4_18 E52 Ale m OPC G1 PG 2 1 OPC G1 PG pre 12vde J1 OPC G1 PG Ji EXT INT 12Vdc 10 15Vde 10 2 1 OPC G1 PG EXP SW1 12V 15V m OPC G1 PG22 2 2 5Vdc 10 2 2 OPC G1 PG22 EC PR 0PC G1 PG OPC G1 PG22 Z SW1 1 SW1 4 ON
62. EGA Ap AO eA ee ob aa bom oak wee dies Deb aad Deedee Soha 3 ME rd CN ee ot Yo od Peek cT 3 PO F6 EDER R e ECL EQ EP QE 3 UU ar Fan DE lasse en hod bee dees ena base et 4 1 9 OPCO PO e saab us d ro o d os iP rani beds Ped aes 4 1 972 ORG HGP GZ uu rera eiut Duca eas e mca coe bed Lor o oec c e e A 5 2 6 3 rr 7 7 3 2 7 3 2 1 8 3 2 2 9 DS EEE Be a ee en Dee er 10 3 4 1 2 2 9 qe Be millbls IS OUT YS een RN 14 3 6 ces cub eeu bar t Eod ole ee reed 14 361 e sees dee Oe 14 3 6 2 WARASBSRFAT SRE cece eee eas 15 4 23 4 1 eR x as 23 Ae hd ee UR EE e de Lut healt ot Padi Sat oT d ddl E du m or ES 23 4 1 2 ee 2 4 2 5 4 2 1 Z
63. F Supplement to Instruction Manual FRENIC MEGA OPC G1 PG OPC G1 PG22 Synchronous Operation Manual EZ J L 7s ACAUTION Thank you for purchasing our PG interface card Read through this manual to become familiar with the PG interface card before proceeding with installation connections wiring operation and maintenance and inspection Deliver this manual to the end user of this product Keep this manual in a safe place until this product is discarded Specifications of this card are subject to change without prior notice for improvement Fuji Electric Systems Co Ltd INR SI47 1462a JE Copyright O 2010 Fuji Electric Systems Co Ltd All rights reserved
64. Manual Chapter 3 Section 3 4 6 Reading maintenance information Table 1 2 Display Items for Maintenance Information Shows the inverter s ROM version as a Inverters ROM version 4 digit code 1 2 Connection between the PG Interface Card and PGs on Reference and Slave Motors For instructions on how to mount the PG interface card refer to the instruction manual of the PG interface card OPC G1 PG or OPC G1 PG22 Connect the PG output signal wires for the reference motor to terminals XA XB and XZ on the PG interface card and those for the slave motor to terminals YA YB and YZ 2 The counterclockwise rotation when viewed from the motor output shaft is regarded as forward 19 rotation see Figure 1 1 The PG output signal wires should be connected so that the PG output pulse during rotation in the forward direction forms the forward signal as shown in Figure 1 2 B phase advances 90 degrees from A phase Forward direction Forward Reverse A signal signal A phase input Vat cu mem c m B phase input Motor PG 90 Figure 1 1 Forward Direction of Motor and PG Figure 1 2 Rotational Direction and Output Signal of PG Table 1 3 lists the relationship between the connection of reference PG output signals the rotational direction of the reference PG and the rotational direction of the slave motor that receives a run co
65. Note This icon indicates information which if not heeded can result in the inverter not e operating to full efficiency as well as information concerning incorrect operations and settings which can result in accidents Tip This icon indicates information that can prove handy when performing certain settings or operations Q This icon indicates a reference to more detailed information 1 Table of Contents Chapter 1 BEFORE USE rain 3 Ted Applicable Inverters seine alien 3 1 2 Connection between the PG Interface Card and PGs on Reference and Slave elre EMEN ELI Nie stehe TT erde 3 1 3 Option Terminals on the PG Interface Card ee nnnnnnnneennnnnnnenenn 5 BI Os 5 13 2 OP CASTER PR 6 Chapter 2 CONNECTION DIAGRAMS sun a an 7 Chapter 3 SYNCHRONOUS OPERATION CONTROL RN 8 3 1 Specifications of Synchronous Operation ppp 8 3 2 Details of Synchronous Operation pp 8 3 2 1 Simultaneous start synchronous operation pp 9 3 2 2 Standby synchronous operation pp 10 3 8 Block Diagrams nenne eek as 11 3 4 Eist of Funetion COGSS Hem 13 35 Unavailable Function COdeS v sie ne ache o eie aa teak 15 3 6 Configuring F nelion Codes see an 15 9 5 1 Motor paratrieters oo are 15 3 6 2 Data setting for synchronous operation ppp 16 Chapter 4 CONFIGURATION EXAMPLES OF SYNCHRONOUS OPERATION 24 4 1 Typical Configuration and Pulse Setting pp 24 4 1 1 Speed reduction ratio settind
66. acity 5 Vdc 10 An external power supply to be connected should assure at least PG power consumption Power output terminal EN Power supply for PG 5 Vide 10 300 mA or below BEEN Common terminal for power supply and PG input EXC Equipotent with the inverter s CM terminal A phase pulse Input terminal for A phase signal issued from input X reference PG External power supply input A phase pulse Input terminal for A phase signal issued from input X reference PG B phase pulse Input terminal for B phase signal issued from input X reference PG B phase pulse Input terminal for B phase signal issued from input X reference PG When these terminals have no connection turn ON selector Z phase pulse Input terminal for Z phase signal issued from 4 on the DIP input X reference PG SW1 Z phase pulse Input terminal for Z phase signal issued from input X reference PG A phase pulse Input terminal for A phase signal issued from input Y slave PG A phase pulse Input terminal for A phase signal issued from input Y slave PG B phase pulse Input terminal for B phase signal issued from input Y slave PG B phase pulse Input terminal for B phase signal issued from input Y slave PG Z phase pulse Input terminal for Z phase signal issued from When these input Y slave PG terminals have no connection Z phase pulse Input terminal for Z phase signal issued fr
67. coder PG resolution makes the system oscillatory try to modify this data Increasing the time constant stabilizes the detected speed and raises the PI processor gain even with ripples superimposed on the detected speed However the detected speed itself delays resulting in a slower speed response larger overshoot or hunting Ly B P gain d03 integral time d04 d03 and d04 specify the gain and integral time of the speed regulator PI processor respectively P gain Definition of P gain 1 0 is that the torque command is 100 10096 torque output of each inverter capacity when the speed deviation reference speed detected speed is 100 equivalent to the maximum speed Determine the P gain according to moment of inertia of machinery loaded to the motor output shaft Larger moment of inertia needs larger P gain to keep the flat response in whole operations Specifying a larger P gain improves the quickness of control response but may cause a motor speed overshooting or hunting undesirable oscillation of the system Moreover mechanical resonance or vibration sound on the machine or motor could occur due to excessively amplified noises If it happens decreasing P gain will reduce the amplitude of the resonance vibration A too small P gain results in a slow inverter response and a speed fluctuation in low frequency which may prolong the time required for stabilizing the motor speed Integral time Specifying a s
68. ctor 2 d17 d62 d63 d16 and d17 specify the factors to convert the speed feedback input pulse rate into the motor shaft speed r min Specify the data according to the transmission ratios of the pulley and gear train as shown below 19 Pulley Transmission ratio cd Radius d YA YB Power supply a in i Radius c Inverter FRENIC MEGA J U V LVR L S LAT Gear irain Conveyor a Transmission ratio a b Ma of teeth b We gf teeth a 3 a Mo of t Beth a Thu gt UIT En a a Motor Figure 3 5 An Example of a Closed Loop Speed Control System Conveyor Listed below are expressions for conversion between a speed feedback input pulse rate and motor shaft speed Motor shaft speed Pulse count factor 2 d17 Pulse count factor 2 d17 Pulse count factor 1 d16 Pulse count factor 1 d16 Pulse count factor 1 d16 Pulse count factor 2 d17 x Encoder shaft speed ae x a o O When enabling Vector control with speed sensor mount the sensor encoder on the motor output shaft directly or on a shaft with the rigidity equivalent to the motor output shaft A backlash or deflection being on the mounting shaft could interfere with normal control For using the Fuji VG motor exclusively designed for vector control the sensor is mounted on the motor shaft directly Set both the pulse count factor 1 d16 and pulse count factor 2
69. d slave systems comes to be identical Set the same values as d15 d16 and d17 Table 4 8 Rotational Direction Rotational direction of Run command at slave inverter Reference PG Slave PG Run forward FWD Run reverse REV Forward FWD For details about the run commands and rotational direction refer to Section 1 2 28 Configuration example 2 Reference conveyer Slave conveyer Reduction ratio Cm E y Reference 4 motor Reduction ratio CD General 2 FRENIC MEGA See purpose No of poles 4 o of poles inverter OPC G1 PG OPC G1 PG22 U V W XA XB XZ Power supply RS T 1000 P R 1000 P R Figure 4 5 Configuration Example of Synchronous Operation System with Z phase compensation Table 4 9 Wiring of PG Refer to Table 4 2 Reference side Slave side OPC G1 PG OPC G1 PG OPC G1 PG22 OPC G1 PG22 Table 4 10 ForSynchronous Operation d41 3 or 4 Refer to Table 4 1 Function Code Setting Remarks Motor No of poles Set the number of poles of the slave motor d15 Slave Pulse In synchronous operation be sure to set the Encoder pulse resolution 1000 same value for both the reference and slave Pulse count factor 1 1 dir _ 1 1 6 d16 SmxSp 1 1 1 Pulse count factor 2 P a ENGLISH Reference Pulse Design the machinery configuration so that the Encoder pulse resolution speed reduction ratio machine shaft encoder shaf
70. d41 2 1 2 5 4 2 2 Z d41 2 2 2 2 6 4 2 3 Z d41 3 4 001 L 2 7 4 2 4 Z d41 3 4 2 2 8 4 3 POZ SIDA RO ER FIR v rei Rex as Rene ee 29 LM ROI ro shab d sol a ECT 30 44 TE 2 gi JUVC o Ive Soo e eed vi bod 30 BAD Fe Ge TI Sede dp ach e aa eb cel daas 30 4 4 3 AMERRE Noo reo eu CI mL M CLE 3 1 RNNOOOOLNNN ed dou Maas bie Sor 3 2 WE AN Ne ernennen 33 DNE LIA MR D XE 33 52 Z4B8B TER 2 4 FL er ee reellen 33 1 1 1 1 1 ROM 1 1 ROM FRENIC MEGA FRNOOOG1O OOO 3000 x Lic ROM 5 5 FRENIC MEGA 3 3 4 6
71. de 21 d73 Synchronous Operation APR positive output limiter d74 Synchronous Operation APR negative output limiter These function codes specify the limits of APR output relative to the reference motor speed See Figures 3 3 3 4 and 3 7 Specification of 999 disables the limiter Reference motor speed gt d7 1 Position deviation d74 Figure 3 7 Operation of APR Output Limiter d75 Synchronous Operation Z phase alignment gain If the APR output is equal to 10 rotations of the encoder shaft per second when the phase angle deviation position deviation between the reference and slave PGs becomes equal to a single rotation of the encoder shaft that gain is assumed to be 1 0 Usually it is not necessary to change the factory default If the reduction ratio is small and the encoder pulse count is low it is necessary to decrease the Z phase alignment gain relative to the factory default d 6 Synchronous Operation Synchronous offset angle In standby synchronous operation the slave inverter delays starting to synchronize the Z phase with that of the reference motor by the offset angle specified by this function code 22 d77 Synchronous Operation Synchronization completion detection angle d77 specifies the synchronization completion detection angle If the absolute value of the phase angle deviation position deviation between the reference and slave PGs becomes equal to or below the
72. e Control Selection To perform synchronous operation select the control with speed sensor F42 3 4 or 6 Usually select V f control with speed sensor F42 3 d01 to d04 Speed Control Speed command filter Speed detection filter P Gain Integral time d06 Speed Control Output filter These function codes control the speed control sequence Speed command filter d01 Output filter dO6 Speed regulator Pl processor Torque command Reference speed P Gain d03 Integral time d04 B Speed command filter dO1 d01 specifies a time constant determining the first order delay of the speed command filter Modify this data when an excessive overshoot occurs against the change of the reference speed Increasing the filter time constant stabilizes the reference speed and reduces overshoot against the change of the reference speed but it slows the response speed of the inverter B Speed detection filter d02 d02 specifies a time constant determining the first order delay of the speed detection filter Modify this data when the control target machinery is oscillatory due to deflection of a drive belt or other causes so that ripples oscillatory components are superimposed on the detected speed causing hunting undesirable oscillation of the system and blocking the PI processor gain from increasing resulting in a slow response speed of the inverter In addition if the lower en
73. e count factor 1 2 10x 1000 x 1 30 333 3333 333 p s Use Menu 4 I O Checking item 4 17 and check that 0 33 is displayed on the keypad Note that on the keypad displayed value pulse rate p sy 1000 Note The maximum input pulse rate that the PG interface card OPC G1 PG OPC G1 PG22 supports is 30 kp s for open collector output or 100 kp s for complementary or line driver output If the pulse rate from the PGs exceeds the maximum limit synchronous operation is not available 30 4 4 Monitoring the Running Status during Synchronous Operation The keypad allows you to monitor the target position current position current deviation in units of angle or pulse of the synchronous operation as well as monitoring the current synchronous operation control status Note The multi function keypad having a ROM version 6400 or later supports synchronous operation The ROM version can be checked by using Menu 5 Maintenance Information page 6 KP 4 4 1 Monitor items Table 4 12 Drive Monitoring Items on the Keypad Standard Multi function keypad eypad BR Item Unit Description LED monitor Page in Symbol shows operation guide 17 E Target position pulse le Shows the target position pulse eier synchronous operation P reference position Current position pulse dise Shows the current position pulse synchronous operation p slave position Current positon Shows the current position deviation p
74. erminals YA and YB Reference PG Normal connection to terminals XA and XB Slave PG Reverse connection to terminals YA and YB Slave s run command Forward Reverse ENGLISH 4 2 Function Code Configuration Examples 4 2 1 For synchronous operation without Z phase compensation d41 2 Configuration example 1 Reference conveyer Slave conveyer a Reduction ratio SM Reference motor G FRENIC MEGA pd de No of poles 4 2 No of poles 4 inverter Reduction ratio CD Reference Slave PG OPC G1 PG P oc 2 OPC G1 PG22 YA YB U VW Power supply R S T 1000 P R 1000 P R Figure 4 2 Configuration Example of Synchronous Operation System without Z phase compensation Table 4 3 For Synchronous Operation d41 2 Function Code Setting Remarks Motor No of poles Set the number of poles of the slave motor d15 Slave Pulse 1000 In synchronous operation be sure to set the Encoder pulse resolution same value for both the reference and slave PGs Pulse count factor 1 di7 1 1 10 d16 SmxSp 1 1 1 Pulse count factor 2 EN Reference Pulse 1000 Set the same value as d15 Encoder pulse resolution Pulse count factor 1 1 1 Pulse count factor 2 d62 SmxCp 1 1 5 Table 4 4 Rotational Direction Rotational direction of Run command at slave inverter Reference PG Slave PG Run forward FWD Run
75. horter integral time shortens the time needed to compensate the speed deviation resulting in quick response in speed Specify a short integral time if quick arrival to the target speed is necessary and a slight overshooting in the control is allowed specify a long time if any overshooting is not allowed and taking longer time is allowed If a mechanical resonance occurs and the motor or gears sound abnormally setting a longer integral time can transfer the resonance point to the low frequency zone and suppress the resonance in the high frequency zone B Output Filter d06 d06 specifies the time constant for the first order delay of the speed controller output filter Use d06 when even adjusting the P gain or integral time cannot suppress mechanical resonance such as hunting or vibration Generally setting a larger value to the time constant of the output filter decreases the amplitude of resonance however a too large time constant may make the system unstable d70 Speed Control Limiter d70 specifies a limiter for the PI value output calculated in speed control sequence under V f control with speed sensor or dynamic torque vector control with speed sensor A PI value output is within the slip frequency x maximum torque in a normally controlled state If an abnormal state such as a temporary overload arises the PI value output greatly fluctuates and it may take a long time for the PI value output to return to the normal level Lim
76. hronous operation refer to Chapter 4 d71 d72 Configuration Examples of Synchronous Operation Synchronous Operation Main speed regulator gain d71 adjusts the main speed regulator gain to control the responsibility and the steady state deviation Usually it is not necessary to change the factory default Selecting simultaneous start synchronization without Z phase compensation d41 2 only enables the setting made with d71 Synchronous Operation APR P gain d72 determines the response of the automatic position regulator APR See Figures 3 3 and 3 4 If the APR output comes to be a single rotation of the encoder shaft per second when the phase angle deviation position deviation between the reference and slave PGs becomes equal to a single rotation of the encoder shaft that gain is assumed to be 1 0 ENGLISH Setting a too large value to the gain data easily causes hunting and setting a too small value results in a large steady state deviation Adjust the gain referring to Figure 3 6 as a guide If the d72 setting is adjusted it is recommended to adjust also the d02 setting as shown in Figure 3 6 d16 1 1 1 Reduction rate d1 1 15 30 d02 Speed Control 0 005 s Time constant of Factory ee speed detection filter A ne sade default d72 u 15 00 Synchronous Operation Large Factory gt Small APR P gain default Figure 3 6 d72 Setting Gui
77. ith Z phase compensation d41 3 or 4 Configuration example 1 Reference conveyer Radius Slave conveyer N Popp 40 Radius Il Ls MS N ay iy Radius Reference rcmb 30 motor Reference Slave PG Radius PG 2000 P R 80 2000 P R No of poles 6 Fcpa Z ribi Radius FRENIC MEGA No of poles 6 urpose 3 A inverter spa 80 OPC G1 PG OPC G1 PG22 XA XB XZ YA YB YZ U V W Power supply R S T Figure 4 4 Configuration Example of Synchronous Operation System with Z phase compensation Table 4 7 For Synchronous Operation d41 3 or 4 Refer to Table 4 1 Function Code Setting Remarks Motor No of poles 6 Set the number of poles of the slave motor d15 Slave Pulse In synchronous operation be sure to set the Encoder pulse resolution 2000 same value for both the reference and slave PGs Pulse count factor 1 Each speed reduction ratio is calculated according to the pulley s radius as shown Pulse count factor 2 below Reference Pulse The reduction ratio of the slave motor is Encoder pulse resolution Sm smb 30 1 n 150 5 The reduction ratio of the slave PG is fsa 80 2 Therefore d16 and d17 data is as follows d17 1 _ 1 10 d16 SmxSp 1 1 1 5 2 Pulse count factor 1 Design the machinery configuration so that the Pulse count factor 2 speed reduction ratio machine shaft encoder shaft of the reference an
78. iting the PI value output with d70 suppresses such abnormal operation 18 d14 to d17 Feedback Input Pulse input format Encoder pulse resolution Pulse count factor 1 Pulse count factor 2 These function codes specify the speed feedback input under vector control with speed sensor F42 3 4 or 6 In conjunction with this section refer to Chapter 4 Configuration Examples of Synchronous Operation This section contains also the descriptions of Command Pulse Rate Input d59 d60 d62 and d63 B Feedback Input Pulse input format d14 d59 d14 specifies the speed feedback input format Pulse input Remarks mode 1 Positive gt i Negative polarity polarity gt Pulse train sign Pulse train input Pulse train sign OFF ON Pulse train input 1 Positive Negative polarity gt polarity gt Forward rotation pulse Reverse rotation puse i Reverse rotation pulse Forward rotation puse i Set the d14 data to 2 for Fuji motors exclusively designed for vector control ENGLISH Run i Run A and B forward gt reverse gt phases with signal signal 90 degree A phase input phase MES 90 degree B phase advanced B phase delayed B Feedback Input Encoder pulse resolution d15 d60 d15 specifies the pulse resolution P R of the speed feedback encoder B Feedback Input Pulse count factor 1 d16 and Pulse count fa
79. mmand FWD or REV There are two types of synchronous operation with without Z phase compensation The former uses the PG s Z phase the latter does not Table 1 3 Connection of the Reference PG Output Signals and Rotational Direction of the Slave Motor Operation without Z phase Operation with Z phase m When the compensation compensation ano o prase rotational If the slave motor receives output signals issued from the direction of a run forward a run reverse a run forward a run reverse reference PG the reference command command command command PG is FWD REV FWD REV It rotates in the following direction terminals XA and terminals XA and If the reference inverter rotates the motor but the slave inverter stops so that a positioning deviation p exceeds the specified deviation detection range an 7 77 alarm occurs If the rotational direction of the reference motor reverses before a positioning deviation exceeds the range however synchronous operation starts at the point where the positioning deviation comes to Zero For details about synchronous operation with without Z phase compensation refer to Chapter 3 Synchronous Operation Control f Note To drive the slave PG in the direction opposite to the reference PG rotation in s synchronous operation with Z phase compensation connect the B and A phase output signals issued from the reference PG to terminals XA and XB respectively See Table 1 3 1 3
80. om turn ON selector input Y slave PG 1 on the DIP SW 1 Incorrect wiring of A B phase could fail to run the motor normally or cause an inverter trip Input signal status pulse rate on terminals XA XB XZ YA YB and YZ can be checked by using Menu 4 I O Checking 4 15 4 16 4 17 and 4 18 on the inverter s keypad For the operating procedure refer to the FRENIC MEGA Instruction Manual Function code E52 2 Chapter 2 CONNECTION DIAGRAMS B Figure 2 1 shows connection diagram examples of the OPC G1 PG 1 When using inverter internal power supply 2 When using external power supply FRENIC MEGA FRENIC MEGA Slave Reference motor motor Slave Reference motor motor r OPC G1 PG J1 sw a 12Vdc 109 15Vdc 10 Figure 2 1 Connection Diagrams of OPC G1 PG Cri Tip When the inverter uses an external power supply SW1 may be set at either 12V or 15V Side B Figure 2 2 shows connection diagram examples of the OPC G1 PG22 1 When using inverter internal power supply 2 When using external power suppl FRENIC MEGA FRENIC MEGA Slave Reference motor motor Slave Reference motor motor OPC G1 PG22 J1 ENGLISH EX gt 5Vdc 10 Figure 2 2 Connection Diagrams of OPC G1 PG22 Note For details about grounding refer to
81. onization completion signal If synchronization is lost so that the deviation exceeds 10 times the excessive deviation setting specified by d78 the inverter shuts down its output with the alarm When d41 4 Simultaneous start synchronization with Z phase if any incorrect count due to electrical noise or other factors is found in the integrated count of A B phases the inverter corrects the error based on the Z phase difference When a run command for the slave motor is ON the inverter continues to monitor the motor positions even if the reference motor stops as long as the synchronous operation is not switched to the single motor drive operation When the reference motor starts running again the inverter restarts to control the slave motor to maintain the Z phase difference between the reference and slave motors Reference PG rotation speed Run command for slave motor Slave PG rotation speed Reference motor integrated pulses Slave motor integrated pulses Excessive deviation detected Deviation of position
82. ount factor 2 13 L LLI Table 3 3 Function Codes Continued Default Data setting range setting Application defined Control Disable Ordinary Mode selection control Enable Simultaneous start synchronization without Z phase Enable Standby synchronization Enable Simultaneous start synchronization with Z phase Only the related items indicated Command Pulse Rate Input Pulse train Pulse input format sign Pulse train input Forward rotation pulse Reverse rotation pulse 2 A B phase with 90 degree phase shift Encoder pulse resolution 0014 to OE10 hex P R 2 20 to 3600 pulses Filter time constant 0 000 to 5 000 Pulse count factor 1 1 to 9999 Pulse count factor 2 1 to 9999 Synchronous Operation 0 00 to 1 50 ime Main speed regulator gain APR P gain 0 00 to 200 00 times 15 0 APR positive output limiter 20 to 200 999 No limiter saw 1 1 ERE 0 APR negative output limiter 20 to 200 999 No limiter Z phase alignment gain 0 00 to 10 00 Synchronous offset angle Synchronization completion detection angle 1 O to 65535 3 Display in units of 10 pulses Excessive deviation detection range 2 When synchronous operation is selected d41 2 3 or 4 the reference and slave sides should use a PG 20 to 3000 P R of the same pulse resolution 3 The standard keypad has a
83. ous Operation Status Transition Table 4 14 Synchronous Operation Status Synchronous Operation Status Status m Synchronous operation is not selected d41 0 Synchronous operation STOP Setting d41 to any of 2 to 4 and setting F01 or C30 disabled to 12 Pulse train input transits to 21 Synchronous operation stopped Synchronous operation SCAN 20 Synchronous operation output is not enabled because canceled PID control or torque control is enabled No run command is entered Turning a run command ON with the Z phase Synchronous operation SOFF 21 compensation selected transits to 22 Waiting for Z stopped phase detection Turning it ON without the Z phase compensation selected transits to 26 Synchronization completed detection i reference and slave PGs detected and waits for Z phase from the slave PG Slave Z phase The inverter detects Z phase from the slave PG and detected Birne amp vndlimenaus Synchronous operation is in progress d SY 25 Note that the position deviation has not converged p within the synchronization completion detection range Synchronization Synchronization is completed completed During The inverter outputs terminal signal SY synchronous operation 1 The status name can be referred to on the LCD monitor of the multi function keypad 2 The status code can be referred to on Menu 3 20 of the standard keypad or on the LCD monitor of the multi function keypad 32 Chapter
84. requency and the reference frequency to apply after switching F07 E10 E12 E14 Acceleration Time F08 E11 E13 E15 Deceleration Time F23 F25 Also in synchronous operation the inverter controls the output frequency according to the acceleration deceleration time as usual Set the acceleration deceleration time as short as possible Be careful that setting the acceleration deceleration time longer than that of the reference inverter loses the following capability of the slave motor Tip Selecting Vector control with speed sensor F42 6 ignores the acceleration deceleration times specified by the function codes running the motor with the acceleration deceleration time 0 0 s F24 Starting Frequency Starting Frequency Holding time F39 Stop Frequency Stop Frequency Holding Time Set the starting frequency and stop frequency as low as possible to the extent that the motor can generate enough torque During synchronous operation set the holding times for the starting frequency and stop frequency at 0 0 s basically Running with the frequency lower than the stop frequency or starting frequency cannot be followed Be careful that specifying the holding time deteriorates the following capability at the time of startup or stop CTp _ Selecting Vector control with speed sensor F42 6 ignores the starting stop frequencies specified by the function codes running the motor with the holding time 0 0 s 16 F42 Driv
85. sts the availability of synchronous operation and the setting values for pulse count factors 1 2 depending on the speed reduction ratio of each reduction gear when the synchronous operation is selected d41 3 or 4 Synchronous operation with Z phase compensation is available only when the shaft rotation speeds of the reference and slave PGs are identical with each other Synchronous operation without Z phase compensation is not subject to the restriction of the reduction ratio however pulse generators with the same pulse resolution P R should be used at both the reference and slave sides Speed reduction ratio Sm EN a SQ e Slave E 2 a x Y ES IS Zara E SEN N Speed reduction 2 EN ratio Cm d SN Reference motor e ra FRENIC MEGA General Speed reduction purpose ratio Cp Reference Slave PG OPC G1 PG inverter PG OPC G1 PG22 XA XB XZ YA YB YZ U V W Power supply R S T Figure 4 1 Configuration Example of Conveyer Synchronization System d41 3 or 4 Table 4 1 Availability of Synchronous Operation d41 3 or 4 and Settings Speed reduction ratio conditions i Synchronous operation of SCIUIOIAOMS Pulse count Motor reduction PG reduction conveyer belts operation of PG Factor gear gear shafts Cp Sp Available Available Cp Sp Available POSEEN S7 d16 SmxSp Cm Sm Cp Sp Not available Available d62
86. t of the reference and slave systems comes to be identical Set the same values as Pulse count factor 2 d15 d16 and d17 Pulse count factor 1 Table 4 11 Rotational Direction Rotational direction of Run command at slave inverter Reference PG Slave PG Run forward FWD Run reverse REV Forward FWD Reverse REV For details about the run commands and rotational direction refer to Section 1 2 29 4 3 Checking PG Pulse Rate Before starting synchronous operation run the motors separately and check that the data settings for number of motor poles PO1 encoder pulse resolution d15 and pulse count factor 1 2 d16 d17 conform to the actual machinery configuration The PG pulse rate can be checked with the keypad by using Menu 4 I O Checking item 4 15 PG pulse rate 1 reference side and item 4 17 PG pulse rate 2 slave side For details refer to the FRENIC MEGA Instruction Manual Section 3 4 5 Checking I O signal status Given below is an example of checking PG pulse rate Example No of motor poles 4P P01 4 Encoder pulse resolution 1000 P R d15 1000 Pulse count factor 1 2 1 30 d16 1 d17 30 Under these above conditions run the motor at 20 Hz Then the motor speed and the pulse rate can be calculated as follows Motor speed r min 120 x Frequency No of poles 120 x 20 4 600 r min 10 r s Pulse rate p s Motor speed r s x Encoder pulse resolution P R x Puls
87. ter corrects the error based on the Z phase difference If the deviation between those two motors falls below the synchronization completion detection angle specified by d77 the inverter issues an SY synchronization completion signal If synchronization is lost so that the deviation exceeds 10 times the excessive deviation setting specified by d78 the inverter shuts down its output with the 4 7 alarm Reference PG rotation speed Run command for slave motor Slave PG rotation speed Reference PG phase angle Slave PG phase angle SY output Start of standby Synchronization completed Figure 3 2 Standby Synchronous Operation Note 1 Synchronous operation cancellation conditions In any of the following cases the synchronous operation is canceled The run command for the slave motor is turned OFF Terminal command BX Coast to a stop or STOP Force to stop is turned ON Any alarm occurs The inverter switches to a single motor drive Assign terminal command Hz2 Hz1 and switch the frequency command source with F01 C30 Under torque control or when the inverter is driven by commercial power 10 3 3 Block Diagrams HSITSNA
88. the related PG interface card instruction manual Recommended grounding for shielded wires differs depending upon the PG interface card OPC G1 PG or OPC G1 PG22 The OPC G1 PG should be basically grounded If it malfunctions due to electrical noise or other factors however changing the connection of the shielded wires could improve the problem When not using Z phases on the OPC G1 PG22 turn ON both selectors 1 and 4 on DIP SW1 3 2 Chapter 3 SYNCHRONOUS OPERATION CONTROL The synchronous operation control enables the slave inverter to detect the reference motor rotation with PG signals and synchronize the slave motor with the reference motor in rotation speed and position The synchronous operation is available in three modes Simultaneous start synchronous operations using Z phase d41 4 and without using Z phase d41 2 and Standby synchronous operation d41 3 Reference motor s PG signals should be fed to terminals XA XB and XZ and slave motor s ones to terminals YA YB and YZ 3 1 Specifications of Synchronous Operation Table 3 1 lists the specifications of the synchronous operation Table 3 1 Specifications of Synchronous Operation Speed control range under V f control with 180 to 3600 r min speed sensor 4 pole motors and PGs with 1024 P R Speed reduction ratio 1 1 under vector control with 1 to 3600 rmin During running at constant speed speed sensor Position control accuracy Electrical
89. ulse pulse BR deviation pulse synchronous operation MODE Control status monitor Shows the current control status synchronous operation For details refer to Section 4 4 3 7 Deviation deg Shows the current angle deviation synchronous operation The pulse count range of the inverter is from 9 999 999 to 9 999 999 The 4 digit LED monitor on the standard keypad alternately shows the upper digits and lower four digits Upper digits for one second and Lower four digits for 3 seconds gt Upper digits for one second and Lower four digits for 3 seconds The LCD monitor on the multi function keypad displays all digits at the same time 4 4 2 Monitor display ENGLISH Table 4 13 Monitor Display of Pulse Count Upper blank digits are no 9 p Jo 39 9 on 999 Jo swe 599 95 99 9999 Minimum value 31 4 4 3 Synchronous operation control status The inverter monitors the synchronous operation control status as shown in Figure 4 6 and Table 4 14 Slave side Output frequency Hz Time XZ Aa AR a AJ w ON FWD 1 3 Standby synchronous operation d41 0 Disable i SS7 ON Multi frequerjcy enabled 1 SY ON 1 N 22 WA Z 23 IN M Synchronous 1 i i operation o sroPl 20 SCAN 21 SOFF M n N 25 SY X 26 SY C N21 SOFF control I I 1 I 1 1 Figure 4 6 Synchron
90. ynchronous operation and standby synchronous operation Read through this manual in conjunction with the PG interface card instruction manual to become familiar with proper handling and correct use Improper handling might result in incorrect operation a short life or even a failure of this product This manual does not contain inverter handling instructions Refer to the FRENIC MEGA Instruction Manual Keep this manual in a safe place B Safety precautions Read this manual thoroughly before proceeding with installation connections wiring operation or maintenance and inspection Ensure you have sound knowledge of the device and familiarize yourself with all safety information and precautions before proceeding to operate the inverter Safety precautions are classified into the following two categories in this manual Failure to heed the information indicated by this symbol may N WARN N G lead to dangerous conditions possibly resulting in death or serious bodily injuries Failure to heed the information indicated by this symbol may ANCAUTI ON lead to dangerous conditions possibly resulting in minor or light bodily injuries and or substantial property damage Failure to heed the information contained under the CAUTION title can also result in serious consequences These safety precautions are of utmost importance and must be observed at all times Icons The following icons are used throughout this manual
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