Encoder Feedback Option Card
PG-X2
1. Part Number: PG-X2.
2. Applicability: F7, G7, GPD515/G5, G5HHP.
3. Introduction: The PG-X2 encoder feedback option card (Figure 1) is mounted on the drive’s Control Board and performs speed feedback using the pulse generator (PG) on the motor to correct speed fluctuation caused by motor slip. Motor rotation direction is detected by phase A and phase B PG pulse inputs. The terms encoder, PG (pulse generator), and pulse train are used interchangeably in this guide. The card can be used for flux vector control or V/Hz with PG feedback control.
4. Receiving: All equipment is tested against defect at the factory. Report any damages or shortages evident when the equipment is received to the commercial carrier who transported the equipment.
5. Cautions: a. Hazardous voltage can cause severe injury or death. Lock all power sources feeding the drive in the “OFF” position. b. This option card uses CMOS IC chips. Use proper electrostatic discharge (ESD) protective procedures when handling the card to prevent I.C. damage or erratic drive operation. c. If other option cards are to be installed at the Option C (2CN) or Option D (3CN) positions (See Figure 2), their installation and wiring should be completed before installation of this option. d. Before installing this option, a technically qualified individual, who is familiar with this type of equipment and the hazards involved, should read this entire installation guide.
Mounting Hole
Connector, Rear
Side of Board to
Control Bd., 4CN
Terminal
Block TA2
Terminal
Block TA1
Variable Resistor,
Adjusts
+12V PG Power
Variable Resistor,
Adjusts
+5V PG Power
Terminal TA3
Connect Shield
Here
Ground Lead Wire-
Connects to Grounding
Terminal on Control Board
2 Mounting Holes
Figure 1. PG-X2 Encoder Feedback Card Figure 2. PG-X2 Option Card installation
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IG.AFD.60, Page 1 of 8
Date: 07/01/04, Rev:04-07
Encoder Feedback Option Card
PG-X2
6. Precautions and Preliminary Installation: a. Remove contents from package. Verify that a mounting spacer
(P/N 5RNT41028-9) is included with the card. See Figure 3. b. Disconnect all electrical power to the drive. c. Remove the drive’s front cover. d. Check that the “CHARGE” indicator lamp inside the drive is off. e. Use a voltmeter to verify voltage at incoming power terminals
(L1, L2, L3) has been disconnected. f. Insert the spacer into the mounting hole in the base of the drive, just above the top edge of the control board. See Figure 2. g. Note: When re-installing the cover, please take care not to pinch
Figure 3. Mounting Spacer any of the encoder wires. h. Important: GPD 515/G5 models 20P2 to 22P2 and 40P2 to 41P5 have two closely spaced mounting holes. Insert the spacer into the hole closest to the control board’s connector 4CN. If inserted in the wrong hole, the spacer WILL
NOT properly align with the PG-W2’s mounting hole.
7. PG-X2 Installation: See Figure 2. a. Position the bottom edge of the option card into the mounting bracket on the control board’s terminal block. Align two mounting holes in the card with pins on the bracket. b. Then angle the top edge of the card into place, carefully aligning connector 4CN on the back of the card with connector 4CN on the control board. Gently press the card into place until 4CN and the spacer click into place.
8. Wiring: Refer to Figure 4 and Tables 1 & 2. Make wire connections between the PG-X2 card and encoder as well as any external monitoring circuits. Observe the following: a. The need for the marker Z (C) channel depends on the installed custom (CASE) software. Standard software does not use the marker pulse. b. Keep the PG-X2 (i.e. control circuit) wiring separate from main circuit input/output wiring. A separate metallic grounded conduit with ONLY the PG wiring running through it is preferred. c. To prevent erroneous operation caused by noise interference, use shielded cable for control signal wiring, and limit the distance to 50m (165 feet) or less. d. Recommended cable is twisted pair, 22AWG, with overall shield, such as Belden 9504. Refer to “Electrical
Installation” in the drive technical manual for further information on use of shielded cable. The shielded sheath connection points on the PG-X2 card are terminal TA3. e. Strip back insulation for a distance of 0.22 in. on wire leads connected to the PG-X2 terminals. f. Connect the option card ground wire (E) to the drive’s ground terminal TB3 (12 for G5).
9. Adjustment: The+12VDC and +5VDC outputs of the PG-X2 card are factory calibrated. No adjustment should be necessary.
10. Cover: Reinstall and secure drive’s front cover.
11. Programming: Table 3 lists all drive parameters related to encoder feedback. Ensure that all of these parameters are programmed to meet the requirements of the application.
12. Start-up: Refer to Section 2 in the drive’s technical manual for testing and start-up information.
13. IG Storage: Place this instruction guide with the drive’s technical manual.
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IG.AFD.60, Page 2 of 8
Date: 07/01/04, Rev:04-07
Encoder Feedback Option Card
PG-X2
Terminal
Block
TA1
Table 1. Terminal Functions
Terminal
Number
Function
Power supply for Pulse Generator (PG).
1 +12VDC
Important: Use either +12V or +5V, but never both at the same time.
2
3
0V
+5VDC
+12VDC, 200mA max
+5VDC, 200mA max
4 +
A Pulse
5 -
6 +
7 -
8 +
B Pulse PG Signal Inputs
RS-422 Level Input
Z Pulse*
9 -
TA2
1 +
2 -
A Pulse
3 +
B Pulse
4 -
5 +
Z Pulse*
6 -
7 IG5 Isolated Common Terminal
TA3 Shield Drain for Encoder Wiring
* Not required for standard software. May be required for custom software.
Pulse Monitor Output
RS-422 Level Output
Terminal Symbol
Terminal
Screw
Table 2. Terminal and Wire Specifications
Clamping Torque
Lb-in (N-m)
TA1, TA2 M2
1.8 to 2.2
(0.22 to 0.25)
Wire Range
AWG (mm
2
)
26 to 16
(Stranded: 0.14 to 1)
(Solid: 0.14 to 1.5)
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IG.AFD.60, Page 3 of 8
Date: 07/01/04, Rev:04-07
Encoder Feedback Option Card
PG-X2
Notes:
(1) Power Supply for PG (from PG-X2)
TA1 1-2: +12VDC, 200mA max.
Ta1 3-2: +5VDC, 200mA max
Do Not Use Both Supplies at the
Same Time.
(2) H20 Dynapar Encoder Connections Shown
Figure 4. PG-X2 Interconnection Diagram
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IG.AFD.60, Page 4 of 8
Date: 07/01/04, Rev:04-07
Encoder Feedback Option Card
PG-X2
14. Application: If the encoder’s power requirement is greater than 200mA, provide a separate power supply source as shown in Figure 5. If the momentary power loss ride thru function of the drive is to be used, include a backup capacitor in the
PG power wiring or take other necessary precautions.
PG Power Supply
AC
0V 12V
PG ENCODER
PG-X2 Card
IP12
IG
TA1
1
2
3
IP5
4
A (+)
5
A (–)
6
B (+)
7
B (–)
8
Z (+)
9
Z (–)
IG
10
*
+
P
P
P
(2)
12V
0V
TA3
* Backup capacitor, for momentary power loss recovery function
Figure 5. Using Separate PG Power Supply
15. Maximum Input Frequency: The maximum input frequency of the PG-W2 card is 300kHz. To find the output frequency of the encoder (PG) in Hertz, use the following formula. Please make sure a 20% safety margin is built-in. f
PG
(Hz) = Maximum Motor Speed (RPM) x Encoder PPR (Pulses/Rev)
60
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IG.AFD.60, Page 5 of 8
Date: 07/01/04, Rev:04-07
Encoder Feedback Option Card
PG-X2
16. Signal type / level requirements: The PG-X2 card requires a “quadrature line driver with compliments” signal type from the encoder (pulse generator). As shown in Figure 6, line driver signals include both a primary signal (Signal A+) and it’s compliment (Signal A-). The compliment is the inverse of the primary signal. This scheme is used to improve the noise immunity of the system. The encoder output signal voltage should be between +5VDC and +12VDC. An “open collector” signal type WILL NOT work with the PG-X2 card.
A quadrature signal is one that lags the primary signal by 90 electrical degrees (1/2 of a pulse). The purpose of this is so that the drive can detect the direction of the encoder rotation. As shown in Figure 6, for “forward” rotation of the encoder, signal A+ will lead signal B+ by 90 o
.
If any one of the four signals is missing, the drive cannot accurately measure the encoder rotation speed or direction.
17. Viewing Signals With An Oscilloscope: The PG-X2 option card has test points that can be used to connect an oscilloscope. Test points PA, PB, and PZ are after the compliment is subtracted out and the signals are buffered through the opto-isolators. See Figure 4. The voltage level on all test points varies between 0 and +5VDC (TTL).
Caution: Always use an un-grounded oscilloscope so no noise is introduced into the common.
Table 3. PG-X2 Test Points
Test Point
GND
PA
PB
PZ
Description
Although labeled GND, it is NOT earth ground. This test point should only be used in conjunction with test points PA, PB, and PZ.
Channel A (Terminals 4 & 5)
Channel B (Terminals 6 & 7)
Channel Z (Terminals 8 & 8)
Note: All signals shown are in relation to power supply common, Terminal 2 of the PG-X2.
Figure 6. Encoder (PG) Signals – Forward Direction
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IG.AFD.60, Page 6 of 8
Date: 07/01/04, Rev:04-07
Encoder Feedback Option Card
PG-X2
Table 3. GPD 515/G5, F7, and G7 Encoder Feedback Parameter List
Control
Method (2)
PG
Option
Setup
PG Pulse/Rev F1-01 PG Constant
PG Fdbk Loss
Sel
PG Overspeed
Sel
PG Deviation
Sel
F1-02
F1-03
F1-04
Operation at
Open PG
Circuit
Operation
Selection at
Overspeed
Operation
Selection at
Deviation
PG Rotation
Sel
F1-05 PG
0 to
60000
0 to 3
0 to 3
0 to 3
0,1
PG Ramp PI/I
Sel
PG Overspeed
Level
PG Overspeed
Time
PG Deviation
Level
PG Deviation
Time
PG# Gear
Teeth 1
F1-07
F1-08
F1-09
F1-10
F1-11
F1-12
Integral
Control during
Accel/Decel
Overspeed
Detection
Level
Overspeed
Detection
Delay Time
Speed
Deviation
Detection
Level
Speed
Deviation
Detection
Delay Time
Number of
Gear Teeth 1
0 to
120%
0 to 2.0s
0 to 50%
0 to 10s
0 to 1000
1024 X
1
1
3
0
115% X
1.0s
10%
0.5s
0
X
X
X
X
X
X
X
X
0: Ramp to Stop
1: Coast to Stop
0,1 0 X
2: Fast-Stop
3: Alarm Only
0: Fwd = CCW
1: Fwd = CW
0: Disabled
1: Enable
PG# Gear
Teeth 2
PGO Detect
Time
Speed
Detection
Filter Selection
F1-13
F1-14
F1-15
Number of
Gear Teeth 2
PGO Detection
Time
Speed
Detection Filter
Selection
0 to 1000
0 to 10s
0, 1
0
2s
1
X
X
X
0: No Average
1: 2 Scan Moving
Average
O
O
O
O
O O
O O
O X
O
O
O
O
O
O
O
O
O
X
X
O
O O
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IG.AFD.60, Page 7 of 8
Date: 07/01/04, Rev:04-07
Encoder Feedback Option Card
PG-X2
Table 3. GPD 515/G5, F7, and G7 Encoder Feedback Parameter List
Control
Method (2)
ASR P Gain 1
ASR I Time 1
ASR P Time 2
C5-01
C5-02
C5-03
ASR
Proportional
Gain 1
ASR Integral
Time 1
ASR
Proportional
Gain 2
ASR Integral
Time 2
0 to
300.00
0 to
10.000s
0 to
300.00
0 to
10.000s
0.00 O
0.00s O
0.00 O
ASR
Tuning
ASR I Time 2 C5-04
ASR Limit
ASR Delay
Time
C5-05
C5-06
ASR Limit
ASR Primary
Delay Time
0.0 to
20%
0.000 to
0.500s
ASR Gain SW
Freq
C5-07
ASR Switching
Frequency
0.0 to
400.00Hz
ASR Integral
Limit
C5-08
ASR Integral
Limit
0 to
400%
0.00s O
0.0% X
0.000s X
0.0Hz X
400% X
O
O
(1) O = Yes, X = No.
(2) O = Available, X = Hidden. The PG-X2 is not applicable for A1-02 = 0 (V/f Control) or 2 (Open Loop Vector).
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IG.AFD.60, Page 8 of 8
Date: 07/01/04, Rev:04-07
