YASKAWA PG-F3 Installation Manual

YASKAWA AC Drive-Option Card

Encoder Type (EnDat)

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.

安川インバータ オプションカード

エンコーダタイプ（

取扱説明書

EnDat 用）

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。

MANUAL NO. TOBP C730600 51A

This Page Intentionally Blank

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.

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 3

4

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.

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual

1 Preface

◆

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.

W ARNING

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.

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 5

1 Preface

■ 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.

6 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual

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

Package

Contents

Option Card

Lead Line

(for grounding)

Screws (M3) Manual (this book)

MANUAL

–

Number of

Items

1 1 3 1

• 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.

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 7

8

3 Option Card Components

3 Option Card Components

◆

Option Card

Figure 1

A B C

F

Underside

D PG-F3

E

A – Terminal block TB1

B – Terminal block TB2

C – Jumper for encoder power supply voltage (CN3)

D – Ground terminal (installation hole)

Figure 1 Option Card

E – Model number

F – Installation hole

G – Connector (CN5)

◆

Terminal Block

Figure 2

G

TB2

IP IG CK CK A+ A– a+ a– FE

TB1

IP IG DT DT B+ B– b+ b–

Figure 2 Terminal Block

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual

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.

W ARNING

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.

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 9

4 Electrical Installation

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.

10 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual

4 Electrical Installation

◆

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

A

E

F

B

C

G

J

D

K

L

H

G

I

A – Connector CN5-C

B – Connector CN5-B

C – Connector CN5-A

D – Drive grounding terminal (FE)

E – Insert connector CN5 here

F – Option card

G – Mounting screw

H – Lead line

I – Use wire cutters to create an opening for cable lines

J – Front cover

K – Digital operator

L – Terminal cover

Figure 3 Installing an Option Card

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 11

4 Electrical Installation

Figure 4

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 Connecting the Ground Terminal

12 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual

4 Electrical Installation

Figure 5

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.

B

A

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.

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.

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 13

4 Electrical Installation

◆

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

R/L1

S/L2

T/L3

U/T1

V/T1

W/T1

Drive

FE

CN5

PG-F3

8V

5V

0V

TB1,TB2

CN3 IP

IP

IG

IG

CK

CK

DT

DT

A+

A–

B+

B–

FE a+ a– b+ b–

Lead line

Cable

(by HEIDENHAIN)

M

EnDat encoder

A pulse monitor signal

B pulse monitor signal main circuit terminal control circuit terminal

Figure 6 Wiring the Option Card and PG

14 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual

4 Electrical Installation

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.

■

Figure 7

Interface Circuit

Encoder PG-F3

120 Ω

A – , B –

A+, B+

2.5 V

Clock

Data output

120 Ω

CK

CK

DT

DT

Data input

26LS31 Level a+ a – b+ b –

Monitor Signal

Figure 7 The Interface Circuit

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 15

4 Electrical Installation

◆

Terminal Functions

Table 2 Terminal Functions

Terminal

Block

Terminal Function

TB1

IP

IG

DT

DT

B+

B–

Description Specifications

Encoder power supply

Encoder power supply common

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.

Comm. data signal I/O

Inverse comm. data signal I/O

Reads and processes encoder data.

Signal level: RS-485 protocol

B pulse signal input

Inverse B pulse signal input

Input for the B pulse sinewave from the encoder.

• Max. input frequency: 50 kHz

• Input signal differential: B+ - B–

0.6 V to 1.2 V b+ b–

B pulse monitor signal output

Inverse 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.

16 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual

4 Electrical Installation

Terminal

Block

Terminal Function

TB2

IP

IG

CK

CK

A+

A– a+ a–

FE

Description Specifications

Encoder power supply

Encoder power supply common

Comm. clock signal output

Inverse comm. clock signal output

Supplies power to the encoder.

Outputs the comm. clock signal to the encoder.

A pulse signal input

Inverse A pulse signal input

Connects to terminal IP on the option card.

Connects to terminal IG on the option card.

Signal level: RS-485 protocol

Input for the A pulse sinewave from the encoder.

• Max. input frequency: 50 kHz

• Input signal differential: A+ - A–

0.6 V to 1.2 V

A pulse monitor signal output

Inverse A pulse monitor signal output

Outputs a ratio of the A pulse frequency.

Ground

Ground terminal for shielded cable.

• 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.

Used for grounding shielded line.

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 17

4 Electrical Installation

◆

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)

Voltage Level 5.0 V ± 5% (default) 8.0 V ± 5%

5 V 5 V

Jumper

8 V 8 V

◆

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

The A pulse leads, followed by the B pulse displaced at 90 degrees

A Pulse

B Pulse

Time  →

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.

18 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual

4 Electrical Installation

◆

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

Encoder Cable Option Card

Terminal

IP

IG

CK

CK

DT

DT

A+

A–

B+

B–

Color

Brown/Green

Blue

White/Green

White

Purple

Yellow

Gray

Pink

Green/Black

Yellow/Black

Blue/Black

Red/Black

Encoder Side

Up

Sensor Up

0V

Sensor 0V

CLOCK

CLOCK

DATA

DATA

A+

A–

B+

B–

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 19

4 Electrical Installation

◆

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

Terminal

SignallNo.l

a+, a–, b+, b–,

FE

Bare Cable

Screw

Size

Tightening

Torque

(N x m)

Possible

Gauges mm 2

(AWG)

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)

Recom mended

Gauges mm 2

(AWG)

0.75

(18)

IP, IG, DT

DT, B+, B–

CK, CK,

A+, A–

<1>

Wiring Gauges with

Crimp Terminals

Possible

Gauges mm

(AWG)

0.25 to 0.5

(24 to 20)

–

2

<1> Use HEIDENHAIN 17-pin Cable. Refer to Encoder Cables on page 19 to for detail.

Recom mended

Gauges mm 2

(AWG)

0.5

(20)

–

Wire Type

Shielded twisted pair, etc.

–

■ 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 d1

6 mm

L d2

Wire Gauge mm 2

(AWG)

0.25 (24)

0.34 (22)

0.5 (20)

Model

AI 0.25 - 6YE

AI 0.34 - 6TQ

AI 0.5 - 6WH

L

(mm)

10.5

10.5

14 d1

(mm)

0.8

0.8

1.1

d2

(mm)

2

2

2.5

Manufacturer

Phoenix Contact

20 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual

4 Electrical Installation

◆

Wiring Procedure

When wiring the option card, wire ends should be prepared as shown in Figure 9 . See Wire

Gauges and Tightening Torque on page 20 to make sure that the proper tightening torque is applied to each terminal end.

Take particular precautions to ensure that each cable is properly connected, and that wire covering has not been accidentally inserted into the terminals.

NOTICE: Insulation or tape may be required to ensure that shielded lines do not come into contact with other wiring. Insufficient insulation may cause a short circuit that can damage the option card and the drive.

NOTICE: Follow the tightening torque specifications in this manual for all terminal screws. Failing to do so may keep the drive from functioning properly and could damage the terminal block.

Figure 9

Shield Insulation

Option Card

Encoder

FE

Ground Terminal

Shield shearth (Insulate with tape)

Figure 9 Treating Terminal Ends for Shielded Line

Figure 10

Avoid fraying wire stands when stripping insulation from wire.

Terminal block

Blade depth of

0.4 mm or less

Blade width of

2.5 mm or less

Strip length 5.5 mm

Figure 10 Terminal Block Wiring

Loosen screw to insert wire.

Single wire or stranded wire

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 21

5 Related Parameters

5 Related Parameters

The following parameters are used to set up the drive for operation with an encoder option card.

Set parameters as needed. Instructions on how to set parameters can be found in the instruction manual for the drive the option card is connected to.

Table 7 Related Parameters

No.

Parameter Description

Setting

Range Default

F1-01

<1>

PG 1 Pulse Setting Sets the pulses to be read from the encoder.

<2> <2>

F1-02

F1-03

F1-04

F1-05

F1-06

F1-08

F1-09

F1-10

F1-11

F1-14

F1-18

PG Feedback Loss

(PGo) Operation

Selection

PG Overspeed (oS)

Operation Selection

PG Deviation (dEv)

Operation Selection

PG 1 Rotation

PG 1 Ratio for PG

Pulse Monitor

PG Overspeed (oS)

Level

Overspeed (oS)

Detection Time

Excessive Speed

Deviation Detection

(dEv) Level

Excessive Speed

Deviation Detection

(DEv) Time

PG Disconnect (PGo)

Detection Time

Reverse Rotation detection for PG 1

(dv3)

0: Ramp to stop (decelerates at time set to C1-02)

1: Coast to stop

2: Fast Stop (decelerates at the time set to C1-09)

3: Continue running

0: Ramp to stop (decelerates at time set to C1-02)

1: Coast to stop

2: Fast Stop (decelerates at the time set to C1-09)

3: Continue running

4: No alarm display

0: Ramp to stop (decelerates at time set to C1-02)

1: Coast to stop

2: Fast Stop (decelerates at the time set to C1-09)

3: Continue running

0: Forward = A pulse leads

1: Forward = B pulse leads

Sets the division ratio for the pulses output from the encoder.

Sets the level for detecting overspeed (oS).

Set as a percentage of the maximum output frequency.

Sets the time required for the motor to exceed the the level set in F1-08 to trigger a fault.

Sets the degree of speed deviation to trigger a dEv fault.

Set as a percentage of the maximum output frequency.

0 to 3

<2>

0 to 3

0, 1

<2>

0 to 120

1

1

<2>

<2>

1

115

0.0 to 2.0

0.0

0 to 50 10

Sets the time required a speed deviation situation to trigger a fault.

0.0 to 10.0

0.5

Sets the time in seconds for encoder disconnect to be detected.

0: Disabled n: Number of times a dv3 situation must be detected to trigger a fault.

0.0 to 10.0

0 to 10

2.0

10

22 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual

5 Related Parameters

No.

Parameter Description

Setting

Range Default

F1-19

F1-20

Reverse Rotation detection for PG 1

(dv4)

PG Option

Disconnection detection 1

0: Disabled n: Number of times a dv4 situation must be detected to trigger a fault.

0: Disabled

1: Enabled

F1-29

F1-48

F1-51 dEv Detection

Condition Selection

Speed Feedback

Resolution

PGoH Detection

Level

0: After speed reference, SFS output and motor speed have matched once.

1: After speed reference, SFS output have matched once.

2: Always during Run

Used to decrease the speed feeback signal resoslution to resolve vibration/oscillation problems at stop. Set as number of bits that are neglected.

Set the level for detecting PG Hardware Fault (PGoH). Set a percentage of

Sin

θ 2 + Cos

θ 2

.

<1> The input frequency from the encoder can be calculated as follows:

0 to 5000 128

0,1

0 to 2

0 to 2

1 to 100

1

2

0

80

Operation at max. output frequency

＝

<2> Varies by drive models.

Motor speed at maximum frequency output (r/min)

60

× PG rating (p/rev)

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 23

6 Troubleshooting

6 Troubleshooting

◆

Error Codes Displayed on the Drive Operator

The table below lists the various fault codes related to the option card and pulse generator.

Further detail on various faults can be found in the instruction manual for the drive.

• Make sure the encoder cable is properly connected.

• Check the cables between the encoder and the option card.

• Make sure the option card is properly installed to the drive.

Table 8 Fault Display

Digital Operator Display dEv

Cause

Load is too heavy.

Acceleration and deceleration times are set too short. / Acceleration and deceleration ramps are set too large.

Fault Name

Speed Deviation (for Control Mode with PG)

The deviation between the speed reference and speed feedback is greater than the setting in F1-10 for longer than the time set to F1-11.

Possible Solution

Reduce the load.

Increase the acceleration and deceleration times (C1-01 through C1-08). /

Decrease the acceleration and deceleration ramps (C1-01 through C1-08)

The load is locked up.

Check the machine.

Parameters are not set appropriately.

Check the settings of parameters F1-10 and F1-11.

Motor brake engaged.

Brake control sequence is incorrect.

Ensure the motor brake releases properly.

Correct the brake control sequence and then verify that the brake has been released.

24 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual

6 Troubleshooting

Digital Operator Display

Cause

E5-11 is not set properly.

An external force on the load side has caused the motor to move.

dv3

Fault Name

Inversion Detection

The torque reference and acceleration are in opposite directions from one another (one is in reverse and the other is forward) while at the same time the speed reference and actual motor speed differ by over 30% for the number of pulses set to F1-18.

Possible Solution

Set parameter E5-11 in accordance with the Δθ value printed on the motor nameplate.

• Make sure the motor is rotating in the right direction.

• Look for any problems on the load side that might be causing the motor to rotate in the opposite direction.

Noise interference along the encoder cable affecting the A or B pulse.

Encoder is disconnected, not wired properly, or the option card or encoder itself is damaged.

Rotational direction for the encoder set to F1-05 is the opposite of the order of the motor lines.

Digital Operator Display

Rewire the encoder and make sure all lines including shielded line are properly connected.

Make sure motor lines for each phase (U, V, W) are connected properly.

dv4

Fault Name

Inversion Prevention Detection

Pulses indicate that the motor is rotating in the opposite direction of the speed reference. Set the number of pulses to trigger inverse detection to F1-

19.

Cause

E5-11 is not set properly.

Possible Solution

• Set parameter E5-11 in accordance with the Δθ value printed on the motor nameplate.

• If the problem continues after cycling power, then replace either the option card or the encoder itself. Replacing the encoder or changing the application and perform Encoder Home Position Tuning.

Noise interference along the encoder cable affecting the A or B pulses.

Encoder is disconnected, not wired properly, or the option card or encoder itself is damaged.

Digital Operator Display

• Make sure the motor is rotating in the right direction.

• Look for any problems on the load side that might be causing the motor to rotate in the opposite direction.

• Rewire the encoder and maker sure all lines including shielded line are properly connected.

• If the problem continues after cycling power, then replace either the option card or the encoder itself.

Fault Name oFA00 Non-Compatible Option Card at CN5-A

Cause

Non-compatible option card connected to port CN5-A.

Possible Solution

Switch the power off and reconnect the option card. See note <1> .

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 25

6 Troubleshooting

Digital Operator Display oFb00

Cause

Non-compatible option card connected to port CN5-B.

Digital Operator Display

Fault Name

Non-Compatible Option Card at CN5-B

Possible Solution

Switch the power off and reconnect the option card. See note <1> .

Fault Name oFC01 Option Card Connection Error at CN5-C

Cause

Problem with the option card code for the card connected to CN5-C.

(Option card is damaged.)

Digital Operator Display

Cause

The option card is damaged.

Digital Operator Display

Cause oFC51

The option card is damaged.

Digital Operator Display

Cause

Encoder cable wiring is wrong.

Encoder cable is disconnected.

Digital Operator Display

Cause oFC50 oFC52 oFC53

Encoder cable wiring is wrong.

Encoder cable is disconnected.

Possible Solution

Switch the power off and reconnect the option card.

Fault Name

Encoder Option AD Conversion Error

Error with the A/D conversion level (VCC level), or A/D conversion timed out.

Possible Solution

Replace the option card

Fault Name

Encoder Option Analog Circuit Error

Incorrect signal level (+2.5 V signal)

Possible Solution

Replace the option card

Fault Name

Encoder Comm. Timeout

Signal encoder timed out waiting to receive data

Possible Solution

Correct the wiring.

Reconnect the cable.

Fault Name

Encoder Comm. Data Error

Serial encoder CRC checksum error

Possible Solution

Correct the wiring.

Reconnect the cable.

26 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual

6 Troubleshooting

Digital Operator Display oFC54

Fault Name

Encoder Error

Alarm reading EnDat absolute position data from encoder

(OR flag from EnDat error for overvoltage, undervoltage, etc.)

Possible Solution Cause

Power supply to encoder is wired incorrectly.

PG-F3 power supply circuit is damaged.

Digital Operator Display

Correct the wiring.

Replace the option card.

Fault Name

Paramerters were set outside the possible range.

Cause oPE02

Parameter Range Setting Error

Use U1-18 to find parameters set outside range.

Possible Solutions

Set parameters to the proper values.

Note: When multiple errors occur at the same time, other errors are given preceedance over oPE02.

Digital Operator Display

Control Method Selection Error

Fault Name oPE06

Cause

A control mode has been selected that requires an option card to be installed, but no encoder is installed (A1-02 =

7).

Digital Operator Display

Correct the setting for the control method.

Possible Solutions

• Connect an option card.

• Correct the value set to A1-02.

Fault Name

Cause

Overshoot is occurring. oS

Inappropriate parameter settings.

Digital Operator Display

Overspeed

The motor speed feedback exceeded the F1-08 setting.

Possible Solutions

Increase the settings for C5-01 and reduce C5-02.

Check the setting for the overspeed detection level and the overspeed detection time (F1-08 and F1-09).

Fault Name

PGo

Cause

Encoder cable is disconnected.

PG Disconnect

Detected when no signals received for a time longer than setting in F1-14.

Possible Solutions

Reconnect the cable.

Encoder cable wiring is wrong.

Correct the wiring.

Encoder does not have enough power. Make sure the correct power supply is properly connected to the encoder.

Brake control sequence is incorrect.

Correct the brake control sequence and then verify that the brake has been released.

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 27

6 Troubleshooting

Digital Operator Display

PGoH

Cause

Encoder cable is disconnected.

Fault Name

PG Hardware Fault

Encoder cable has become disconnected.

Possible Solutions

Reconnect the cable.

<1> Depending the type of option card, only a certain number of cards may be connected at the same time. Refer to table below. More details can be found in the option card section of the drive instruction manual.

Table 9 Option Card Installation

Option Card

AI-A3, DI-A3, SI-C3, SI-N3, SI-P3, SI-S3 <2>

AO-A3, DO-A3

PG-B3, PG-X3

PG-F3

Connector

CN5-A

CN5-A, B, C

CN5-B, C

CN5-C

Number of Cards Possible

1

1

2 <3>

1

<2> The AI-A3, DI-A3 option can also be installed to option ports CN5-B and CN5-C, but are then used for monitoring purposes only. Input levels are then displayed in U1-17, U1-21 to U1-23. Here, the option cards cannot be used to set the frequency reference or replace the drive analog input with higher resolution inputs.

<3> If only PG-B3/PG-X3 option card is connected to the drive, use the CN5-C connector. If two PG-B3/PG-X3 option cards are connected, use both CN5-B and CN5-C.

28 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual

7 Specifications

7 Specifications

◆

Specifications

Table 10 Option Card Specifications

Option Card

Encoder Type

Multi-turn

Encoder Wiring

Length

Encoder Power

Supply

Compatible

Control Modes

Maximum Input

Frequency

Pulse Monitor

Output

Encoder Disconnect

Detection

Ambient

Temperature

Humidity

Storage

Temperature

Area of Use

Altitude

PG-F3

EnDat 2.1/01, EnDat 2.2/01 (HEIDENHAIN)

ECN1313 (EnDat 2.1/01, EnDat 2.2/01)

ECN113 (EnDat 2.1/01, EnDat 2.2/01)

ECN413 (EnDat 2.1/01, EnDat 2.2/01)

Not available

20 m max. Wiring length over 10 m requires two connections to both IP and IG.

Output voltage: 5 V ± 5%, 8 V ± 10%

Max. Output Current: 200 mA

Closed Loop Vector for PM motors

50 kHz

Monitor for A and B pulse output

Matches RS-422 Level

Software detection

–10 ° C to 50 ° C

95% RH or less with no condensation

–20 ° C to 60 ° C allowed for short-term transport of the product

Indoor (free of corrosive gas, airborne particles, etc.)

1000 m or less

YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual 29

7 Specifications

◆

Revision History

The revision dates and numbers of the revised manuals are given on the bottom of the back cover.

MANUAL NO.

  TOBP C730600 51A

Published in Japan July 2009 09-7

Date of

Publication

July 2009

Date of publication

Date of original publication

Rev.

No

−

Section

− First edition

Revised Content

30 YASKAWA ELECTRIC TOBP C730600 51A YASKAWA AC Drive-Option Card PG-F3 Installation Manual

英文 No.10-5（140×182） インバータ製品用

YASKAWA AC Drive-Option Card

Encoder Type (EnDat)

Installation Manual

IRUMA BUSINESS CENTER (SOLUTION CENTER)

480, Kamifujisawa, Iruma, Saitama, 358-8555, Japan

Phone: 81-4-2962-5696 Fax: 81-4-2962-6138

YASKAWA ELECTRIC CORPORATION

New Pier Takeshiba South Tower, 1-16-1, Kaigan, Minatoku, Tokyo, 105-6891, Japan

Phone: 81-3-5402-4511 Fax: 81-3-5402-4580 http://www.yaskawa.co.jp

YASKAWA ELECTRIC AMERICA, INC.

2121 Norman Drive South, Waukegan, IL 60085, U.S.A.

Phone: (800) YASKAWA (800-927-5292) or 1-847-887-7000 Fax: 1-847-887-7370 http://www.yaskawa.com

YASKAWA ELÉTRICO DO BRASIL COMÉRCIO LTDA.

Avenda Fagundes Filho, 620 Bairro Saude, São Paulo, SP04304-000, Brasil

Phone: 55-11-3585-1100 Fax: 55-11-5581-8795 http://www.yaskawa.com.br

YASKAWA ELECTRIC EUROPE GmbH

Hauptstra β e 185, 65760 Eschborn, Germany

Phone: 49-6196-569-300 Fax: 49-6196-569-398

YASKAWA ELECTRIC UK LTD.

1 Hunt Hill Orchardton Woods, Cumbernauld, G68 9LF, United Kingdom

Phone: 44-1236-735000 Fax: 44-1236-458182

YASKAWA ELECTRIC KOREA CORPORATION

7F, Doore Bldg. 24, Yeoido-dong, Youngdungpo-Ku, Seoul, 150-877, Korea

Phone: 82-2-784-7844 Fax: 82-2-784-8495

YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.

151 Lorong Chuan, #04-01, New Tech Park, 556741, Singapore

Phone: 65-6282-3003 Fax: 65-6289-3003

YASKAWA ELECTRIC (SHANGHAI) CO., LTD.

No. 18 Xizang Zhong Road, Room 1702-1707, Harbour Ring Plaza, Shanghai, 200001, China

Phone: 86-21-5385-2200 Fax: 86-21-5385-3299

YASKAWA ELECTRIC (SHANGHAI) CO., LTD. BEIJING OFFICE

Room 1011A, Tower W3 Oriental Plaza, No. 1 East Chang An Ave.,

Dong Cheng District, Beijing, 100738, China

Phone: 86-10-8518-4086 Fax: 86-10-8518-4082

YASKAWA ELECTRIC TAIWAN CORPORATION

9F, 16, Nanking E. Rd., Sec. 3, Taipei, Taiwan

Phone: 886-2-2502-5003 Fax: 886-2-2505-1280

YASKAWA ELECTRIC CORPORATION

YASKAWA

In the event that the end user of this product is to be the military and said product is to be employed in any weapons systems or the manufacture thereof, the export will fall under the relevant regulations as stipulated in the Foreign Exchange and Foreign Trade Regulations. Therefore, be sure to follow all procedures and submit all relevant documentation according to any and all rules, regulations and laws that may apply.

Specifications are subject to change without notice for ongoing product modifications and improvements.

© 2009 YASKAWA ELECTRIC CORPORATION. All rights reserved.

MANUAL NO. TOBP C730600 51A

Published in Japan July 2009 09-7

09-1