YASKAWA Varispeed G7 User manual

Software Number: VSG13306X, Drive Models: CIMR-G7UXXXXX-117

Document Number: TM.G7SW.117, Date: 05/16/08, Rev: 08-05

Motion Control

G7 Drive Software

Technical Manual

Date: 05/16/08, Rev: 08-05 Page 2 of 38 TM.G7SW.117

Contents:

1.0 Overview ................................................................................ 3

2.0 Changes from Standard Product ............................................ 4

3.0 Limitations .............................................................................. 4

4.0 Related Parameters and Functions ........................................ 5

5.0 Function Descriptions ........................................................... 14

6.0 Appendices .......................................................................... 35

This document is intended to provide proper installation and use of the Yaskawa drive with custom software. This

document is a supplement to the standard drive technical manual. It describes the effects on the drive parameters

and functions with the software installed. Read and understand this document and the standard drive technical

manuals before attempting to install, adjust, operate, inspect or maintain the drive. Observe all cautions and

warnings in this document and the standard drive technical manuals. Custom software is written to add

functionality to a standard AC drive to enhance or enable use in a specific application. The software is loaded to

the flash ROM area of the control board, and replaces the standard drive software. Custom software can add new

functions, modify standard functions, or even inhibit standard functions. It can be used to modify display text or

parameter names. Custom software is usually loaded to the drive before delivery. The control board and drive

nameplate are assigned unique part numbers and the software is registered, archived, and retrievable.

When seeking support for a drive with custom software, it is imperative to provide the unique part number shown

on the drive nameplate. The software has been flashed to the control board memory and the operation of

parameters, functions, and monitors is different from the standard drive software, as described herein.

Date: 05/16/08, Rev: 08-05 Page 3 of 38 TM.G7SW.117

The drive becomes a simple position regulator. The software does this by internally taking control of the drive’s

frequency reference. All time-critical calculations are completed in a scan that is 2.5 ms or faster.

This software gives the G7 simple position control capability.

•Linear Absolute Motion

•Rotary Absolute Motion

•Relative Motion w/o Memory

•Relative Motion with Memory

•All position commands and position feedback monitors are displayed in engineering units. A parameter

selects from the following list of engineering units: “inches,” “feet,” “centimeters,” “meters,” “degrees,”

“revolutions,” or none.

•Position command via modbus registers.

•Absolute Incremental Encoder Support “TR ISI style Absolute Encoder”

•Momentary or Maintained Move Command

•Several different homing sequences to choose from.

•Serial Communications Compatible

•Incremental Encoder

•Dual Incremental Encoders

•Absolute Gray-Code Encoder Support (18 bit)

•16 Preset Positions Plus Home

•Distance Command via High-speed Frequency Reference Register (in engineering units)

•“Pre-Activation” Digital Output (settable in engineering units)

•Ability to monitor and command a 32 bit (31 bits + sign) bi-polar position over network communication.

•An additional “Distance Select” selection is added, which when selected, re-purposes two existing

Modbus registers to be combined into one 32 bit (31 bits + sign) position register.

•Two read-only 16 bit Modbus registers are added to monitor position with offset (distance from home)

in encoder quadrature counts, for a total of 32 bits (31 bits + sign).

•A read-only 16 bit Modbus motion control status register is added sequentially after the 32 bit position

registers so that the position and the status of the drive can be read with one Modbus “Read Multiple”

command.

1.0 Overview

Date: 05/16/08, Rev: 08-05 Page 4 of 38 TM.G7SW.117

•Due to parameter limitations, the “User” access level and all of the associated “A2” parameters are

deleted.

•3-Wire control is not allowed when the motion software is enabled.

•Parameter b1-01 (Reference Source) is only effective when motion control is disabled (P1-01 = 0).

When motion control is enabled, parameter b1-01 is ignored, and the frequency reference originates

from the motion control routine.

•Parameters d2-02 and d2-03 are disabled, which fixes the minimum output speed at 0%.

•Accel and Decel ramp switching via multifunction digital input or via speed sensing is disabled when a

move is in progress. Accel and Decel ramp switch is controlled by the motion software during a move.

•Encoder direction selection F1-05 is not available when encoder type is “Serial Abs Ch1” (P3-01 = 3).

•PG Channel 2 parameters F1-21 and F1-22 have no effect when motion control is enabled.

•All 230V units will have a default carrier frequency of 2.0 kHz. The maximum carrier frequency setting

on models G7U2075 and smaller is limited to 4.0 kHz.

•The Motion Control algorithm is only available when the drive is in the Flux Vector control method

(A1-02 = 3).

•The distance from home cannot exceed 109encoder counts.

•The 32 bit position monitor registers should be read using a “Read Multiple” Modbus command (03h)

to ensure that the data from high and low words are read together for an accurate reporting of position.

•Using the 32 bit position command, the drive can now operate in a position beyond what the digital

operator can display.

•The drive must be re-homed after a PG Open (PGo) fault occurs.

2.0 Changes from Standard Product

3.0 Limitations

Date: 05/16/08, Rev: 08-05 Page 5 of 38 TM.G7SW.117

Function P1 – Motion Setup

Function P2 – Homing Setup

Function P3 – Advanced Motion Setup

Function P4 – Preset Position Setup

4.0 Related Parameters and Functions

4.1 Parameters

Parameter

Number

Modbus

Address

Parameter

Name

Digital

Operator

Display

Description

Range

Default

Change

During Run

Control Mode

V/f

V/f w/ PG

O.L.V.

Flux

Vector

O.L.V. 2

P1-01 600h

Motion Type

0: Disabled

1: Linear Absolute

2: Rotary Absolute

3: Relative Mem Off

4: Relative Mem On

0 ~ 4 0 N - - - A -

P1-02 601h

Distance Select

0: Preset P4-XX

1: Modbus (061Ch and 061Dh) (1)

2: Hi-Speed Option Card

Frequency Reference Register

(2)

A multifunction input selection

of “Distance Select” will

override this parameter.

3: Modbus 32-Bit (061Ch and

061Dh) (3)

0 ~ 3 0 N - - - A -

P1-03 602h

Move Command

Type

Move Cmd. Type

0: Maintained – Move command

must be maintained for the

entire move.

1: Rising Edge – Move command

is edge-triggered.

2: Falling Edge – Move command

is edge-triggered.

0 ~ 2 0 N - - - A -

P1-04 603h

Positioning

Proportional Gain

Pos P Gain

Proportional gain used for the

position controller. 1.0 ~ 20.0 1.0 Y - - - A -

P1-05 604h

Decel Start

Compensation

Distance

Decel Comp Dist

Starts the deceleration ramp early.

Increase if there is overshoot,

decrease if there is undershoot.

0 ~ 65535

cts 0Y---A-

P1-06 605h

Positioning Speed

Compensation

Pos Spd Comp

Provides fine adjustment for the

automatically calculated

positioning speed.

10.0 ~

200.0 % 100.0 Y - - - A -

P1-07 606h

Triangle Move

Compensation

Trig Mov Comp

Determines response for a

triangular move. Increase if

overshooting, decrease if

undershooting when performing a

“Triangle” move instead of a

“Trapezoid” move.

0.0 – 10.0 1.0 Y - - - A -

Date: 05/16/08, Rev: 08-05 Page 6 of 38 TM.G7SW.117

P1-08 607h

In Position Window

In Posit. Window

Controls when the “Move

Complete” digital output turns on.

Also determines when another

edge-triggered move will be

accepted.

0 ~ 65,535

cts 200.0 Y - - - A -

P1-09 608h

Counts Per Unit

This parameter is multiplied by the

distance command, in order to

determine move length in counts.

1 ~ 65,535

cts 4096 N - - - A -

P1-10 609h

Distance Display

Units

Distance Units

0: none

1: in (inches)

2: ft (feet)

3: cm (centimeters)

4: m (meters)

5: o(degrees)

6: rev (revolutions)

0 ~ 6 0 N - - - A -

P2-01 60Ah

Homing Type

Homing Type(5)

0: Home Negative

1: Home Neg with Backup

2: Home Positive

3: Home Pos with Backup

4: Negative with Marker Pulse

5: Positive with Marker Pulse

6: Manual

0 ~ 6 1 N - - - A -

P2-02 60Bh

Homing Speed

Speed reference used during

course homing.

0.0 ~

400.0 Hz 10.0 Y - - - A -

P2-03 60Ch

Homing Back-Up

Speed

Homing BU Speed

Speed reference used during the

back-up portion of the homing

routine.

0.00 ~

20.00 Hz 2.00 Y - - - A -

P2-04 60Dh

Homing Final Speed

Homing Final Spd

Speed referenced used during the

final portion of the homing routine.

0.00 ~

20.00 Hz 1.00 Y - - - A -

P2-05 60Eh

Switch Type

Sets the normal (not activated)

state of the home and over-travel

limit switches.

0: Both NO

1: OT NO Home NC

2: OT NC Home NO

3: Both NC

0 ~ 3 0 N - - - A -

P2-06 60Fh

Home Offset

Distance

Home Offset Dist

Distance from the home limit

switch that is considered home.

-99.99 ~

99.99

Units (4)

0.00 N - - - A -

P2-08 611h

Pre-Action Distance

Pre Act Dist

During a move, when the machine

is this distance from the

destination, a digital output

(H2-0X = 46) will activate until the

“In Position” window is reached.

0.00 ~

500.00

Units (4)

0.00 Y - - - A -

P3-01 614h

Position Encoder

Source

Encoder Source

0: PG-X2, PG-B2, or

PG-W2 Channel 1

1: PG-W2 Channel 2

2: Absolute Gray Code

(connected via DI-16H2)

3: TR Encoder Channel 1

4: TR Encoder Channel 2

0 ~ 4 0 N - - - A -

4.1 Parameters (Continued)

Parameter

Number

Modbus

Address

Parameter

Name

Digital

Operator

Display

Description

Range

Default

Change

During Run

Control Mode

V/f

V/f w/ PG

O.L.V.

Flux

Vector

O.L.V. 2

Date: 05/16/08, Rev: 08-05 Page 7 of 38 TM.G7SW.117

P3-02 615h

Positioning Encoder

Pulses Per

Revolution

Second Encoder

PPR

Encoder pulses per revolution

when P3-01 = 1, encoder counts

per revolution when P1-01 = 2.

60 ~

10,000

PPR

1024 N - - - A -

P3-03 616h

Positioning Encoder

Numerator

Second Encoder

NUM

Machine mounted encoder ratio

numerator. Used in conjunction

with P3-04. Effective only when a

second machine-mounted

encoder is used.

1 ~ 65,535 1 N - - - A -

P3-04 617h

Positioning Encoder

Denominator

Second Encoder

DEN

Machine mounted encoder ratio

denominator. Used in conjunction

with P3-03. Effective only when a

second machine-mounted

encoder is used.

1 ~ 65,535 1 N - - - A -

P3-07

(6) 61Ah

Length Of One

Rotation (Encoder

Revolutions)

Len 1 Rotate REV

Sets the distance of one complete

revolution of the rotary machine.

Effective only when P1-01 = 2.

One Rotation (counts) =

(P3-07 * F1-01* 4) + P3-08

0 ~ 9999

Rev 0N---A-

P3-08

(6) 61Bh

Length Of One

Rotation (Encoder

Counts)

Len 1 Rotate CTS

Sets the distance of one complete

revolution of the rotary machine.

Effective only when P1-01 = 2.

One Rotation (counts) =

(P3-07 * F1-01* 4) + P3-08

0 ~ 40,000

cts 0N---A-

P4-01 106h

Position 1

Position Reference in units.

Position Ref. (counts) = P4-01 *

P1-09.

0.00 –

655.35

Units (4)

0.00 Y - - - A -

P4-02 107h

Position 2

Position Reference in units.

Position Ref. (counts) = P4-02 *

P1-09.

0.00 –

655.35

Units(4)

0.00 Y - - - A -

P4-03 108h

Position 3

Position Reference in units.

Position Ref. (counts) = P4-03 *

P1-09.

0.00 –

655.35

Units (4)

0.00 Y - - - A -

P4-04 109h

Position 4

Position Reference in units.

Position Ref. (counts) = P4-04 *

P1-09.

0.00 –

655.35

Units (4)

0.00 Y - - - A -

P4-05 10Ah

Position 5

Position Reference in units.

Position Ref. (counts) = P4-05 *

P1-09.

0.00 –

655.35

Units (4)

0.00 Y - - - A -

P4-06 10Bh

Position 6

Position Reference in units.

Position Ref. (counts) = P4-06 *

P1-09.

0.00 –

655.35

Units (4)

0.00 Y - - - A -

P4-07 10Ch

Position 7

Position Reference in units.

Position Ref. (counts) = P4-07 *

P1-09.

0.00 –

655.35

Units (4)

0.00 Y - - - A -

P4-08 10Dh

Position 8

Position Reference in units.

Position Ref. (counts) = P4-08 *

P1-09.

0.00 –

655.35

Units (4)

0.00 Y - - - A -

P4-09 10Eh

Position 9

Position Reference in units.

Position Ref. (counts) = P4-09 *

P1-09.

0.00 –

655.35

Units (4)

0.00 Y - - - A -

4.1 Parameters (Continued)

Parameter

Number

Modbus

Address

Parameter

Name

Digital

Operator

Display

Description

Range

Default

Change

During Run

Control Mode

V/f

V/f w/ PG

O.L.V.

Flux

Vector

O.L.V. 2

Date: 05/16/08, Rev: 08-05 Page 8 of 38 TM.G7SW.117

(1) When P1-02 = 1, the actual commanded destination is calculated as follows:

Destination = modbus register 61CH * P1-09 / 100

(2) Actual destination (in encoder quadrature counts) is calculated as follows:

(3) When P1-02 = 3, the actual commanded destination is the combined value of Modbus registers 61Ch (low word)

and 61Dh (high word). Parameter P1-09 has no effect as this is strictly a command in encoder quadrature counts.

Speed for this profile is set by d1-01, the acceleration time is set by C1-01, and the deceleration time is set by

C1-02.

(4) The units text displayed in the digital operator is determined by parameter P1-10. Actual destination in encoder

counts is calculated by multiplying the preset position reference by P1-09.

(5) When parameter P3-01 = 3 or 4 (encoder type = TR Encoder), the Homing Type (P2-01) parameter has no

effect. Instead, when a home command is issued, the drive is base-blocked and then the position is read from the

encoder via channel 2 on the PG-W2 option board. This will only happen if the drive does not have a run

command.

(6) If P3-01 = 1, then parameter P3-02 is used in place of parameter F1-01 when determining actual distance.

P4-10 10Fh

Position 10

Position Reference in units.

Position Ref. (counts) = P4-10 *

P1-09.

0.00 –

655.35

Units (4)

0.00 Y - - - A -

P4-11 110h

Position 11

Position Reference in units.

Position Ref. (counts) = P4-11 *

P1-09.

0.00 –

655.35

Units (4)

0.00 Y - - - A -

P4-12 111h

Position 12

Position Reference in units.

Position Ref. (counts) = P4-12 *

P1-09.

0.00 –

655.35

Units (4)

0.00 Y - - - A -

P4-13 112h

Position 13

Position Reference in units.

Position Ref. (counts) = P4-13 *

P1-09.

0.00 –

655.35

Units (4)

0.00 Y - - - A -

P4-14 113h

Position 14

Position Reference in units.

Position Ref. (counts) = P4-14 *

P1-09.

0.00 –

655.35

Units (4)

0.00 Y - - - A -

P4-15 114h

Position 15

Position Reference in units.

Position Ref. (counts) = P4-15 *

P1-09.

0.00 –

655.35

Units (4)

0.00 Y - - - A -

P4-16 115h

Position 16

Position Reference in units.

Position Ref. (counts) = P4-16 *

P1-09.

0.00 –

655.35

Units (4)

0.00 Y - - - A -

4.1 Parameters (Continued)

Parameter

Number

Modbus

Address

Parameter

Name

Digital

Operator

Display

Description

Range

Default

Change

During Run

Control Mode

V/f

V/f w/ PG

O.L.V.

Flux

Vector

O.L.V. 2

Destination Frequency Reference (Hi-speed register)

100

------------------------------------------------------------------------------------------------------------------- P1 - 09×=

Date: 05/16/08, Rev: 08-05 Page 9 of 38 TM.G7SW.117

Note: Stall prevention during decel increases the deceleration distance even when the bus voltage remains at

the nominal level. For this reason, it is important to leave L3-04 set to “Disabled” (0).

Note: The ENTER command is not required when writing to these registers.

4.2 Modified Existing Parameters

Parameter

Number

Modbus

Address

Parameter

Name Description

Range

Default

Change

During Run

Control Mode

V/f

V/f w/ PG

O.L.V.

Flux

Vector

O.L.V. 2

C1-01

C1-08

200h

207h

Accel Time 1

Decel Time 8

Acceleration and Deceleration

Times

0.0 ~

6000.0

Sec.

2.0 Y---A-

C2-01

C2-03

20bh

20dh

S-Crv @ Acc Start

S-Crv @ Acc End

S-Crv @ Dec Start

S-curve Times

0.00 ~

2.50

Sec.

0.00 N---A-

d1-09

d1-16

280h

291h

Frequency Ref. 9

Frequency Ref. 16

Digital Preset Speeds

0.00 ~

400.00

6.09

6.16

Y---A-

L3-04 492h Stall Prevention

During Decel

0: Disabled

1: General Purpose

2: Intelligent

0 ~ 2 0N---A-

4.3 Modbus Registers

Modbus

Address Description Scaling

061Ch Modbus Communication Speed Reference during a Move. Effective only when P1-02 = 2. 0.01 Hz

100 = 1.00 Hz

061Dh

Modbus Communication Position Reference (Engineering Units)

Actual position reference in encoder counts = 61Dh * P1-09.

Range is: 0.00 ~ 655.35 units. Effective only when P1-02 = 2.

0.01 Units

100 = 1.00 Units

061Ch Modbus 32-bit Communication Position Reference (low word). Effective only when P1-02 = 3. Quadrature

Encoder Counts

061Dh Modbus 32-bit Communication Position Reference (high word). Effective only when P1-02 = 3.

0734h

32 Bit Distance From Home (low word)

Distance from home (+ home offset) for absolute applications, or distance from start of previous

move for relative applications. Read only. Quadrature

Encoder Counts

0735h

32 Bit Distance From Home (high word)

Distance from home (+ home offset) for absolute applications, or distance from start of previous

move for relative applications. Read only.

0736h

Motion Control Modbus Status Register

Bits 0 ~ 5 are a copy of the information in monitor U1-11. Bits 6 ~ C behave the same as the

motion control digital outputs (H2-0X = 40 ~ 46). Read only.

Bit 0: Digital Output Status – M1-M2

Bit 1: Digital Output Status – M3-M4

Bit 2: Digital Output Status – M5-M6

Bit 3: Digital Output Status – P3-C3

Bit 4: Digital Output Status – P4-C4

Bit 5: Not Used

Bit 6: Not Used

Bit 7: Digital Output Status – MA-MB-MC (fault)

Bit 8: Move In Progress

Bit 9: Move Complete

Bit A: Homing Complete

Bit B: Homing Needed

Bit C: At Home

Bit D: Learn Successful

Bit E: Pre-Action Output

Bit F: Not Used

(N/A)

Date: 05/16/08, Rev: 08-05 Page 10 of 38 TM.G7SW.117

(7) The actual units text displayed in the digital operator is determined by parameter P1-10. Actual distance in

encoder counts is calculated by multiplying the monitor output by P1-09. If the monitor is in excess of 327.67 units,

the display will be clamped at 327.67 units. If the monitor is less than -99.99 units, the display will be clamped at

-99.99 units.

(8) The actual units text displayed in the digital operator is determined by parameter P1-10. Actual distance in

encoder counts is calculated by multiplying the monitor output by P1-09. If the monitor is in excess of 32,767 units,

the display will be clamped at 32,767 units. If the monitor is less than -9999 units, the display will be clamped at

-9999 units.

4.4 Monitors

Parameter

Number

Modbus

Address

Parameter

Name

Digital

Operator

Display

Description

Analog

Monitor

Scaling

Units

Control Mode

V/f

V/f w/ PG

O.L.V.

Flux

Vector

O.L.V. 2

U1-90 720h

Distance From

Home (Fine)

Dist From Home f

Distance from home (+ home offset) for

absolute applications, or distance from

start of previous move for relative

applications. Displayed with fine

resolution (0.01 units).

N/A 0.01 Units

(7) --- A -

U1-91 721h

Distance To Go

(Fine)

Dist To Go f

Distance from the destination. Displayed

with fine resolution (0.01 units). N/A 0.01 Units

(7) --- A -

U1-92 722h

Commanded

Destination (Fine)

Commanded Dest f

Commanded destination. Displayed with

fine resolution (0.01 units). N/A 0.01 Units

(7) --- A -

U1-93 723h

Distance From

Home (Coarse)

Dist From Home c

Distance from home (+ home offset) for

absolute applications, or distance from

start of previous move for relative

applications. Displayed with coarse

resolution (1 unit).

N/A 1 Unit

(8) --- A -

U1-94 724h

Distance To Go

(Coarse)

Dist To Go c

Distance from the destination. Displayed

with coarse resolution (1 unit). N/A 1 Unit

(8) --- A -

U1-95 725h

Commanded

Destination (Coarse)

Commanded Dest c

Commanded destination. Displayed with

coarse resolution (1 unit). N/A 1 Unit

(8) --- A -

U1-96 726h

Commanded Speed

Reference

Cmd Speed Ref

Commanded speed for the selected

destination. N/A 0.01 Hz - - - A -

U1-97 727h

Raw Gray Code

Encoder Position

Raw Gray Pos.

Position of the gray code absolute

encoder in “tens” of counts. N/A

1 dct

(deka-

count)

--- A -

U1-99 729h

TR Absolute

Incremental Encoder

Position Request.

Ser Enc Pos Req

TR Absolute Incremental Encoder

Position Request.

Used by the drive to request absolute

position information from the encoder.

(Analog output only, no display)

10V =

Request

Position

- -----

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