Yaskawa Manuals 212

Inverter
Technical Information No. 97020 Date: 12/8/97
MC5
VS-626MC5 Spindle Inverter Supplemental Manual
u, v, w, x, y, z u, v, w
MC5
Magnetic Contactor (for switching Y and ) Inverter
6-Lead Spindle Motor
Contents
Page 1. Introduction.............................................................................................2 2. Winding Change Application .................................................................2 2.1 Winding Change Methods ................................................................ 2.2 Winding Selection Magnetic Contactor............................................ 2.3 Magnetic Contactor Answer-back Failure Detection ....................... 3. Parameters................................................................................................. 3.1 Parameter Modification for MC5 ..................................................... 3.2 Parameter Set-up and Adjustment .................................................... 4. Auto Tuning and Motor Parameter Adjustment ....................................... 4.1 Procedure .......................................................................................... 5. Troubleshooting ........................................................................................ Appendix A: Application Examples .............................................................. Appendix B: Parameter Modification List from G5 to MC5.........................
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CONFIDENTIAL - DO NOT DISTRIBUTE
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MC5
1. Introduction
The Yaskawa Varispeed-626MC5 inverter, a derivative of VS-616G series, is a compact and versatile spindle drive specially designed for machine tool application. The features of the MC5 inverter include: Winding change on-the-fly for the wide constant power range operation Auto-tune for dual winding motors
This supplemental manual is intended to be used with the Varispeed-616G5 Instruction Manual (TOES616-10) and Varispeed-616G5 Descriptive Manual For Constants (TOEZ-S616-10).
2. Winding Change Application

A six-lead three-phase AC induction motor can be connected in two different ways, namely Y- and windings (Figure 2.1). The base frequency of the Y-winding is lower than that of -winding, providing higher torque at low speed.
6 Lead Motor Winding

U U Z
X-Y-Z X V V W Y W
Y-Winding (Y-Connection) Low Speed, High Torque
-Winding (-Connection) High Speed, Low Torque
Figure 2.1 Y and Windings
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In contrast, the maximum speed of the -winding is much higher than that of Y-winding (Figure 2.2).
Power
Y-Winding
Y-Winding provides high torque at the low speed.
0 0 Power
Y-base Y-max.
Freq. winding change done in this area
-Winding covers the high speed Figure 2.2 range.

0 0
-Winding
Freq.
-base -max.
Figure 2.2 Performance Curves of Y and Windings
By switching between the two winding connections, a wide constant power range can be obtained (Figure 2.3), beneficial for driving the spindle of a lathe or a milling machine. This type of application is called the Y/ winding change, or simply winding change. Winding change technology provides high torque and wide constant power range with a relatively small size inverter.
high torque at low speed
Power
Y-Winding
-Winding
Wide Constant Power Range:
A : B = up to 1:12 !!
0 0 Motor Speed
A
Y-base Speed
B
-max. speed
Figure 2.3 Winding Change Application Performance Curve
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The VS626MC5 has two separate sets of motor parameter settings (motor 1 parameters [E1, E2] and motor 2 parameters [E3, E4, and E5]). For the winding change application, the motor parameters and the V/f patterns are individually set for the two windings. The VS626MC5 is similar to a two-motor application, except that the winding change control is performed on-the-fly, i.e., during operation. A magnetic contactor is used to switch between the two windings. (The magnetic contactor must have transfer contacts that can be directly driven by the inverter.) Note: Although the MC5 can perform a winding changeover during cutting, this function is not supported by Yaskawa. Cutting performance cannot be guaranteed due to reliance on factors outside of Yaskawas control, such as load inertia. 2.1 Winding Change Methods
The MC5 drive offers two different methods for winding change, internal winding change and ex-
ternal winding change, namely. External Winding Change Method In this method, an external signal is given to one of the multi-function inputs (set as 80H) to trigger the winding changeover. Figure 2.4 illustrates a wiring example of this application (in this case, the external signal is given from the CNC). Figure 2.5 on the next page illustrates the sequence of changing motor parameter for this method.
1 230V 17 18 3 230V R S T U V W 2 4 6 0V 9 Change Winding 7 8 Common 11 10 +24V 13 X 14 15 16 17 9 11 X V Dual Winding Motor U Z
MC5
CNC
Y W
+24VDC Supply
HV-75AP3 Magnetic Contactor MC Ansback
Figure 2.4 Sample Wiring for External Winding Change (Open Loop Vector Mode)
B1-02 = 4 H1-05 = 80H H1-06 = 82H H2-01 = 41H A1-02 = 2 E3-01 = 2
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Hz Fout
SpdSrch Dec Time b3-03
The ramp time is dependent on the accel timesetting.
V Output Voltage
Voltage recovery time L2-04 0 Torque Limit 64msec 50%
0% Total base block time
2nd motor parameter calculation time
Minimum baseblock time L2-03
During speed search RUN Command Motor 1 Motor 2
Note)
When the closed loop vector control mode is selected, the torque reference increases from zero with 64msec instead of 50% of torque limit for the open loop vector mode.
Figure 2.5 External Winding Change Sequence
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To use this method, the user must set 80H to the multi-functional digital input which is intended to receive the winding changeover signal. This setting enables the drive to select Motor 1 parameters (E1 and E2) when the input is open and Motor 2 parameters (E4 and E5) when the input is closed. Note that when this method is used, the internal winding change parameters (P1-01 and P1-02) are ignored. Internal Winding Change Method In this method, no external signal is used for triggering the winding change. Instead, the changeover and the selection of the Motor 1 or Motor 2 parameters are determined internally by the preset parameters, such as changeover frequency level (P1-01) and frequency width (P1-02). Figure 2.6 illustrates this example. Do not set 80H to the multi-function digital input when the internal winding change is used.
1 230V 17 18 3 230V R S T U V W 2 4 6 0V +24V 13 X 14 15 16 17 9 11 x PG X V Dual Winding Motor U Z
MC5
Y W
+24VDC Supply 8 11
PG-X2 Card (Option)
26 27
HV-75AP3 Magnetic Contactor
Figure 2.6 Sample Wiring for Internal Winding Change (Flux Vector Mode)
B1-02 = 4 H1-06 = 82H H1-03 = 41H P1-04 = 1 A1-02 = 3 E3-01 = 3
In both the external and internal methods, the multi-function digital output terminal which is connected to the magnetic contactor must be set to either 1CH or 41H, depending on the type of contactor. This setting allows the drive to give a signal to the magnetic contactor to close/open the contact for Y/ switching.
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2.2 Winding Selection Magnetic Contactor In regard to the winding change application with the MC5 drive, use of a Yaskawa magnetic contactor is recommended (Table 2.1, Figure 2.8). The contactor is specially designed for motor winding selection control and motor switch operation. The inverter directly controls the contactor switching function. Table 2.1
Model Number Contact Arrangement Rated Isolation Voltage Rated Energizing Current Max. Breaking Current Max. Operation Frequency (Switching Duty) Mechanical Life Ratings of Applicable Magnetic Coils Ambient Temperature Humidity Approximate Mass Dimensions (H x W x D, mm) 75A (Continuous) 87A (30 min. 33% ED)* 200 A 600 times/hour 5,000,000 times 200V 50/60 Hz, 220V 50/60 Hz, 230V 60 Hz -10 to +55 C (14 to 131 F) 10 to 95% RH (non-condensing) 2.5 kg 115 x 160 x 93 5.0 kg 164 x 192 x 107 HV-75AP3 HV-150AP3
Main Contact: 3NO3NC, Auxiliary Contact: 1NO 600V 150A (Continuous) 175A (30 min. 33% ED)* 400 A
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Dimensions in mm
Status of Operation
Selective Signal 13-14 +24V 0V Main Contacts 1-2 3-4 5-6 OPEN CLOSE 7-8 9-10 11-12 CLOSE OPEN Auxiliary Contacts 15-16 OPEN CLOSE Y Connection
Figure 2.8 Yaskawa Magnetic Contactor for Winding Selection
The Yaskawa magnetic contactor requires a single phase 230V power supply and +24VDC for switching signal. The +24VDC must be supplied by the user.
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2.3 Magnetic Contactor Answer-back Failure Detection Magnetic contactors commonly have an answer-back signal to feedback when the connection change is accomplished. The MC5 drive includes an option to check this signal and give an alarm in the event of a magnetic contactor failure. When the multi-function digital input is set to 81 or 82 (MC Ansback Input), the digital input terminal functions as the MC answer-back signal from the Y/ switching magnetic contactor. The answer-back fault is detected when one of the following two cases occur (Figure 2.9): Case 1) The motor parameter switching command is given and the auxiliary contact of Y/ magnetic contactor does not change the state within the specified time limit (P1-05). Case 2) The magnetic contactor changes the state without issuing the triggering signal.
V S-626M C 5
D C 2 4V M u lti-digital ou tpu t M o to r 2 Selected 9 11 M u ltifun ctio n Inp ut M C An sback N.C . or M C An sback N.O . M o to r 2 P1 -03 M C A n sb ack o n M o to r 1 P1 -03
WY ye con nection Connection D elta co nn ectio n
Connection
10
CA S E 1 M o to r 1 M C An sback off
M C An sback off M C An sback Fau lt
When motor parameter switching command is given given and and th the Wh en thethe mo to r p aram e ter switchin g com m and is e auxiliary a ux iliary contact co ntact of o fY/ Y/ m agn etic magnetic contactor change the state within P1-03 time, theinv inverter detects MCM Answerback failure. co ntactor dodoes esnt not c han ge the state w ith in P1 -03 tim e , the erte r w ill detect C A n sw erb ack fa ilure.
CA S E 2 M o to r 1 M C An sback off M C A n sb ack o n P1 -03 M C An sback Fau lt
Figure 2.9 Magnetic Contactor Answer-Back Failure Detection
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Although use of the magnetic contactor answer-back failure detection is optional, Yaskawa recommends using this feature to protect the motor and/or inverter in the event of contactor failure. When a Yaskawa magnetic contactor (HV-75AP3 or HV-150AP3) is used, the setting should be 82.
3. Parameters
3.1 Parameter Modification for MC5 The VS-626MC5 software (VSG105421) is a modification of the VS-626G5 software (VSG101042). Modification includes addition of new winding change parameters and settings, and elimination of some parameters. (Refer to Appendix A.) Tables 3.1, 3.2 and 3.4 describe the modification in detail, whereas Table 3.3 describes the pre-existing parameters which affect the winding changeover performance.
Table 3.1 New Parameters in the MC5 Parameter # E3-XX, E4-XX, E5-XX P1-01 Name Motor 2 Parameters Description Refer to Table 3.3 Unit Setting Range Default
Changeover Frequency
Winding change-over frequency from Y (low speed) winding to (high speed) winding Hysterisis for change-over frequency. Change-over frequency from to Y = P1-01 - P2-02 Detection delay time setting for the magnetic contactor answerback signal at winding change Selection of motor parameter sets (motor 1 or motor 2) for Y-winding Enable or disable MENU and ESC keys during operation
0.1Hz
0.0 ~ 400.0Hz
0.0Hz
P1-02
Frequency Width
0.1Hz
0.0 ~ 20.0Hz
5.0Hz
P1-03
Ansback Det Time
0.01 sec
0.20 ~ 1.00 sec
0.20 sec
P1-04
Y-Winding Sel
0: Motor 1 for Y 1: Motor 2 for Y 0: Disabled 1: Enabled
P1-05
ProgramMode@ Run
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Table 3.2 Parameters with Additional (New) Settings Parameter B1-02 (Run Source) L8-01 (DB Resistor Protection) Additional (new) Setting 4: /Y Seq. 1: 10% ED during RUN 2: 3% ED 3: 10% ED 80: Y/ Change Open: Motor 1 parameters are used Closed: Motor 2 parameters are used H1-01 ~ H1~06 (Multi function digital input) 81: MC Ansback N.C. Open: No ansback when MC is open Closed: Ansback when MC is closed 82: MC Ansback N.O. Open: No ansback when MC is closed Closed: Ansback when MC is open 40: Zero Speed 2 Closed: Zero speed condition except during D/Y changeover H2~01~H2-03 (Multi function digital output) 1C: Close Motor 2 Sel Open: Motor 1 is selected Close: Motor 2 is selected 41: Open Motor 2 Sel Open: Motor 2 is selected Close: Motor 1 is selected Description/Remarks Must be selected for winding change application When options 2 or 3 are selected, the braking transistor is always turned on when the DC bus voltage exceeds the preset level, except during a fault condition. Parameters P1-01 and P1-02 are disabled when 80H is selected.
To use the magnetic contactor answer-back signal for the contactor fault detection When Yaskawa HV-75AP or HV-150AP contactors are used, the setting is 82 (MC. Ansback N.O.)
Setting this avoids the Zero Speed signal output during winding changeover External winding changeover signal selection. If 1C is set, when the motor 1 parameters are selected, the signal is open. When the motor 2 parameters are selected, the signal is closed. If 41 is set, the effect is the opposite of 1C setting.
Table 3.3 Other Parameters Which Affect Winding Changeover Performance Parameter # B3-03 L2-03 L2-04 Name Speed search deceleration time Minimum baseblock time (PwrL Baseblock t) Voltage recovery time (PwrL V/F Ramp t) See Figure 2.5 for detail Description Unit 0.1 sec 0.1 sec 0.1 sec Setting Range 0.0 ~ 10.0 sec 0.0 ~ 5.0 sec 0.0 ~ 2.0 sec Default 2.0 sec Depends on inverter size 0.3 sec
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Table 3.4 Motor Parameters Motor 1 Parameters Motor 2 Parameters (new parameters) Description V/f A1-02 E1-01 E1-02 E1-03 E1-04 E1-05 E1-06 E1-07 E1-08 E1-09 E1-10 E1-11 E1-12 E1-13 E2-01 E2-02 E2-03 E2-04 E2-05 E2-06 E2-07 E2-08 E2-09 E3-01 E4-01 E4-02 E4-03 E4-04 E4-05 E4-06 E4-07 E5-01 E5-02 E5-03 E5-04 E5-05 E5-06 Control method selection Input voltage setting Motor selection V/f pattern selection Max. frequency Max. voltage Base frequency Mid. frequency Mid voltage Start frequency Start voltage Mid frequency (2) Mid voltage (2) Base voltage Full load current at base frequency Full load slip at base frequency No load current at base frequency Number of poles Line to line resistance Leakage inductance Saturation coefficient 1 Saturation coefficient 2 Mechanical loss Q Q Q Q Q Q Q Q Q Q Q A A A A A A X A X X X X Parameter Access (Motor 1) V/f w/ PG Q Q Q Q Q Q Q Q Q Q Q A A A Q A A Q A X X X X OLV Q Q Q X Q Q Q A A Q A A A Q Q Q Q X A A A A X A A Q Q Q Q Q A A A A A A A A X A X A A A A A X A FV Q Q Q X Q Q Q A A A A A A A A A A A A A A A A A X A A A A A A A A V/f A Parameter Access (Motor 2 ) V/f w/ PG A A A A A A A A A A A A OLV A FV A
Q: A:
Quick start (A1-01 = 2) Advanced (A1-01 = 4)
B: X:
Basic (A1-01 = 3) Setting/Reading disabled
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3.2 Parameter Set-up and Adjustment Run Source (B1-02) When using the MC5 inverter for the winding change application, this parameter must be set to 4 (Y/ seq.). Speed Search Deceleration Time (B3-03) This parameter determines the deceleration time during speed search after the winding changeover. Reducing the value of this parameter results in a reduction of the overall changeover time. However, an over voltage (OV) fault may occur if the setting is too small. Yaskawa recommends using the default setting. Control Mode of Motor 1 (A1-02) and Motor 2 (E3-01) Select the control method used for each winding. The setting values are as follows: 0: V/f mode without PG 1: V/f mode with PG 2: Open loop vector mode (without PG) 3: Flux vector mode (with PG) Set the same value to both A1-02 and E3-01. Motor Parameters Varispeed-626MC5 has two individual sets of motor parameters, namely motor 1 and motor 2 parameters. They are as follows: Motor 1 Parameters A1-02 : Motor 1 Control Method E1-XX : Motor 1 V/f Pattern E2-XX : Motor 1 Set up Motor 2 Parameters E3-01 : Motor 2 Control Method E4-XX : Motor 2 V/f Pattern E5-XX : Motor 2 Set up
Parameters for each of the Y- and -windings can be set individually as motor 1 and motor 2 parameters for a winding change application. The setting ranges and default setting of motor 2 parameters are identical to the corresponding motor 1 parameters. To set E1~E5, refer to Section 4, Auto-Tuning and Motor Parameter Adjustment
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Multi-Function Digital Input/Output (H1 and H2) For the winding change application, the user must set the multi-function digital input and output properly. Table 3.3 shows the new (additional) settings for H1 and H2 parameters. Minimum Base Block Time (L2-03) This parameter determines the base block time during winding change. Reducing the setting will result in the reduction of the overall winding changeover time. However, an overcurrent (OC) fault caused by back EMF may occur if the setting value is too small. Yaskawa recommends using the default setting. Voltage Recovery Time (L2-04) This parameter determines the duration of the voltage recovery time after base block at the winding changeover. A larger setting allows the inverter to ramp the voltage at recovery. However, an overcurrent (OC) fault may occur if the setting value is too small. Yaskawa recommends using the default setting. DB Resistor Protection (L8-01) This is the breaking resistor protection rating selection, as illustrated in Table 3.5.
Table 3.5 Braking Resistor Overheat Protection L8-01 setting 0 1 2 Display of setting Not provided 10% ED during run 3% ED Description There is no braking resistor overheat protection. The overheat protection for the 10% duty braking resistor is provided when the inverter is running. The overheat protection for the 3% duty (YASKAWA internal resistor ) braking resistor is provided whether or not the inverter is operating. The overheat protection for the 10% duty braking resistor is provided whether or not the inverter is operating.
10% ED
Note: When L8-01 is set to 2 or 3, this software allows braking resistor to be turned on any time after the bus voltage exceeds the level at which the braking transistor turns on, except during an inverter fault condition.
Winding Change-Over Frequency (P1-01) This parameter is responsible for the winding change-over frequency from Y (low speed) winding to (high speed) winding when the automatic winding change is used. The P1-01 setting must be smaller than the maximum frequency of the Y (low speed) winding.
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Winding Change-Over Hysterisis (P1-02) This parameter determines the winding change-over hysterisis; that is, the change-over frequency from - (high speed) winding to Y- (low speed) winding when automatic winding change is P1-01 ~ P1-02. Yaskawa recommends setting P1-02 so that the value of P1-01 ~ P1-02 is above the base speed of the (high speed) winding. MC (Magnetic Contactor) Answer-Back Error Detection Time (P1-03) This parameter determines the waiting time for the MC answer-back error detection. The parameter is used only when one of the multi-function digital inputs (H1-01 ~ H1-06) is set to 81 or 82. Motor Parameter Selection (P1-04) This parameter determines which of the two sets of motor parameters are assigned to Y- and windings. The setting is as follows: (Note: The default setting is 0 [disabled].) 0: Motor 1 parameters (E1 and E2) are used for Y-winding, motor 2 parameters (E3, E4 and E5) are for -winding. 1: Motor 2 parameters (E3, E4 and E5) are used for Y-winding, motor 1 parameters (E1 and E2) are for -winding. Yaskawa recommends using the setting 1 for the following reason. At 0 (high speed) winding, the motors maximum speed may be much higher than the base frequency (1:3 t 1:4 typically). In such a case, no-load voltage at such high speed operation may be higher than that of the base speed. This requires a different V/f pattern setting for the base and maximum speed. Only the Motor 1 parameters (E1 and E2) allow the setting of different base and maximum V/f. Program Mode at RUN (P1-05) This parameter enables or disables the MENU and ESC keys that normally allow the drive to go into the program mode during operation. The default setting is 0 (disabled). 0: Disabled -The operator key stroke (MENU and ESC) to enter the program mode is disabled. 1: Enabled - The MENU and ESC keys are enabled to use any time. When 1 is selected, the user can enter the program mode by pressing the MENU or ESC key. If the winding changeover is attempted while the inverter is in the program mode, the motor will coast to a stop. Setting P1-05 = 0 prevents this from occurring, but the user cannot go into the program mode during run.
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4. Auto Tuning and Motor Parameter Adjustment

Motor parameters for both Y- and -windings need to be set correctly for the optimum performance of the motor. This is especially vital for the vector control modes (either open loop vector mode [without PG] or flux vector mode [with PG]). The VS626MC5 drive has a built-in auto-tune feature for the vector modes (open loop vector and flux vector) to help the user set the motor parameters correctly for the optimum performance of the motor and drive in combination. 4.1 Tune-up Procedure The following describes the step-by-step procedures for auto-tuning and adjusting the motor parameters Step 1) Obtain motor data Obtain the following data from the motor used (required to start auto-tuning and to set the proper motor data): 1. Voltage level of AC power supply 2. Number of motor poles 3. The following data for both windings (Y and ) a. Frequency at design base speed b. No-load voltage at base speed c. Full load current at base speed d. Full load base speed in rpm or full load slip frequency e. Maximum frequency f. No load voltage at maximum speed (if different from 4) g. Leakage inductance (if available) Step 2) Selection of Inverter Select an inverter according to the motors full load current. The inverters rated current (A) must be equal or larger than the motors full load current (A). Note that high speed spindle motors are commonly high current, low voltage type, and in such a case, it may be necessary to size up the inverter to match the motor current. Step 3) Wiring Wire the inverter, motor, magnetic contactor, 24VDC power supply, and encoder. (See figures 2.4 and 2.6 for examples.)
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Step 4) Parameter check before auto-tune Before auto-tuning and testing, set-up or verify the following parameters: (Refer to 3.2. Parameter Set-up and Adjustment for proper set-up.) A1-01 (Access mode) = 4 (advanced) A1-02 (Control method selection of Motor 1) = 2 (open loop vector) or 3 (flux vector mode) B1-02 (Run source) = 4 (/Y) E1-01 (Input voltage setting): Set inverter input voltage. E2-06 (Motor 1 leak inductance) and E5-06 (motor 2 leak inductance) = Calculate using the data and using Technical Sheet (EZZ007896). If there is no data, use the default value. E3-01 (control method selection of Motor 2) The setting of A1-02 must be the same as E3-01. O2-04 (kVA setting): Verify that it matches the inverter model number. P1-04 (Y-winding Sel): Step 5) Auto tune for Motor 1 Auto-tune to find the Motor 1 parameter setting in the following manner: 1. On the main menu of the digital operator, select Auto-Tuning. 2. On the auto-tune screen, input the following winding data to be set for Motor 1 parameters: Rated voltage : Set the no load voltage at base speed Rated current : Set the full load current at base speed Rated frequency : Set the base frequency Rated Speed: Set the base frequency at full load after slip Number of Poles: Set the number of poles Select Motor = 1 At the Tuning Ready? prompt, press the RUN key to begin auto-tuning. Note: In general, the following relationship exists: Base frequency of -winding = 1.732 x Base frequency of Y-winding 3. After successful auto-tune, write down the Motor 1 parameters (E2s).
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4. Repeat the auto-tuning (#2 through #3)and record the resulting parameters (E2s) for at least three trials. Verify for consistency. Take the average value and set the average values into E2 parameters as the final Motor 1 data.
Step 6) Auto-tune for Motor 2 Auto-tune to find the Motor 2 parameter setting in the following manner: 1. On the main menu of the digital operator, select Auto-Tuning. 2. On the auto-tune screen, input the following data of the winding to be set for Motor 2 parameters: Rated voltage : Set the no load voltage at base speed Rated current : Set the full load current at base speed Rated frequency : Set the base frequency Rated Speed: Set the base frequency at full load after slip Number of Poles: Set the number of poles Select Motor = 2 At the Tuning Ready? prompt, press RUN key to start auto-tuning. 3. After successful auto-tune, write down the Motor 2 parameters (E2s). 4. Repeat the auto-tuning (#2 through #3)and record the resulting parameters (E5s) for at least three trials. Verify for consistency. Take the average value and set the average values into E5 parameters as the final Motor 2 data. Step 7) V/f Pattern Adjustment After completing auto-tuning to find both Motor 1 and Motor 2 parameters, adjust the V/f patterns (E1s for Motor 1 and E4s for Motor 2). This is especially important when the maximum frequency is higher than the base frequency. Adjust E1-05 and E4-02 (maximum voltage), then set the maximum frequency of the -winding to both E1-04 and E4-01. It is essential to have the setting of E1-04 equal to E4-01 for the winding change to work properly. Step 8) Test Run from Local Mode If possible, test run the motor from local mode to verify that the winding change is done properly at the desired frequency range. Adjust the parameters on Table 3.3 if necessary.
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5. Troubleshooting
Table 5.1 shows the additional fault codes of VS-626MC5. Table 5.2 is a troubleshoot guideline to the problems related to winding change applications. If any of the faults described in Tables 5.1 and 5.2 occur, check the cause and perform a relevant corrective action. If the inspections and corrective actions do not solve the problem, contact your Yaskawa representative.
Table 5.1 Additional Fault Codes and Corrective Actions Fault Code OPE12 (Y/ Seq Fault) Description One of the following conditions occurred: 1. Multi-function digital inputs are selected to 80 (Y/ Change) and 16 (Motor 2 Select) at the same time. Multi-function digital inputs are selected to 81 (MC Ansback N.C.) and 82 (MC Ansback N.O.) at the same time. Multi-function digital inputs are selected to 80 or P1-01 (Changeover Freq) is not equal to zero, but B1-02 (Run Source) is not set to 4 (Y/ Seq). Wrong setting of H1 parameter (81 or 82) Magnetic contactor is not energized. Loose wiring 2. Magnetic contactor changed the winding unexpectedly. Defective magnetic contactor Correct the parameter setting Apply power to the magnetic contactor Correct wiring Replace the magnetic contactor Check Point Check the parameter setting Corrective Action Correct the parameter setting
2.
3.
One of the following conditions occurred: MCANS (MC Ansback Fault) 1. Expected answer-back signal from the magnetic contactor is not received within the time specified by P1-03.
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Table 5.2 Winding Change Related Failures and Corrective Actions Fault Motor does not change winding Possible cause / Checkpoint Is the magnetic contact answerback fault detection used? Magnetic contactor is not energized. Loose wiring on the magnetic contactor Defective magnetic contactor Wrong motor wiring Changeover trigger signal is not received (external winding change) Changeover frequency (P1-02) and/or hysterisis (P1-02) is not set correctly (internal winding change) Maximum frequency setting of motor 1 (E1-04) and motor 2 (E4-01) are not equal Magnetic contactor clicks more than once at changeover Wrong setting value of one or more of the following parameters (too large): L2-03 (PwrL Baseblock t) L2-04 (PwrL V/F Ramp t) B3-03 (SpdSrch Dec Time) C1-01 (Accel Time 1) OV (Overvoltage) occurs during winding change Setting value of L2-04 (PwrL V/F Ramp t) is too small. Heavy cutting is performed during winding change OC (Overcurrent) occurs during winding change Setting value of L2-03 (PwrL Baseblock t) and/or L2-04 (PwrL V/F Ramp t) is too small. Heavy cutting is performed during winding change Correct the parameter setting Avoid heavy cutting during winding change Correct the parameter setting Corrective Action Use magnetic contactor answerback fault detection (see section 2.3) Apply power to the magnetic contactor Correct wiring Replace the magnetic contactor Correct the wiring Correct the setting Correct the parameter setting
Correct the parameter setting Correct the parameter setting
Avoid heavy cutting during winding change
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Appendix A: Auto-Tuning and Parameter Adjustment Examples

Example 1: Using a general purpose AC induction motor in open loop vector mode In this example, the motor is a 20HP general purpose AC induction type, modified by the user for high speed spindle application. Originally the motor connection is Y-winding only (3 leads), but it was modified so that both Y and windings are available (6 leads). The rotor was re-balanced and the bearings were replaced with the high speed type to enable the maximum speed of 8000 rpm. The user prefers to the use internal winding change method. A Yaskawa magnetic contactor with answer-back will be used. The user wants to use motor 1 parameters for -winding and motor 2 parameters for Ywinding, and to perform the winding change in the 70~80Hz range. Step 1. Obtain motor data. The following motor data is obtained from the motor name plate: AC power supply voltage level = 230V Number of motor poles = 4 Y-winding data: Base frequency = 60 Hz No load voltage at base frequency = 200V Full load current at base frequency = 58 A Full load base speed = 1750 rpm Maximum frequency = unknown No load voltage at maximum speed = unknown Leakage inductance = unknown -winding data is unknown Step 2. Select an Inverter. The motors full load current at base speed is 58A and the inverters rated current must be at least this much. For the 200V class MC5 inverter, this is the CIMRMC52015 (rated current is 64A). Step 3. Wiring: Figure A.1 shows the wiring diagram required for this example.
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1 230V 17 18 3 230V R S T U V W 2 4 6 0V 9 8 11 10 +24V 13 X 14 15 16 HV-75AP3 17 9 11 X V Dual Winding Motor U Z
MC5
Y W
+24VDC Supply
Figure A.1 Example 1 Wiring Diagram
Step 4. Parameter set-up. The following parameters are set before auto-tuning: A1-01 = 4 (access mode = advanced) A1-02 = 2 (open loop vector for motor 1) B1-02 = 4 (Run source = /Y) E1-01 = 230V (Inverter input voltage) E3-01 = 2 (open loop vector for motor 1) H1-06 = 82 (Terminal 8: magnetic contactor answer-back, N.O.) H2-01 = 41 (Terminal 9-10: open magnetic contactor when motor 2 is selected) O2-04 = 8 (2015) (verify the inverter model #) P1-01 = 80 Hz (Y to winding change frequency) P1-02 = 10 Hz (Winding changeover hysterisis) P1-04 = 1 (Motor 2 for Y-winding) Use the default setting for all other parameters
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Step 5. Auto-tune for motor 1 parameters (in this case, -winding) as follows: a.) Select the Auto-Tuning from MENU b.) Input the following data from the digital operator: Rated Voltage = 200V (no load voltage at base freq. of -winding) Rated Current = 58A (full load amp at base freq. of -winding) Rated Frequency = 60 Hz (base freq. of -winding) Rated Speed = 1750 rpm Number of Poles = 4 Select Motor = 1 At the Tuning Ready? prompt, press RUN key to start auto-tuning. c. Auto-tuning was repeated successfully and the resultant motor parameters (E2) are as follows below. Set the average values in the corresponding parameters.
Parameter E2-02 E2-03 E2-05 E2-07 E2-08
1st Trial 0.62Hz 35.2A 0.158 0.47 0.71
2nd Trial 0.64Hz 35.6A 0.157 0.47 0.72
3rd Trial 0.68Hz 35.5A 0.157 0.48 0.72
Average 0.65Hz 35.5A 0.157 0.47 0.72
Step 6. Auto-tune for motor 2 parameters (in this case, Y-winding) as follows: a.) Select Auto-Tuning from the MENU
b.)
Input the following data from the digital operator: Rated Voltage = Rated Current = 200V (no load voltage at base freq. of Y-winding, assumed to be the same as -winding) 58A (full load amp at base freq. of -winding, assumed to be the same as -winding)
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Rated Frequency = 103.9 Hz (base freq. of Y-winding = 1.732 x base freq. of -winding) 3031 rpm (base rpm of Y-winding =1.732 x base rpm of winding) 4 2
Rated Speed =
Number of Poles = Select Motor =
At the Tuning Ready? prompt, press RUN key to start auto-tuning. c. Auto-tune #2 was repeated successfully and the resultant motor parameters (E5) are found as follows below. Set the average values in the corresponding parameters.
Parameter E5-02 E5-03 E5-05
1st Trial 0.62Hz 35.2A 0.158
2nd Trial 0.64Hz 35.6A 0.157
3rd Trial 0.68Hz 35.5A 0.157
Average 1.14Hz 20.5A 0.292
Step 7. The V/f patterns are adjusted as follows: E1-04 = 266.7Hz (maximum frequency of motor 1) E1-05 = 200V (voltage at maximum frequency of motor 1) E4-01 = 266.7Hz (maximum frequency of motor 2)
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The following table shows the resultant motor parameter setting. (Values appearing in boldface type indicate that they are different from the default value).
Table A.1 Motor Parameters Determined for Example 1 -Winding Parameter No. E1-01 E1-04 E1-05 E1-06 E1-07 E1-08 E1-09 E1-10 E1-11 E1-12 E1-13 E2-01 E2-02 E2-03 E2-04 E2-05 E2-06 E2-07 E2-08 Setting Value 230V 266.7Hz 200V 103.9Hz 3Hz 12.6V 0.5Hz 2.3V 0 0 200V 58A 0.65Hz 35.5A 4 .157 17.2% 0.47 0.72 satur. coef 2 E5-05 E5-06 E5-01 E5-02 E5-03 .292 17.2% 58A 1.14Hz 20.5A E4-01 E4-02 E4-03 E4-04 E4-05 E4-06 E4-07 Y -Winding Parameter No. 266.7Hz 200V 60Hz 3Hz 12.6V 0.5Hz 2.3V Setting Value Remarks Inverter V maximum Hz maximum volt base Hz mid Hz mid V start Hz start V mid Hz (2) mid V (2) base V f/l Amp at base f/l slip at base n/l Amp at base poles line to line leak inductance satur. coef. 1
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Step 8. Run the motor using local mode, and verify that the winding change is performed properly at the designated frequency. Adjust the parameters on table 3.3 if necessary. Example 2: Use a high speed dual winding spindle motor in flux vector mode In this example the motor used is a high speed dual winding spindle motor. The motor is equipped with a 1024ppr encoder with A and B phase, and the user prefers to use a flux vector mode. The user would like to control the winding change switching from the CNC, and needs to have the frequency detection 1 signal at a multi-function digital output for the winding changeover logic control. A Yaskawa magnetic contactor with answer-back will be used. The winding change should be performed between the base frequency to 5 Hz higher than that. Step 1. Obtain motor data. The following motor data is obtained from the motor manufacturer: AC power supply voltage level = 230V Number of poles of the motor = 4 Y-winding data: Base frequency = 20Hz No load voltage at base frequency = 128.4V Full load current at base frequency = 74.8A Full load slip frequency at base = 1.198Hz Maximum frequency = 33.3Hz No load voltage at maximum speed = 132.4V Leakage inductance = 1.2674mH (L1+L2) -winding data: Base frequency = 33.3Hz No load voltage at base frequency = 127.8V Full load current at base frequency = 86.3A Full load slip frequency at base = 0.681Hz Maximum frequency = 6000Hz No load voltage at maximum speed = 129.5V Leakage inductance = 0.4511mH (L1+L2)
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Step 2. Select an Inverter. The motors full load current at base speed is 86.3A for the -winding and the inverters rated current must be at least this much. For the 200V class MC5 inverter, this is the CIMR-MC52022 (rated current is 96A). Step 3. Wiring: Figure A.2 shows the wiring diagram required for this example.
1 230V 17 18 3 230V R S T 2 4 6 U V W
MC5
9 From CNC 10 7 CHW 8 MCANS 11 COM
PG-X2 Card (Option)
0V
+24V
13 X 14 15 16 HV-75AP3 7 9 11 X Y Z
+24VDC Supply
26 27
PG x
1024 PPR AB
To CNC
Figure A.2 Example 2 Wiring Diagram Step 4. Parameter set-up: The following parameters are set before auto-tuning: A1-01 = 4 (access mode = advanced) A1-02 = 3 (Flux vector mode for motor 1) B1-02 = 4 (Run source = /Y) E1-01 = 230V (Inverter input voltage) E2-06 = 25.7% (Leakage inductance calculated using Technical Sheet EZZ007896) E3-01 = 3 (Flux vector mode for motor 1) E5-06 = 5.7 % (Leakage inductance calculated using Technical Sheet EZZ007896) F1-01 = 1024 (PG pulses/rev) F1-05 = 1 (PG direction is cw)
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H1-05 = 80 (Terminal 7: external Y/ change) H1-06 = 82 (Terminal 8: magnetic contactor answer-back, N.O.) H2-01 = 41 (Terminal 9-10: open magnetic contactor when motor 2 is selected) H2-03 = 04 (Terminal 26-27: frequency detection 1) L4-01 = 33.3Hz (speed agree detection level) L4-02 = 5Hz (speed agree detection width) O2-04 = A (2022) (verify the inverter model #) P1-04 = 1 (Motor 2 for Y-winding) Use the default setting for all other parameters Step 5. Auto-tune for motor 1 parameters (in this case, -winding because of the V/f pattern at high speed) as follows: a.) Select Auto-Tuning from the MENU b.) Input the following data from the digital operator: Rated Voltage = 127.8V (no load voltage at base freq. of -winding) Rated Current = 86.3A (full load amp at base freq. of -winding) Rated Frequency = 33.3Hz (base freq. of -winding) Rated Speed = 980 rpm (base rpm of Y-winding, calculated from full load slip freq. and rated freq.) Number of Poles = 4 Select Motor = 1 At the Tuning Ready? prompt, press RUN key to start auto-tuning. c.) Auto-tuning was repeated successfully and the resultant motor parameters (E2) are as follows. Set the average values in the corresponding parameters.
Parameter E2-02 E2-03 E2-05 E2-07 E2-08 1st Trial 0.64Hz 39.7A 0.077 0.37 0.62 2nd Trial 0.64Hz 39.7A 0.077 0.37 0.65 3rd Trial 0.66Hz 40.0A 0.075 0.38 0.64 Average 0.65Hz 39.8A 0.076 0.37 0.64
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Step 6. Auto-tune for motor 2 parameters (in this case, Y-winding) as follows: a.) Select Auto-Tuning from the MENU b.) Input the following data from the digital operator: Rated Voltage = Rated Current = Rated Frequency = Rated Speed = 128.4V (no load voltage at base freq. of Y-winding) 74.8A (full load amp at base freq. of Y-winding) 20.0Hz (base freq. of Y-winding) 564 rpm (base rpm of Y-winding, calculated from full load slip frequency and rated frequency) 4 2
Number of Poles = Select Motor =
At the Tuning Ready? prompt, press RUN key to start auto-tuning. c. Auto-tune 2) was repeated successfully and the resultant motor parameters (E5) are found as follows. Set the average values in the corresponding parameters.
Parameter E5-02 E5-03 E5-05
1st Trial 1.17 Hz 21.8 A 0.198
2nd Trial 1.16 Hz 21.8 A 0.199
3rd Trial 1.15 Hz 21.9 A 0.198
Average 1.16 Hz 21.8 A 0.198
Step 7) The V/f patterns are adjusted as follows: E1-04 = 200Hz (maximum frequency of motor 1) E1-05 = 129.6V (no load voltage at maximum frequency of motor 1) E4-01 = 200Hz (maximum frequency of motor 2) E4-02 = 132.4V (no load voltage at maximum frequency of motor 2) The following table shows the resultant motor parameter setting (Values appearing in boldI-TI-97020-MC5 Page 29 of 31
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face type indicate that they are different from the default value).
Table A.2: Motor Parameters Determined for Example 2 -Winding Parameter No. E1-01 E1-04 E1-05 E1-06 E1-07 E1-08 E1-09 E1-10 E1-11 E1-12 E1-13 E2-01 E2-02 E2-03 E2-04 E2-05 E2-06 E2-07 E2-08 Setting Value 230V 200.0Hz 129.6V 33.3Hz 3Hz 12.6 V 0.5 Hz 2.3 V 0 0 127.8 V 86.3 A 0.65 Hz 39.8 A 4 0.076 19.5 % 0.37 0.64 E5-04 E5-05 .292 19.5 % E5-01 E5-02 E5-03 74.8 A 1.16 Hz 21.8 A E4-01 E4-02 E4-03 E4-04 E4-05 E4-06 E4-07 200.0Hz 132.4V 20Hz 3Hz 12.6 V 0.5 Hz 2.3 V Y -Winding Parameter No. Setting Value Remarks Inverter V maximum Hz maximum volt base Hz mid Hz mid V start Hz start V mid Hz (2) mid V (2) base V f/l Amp at base f/l slip at base n/l Amp at base poles line to line leak inductance satur. coef. 1 satur. coef 2
Step 8. Test run the motor and verify that the winding change is performed properly at the designated frequency. Adjust the parameters on table 3.3 if necessary.
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Appendix B: Parameter Modification List from G5 to MC5
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Inverter

Technical Information No. 97020 Date: 12/8/97

VS-626MC5 Spindle Inverter Supplemental Manual

Magnetic Contactor (for switching Y and ) Inverter

6-Lead Spindle Motor

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VS-626MC5 Spindle Inverter Supplemental Manual

2. Winding Change Application

6 Lead Motor Winding

Y-Winding (Y-Connection) Low Speed, High Torque

-Winding (-Connection) High Speed, Low Torque

Figure 2.1 Y and Windings

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VS-626MC5 Spindle Inverter Supplemental Manual

Y-Winding provides high torque at the low speed.

Freq. winding change done in this area

-Winding covers the high speed Figure 2.2 range.

Figure 2.2 Performance Curves of Y and Windings

Wide Constant Power Range:

Figure 2.3 Winding Change Application Performance Curve

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VS-626MC5 Spindle Inverter Supplemental Manual

1 230V 17 18 3 230V R S T U V W 2 4 6 0V 9 Change Winding 7 8 Common 11 10 +24V 13 X 14 15 16 17 9 11 X V Dual Winding Motor U Z

HV-75AP3 Magnetic Contactor MC Ansback

B1-02 = 4 H1-05 = 80H H1-06 = 82H H2-01 = 41H A1-02 = 2 E3-01 = 2

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VS-626MC5 Spindle Inverter Supplemental Manual

SpdSrch Dec Time b3-03

The ramp time is dependent on the accel timesetting.

Voltage recovery time L2-04 0 Torque Limit 64msec 50%

0% Total base block time

2nd motor parameter calculation time

Minimum baseblock time L2-03

During speed search RUN Command Motor 1 Motor 2

Figure 2.5 External Winding Change Sequence

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VS-626MC5 Spindle Inverter Supplemental Manual

1 230V 17 18 3 230V R S T U V W 2 4 6 0V +24V 13 X 14 15 16 17 9 11 x PG X V Dual Winding Motor U Z

HV-75AP3 Magnetic Contactor

B1-02 = 4 H1-06 = 82H H1-03 = 41H P1-04 = 1 A1-02 = 3 E3-01 = 3

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VS-626MC5 Spindle Inverter Supplemental Manual

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VS-626MC5 Spindle Inverter Supplemental Manual

Figure 2.8 Yaskawa Magnetic Contactor for Winding Selection

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VS-626MC5 Spindle Inverter Supplemental Manual

WY ye con nection Connection D elta co nn ectio n

M C An sback off M C An sback Fau lt

Figure 2.9 Magnetic Contactor Answer-Back Failure Detection

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VS-626MC5 Spindle Inverter Supplemental Manual

Ansback Det Time

0.20 ~ 1.00 sec

0: Motor 1 for Y 1: Motor 2 for Y 0: Disabled 1: Enabled

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VS-626MC5 Spindle Inverter Supplemental Manual

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VS-626MC5 Spindle Inverter Supplemental Manual

Quick start (A1-01 = 2) Advanced (A1-01 = 4)

Basic (A1-01 = 3) Setting/Reading disabled

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VS-626MC5 Spindle Inverter Supplemental Manual

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