VE Training in 2006 Tainan Plant Dunrong Lee Taoyuan Plant Zhiming Xu 2006/12/18.

VE Training in 2006VE Training in 2006

Tainan Plant Dunrong LeeTaoyuan Plant Zhiming Xu

2006/12/18

1. VE Presentation

2. Q & A

3. Demo

4. Actual Operation

Outline

1. Product Specifications and Features

2. Differences between VE and V

3. New Accessories of VE series

4. Functions

5. Applications

Model Number VFDxxxVxxA-2

Models

3-phase 460V 340~510Vac

3-phase 230V 180~265Vac

Voltage Tolerance0.75 1.5 2.2 3.7 7.55.5 1511 18.5 22 30

Applicable Motor Output (kW)

4537 55 75

Built-in Brake Chopper

Built-in Brake Chopper

Built-in DC Reactor

Built-in DC Reactor

B Frame

B Frame

C Frame D Frame E1 Frame

C Frame D Frame E Frame E1 Frame

*2. Fan cooling for all series (except 1HP)*3. No built- in EMI for all series *4. Built-in digital keypad(KPV-LE01)

*1. VFD110V43B-2 is C Frame under development VFD550V/750C 43C-2 is E1 Frame under development

3-p

ha

se

23

0V

1

80

~2

65

Va

c

Two Rated CT/VT

007 015 022 037 055 075 110 150 185 220 300 370 450 550 750Codes

5 7.5 11 17 25 33 49 65 75 90 120 146 CT Rated Current

CT: It is applied to constant-torque load. Take conveyer belt for example. Its necessary torque does not change with the motor speed. And constant torque usually needs larger starting torque. As the motor generates heat easily when constant torque is applied to lower speed, it is better to increase the horsepower or use the motor special for AC motor drive with constant cooling fan. VT: It is applied to variable-torque load. Such as pump, fan…etc. They are centrifugal machines, who use AC motor drive usually for energy saving. For example, when a fan is running at 50% of the full speed, its necessary torque is smaller than when it is running at full speed. As for the drive with variable torque, it can provide the motor only with necessary torque to save energies. In the applications like this, the maximum transient loads needn’t to be provided extra power. So the drive with variable torque is applied widely for its load endurance. What’s more, the overload current endurance of the drive with constant torque is 150% of rated current for 1 minute, while the drive with variable torque only 120% of rated current for 1 minute because the current of centrifugal machines rarely exceed the rated current. In addition, its starting torque is smaller than that of constant torque.

CT Overload Endurance: 150% of rated current for 1 minute, VT Overload Endurance: 120% of rated current for 1 minute

* Designed for standard motor application

1 2 3 5 7.5 10 15 20 25 30 40 50Applicable

Motor Output (HP)

6.25 9.4 13 21 31 41 61 81 93 112 150 182 VT Rated Current

1.5 2.5 4 7.5 10 15 20 25 30 40 50 60Applicable

Motor Output (HP)

3-p

ha

s 4

60

V

34

0~

51

0V

ac

3 4.2 6 8.5 13 18 24 32 38 45 60 73 91 110 150CT Rated Current

1 2 3 5 7.5 10 15 20 25 30 40 50 60 75 100Applicable

Motor Output (HP)

3.8 5.3 7.5 10 16 22 30 40 47 56 75 91 113 138 188VT Rated Current

1.5 2.5 4 7.5 10 15 20 25 30 40 50 60 75 100 125Applicable

Motor Output (HP)

Mo

tor P

rotectio

n

Maxim

um

O

utp

ut

To

rqu

e L

imit

Startin

g

To

rqu

e

VE Standard feature

Tu

nin

g

Tech

niq

ue SPWM tuning

technique

Co

ntro

l Mo

de

V/f control /PGFOC vector control /PGSVC(sensor less)Torque control /PG Position controlPID

Sp

eed

Co

ntro

l R

ang

e

V/f control 1:10FOC vector control 1:100FOC+PG1:1000

0.5Hz 150%0Hz 150% for FOCPG mode

Sp

eed

con

trol

accurac

y FOC±0.2%FOC+PG ±0.02%

Sp

eed

Resp

on

se A

bility

FOC+PG 40Hz

Max 250% of rated current

To

rqu

eA

ccura

cy ±5%

0~ 600 HzVEH up to 3600Hz

Acce

l/Dec

el Ti

me 0.00~ 600.00 sec

0.0~ 6000.0 sec

Accel/

Decel

Cu

rve

4 steps S curve for set Acc./Dec. start and stop time independently

Accel/ D

ecel S

teps

1. 4 group Acc./Dec. time2. Jog Acc./Dec. time3. Auto Acc./Dec. setting

Vo

ltage/

Freq

uen

cyRandom V/f curve setting by using 4 independent points1.5/2.0 power curve

1. 2 sets of electronic thermal Protection2. PTC temperature sensor3. 2 sets over torque protection 4. Current limit5. Stall prevention during acceleration6. Stall prevention during operation

Overlo

ad

En

du

ranc

e 150% 60sec200% 2sec

AC

Mo

tor D

rive P

rotectio

n

1. Over-current: 300% of rated current 2. Overload: 150% 60sec 200% 2sec3. Over-voltage: 290/580Vac4. Low-voltage: 135/269Vac5. Current leakage: 50% of rated current6. Electric shock MOV7. Over-temperature: 90oC8. Compensation for the momentary power loss9. Phase loss protection

Param

eter sT

un

ing

1. Motor dynamic/static test2. Inertia estimation3. High- speed field weakening curve estimation

Po

sition

Co

ntro

l

0 speed control PI gain setting16 point to point control P to PHome return positioning 16 point position instructionPulse that following speed and locationDivision frequency output

VE Advanced feature

Sp

ecialized

Ap

plicatio

n

Double rated motor Y- switch△Light-load auto energy-savingDEB decelerationMechanical braking control10 convenient communication block transmitSerial I/O pulse position controlTorque and speed mode switch

En

viron

men

tal

NEMA 1/IP21Operation temperature: -10oC~40 oCStorage temperature: -20oC~60 oCAmbient humidity: below 90%RHVibration: 20Hz below 1G 20~60Hz 0.6GFan coolingAltitude limit: 1000m

Co

ntro

l Interface

Dual communication port RS485 KPV-CE01Communication KeypadPG Encoder Feedback cardBUS GatewayMonitor card and Software Digital I/O, analog I/O

VFD-VE seriesVFD-V series

Differences between VE and V (hardware-control board)

7045

PG03 card

7149

Monitor card

PG card terminals

DFMoutput selection J5

SW1:Sink/Source mode

AFM output selection J8

ACI input selection J4

Same power board

I/O pin to pin

EDCM REV MI2 MI4 MI6

+24V FWD MI1 MI3 MI5

Multi-function digital input terminalSW1:Sink/SourceMI1:02-01(3-wire designated terminal)MI2:02-02MI3:02-03MI4:02-04MI5:02-05MI6:02-06(TRG-designated terminal)

MO1 MO2

MCM

Multi-function digital outputMO1:02-13MO2:02-14(Open collector output type)

ACIAUI

ACM+10V AVI

Multi-function analog input terminals 03-00~03-17AVI:0~+10V 10bitsACI:4~20mA or 0~+10V selected from J4AUI:-10~+10VCaution: J4 cannot be set while the power is applied.

AFM

AFM: multi-function analog output terminal 03-18,19,20It is selected from J8 that output is 0~10V or 0~20mA.

DFM

DFM: Digital frequency output terminal 02-18It is selected from J5 that Output type is voltage or open collector.

MRC

MRA

RB

RA RC

Multi-function Relay outputRelay 1:02-11(RA,RB,RC)Relay 2:02-12(MRA,MRC)

I/O Control Terminal

1. All digital terminals use photocoupler. 2. All analog circuits are no isolated.

Differences between V and VE (Keypad)

V type VFD-PU05

VE typeKPV-CE01

It can memorize 2 groups of parameters. It can memorize 4 groups of parameters.

Speed Feedback Card of VE (PG)

1. 5V/12V encoder power supply2. PG1: encoder feedback 3. PG2: pulse command input4. No pulse output terminal5. Acceptable encoder signal types: Open Collector, Line drive, Voltage and Complementary type6. Bandwidth: 300kP/sec

1 EMV-PG01X

1. 5V/12V encoder power supply2. PG1: encoder feedback3. PG2: pulse command input4. Division Pulse output: Open Collector type5. Acceptable encoder signal types: Open Collector, Line drive, Voltage and Complementary type6. Bandwidth: 300kP/sec

2 EMV-PG01O

1. 5V encoder power supply2. PG1: encoder feedback3. PG2: pulse command input4. Division Pulse output: Line drive type5. Acceptable encoder signal types: Open Collector, Line drive, Output Voltage and complementary type6. Bandwidth: 300kP/sec

3 EMV-PG01L

FSW3Encoder Power supply VP terminal 5V/12V switch

FSW1PG1 encoder signal

mode switch

FSW2PG2 pulse signal

mode switch

A1 A2A1 B1 B1 Z1 Z1 DCM VP A2 B2B2

PG1 motor encoder feedback input terminal Power supply terminal PG2 pulse command input terminal

PG Card-EMV-PG01X/O/L

PG1 output terminals of pulse frequency division

A/O

A/O

B/O

B/O

Z/O

Z/O

E

VP

DCM

A/O

B/O

Z/O

01L01O01X

Lin

e D

rive

Ou

tpu

t T

yp

e

Op

en

Co

llec

tor o

utp

ut

Ty

pe

EMV-PG01O

EMV-PG01X

1. Can be applied to winding & tension systems

2. VE’s Acc./Dec. characteristics can be use in more type of CNC machine

3. PDFF function and load inertia tuning

4. Stable run at zero speed and home search function

5. Improvement of noise endurance and signal treatment with new PG card

6. Monitor card and software which makes parameter setting and problems

solving more convenient.

7. Y- switch control for wide-range motor in CNC machine field△8. Easy parameter setting and control for the elevator

9. Light load auto energy saving function to avoid motor burn-out duo to

long time running especially in CNC machine application

10. Motor temperature feedback (PTC) function for motor over heat protection

Differences between VE and V (software)

RS

-48

5 Co

mm

unica

tion P

ort

RS

-48

5 Co

mm

unica

tion P

ort

VE Communication Connection Diagram

RS485

Keypad Communication Port

V/f FOC

Control Parameters

Position Control

Torque Control

Speed Control

Torque

Torque Control at Low Speed

Torque Control at Zero Speed

Frequency： the function of running speed Voltage: constant V/Hz to maintain constant flux.

Frequency, voltage and vector ( phase relations among magnetic field, rotor and stator) use precise current loop adjustor to control current.

No control. Speed error is relevant to the motor slip curve. The torque is proportional to the slip.

To calculates the optimum slip so that can generate maximum torque and apply it into the whole speed range.

Open-loop control. The running speed is not linear in the speed range.

It provides linear speed control from 0 to basic speed.

Slip induces rotor current to generate torque. Because current and toque can not be instantly controlled, so dynamic response is not good.

Magnetic rotor’s flux vector value would be precisely controlled, so that torque can be controlled instantly.

Can not be done cause couldn’t control motor torque and it is open-loop control which mean no encoder feedback.

Vary precisely because the current of generating torque and the excitation current can be precisely and separately controlled. Also It is available to use encoder feedback for position control.

Worse; because frequency reduced will cause rotor’s impedance increase which makes stator and rotor’s coupling become smaller. Armature current does not generate proportional torque which makes motor running efficiency worse.

Better: Rotor’s flux vector can be controlled so that it makes rotor’s flux and current vector maintain at 90°.

Stator and rotor has the minimum coupling effect which normally only 30% of the rated torque

It can be up to 150% of rated torque.

AC Motor Drive Comparison between V/Hz and FOC

FOC Introduction

The FOC control is a method that controls 3-phase AC motor drive like DC motor, whose torque is proportional to its output current .

DTC : Direct Torque Control

V/F FOC DTC

No Encoder Feedback

V/F+PG FOC+PG

Encoder Feedback

Speed Control

Torque Control

FOC DTC

No Encoder Feedback

FOC+PG

Encoder Feedback

Control Family

Variable Speed Control Family of AC Motor

As AC motor has been widely used in industry, the methods relevant to variable speed control have had developed a lot with technology. According to its frame and method, they are sorted as below:

Pulse width modulation (open loop)

VVCF ControlCVVF Control VVVF Control

Control family

Slip tuning control (closed loop)

Slip ratio of voltage source inverterSlip ratio of current source inverter

FOC (closed loop)

(Direct Field-Oriented Control)(Indirect Field-Oriented Control) (Slip Torque Control) (Field Acceleration Control)

Variable speed control without sensor (Virtual control of closed circuit)Magnetic field control with motor speed estimated and voltage/current feedback Magnetic field control with motor speed estimated and current feedback

FOC Introduction

e

*Reference AC Motor Control by Changhuan LiuVE adopts indirect method of the summation of rotor’s magnetic orientation and encoder

FOC Family

1.Install flux-meter to measure flux angle.2.Estimate flux angle.

Direct method Rotor’s magnetic

orientation

Stator’s magnetic

orientation

Gas’s magnetic orientation

Flux reference coordinatesMethods of get synchronous flux angle Motor Mechanical Speed

With Feedback Sensor

No Feedback Sensor

Indirect method

Use the summation of motor slip frequency and motor’s electric speed then after integral to get the flux angle.

AC motor’s torque would in direct proportion to stator current

FOC Profile

Stator

Rotor

Id

Iq

Coordinates conversion

w

ids

iqs

Ids flux current

Iqs torque current

Rotor and Id axes overlaps， ids maintains fixed value

D.C.

w

Is

Ia

Ib

Ic

90o 180o 270o 360o 450o 540o

Ia Ib Ic Ia

T

IIa+Ib+Ic=0

Ia+Ib+Ic=Is

T

I

To calculate Is’s vector sum by mathematical integralIs includes two elements of flux Id and torque IqIt changes the phase’s space position via control Ia Ib and IcUsing instant math mode and according to the position to separate Is into Id flux and Iq torque.Id as the element of DC generates magnetic field while Iq as the element of current generates torque. Keep Ids steady as constant while output torque can be changed directly by changing Iqs.

Yaskawa G7Mitsubishi

A500

(SVC)

ABB ACS800

(DTC)Mode 1

(SVC)

Mode 2

(FOC)

Step-load performance

Low speed 2 4 1 3

Mid speed 2 4 1 3

High speed 2 4 1 3

＊ Currently Delta use SVC (Sensor-less Vector Control) control mode. The FOC (Field Oriented Control) is under development.

＊ It is marked mainly according to the dynamic response and steadiness.

Comparison between FOC and SVC

Brand name

Order of characteristics

Wm(speed control)

Wr

ide

iqe (torque control)

Qe

iq

current control

flux control

2/3

decouple

iqe

tr*ide

ibiaWsl

id

Control diagram

This is torque control

*Reference AC Motor Control by Changhuan Liu

Indirect rotor’s magnetic orientation control diagram

Rs Lls Llr

RrLmVs

Induction Motor Equivalent Circuit and Parameters Auto-tuning

05-0605-18

05-0705-19

05-0805-20

05-0905-21

Traditional Electrical engineer Equivalent circuit

Rs Lσ

RRLMVs

VE Equivalent circuit

Rs : Stator resistance Lσ : Stator’s inductanceRr : rotor’s inductanceLm : Flux mutual inductanceLlr : rotor’s leakage inductance

Parameter adjust and V/f mode Trial RunThis is mainly means spindle motor. Because the spindle motor nameplate normally will not match its spec. So, take V/F trial run first.

Parameters are set as factory values and make sure all the wiring is correct.

1

To set up:Maximum frequency: 01-00Rated frequency: 01-01Rated voltage: 01-02Control mode 00-10=0( VF control mode)

Set the Running frequency as the motor's rated frequency.

2

RUN

NOIs the current and speed logically?

Is the current and speed logically?

To check output current and motor’s speed.

3

Increase Frequency (slowly) to maximum operation frequency.

4

Congratulations! V/F curve is correct and motor can run at high speed.

STOP

5

Please re-adjust V/F curve and operate again

STOP6

Motor may not run at over frequency.

STOP7

YES

NO

YES

Check point1.Does current near or exceed full load current?2.Is the slip too big?

Check Point1. Does current decreases when speed is increasing2. Is the slip too big?

Motor Parameters Auto- tuning

YES

NO1

Can the load be removed from motor?

3.2

Input motor no load current 05-05(guessed)

Set 05-00 to 2(static tuning), then press RUN

3.3

Set 05-00 to 3(static tuning and motor’s axis should be locked), then press RUN. (If it not locked motor will run)

Parameters are set as factory values and the all wiring is correct.

1

according to motor’s nameplate:Rated voltage: 01-02Rated frequency: 01-01Full loaded current: 05-01Motor power: 05-02Rated speed: 05-03motor’s poles: 05-04

According to motor’s power to input suitable ACC./DEC. time: 01-12, 01-13

If motor’s base frequency is bigger than maximum operating freq.(01-00), please set 01-00 as the same with 01-01

2

Set 05-00 to 1(dynamic tuning), then press RUN. (Notice: motor will run)

3.1

NO2

For a while, it is completed when motor has stopped. This process need about 30 s, with small motor. For large motor, it determined by ACC./DEC. time.

It will display AUE when it fails. Please check whether wiring and parameters are all correct.

Check parameters05-00,05-06,05-07,05-08,05-09 whether have successfully been written in

4

FOC+PG control mode -Trial Run

Select PG feedback card that is suitable to encoder power source and signal type.

1

Correctly installed into drive’s slot and wiring correctly.

Input PPR of encoder : 10-00

2

Input encoder’s signal type: 10-01

EMV-PG01X

EMV-PG01O

EMV-PG01L

Set control mode 00-10= 3 (FOC+PG)

Set lower Fcmd for testing

RUN

Any PG error or abnormity

speed?

Check other frequencyA

Change running direction

STOP

PGF1 check parametersPGF2 wire disconnectedPGF3 feedback stallPGF4 slip abnormity

B

Operate again after elimination

Current abnormity

CCheck the numbers of pulse of the encoder weather is the same with parameters10-00Check whether the settings of mechanical electronic gear ratio 10-27,10-28 is all rightOperate again after elimination

YES

NO

Inertia Estimation

Check the coupling of load and motor are all correctly

Adjust ACC./DEC. time according to load inertia. The less load inertia need shorter ACC./DEC. time

2

RUN

NO

YES

Do FWD/REV running quickly and observe the change of parameters 11-01

3

FWDREV

Parameters 11-01 has convergence

or not

Parameters 11-01 has change or not

Stop motor’s running4 Press the PROG/DATA

key for set last convergence into 11-01PROG

DATA Set 11-00 as 0

Inertia is estimated wrongly. Decrease the frequency command and estimate again.

Continue to estimate

1

Confirm drive control mode 00-10=3

Set Fcmd to 2/3 of motor’s rated frequency

Set 11-00 as 2

YES

NO

Convergence speed is according to different load inertia. The bigger inertia convergence is slower and needs do more test

0 2 4 6 8 10 12 14 16 18 20-60

-40

-20

0

20

40

60

0 2 4 6 8 10 12 14 16 18 20800

1000

1200

1400

1600

1800

(Hz)

(PU)

SpdRef

inertia

Inertia Estimation

Frequency command

Load inertia value

System will run

Convergence

Vector control diagram

00-20P

I

+ +

+

++

÷

-

Current control

PWM00-17

M

coordinateschange

Encoder10-00, 10-01

Actual frequency

Current feedback

Weak magnetism curve

Torque bias

07-28

No bias

According to 03-00 analog multi-function

According to 07-28 torque bias

According to multi-function input terminals

Torque limit

ASR low-pass filter 10-09

07-32~07-35

10-21/10-22 zero speed PI10-04/10-05 middle speed PI10-06/10-07 high speed PI

Base voltage/current: 01-01/01-02

Motor’s parameters05-01~05-09

Source of frequency command

PI adjustor

Vector control -Adjust Methods

YES

Estimate Jm value

NO

Set auto gain adjustment 11-00=1

Adjust 11-02, 11-03 & 11-11 separately for difference speed which its response need

Adjust if it is require 11-04 (PDFF function)

Adjust by requirement 10-08 (ASR1/ASR2 switch frequency)

Adjust by requirement 07-32~35 (torque limit)

Manual gain adjust11-00=0 (factory setting)

Adjust 10-04, 10-05 : middle speed10-06, 10-07: high speed 10-21, 10-22: 0 speed

Adjust by requirement 10-09(normally no need to adjust)

Vector control- PI Adjustor

To adjust 11-11 for output higher torque at 0Hz

10-0610-07

10-0410-05

10-2110-22

0 Hz 10-08 Hz

PI

5 Hz 5 Hz

(PI adjustment-Manual gain adjust)

11-03

11-02

11-11

0 Hz 10-08 Hz

PI

5 Hz 5 Hz

1.Must known inertia first2.Set 11-00 as 1

(PI adjustment-auto gain adjust)

To adjust 10-21, 10-22 for output higher torque at 0Hz

Beside traditional PI control, VE-series also provides PDFF function to reduce overshoot. To enable PDFF function, it need to:

1.Must know inertia first

2.Set 11-00 to 13.Adjust 11-04 (the larger number is set and the suppressed overshoot function will be better. But it will cause worse system response)

Vector control-PDFF

It is recommended to disable this function (Pr.

11-04=0) for Y- △connection switch and

ASR1/ASR2 switch application

PDFF

PI

For the spindle application, the adjustment method is1. To run the motor at its max. frequency2. Monitor the output voltage3. Adjust settings of Pr.11-05 (motor 1) or Pr.11-06 (motor 2) to make

the output voltage reach motor rated voltage4. The larger number it is set, the larger output voltage you will get.

Vector control-Flux Weakening Curve

Fbase

11-05 / 11-06

Hz

N-m

Vector control-Speed Feedforward

For the spindle motor fast ACC./DEC application

The adjustment method is:1. With factory default and it can not meet the requirement of

system ACC./DEC. time

2. Adjust 11-12, the larger number you set, the faster response you

will get.

3. For general, no need to adjust.

10-23Position feed forward

Position Control diagram

P

I

+ +

+

÷

-

Currentcontrol

PWM00-17

M

coordinateschange

Encoder

Actual frequency

Current feedback

Weak magnetism curve

Toque bias

07-27

No bias


According to 07-28 toque bias

According to multi-function to input terminals

Toque limitASR low-pass filter 10-09

07-32~07-3506-12


10-0010-01

PI adjustor

P

D

Integral

+

-

++

Actual position

10-21Positioncommand

Frequency command

Tuning-Position

10-23

P

D+ +

+Position command Frequency command

Actual position

10-21

Positionselection

10-19

I/O serial position

PG card Pulse command

According to multi-function Input

-

10-19 internal position (Home) Multi-input uses external terminals to set 34 multi-step position

function enable (multi-point position) Serial, uses external terminals to set 41 serial position clock and 42

serial position (multi-point position)All above need to use external terminals to set 35 position control

PG reference input, use 00-20 = 5, 10-15 PG ref input EnableExternal terminals set 37 pulse position command input enable (position following)

Torque Control diagram

P

I

+ +

+

+

÷

-

Currentcontrol

PWM00-17

M

Encoder

Actual frequency

Current feedbackWeak magnetism curve

Toquebias

07-27

No bias


According to multi-function to input terminals

Toque limit06-12

ASR low-pass filter 10-09

Toque limit07-32~07-35


10-0010-01

PI adjustor

The source of toque command can through 07-21 to select KP/communication/analog

Toque limit

Toque command filter time 07-23 s

pe

ed

/toq

ue

Mo

de

se

lec

tion

+

Speed limit command is selected by 07-24 , 00-20 or 07-25/07-26

coordinateschange

According to 07-28 toque bias

06-12 current limit06-12 current limit

06-12 current limit 06-12 current limit

Torque Limit of FOC

Quadrant 1

Quadrant 4Quadrant 3

Quadrant 2

Forward motor modeReverse generator mode

Reverse motor mode Forward generator mode

ForwardReverse

speedspeed

Positive torque

Negative torque

The minimum of the comparison result of the three layers will be torque limit

Analog terminal 03-00~02d7: positive torque limitd9: regenerative torque limit d10: positive/negative torque limit

Analog terminal 03-00~02d7: positive torque limitd10: positive/negative torque limit

Analog terminal 03-00~02d8: negative torque limitd9: regenerative torque limit d10: positive/negative torque limit

Analog terminal 03-00~02d8: negative torque limitd9: regenerative torque limit d10: positive/negative torque limit

Reverse regenerative torque Limit 07-35

Forward regenerative torque Limit 07-33

Forward motor torque Limit 07-32

Reverse motortorque Limit 07-34

Torque Control-Speed Limit Method

Method 107-24=0 Speed limit is from Pr.07-25,Pr.07-26

Torque

frequency/speed

Forward 07-25Reverse 07-26

Method 2 07-24=1 Speed limit is from Pr.00-20(Source of the frequency command )

Torque

frequency/speed

Reverse 00-20Reverse 07-26

Toque

frequency/speed

Forward 07-25Reverse 00-20

When 07-24=1,Speed limit is positive,then negative speed limit is determined by 07-26

When 07-24=1,Speed limit is negative, then positive speed limit is determined by 07-25

Torque Control

Speed Control

Torque Control

Speed Control

ON

RUN

Speed/Torque Control Switch

ON

Multi-function InputDefault: d26 Torque/Speed Mode Switch OFF OFF

Speed LimitSpeed

CommandSpeed Limit

Speed Command

Torque Command

Torque Limit

Torque Command

Torque Limit

Run/Stop

03-00~03=d1AVI/AUI/ACI:Fcmd

03-00~03=d2AVI/AUI/ACI:Tcmd

Control ModeSpeed Control

(Ramp to Stop)

STOP STOP

Speed/Torque Control Timing Chart00-10 =d03/d04

Motor Y- Switch Function (Wiring)△

Y- connection switch: can be used for wide range motor△Y connection for low speed: higher torque can be used for rigid tapping

△ connection for high speed: higher speed can be used for high-speed drilling

IM

U V W

X Y Z

△connection control02-11~14=d32

Y connection control02-11~14=d31

RA

MRA

UVW△connection is completed

02-01~06=d30

Y-connection is completed02-01~06=d29

MI1

MI2

Wiring diagram of Y- connection switch function△

Motor Y- Switch Timing Chart△

ON ON

ON ON

ON

ON

If switch F setting is 60Hz, then real switch F is 62Hz at acceleration

05-11 Y-△Switch frequency

Real switch F is 58Hz at Deceleration

Motor speed/frequency

1. Here motor is in free run status, VFD stops outputting

2. Motor speed will decreases according to load inertia

Y-connection control signal output

Y-connection confirmation input

△connection Control signal output02-11~14=d32

△ connection confirmation input02-11~14=d30

Mechanical spring time

02-11~14=d31

02-11~14=d29

Switch waiting time is 05-30 min.=0.2sec

Band is 2Hz

RUN

Mechanical brake release

DC brake DC brake

Brake Control Function

Mechanical brake Control function can work together with zero speed holding or DC brake to get the purpose of load would not slide or pause when starting up. So it can be widely used in the field of elevator and crane.

Motor speed/frequency

02-31 brake release delay timeBrake delay release output 02-11~02-14=d12

Mechanical brake braked braked

07-02 DC braking time during start

07-03 DC braking time during stop

RUN/STOP STOP

DEB Function (Deceleration Energies Regeneration)

The DEB (Deceleration Energy Backup) function is the AC motor drive decelerates to stop after momentary power loss. When the momentary power loss occurs, this function can be used for the motor to decelerate to 0 speed with deceleration stop method. When the power is on again, motor will run again after DEB return time. ( Can be applied to high speed spindle motor)

It doesn't need multi-

function terminals

DC BUS

LV level

Soft-start relay ON level (LV+30V)

DEB return time counting level (LV+30V+58V)

07-14

Soft-start Relay

DEB function is activated

Output frequency

DEB return time

Pr. 07-13 DEB DEC. Time

Status 1: Insufficient power supply due to momentary power-loss/ unstable power (due to low voltage)/ sudden heavy-load

When Pr. 07-14 is set to 0, the AC motor drive will be stopped. Drive will not ACE. To the frequency before DEB even the power has return

Status 3:Some brand can enable DEB function via external terminal. For VFD-VE series, the DEB function can be used by combine deceleration time and EF function. For example, in textile machinery, you will hope that all the machines can be decelerated to stop to prevent broken stitching when power loss. In this case, the system controller will send a signal to the drive, thus, it can be done via combine DEB and EF function.

DEB Function (Sequel)

DC BUS voltage

LV levelSoft-start relay ON level (LV+30V)

DEB return counting time level (LV+30V+58V)

07-14

Soft start relay

DEB function is activated

Output frequency

DEB return time

DEB DEC. time 07-13

Status 2: unexpected power off, such as momentary power loss

•This function is used to enhance the unstable speed/position due to analog resolution no enough. •It needs to use with external input terminals (Pr 02-11~Pr.02-14 set 43).•Set Pr. 10-25 as analog input resolution switch frequency

Max. frequency for resolution switch of analog simulation value

Resolution switch02-11~02-14=d43

FORWARD REVERSE

AUI 0V

AUI +10V

AUI -10V

Max. output frequency Pr.01-00

Resolution switch frequency

Pr. 10-25

Output frequency

0Hz

Max, frequency switch waiting time

Max, frequency switch waiting time

Spindle motor (0.75kW~11kW) Main applying function:0~3600Hz

High speed curving machinePCB drilling machine

Spindle motor

Market Application 1

Elevator (7.5kW~22kW) (90m/min), craneMain applying function: FOCPG control, auto DC brake and mechanical brake control


Drilling, lathe, milling and curving Integrated CNC machine, tools boxMain applying function: home position, multi-step position, pulse command position , electronic gear ratio, mechanical gear ratio, Y- start-up switch and speed search△


Printing machineMain applying function : toque control (TQRPG)

Surface and intaglio printing machine, flexible printing machine


Customer allow toreceive

OK OK OK Testing

Controler Franc Centrido 新代智元Driver Model 075V23A-2 075V23A-2 055V43A-2 075V23A-2Motor power 5.5kW 5.5kW 5.5kW 3.7kW( Hidden principal axis)

Encoder 1024ppr 1024ppr 1024ppr 1024pprApllying machines Lathe 車铣複合機 Milling machine Lathe

Original usingbrand

Franc VFd-V KEB Fuji MS5

Spindle speed 3000rpm 6000rpm 12000rpm 6000rpmMotor speed 3000rpm 6000rpm 8000rpm 6000rpm

Accel/decel time No requirement 2 seconds No requirement 3.5 secondsPosition No Yes Yes 12

Requirment ofprocessing

characteristics

1500 rpm flexible tapping position and tools change High/low speed 0.5mm

Y-D switch No No No Yesmulti-step position No No No YesPulse command

inputNo No No

V command Yes AVI: 0~10V YesCustomer profits Cost down Improvement of the old

problems of instability andvibration of V positioning

The whole machine adoptslocal components

Cost down

V2 problems V command linear problems No Quick positoning whenmoving

Nots Currently, no feedbackproblems from customers

Been produced Testing Testing

Base problem New functions is need

Application Example 1

Application 1 (flexible tapping-Wiring)

FWD

REV

AVISpeed command

MI1

Accel time 1 and 2 switch

RLY1Driver is ready

MO1Speed attained

MO2Zero speed including stop

U.V,W

1024pprLine-drive

PG in

VFDcontroller

Motor

Spindle1024pprLine-drive

Application 1 (flexible tapping-Time chart)

SpdRef

Run StopFWD

MI1 =1/2 accel/decel switch

Drilling Flexible tapping

Run

1st step accel/decel 2nd step accel/decel

Z axis in Spindle decelerateZ axis doesn't move

Principle axisZ 軸 out

2 3 4 5 6 7 8 9 10 11 12-50

0

50

100

2 3 4 5 6 7 8 9 10 11 12-100

-50

0

50

100

2 3 4 5 6 7 8 9 10 11 12-100

-50

0

50

100

(Hz)

(A)

(A)

SpdRef SpdFdb

iqRef

ias

Drilling Flexible tapping

Application 1(flexible tapping-Wave Form)

1000rpm

Application 1 (High-Speed Position -Wiring)

FWD

REV

AVISpeed Command

MI4Position Control ON

RLY1 Error indication

MO1

At speed (Setpoint at running)

MO2

Zero Speed including Drive Stop(INV fout)

U.V,W

PG in

AC Motor DriveController

Motor

Spindle

1024pprLine-drive

MI5Reset

RLY2 On Position

PG out

Application 1 (High-Speed Position –Time chart)

SpdRef

RunStopFWD

MI4 =Position Control (35)

Speed Mode Position Mode(internal position, home 10-19)

RLY2 =On Position (39)

MO1 =At Speed (2)

MO2 = Zero Speed(34)

Application 1(High-Speed Position-Wave Form)

2 4 6 8 10 12 14 16 18-100

0

100

200

300

2 4 6 8 10 12 14 16 18-50

0

50

100

2 4 6 8 10 12 14 16 18-50

0

50

(Hz)

(A)

(A)

SpdFdb

iqRef

ias

High speed internal position

4 6 8 10 12 14 16-50

0

50

100

150

200

250

4 6 8 10 12 14 16-40

-30

-20

-10

0

10

20

30

40

(Hz)

(A)

SpdFdb

ias

Application 1 (Motor Y-D Switch) Y

Delta Y

Customer allowto reiceive

Verifying Verifying Verifying Verifying

Controller 新代工研院智元新代Driver Model 055V23A-2 VFD075V23A-2 VFD037V23A-2 VFD075V23A-2Motor Power 5.5kW 5.5KW 3.7KW 5.5KW

Encoder 1024ppr 1024ppr 1024ppr 1024pprApplyingMchine

中心加工中心加工中心加工 Specialized machine

Former Brand 新代+VFD-V VFD-V NEW VFD-VSpindle Speed 12000rpm 12000rpm 12000rpm 3500rpmMotor Speed 12000rpm 12000rpm 12000rpm 3500rpmAccel/decel

Time4 sencods 4 sencods 4 sencods 4 sencods

Position Yes Yes Yes YesRequirment of

processingcharacteristics

Rigid Tapping Rigid tapping, position andtools change

Rigid tapping, position andtools change

Rigid tapping, position andtools change

Y-D Switch No No No NoMulti-stepPosition

No No No No

PulseCimmand Input

Yes Yes N/A No

V command No No No YesCustomerProfits

Improvement of the oldproblems of instability andvibration of V positioning

Improvement of the oldproblems of instability andvibration of V positioning

Trial-run for new model Improvement of the oldproblems of instability andvibration of V positioning

V2 Problems Waiting for new edition test Waiting for new edition test Waiting for new edition test Temporarily use V-typeNots Ecoder wire is long,

occationallly positioninaccurately because of noise

Inaccurate position caused bynoise

Inaccurate position causedby noise

Inaccurate position causedby noise

Base Problems Hardware of PG cardinterrupted by environment

Hardware of PG cardinterrupted by environment




Application 2 (Fast Acceleration/Deceleration)

0 2 4 6 8 10 12-100

0

100

200

300

400

500

0 2 4 6 8 10 12-20

0

20

40

0 2 4 6 8 10 12-40

-20

0

20

40

(Hz)

(A)

(A)

SpdFdb

iqRef

ias

About 4 seconds

12000rpm

About 2 seconds

Customer allow toreceive

The sencond stage 2007/4/1 The sencond stage 2007/4/1 The sencond stage 2007/6/1

Controler Centrido CNC Fanuc 海德漢Driver Model 075V23A-2 075V23A-2 075V23A-3Motor power 5.5KW 5.5kW 7.5kW

Encoder 1024ppr 1024ppr 1024pprApllying machines Milling machine Lathe Lathe

Former brand A700 Franc或三菱+Qma The first generation of Lathe

Spindle speed 3000~6000rpm 3600rpm 8000rpmMotor speed 6000rpm 5760rpm 8000rpm

Accel/decel time 2 senconds 3 senconds RequiedPosition Internal single position No Yes

Requirment ofprocessing

characteristics

Position and tools change,mechanical gear ratio switch

1200 rpm flexible tapping and side-cutting multi-position

Resolution and response

Y-D switch No No Nomulti-step position No No YesPulse command

inputNo No No

V command AVI: 0~10V AVI: 0~10V AUI: -10~+10VCustomer profits Have'nt adopted V Cost cut Cost cutV2 problems Two mechanical gear ratio 28:28 and

28:56mechanical gear ratio Use closed loop of Vcommand

system to position, AUI resolutionis deficient

Nots 1)New requirement of noticing VFDto switch two gears ratio by externalIO2)Can replace A700

Arranging testing, currently multi-position output need to besupplimented

Need to improve resolution so asto observe response

Base problems New function, waiting for adding D/Idefinition

Waiting for adding D/O definition AD resolution


Application 4 (Tension Control - Wiring)

FWD

REV

AVISpeed Limit

AUITorque Command (0~10V)

MO1 Error indication

U.V,W

PG in


Motor

1024pprLine-drive

PG out

Diagram 1: V Wiring

As for VFD-V, FWD/REV specifies torque command and speed limit direction.

Application Example 4 (Tension Control –VE Wiring)

FWD

REV

AVISpeed Limit

AVI2Torque Command (0~10V)

MO1 Error indication

U.V,W

PG in


Motor

1024pprLine-drive

PG out

Diagram 2: VE Wiring

MI1direction of Torque command

If the torque command is from AUI, then, torque direction is decided by the by AUI.

Application 4 (Tension Control –Time chart)

SpdLimit

RunStopFWD

MI1 = direction ofTorque command

Torque Command

SpdLimit

RunStopREV

MI1 = direction ofTorque command

Torque Command

Control Time chart: (a) FWD Torque Command; (b) REV Torque Command

(a)

(b)

Speed limit have accelerate/decelerate

Speed limit have accelerate/decelerate

Application 4 (Tension Control-Wave Form)

4 6 8 10 12 14 16 18 20-50

0

50

100

150

200

4 6 8 10 12 14 16 18 20-200

-100

0

100

200

4 6 8 10 12 14 16 18 20-10

-5

0

5(Hz)

(A)

(A)

SpdLimit SpdFdb

Tq Command

ias

Torque Mode Speed Mode

PG feedback signals are interfered, which causes unstable speed.

Application 5 (Elevator Control-Wiring)

Eric (seem G5) Cable Number VE

Pin Def. Set Pin Set

19 RBError indication

028 RBError indication

20 RC 0028 RC

9 MRADuring Run

002 MRABrake release function

10 MRC 006 MRC

11 DCM 018 DCM

6 S6 Multi-Speed 2 (25Hz) 023 MI 1 Multi-Speed 2 (25Hz)

5 S5 Emergency Stop 0022 MI 4 Emergency Stop

1 S1 FWD 020 FWD

2 S2 REV 021 REV

7 S7 Multi-Speed 3 (6Hz) 022 MI 2 Multi-Speed 2 (6Hz)

8 S8 Jog (0Hz) 024 MI 5 Multi-Speed 3 (0Hz)

3 S3Multi-Acc/Dec 1

(connect to pin7)MI 3

Multi-Acc/Dec 1

(connect to MI 2)

4 S4Multi-Acc/Dec 2

(connect to pin8)MI 6

Multi-Acc/Dec 2

(connect to MI 5)

Application 5 (Elevator Control -Timing)

SpdRef

Motor Operation Indication

Run/Stop Command

DCI

Brake

40Hz

6Hz

0Hz DCI

MI2 & MI3

MI5 & MI6

2nd step speed6Hz

3rd step speed 0Hz

Application 5 (Elevator Control –Wave Form)

0 2 4 6 8 10 12 14 16 18 20-10

0

10

20

30

40

50

0 2 4 6 8 10 12 14 16 18 200

10

20

30

40

50

0 2 4 6 8 10 12 14 16 18 20-50

0

50

(Hz)

(A)

(A)

Spd*

Spd

iq*

ias

Thank You

+/-Multi-function terminalsPID cancelled02-01~02-06=d21

d/dt

∫Integral timeupper limit08-04

Delay time08-07

PID Freq. Output

Command limit08-05

Feedback signal offset08-14 feedback signal offset value08=15 feedback signal detect time

PID offset value08-06

+

+

+

Frequency command Fcom

Warn and keep operatingd0

Warn and ramp to stopd1

Warn and coast to stopd2

Warn and keep at last frequencyd3

Treatment of ACI feedback signal break 08-09 Detect time 08-08

Multi-function simulation value

03-00,03-0103-02

PG2 pulse input10-15


03-00,03-0103-02

Multi-function digital terminalMI1~MI6

02-01~02-06

PID feedback display00-04=d10

Input Selection of the PID targeted Value 00-20

Analog signal filter time03-13,03-14,03-15

PID feedback source08-00

Analog signal filtertime 03-13,03-14,03-15

PG2 signalfilter time 11-17

Integral timeI(08-02)

Derivative timeD(08-03)

P gain

Proportional gain P(08-01)

Σ

+Σ Σ

PID feedback source 08-00

No PID feedbackd0

Positive PID feedback from AVId1

Positive PID feedback from PG card skip directiond2

Positive PID feedback from PG2 inputd3

Negative PID feedback from AVId4

Negative PID feedback from PG2 skip directiond5

Negative PID feedback from PG2 d5

No functiond0

AVI analog input 03-00d5

ACI analog input 03-01d5

AUI analog input 03-02d5

Multi-function analog function

PID source of the master frequency command 00-20

Digital keypadd0

RS-485 serial communication

d1

Multi-function analog terminals

d2

By multi-function digital terminals

d3

PG2 pulse input skip direction

d4

PG2 pulse inputd5

No functiond0

AVI analog input 03-00d4

ACI analog input 03-01d4

AUI analog input 03-02d4

Multi-function analog input

No functiond0

A phase lead B phased1

B phase lead A phased2

A is pulse, B is directiond3

PG2 pulse input 10-15

B is pulse, A is directiond4

Frequency UP commandd19

Frequency DOWN commandd20

Multi-step commandd1,d2,d3,d4

Multi-function digital terminals02-01~02-06(MI1~MI6)

JOG commandd5

Proportional gainP(08-01)

+/-

Multi-function PID cancelled02-01~02-06=d21

Derivative timeD(08-03)


Integral timeupper limit08-04

Delay time08-07

PID outputupper limit 08-05

Feedback fault treatmentIf Fout>08-05 detection time

or feedback fault 08-09

PID offset value08-06

+

+

+

Frequency command Fco

m

Feedback signals filter time08-15

08-14 08-15

+/-

Warn and keep operatingd0

Warn and ramp to stopd1

Warn and coast to stopd2


Treatment of ACI feedback signal fault 08-09 Detect time 08-08

Proportional gain P(08-01)

+/-

Multi-function PID cancel02-01~02-06=d21

Differential time

D(08-03)


Integral time Upper limit08-04

PID delayTime08-07

08-05 PID Freq. Output

Command limit

Treatment of the feedbackSignal faultIf Fout>08-05

Time over 08-09

PID offset08-06

+

+

+

Frequency command Fcom

Warn and keep operating d0

Warn and RAMP to stopd1

Warn and COAST to stopd2


Treatment of ACI feedback signal fault 08-09 Detect time 08-08ACI feedback signal

Feedback signal filter time08-15

08-14 08-15

+/-


03-00,03-0103-02

PG2 pulse input10-15

Multi-function simulation value03-00,03-01

03-02

Multi-function digital terminalMI1~MI6

02-01~02-06

PID feedback display00-04=d10

Input Selection of the PID targeted Value 00-20

Analog signal filter time03-13,03-14,03-15

PID feedback source08-00

VE Training in 2006 Tainan Plant Dunrong Lee Taoyuan Plant Zhiming Xu 2006/12/18.

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Transcript of VE Training in 2006 Tainan Plant Dunrong Lee Taoyuan Plant Zhiming Xu 2006/12/18.