PG Interface Card "OPC-G1-PG"
Contents
1. determine the mounting position Insert connector CN1 on the card into the C port CN6 on the inverter s control PCB Figure 3 In the case of 0 4 kW Figure 4 Mounting PG Interface Card Figure 5 Mounting Completed 3 Wiring A WARNING In general the covers of the control signal wires are not specifically designed to withstand a high voltage 1 e reinforced insulation is not applied Therefore if a control signal wire comes into direct contact with a live conductor of the main circuit the insulation of the cover might break down which would expose the signal wire to a high voltage of the main circuit Make sure that the control signal wires will not come into contact with live conductors of the main circuit Failure to observe this precaution could cause electric shock or an accident A CAUTION Noise may be emitted from the inverter motor and wires Take appropriate measures to prevent the nearby sensors and devices from malfunctioning due to such noise An accident could occur Perform wiring properly referring to the Terminal Allocation and Symbol Diagram Terminal Specifications and Internal Block Diagram shown below Table 1 Terminal Specifications Terminal Size Recommended Wire Gauge Insulated wires with allowable temperature of 105 C UL listed are recommended Figure 6 Terminal Allocation and Symbol Diagram Figure 7 Internal Block Diagram To prevent malfunctioning due to noise2. of the switch 6 Drive Control LL For details of PG interface functions available refer to the FRENIC MEGA Instruction Manual Chapter 5 Section 5 2 Details of Function Codes or the FRENIC MEGA User s Manual 6 1 Pulse train input This function gives a frequency command to the inverter in pulse train format Three types of formats are available pulse train sign pulse train input run forward run reverse pulse train and 90 degree phase shifted A B pulse trains Use XA and XB terminals for the pulse train frequency command input 6 1 1 Pulse train input format Table 3 lists pulse train input formats and operations of this option card Table 3 Pulse Train Input Format and Operations Gives the speed command to the inverter following the pulse input Pulse train sign pulse train input frequency on the XB terminal Switching the terminal XA ON OFF determines polarity of the speed command Gives the run forward speed command to the inverter following the pulse Run forward run reverse pulse input frequency on the XB terminal if any train Gives the run reverse speed command to the inverter following the pulse input frequency on the XA terminal if any Gives the run forward or run reverse speed command to the inverter following 90 degree phase shift and frequency information of two pulse inputs on XA and XB terminals 90 degree phase shifted A B pulse trains Actual rotation direction of the motor i
3. separate the wires for the PG interface card as far apart as possible from those for the main circuits Also inside the inverter bundle and fix the wires for the PG interface card so that they do not come into direct contact with live parts of the main circuits for example the main circuit terminal block Sse Note When grounding the shielded cable use a crimp ring terminal R1 25 3 or the like and fasten it together with the card using this screw Seay of Mnene meni UA Location for grounding AA ROW To N the shielded cable yy In the case of 0 4 KW In the case of 75 kW Pass the wires from the PG interface card between the control circuit terminal block and the front cover 4 Specifications 4 1 Specifications for pulse train inputs APAA N 30 kHz max Open collector output pulse frequenc 100 kHz max Complementary ee Open collector circuit Maximum cable length 20 m PG pulse output circuit beast Complementary circuit Maximum cable length 100 m High level gt 8 VDC Low level lt 3 VDC For 12 VDC power supply High level gt 10 VDC Low level lt 3 VDC For 15 VDC power supply 4 2 Specifications of applicable PG and PG interface card Encoder pulse resolution 20 to 3000 P R A B and Z phase pulse trains in incremental format PA EE EEE Open collector Maximum cable length 20 m P Complementary Maximum cable length 100 m High level gt 8 VDC Low l
4. F gt Instruction Manual PG Interface Card OPC G1 PG Thank you for purchasing this PG interface card OPC G1 PG Installing this card to your FRENIC MEGA enables speed control with speed sensor and pulse train input Note e Installing this card disables pulse train inputs to the inverter s terminal X7 The FRENIC MEGA has three option connection ports A B and C ports Connect this PG interface card to the C port Do not connect it to any other port 1 Check that 1 A PG interface card and two screws M3 x 8 are contained Screw hole left in the package Shortrame YI Release knob CN1 2 The PG interface card is not damaged during transportation no defective devices dents or warps 3 The model name OPC G1 PG SY is printed on the back of the PG interface card as shown in Figure 2 The PG SY on the front is a short name as shown in Figure 1 Model name a If you suspect the product is not working properly or if you have any questions about your product contact the shop where you bought the product or your local Fuji branch office Figure 1 Front of Card Figure 2 Back of Card Positioning cutout Screw hole right 2 Installation A WARNING Before starting installation and wiring turn OFF the power and wait at least five minutes for inverters with a capacity of 22 kW or below or at least ten minutes for inverters with a capacity of 30 kW or above Make sure that the LED monitor and
5. charging lamp are turned OFF Further make sure using a multimeter or a similar instrument that the DC link bus voltage between the terminals P and N has dropped to the safe level 25 VDC or below Otherwise electric shock could occur 1 Remove the front cover from the inverter and expose the control printed circuit board control PCB As shown in Figure 3 the PG interface card can be connected to the C port CN6 only LL To remove the front cover refer to the FRENIC MEGA Instruction Manual Section 2 3 For inverters with a capacity of 30 kW or above open also the keypad enclosure 2 Insert connector CN1 on the back of the PG interface card Figure 2 into the C port CN6 on the inverter s control PCB Then tighten the two screws that come with the card Figure 4 a Check that the positioning cutout Figure 1 is fitted on the tab in Figure 4 and connector CN1 is fully inserted in Note Figure 4 Figure 5 shows the PG interface card correctly mounted Do not connect the PG interface card to the ports other than C port Doing so may damage the card 3 Perform wiring on the PG interface card Refer to Section 3 Wiring 4 Put the front cover back into place HI To put back the front cover refer to the FRENIC MEGA Instruction Manual Section 2 3 For inverters with a capacity of 30 kW or above close also the keypad enclosure Fit the positioning cutout of the card over the tab on the inverter to
6. evel lt 3 VDC For 12 VDC power supply High level gt 10 VDC Low level lt 3 VDC For 15 VDC power supply Input pulse threshold Input power requirements Pulse output current 8 mA or less PG m lya 12 VDC 10 120 mA or less or AE 15 VDC 10 120 mA or less If a power level required by the PG exceeds 120 mA use an external power supply 5 Terminal Functions Table 2 lists terminal specifications Table 2 Terminal Specifications Terminal Name Functions symbol Connects external power supply for the PG 12 VDC 10 or 15 VDC 10 Use the power supply which is 150 mA more than PG current consumption Connects the PG power input 12 VDC 10 120 mA or 15 VDC 10 120 mA PG power common terminal equipotent with CM terminal of the inverter Use an external power supply if the PG current consumption exceeds 120 mA When using an external power supply turn the slide switch JI shown below to the EXT position 2 Turn the internal switch SW1 to the proper position according to the PG power requirement The factory default position is 12V ON To move a switch slider use a tool with a narrow a Jot gt tip e g tweezers Be careful not to touch other electronic parts etc If the slider is in an ambiguous position the circuit is unclear whether it is turned ON or OFF and the digital input remains in an undefined state Be sure to place the slider so that it contacts either side
7. on Manual and FRENIC MEGA User s Manual 6 2 1 Control specifications Table 4 lists the specifications of vector control with speed sensor Table 4 Specifications of Speed Control Maximum output frequency 25 to 200 Hz 2 Minimum speed Base speed 1 1500 Speed control range Control For 4 pole motors 1 to 1500 r min specificatio When a VG motor 1024 P R ns 1 Analog setting 0 2 or less of maximum frequency is connected at 25 10 C Digital setting 0 01 or less of maximum frequency at 10 to 50 C Speed control accuracy Specified values of the motor controllability will greatly vary depending on the pulse resolution P R Pulses Revolution The recommended P R is 1024 or more 2 Ifthe output frequency exceeds 200 Hz the inverter trips with the alarm Os 6 2 2 Connection diagram examples Figure 9 shows the connection diagram example for speed control When using inverter internal power supply When using external power supply FRENIC MEGA FRENIC MEGA Fr OPC G1 PG OPC G1 PG J1 5 J1 5 EXT INT ox 12 VDC 10 15 VDC 410 When a Fuji VG motor exclusively designed for vector control is connected the signal names in parentheses apply 2 The terminal YZ is not used for control If the PG issues Z phase outputs there is no need to connect the PG wire to this terminal 3 For wiring between the PG and the inverter use a shielded cable Basically the shielded laye
8. r should be grounded If any malfunction occurs due to noise however connecting the shielded layer to the terminal CM may reduce the problem If the wiring between the PG and the inverter is long interference of A and B phases may cause PG signal malfunctions resulting in abnormal noise or torque pulsation In such a case minimizing the wiring length by reviewing the wiring route or using a cable with a smaller stray capacitance may reduce the problem 4 The terminal SS of the VG motor should be opened 5 When using the inverter internal power supply turn the slide switch J1 on the PG interface card to the INT position when using an external power supply to the EXT position Figure 9 Connection Diagrams for Speed Control Fuji Electric FA Components amp Systems Co Ltd Mitsui Sumitomo Bank Ningyo cho Bldg 5 7 Nihonbashi Odemma cho Chuo ku Tokyo 103 0011 Japan Phone 81 3 5847 8011 Fax 81 3 5847 8172 URL http www fujielectric co jp fcs INR S147 1283 E
9. s specified by a combination of the pulse input command polarity and FWD REV command in the inverter 6 1 2 Connection diagram examples Figure 8 shows the connection diagram example for pulse train input When using pulse train generator When using PG FRENIC MEGA FRENIC MEGA Pulse train generator For wiring between the encoder and the inverter use a shielded cable Basically the shielded layer should be grounded If any malfunction occurs due to noise however connecting the shielded layer to the terminal CM may reduce the problem If the wiring between the encoder and the inverter is long interference of A and B phases may cause encoder signal malfunctions resulting in abnormal noise or torque pulsation In such a case minimizing the wiring length by reviewing the wiring route or using a cable with a smaller stray capacitance may reduce the problem Figure 8 Connection Diagrams for Pulse Train Input 6 2 Speed control Vector control with speed sensor The inverter detects the motor s rotational speed from PG feedback signals decomposes the motor drive current into the exciting and torque current components and controls each of components in vector The vector control enables speed control with high accuracy and high response A recommended motor for this control is a Fuji VG motor exclusively designed for vector control LL For settings and adjustments of the vector control refer to FRENIC MEGA Instructi
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