G7/E7/F7/P7/G5/P5/PS5 Drive Simulator User Manual
Contents
1. YASKAWA Pe This Manual G7 E7 F7 P7 G5 P5 PS5 Drive Simulator D User Manual if also avanabie on WWW orves com 1 Document Number TM AFD 07 Simulator Models UUX000166 Figure 1 Simulator unit with no control card installed 1 Introduction This control board tester and variable power factor load emulator allows the user to test all the basic and advanced functions of above mentioned control cards without any need for actual drive power supply sections motor stand load stand and power stages All of the required signals to operate the cards are simulated through DC and AC voltages and currents adjustable by potentiometers and switches LED s for digital and VU meters for analog signals monitor all the control and user outputs Yet all the signals are provided at test points for external access PC serial 9 pin connector can be routed to card s RS232 RS485 or RS422 ports through on board converters Two master slave PG emulators are capable of emulating wide PPR range of encoders A true three phase on board emulator can simulate induction motors with adjustable load and power factor for both 2 and 3 level drives A current limited pulse reference generator can provide adjustable amplitude and frequency independently An automatic power recycling circuit reboots the control card safely with feedback Bipolar I O references active current source external access port supply voltage monitors and capabil2. 6788 2878 YEA TAICHUNG OFFICE IN TAIWAIN B1 6F No 51 Section 2 Kung Yi Road Taichung City Taiwan R O C Phone 886 4 2320 2227 Fax 886 4 2320 2239 5 12 2003 Rev 03 05 Data subject to change without notice Yaskawa Electric America Inc
3. J2 for user I O RS422 485 Routing Through S38 RS422 485 PC RS232 will be routed converted to RS422 of the drive and keypad will be routed to control card s keypad port MEMACCESS PC RS232 will be routed to control card s keypad port and keypad will be disconnected MEMFLASH PC RS232 will be routed to control card s keypad port in FLASH mode and keypad will be disconnected In communication router switch S38 mode of RS 422 485 the connected PC through its RS 232 will be also able to participate as a RS 485 network participant Therefore flow control will be through its RTS pin and accessible through S14 1 switch set to External Also the related parameter in the drive should be set accordingly H5 07 lt 1 for the network side flow control Note The unit in this mode does not compromise the network drive isolation as the control card s link to network will be differential anyway e Power supply module 1 W Voltages available 15VDC 24VDC 5VDC IP5VDC 10V unregulated IP12VDC 19V unregulated unloaded IP24VDC 26V unregulated unloaded All supplies monitored by LED s D56 D59 D31 D33 Power Recycle Manually through push button S37 Power Recycle and externally through EAP External Access Port recycled and monitored toward the control card in almost 1 second The ready signal will be also generated and available to EAP after 2 seconds for automatic testing purposes LED s D148 READY and D1
4. LTD 1 Hunt Hill Orchardton Woods Cumbernauld G68 9LF Scotland United Kingdom Phone 44 12 3673 5000 Fax 44 12 3645 8182 Document Number TM AFD 07 Simulator YASKAWA ELECTRIC KOREA CORPORATION Paik Nam Bldg 901 188 3 1 Ga Euljiro J oong Gu Seoul Korea Phone 82 2 776 7844 Fax 82 2 753 2639 YASKAWA ELECTRIC SINGAPORE PTE LTD Head Office 151 Lorong Chuan 04 01 New Tech Park Singapore 556741 Singapore Phone 65 282 3003 Fax 65 289 3003 TAIPEI OFFICE AND YATEC ENGINEERING CORPORATION 10F 146 Sung Chiang Road Taipei Taiwan Phone 886 2 2563 0010 Fax 886 2 2567 4677 YASKAWA J ASON HK COMPANY LIMITED Rm 2909 10 Hong Kong Plaza 186 191 Connaught Road West Hong Kong Phone 852 2803 2385 Fax 852 2547 5773 BEIJING OFFICE Room No 301 Office Building of Beijing International Club 21 J ianguomanwai Avenue Beijing 100020 China Phone 86 10 6532 1850 Fax 86 10 6532 1851 SHANGHAI OFFICE 27 Hui He Road Shanghai 200437 China Phone 86 21 6553 6600 Fax 86 21 6531 4242 SHANGHAI YASKAWA TONJ IM amp E CO LTD 27 Hui He Road Shanghai 200437 China Phone 86 21 6533 2828 Fax 86 21 6553 6677 BEIJING YASKAWA BEIKE AUTOMATION ENGINEERING CO LTD 30 Xue Yuan Road Haidian Beijing 100083 China Phone 86 10 6232 9943 Fax 86 10 6234 5002 SHOUGANG MOTOMAN ROBOT CO LTD 7 Yongchang North Street Beijing Economic amp Technological Development Area Beijing 100076 China Phone 86 10 6788 0551 Fax 86 10
5. port EAP on the simulator Figure 6 Power entry module with on off switch and spare fuse inserts TM AFD Simulator Page 10 77 YASKAWA G7 E7 F7 P7 G5 P5 PS5 Drive Simulator YASKAWA ELECTRIC AMERICA INC Drives Division 16555 W Ryerson Rd New Berlin WI 53151 U S A Phone 800 YASKAWA 800 927 5292 Fax 262 782 3418 Internet http www drives com YASKAWA ELECTRIC AMERICA INC Chicago Corporate Headquarters 2121 Norman Drive South Waukegan IL 60085 U S A Phone 800 YASKAWA 800 927 5292 Fax 847 887 7310 Internet http www yaskawa com MOTOMAN INC 805 Liberty Lane West Carrollton OH 45449 U S A Phone 937 847 6200 Fax 937 847 6277 Internet http www motoman com YASKAWA ELECTRIC CORPORATION New Pier Takeshiba South Tower 1 16 1 Kaigan Minatoku Tokyo 105 0022 J apan Phone 81 3 5402 4511 Fax 81 3 5402 4580 Internet http www yaskawa co jp YASKAWA ELETRICO DO BRASIL COMERCIO LTDA Avenida Fagundes Filho 620 Bairro Saude Sao Paolo SP Brasil CEP 04304 000 Phone 55 11 5071 2552 Fax 55 11 5581 8795 Internet http www yaskawa com br YASKAWA ELECTRIC EUROPE GmbH Am Kronberger Hang 2 65824 Schwalbach Germany Phone 49 6196 569 300 Fax 49 6196 888 301 MOTOMAN ROBOTICS AB Box 504 538525 Torsas Sweden Phone 46 486 48800 Fax 46 486 41410 MOTOMAN ROBOTEC GmbH Kammerfeldstrabe 1 85391 Allershausen Germany Phone 49 8166 900 Fax 49 8166 9039 YASKAWA ELECTRIC UK
6. range Adjustable through S32 for most carrier frequencies Inductance tuning 0 1 to 0 99 for most carrier frequencies through VR6 Carrier frequency support 400Hz 15kHz from the control card Multi level PWM Two and three level topologies and floating through S35 Load current signal Fully adjustable between 0 200 through VR7 IUVW IU IV IW output for ground current measurements at J1 monitors This signal is an exact emulation to the one generated inside the control card for threshold testing purposes PWM Monitoring Twelve 2 level phase leg positioned LED s for both 2 or 3 level fire pulse PWM signals 2 levels are red and 1 levels are green D1 D12 Output signal access Selectable through S22 S23 S24 Internal OFF External PWM outputs loading 0 10Vrms at 500 Ohms minimum load impedance e Control I O and External Access Port EAP l 2 u FONA All the control side analog inputs are selectable between internal and external sources at EAP through S16 All the control side digital I O s are selectable between internal and external sources at EAP through S13 to S18 MCON and BTRA signals have Auto Off On modes through S19 and S20 VCLL VCHL VCFL SCL FUL signals have High Low External modes through S13 S15 S17 and S18 Digital outputs routed to EAP are all open collector 24V 40mA max All the digital inputs are 5V TTL except MCOPL being 24V 2mA Analog inputs to the control card THM 0 5VDC inter
7. rising DC Bus voltage and BTRON is the drive s response feedback for it 29 MCOPL Digital 24VDC MOON is the drive s command to close the soft start relay when its 30 MCON capacitors are charged up and MCOPL is the drive s response feedback 31 FAN Digital 5V TTL Drive s command to control the heat sink blowers during motor is running 32 VCLL Low Active or negative logic signals to report drive s power section status 33 VCHL Digital 5V TTL VCLL and VCHL report the power supply safe voltage levels in specific 34 VCFL drives VCFL SCL in G5 reports power supply or braking transistor 35 FUL failure and FUL reports the main DC Bus fuse failure to the drive 36 PGICKO Digital 5V TTL TTL Resolved independent sweep clocks to feed the PG1 and PG2 37 PG2CKO encoders from any selected source at double the encoder frequencies 38 PGCKIN Digital 5V 24V External Clock source input to both encoder emulators routed by S26 S30 39 REC5V Supply SV TTL Main 5V supply to control card under test recycled by 37 push button 40 IP24VDC Supply 24VDC Unregulated 25 VDC supply for external use 5 0mA maximum load Table 1 The simulator signal descriptions available at the Test Points connector J1 Note 1 Although all the test point signals are protected against shorts or overloads but can still distort the normal logical operations of the unit circuitries or even cause damage to them by improper connections or shorting Note 2 These 4 PWM signa
8. rotated toward left or right ends Please adjust it around the middle until the faults go away automatically Figure 4 Simulator with G5 P5 PS5 control card installed TM AFD Simulator Page 5 5 Module Description and Usage Guide e User I O terminal 1 2 Si Digital inputs middle positioned toggle switches ON EXT OFF S1 S12 Digital outputs Four green D19 D22 and two red LED s D23 and D24 Analog inputs 0 10V 10V or external for AIN1 and AIN3 4 20mA for AIN2 VRI is Al VR2 is A2 and VR3 is A3 The reference voltage will be selected through S21 from 10V 410V and External Analog outputs Two 10 LED displays U31 U33 with negative sign LED s D140 and D141 will monitor the AM and FM outputs in almost 1V steps e Pulse generator module 1 2 Ji Amplitude adjustable through VR5 between 0 22V Current Limited and short circuit protected at 25mA dynamically Frequency Adjustable through VR4 between approx 15Hz 25kHz e Communication module 1 2 3 4 RS 232 RS 485 and RS 422 standards and voltage levels are supported RS 422 RS 485 flow control selectable between internal or RTS signal through 14 position1 switch internal is RS422 and external is RS485 through RS232 Four LED s D13 D16 monitor all the transmission and reception activities Connectors RJ 45 for Keypad DB9 for RS 232 and Header for RS422 485 J4 to connect to control board s keypad connector J5 for PC J3 for keypad
9. sum of the emulated three phase currents 10 FAN Output Digital TTL None High Goes high should the blowers start working 11 MCON Output Digital HTL None Low Goes low when DC Bus Caps voltage is normal 12 NWL PE Two PWM signals for lower half of one phase le 13 NW2L RIOR PIA TIL Agnes Pow PO Goa control card See Note 4 i 14 BTRA Input Digital TTL S14 3 High Should go high when braking transistor is on 15 BTRON Input Digital TTL S14 4 Low Should go low to turn the braking transistor on 16 MCOPL Input Digital HTL S16 1 High Should go high to report soft starter relay is closed 17 THM Input Analog 0 5V S16 2 N A Lower the voltage higher the temperature 18 VDET Input Analog 7 5V S16 3 N A 0 gt 7 5V more negative higher DC bus voltage 19 CUV Input Analog 3 5V S16 4 N A Lower the voltage less the control side voltage 20 VCLL Input Digital TTL S13 Low Should go low to report drive control low voltage 21 VCHL Input Digital TTL S15 Low Should go low to report drive control high voltage 22 VCFL Input Digital TTL S17 Low Should go low to report power supply failure SCL 23 LU S22 They provide any arbitrary current waveform for the 24 LV Input Analog 15V S23 N A control card under test in any combination with or 25 IW S24 without the internally emulated controlled ones 26 GND REF N A OV N A N A GROUND reference for all the I O signals a
10. 51 R5V monitor the whole recycling process either way Please note that this feature is exactly like recycling the main power switch of the unit with exactly same functionality and effect Current available to external devices is limited at less than 50mA for all supplies Please refer to the pin array on the left side of the unit e Dual Encoder emulator module 1 2 3 PG I is assumed to be the slave motor encoder and PG II the master motor encoder However they are independently interchangeable based on application Logic level 5V TTL differential Max frequency Approx 25Hz to 44kHz separately adjustable and range selectable through VR8 VR9 and S28 25Hz 44kHz 250Hz 44kHz and 2 5kHz 44kHz Signal format 90 Phase shifted quadrature differential A A B B C C TM AFD Simulator Page 6 TN go Loading 20mA max each channel Direction of rotation is controlled by slide switches S25 and S29 as CW OFF CCW Clock source Selectable from internal generators control card s pulse output for PG I only external source or PG I for PG II only through S26 and S30 The ratio between input clock to output encoder frequency is 2 1 Pulse per Revolution Each encoder s PPR can be set by S27 and S31 to values of 32 64 512 1024 2048 4096 and 8192 PPR One switch position at all times should be on only otherwise the smallest ratio would become the PPR anyway e Load Emulator module DR ON 99 Load Inductance
11. cal environment access to all ports and signals easy access test points measurement and monitoring features actual PWM signal outputs dual encoder emulations and extensive test points and EAP will all be the ultimate platform for hardware development Cross Referencing of different drive generations In order to compare drives performances for an application or even having all the above features for other old or new drives their control cards can easily be tested on this unit through cable adaptors Therefore it can replace most of the present or even future test units Automatic Test Setup Almost all the hardware and software platforms options extensions communication protocols and controls Wizard tools and Test tools can be either implemented for production or tested during their development phases D D E E s 1 EAM Wetec et NAI titi brotha Si mao Figure 2 Simulator with G7 control card installed and running under simulated load TM AFD Simulator Page 3 Precautions This unit is designed for office lab environment and not for harsh industrial conditions Also as an open chassis electrical system all the usual precautions for these devices are expected accordingly Any conductive liquid spills tool drops wiring shortages heavy physical blows or extensive electrostatic discharges can cause damage to it and or its connected accessories However due to the applied precautions in its design these damages migh
12. emulating the actual motor itself 11 NUL Digital Sine weighted multi level PWM signals generated by the control card 12 NU2L under test All four signals from one phase leg U are brought here NU2L 13 PUL SV TTL and PU2L are only available from two level drives though such as G7 14 PU2L 400V class and will be off for regular one level drives See note 2 below 15 USI The power rating of the drive or US CODE provided to the will be 16 US2 ina actually present at these pins These signals are high active or positive 17 US3 Digital SV TTL logic These four signals constitute a half byte or nibble code with US4 18 US4 being the MSB and USI the LSB This code is a drive parameter content 19 THM Analog control signals from drive s power section to the control card 20 VDET Analog 10VDC_ THM reports the heat sink temperature VDET reports the DC Bus voltage 21 CUV and CUV monitors the power supply voltage to control card 22 AIN2 Analog signals from the user I O terminal AIN2 is reference input 2 4 23 MONTI1 Analog 10VDC 20mADC when disconnected from the drive 1 5 VDC when connected 24 MONT2 MONTI and MONT2 are the two user analog outputs from the drive 25 PLS IN Digital 24VDC PLS IN is the pulse reference input of the drive fed by the unit pulse 26 PLSOUT generator 0 24VDC 15Hz 25kHz PLSOUT is drive s pulse output 27 BTRA Digital SV TTL BTRA is the drive s command to turn on the Braking transistor in case of 28 BTRON
13. ity of supporting a very wide range of control cards are also provided TM AFD Simulator Page 2 Please note that this equipment is intended for qualified engineering personnel only familiar with Yaskawa Drives and technical principles of variable speed AC drives and or software engineering 2 Features and Applications CASE development As this unit provides all the digital and analog I O available in the control cards with the monitoring and measurement capabilities it will be ideal for any level of CASE design and verification Firmware development In addition to the general I O different emulators provide reference feedback load and power factor virtual signals for the firmware designer to test under the most realistic environment even for different PWM index implementations Drive application engineering Versatile communication routers loading emulators reference and feedback encoders and generators capabilities in addition to I O handling and easy access test points will make it ideal for application verifications and testing Wizard software and utilities development and testing In addition to all the above External Access PLC port EAP opens a gate to automatic repetitive tests usually required for communication software verifications The manual or externally controlled automatic power recycling is another unique feature to help out the software test and development engineers Hardware Development The realistic physi
14. ls from the control card NUL NU2L PUL and PU2L should be probed very carefully otherwise they can cause damage to the control card and or unit motor emulator circuitry in case of interference e External Access Port EAP Connector Standard dual row header 100 pitch 40 pins shrouded protected Loading All short circuit protected measurement impedance 10kOhm min See Note 3 Application Automatic hardware software test setups PLC driven controls Load Emulation Available Signals Both inputs and outputs digital and analog signals are provided at this 1 2 3 4 connector Most outputs are open collector 24V and most inputs are 5V TTL compatible TM AFD Simulator Page 8 Pin Name 1 0 Type Level Router Logic Description 1 USI 2 US2 KG The 4 Bit input code to assign the drive size with a KA a BA ele ow USI Sea the LSB and US4 the MSB 4 US4 5 IP24V Output Supply HTL N A High Unregulated 24VDC 200mA 25VDC supply 6 RDY Output Digital TTL None Low Goes Low when recycled control card is ready again 7 FUL Input Digital TTL S18 Low Should go low to induce a main DC Bus fuse failure 8 RST Input Digital TTL None Low Should go low to recycle reset control card power 9 I STAR Output Analog 15V None N A Displays
15. nally through VR10 VDET 10VDC 0VDC internally through VR11 CUV 3 3VDC 5VDC internally through VR12 e US CODE module 1 2 Selectable between internal HEX rotary switch S36 and EAP through S14 Format 5V TTL inputs from EAP low active negative logic e Test Points Connector J1 l 2 3 Connector Single row header 100 pitch 40 pins Loading All short circuit protected measurement impedance 10kOhm min See Note 1 Available Signals All the signals at this connector are outputs except one Pin 38 PGCKIN All the signals in detail are described in the next page table 1 TM AFD Simulator Page 7 Pin Label Type Level Description 1 IU OUT Emulated motor current signals from the three phases individually 2 IV OUT amplitude controlled and phase controlled power factor or inductive load 3 IW OUT through VR6 and VR7 4 IUVW Analog 15VDC Emulated sum of the three phase currents inside the drive 5 PF_U Emulated motor current signals from the three phases individually only 6 PF_V phase controlled load power factor or the level of inductance through 7 PF_W VR6 without amplitude control 8 UPWM Emulated IGBT outputs from the drive to run a motor Later these power 9 VPWM 15VDC signals will be fed to the power factor and level control circuits for 10 WPWM
16. rds G7 E7 F7 and G5 PS5 have their own connector on the unit Please refer to the labels next to each connector before doing any wiring to the control cards G7 E7 F7 to J9 and G5 PS5 to J10 Depending on their screw hole positions you can use the provided spacers to mount them on the unit Figure 3 Simulator with E7 I O card installed TM AFD Simulator Page 4 4 Initial Switches and Potentiometers Settings Default positions for switches and pots to minimize the faults on the connected control cards SWITCH TOP MIDDLE BOTTOM S1 S12 X S21 X S22 524 X S19 amp S20 X S14 amp S16 Set Toward Internal Sources only S13 X S15 X S17 X S18 X S38 X S35 X S32 Set to Low Inductance position for most cases S28 X S26 amp S30 X S25 amp S29 X S27 amp S31 First position only ON for 32PPR S36 Set as to control card s Power ratings in 02 04 Potentiometer Leftmost Middle Rightmost VRI VR3 X VR10 X VR12 X VRII X k VR6 X VR7 X VR8 and VR9 X VR4 X VR5 X X Please note that when mounting a control card to the unit in order to keep all the settings inside control card unchanged you might need to try every single setting of S36 and recycle the power each time by S37 push button to check which code matches with the control card s This will take about 1 minute at the worst case VR11 will cause OV or UV faults when
17. t be very limited and easily repairable while other modules keep on functioning properly There is no level of electrical isolation in this unit and as soon as any control card gets connected to this unit it loses its isolation barriers This is for ease of operation probing lowering the costs etc This is done as to the application and purpose of the unit which is not definitely industrial control There are only two isolated unregulated IP5 IGS and IP12 IG12 voltage sources accessible through test points on J1 Only mounting I O terminal cards and providing external 24VDC AC level commands will revive this isolation The external access port EAP pins are all protected against static and dynamic HV HC HF interferences but still applying wrong signals or shorting might interfere with the unit logic and cause invalid reactions and or readings Please refer to this manual for the appropriate probing and signal applications for each pin The power supply pins provided to the user at J1 test points and J8 EAP are all current limited to 830mA Any loading more than 100mA may cause damage to the protective current limiting resistors and the unit There are no high voltages above 24VDC present on this unit anywhere except the components and power supply module inside the grounded chassis which carry the Mains voltage Care should be taken to use the provided grounded AC cord and outlets in order to have full ground protection of the unit Control ca
18. vailable 27 DI 1 Sl 28 DI 2 S2 29 DI 3 S3 Provides the access to the user digital inputs of the 30 DI 4 S4 control card under test DI 1 and DI 2 are reserved 31 DI 5 S5 for Run commands in all drives DI 1 DI 7 inputs are 32 DI 6 Input Digital HTL S6 High used in F7 E7 drives and DI 1 DI 8 for F7 drives 33 DI 7 24V S7 All 12 inputs are available to G7 drives Should go 34 DI 8 S8 high to activate the inputs To route each input to the 35 DI 9 SO external port pins the associated switch should be set 36 DI 10 S10 to EXT external position 37 DI 11 S11 38 DI 12 S12 39 AIN1 To feed the external reference value to the drive VR1 40 AIN3 Popul ATARE SOY nai NA and or VR3 should be set to minimum left position Note 3 Although all the I O pins in this port are protected against shorts or overloads but can still distort the normal logical operations of the unit and or control card under test circuitries causing damage to them by improper connections high voltages or shorting Note 4 These 2 PWM signals from the control card NWL and NW2L should be probed monitored very carefully otherwise they can cause damage to the control card and or unit motor emulator circuitry in case of interference TM AFD Simulator Page 9 mb CONROL AL nai i pub FAM VUL AHALOGPBIGIT ki LLIT LI ELLOT AN T T eee i Tags I612 13V Terie DH Figure 5 The test points and external access
Download Pdf Manuals
Related Search