MC5 VS-626MC5 Spindle Inverter Supplemental … 3 of 31 MC5 VS-626MC5 Spindle Inverter Supplemental Manual Inverter Technical Information No. 97020 Date: 12/8/97 CONFIDENTIAL - DO

VS-626MC5 Spindle Inverter Supplemental ManualMC5

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

ContentsPage

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.........................

MC5

u, v, wu, v, w, x, y, z

Inverter

6-Lead Spindle Motor

Magnetic Contactor(for switching Y and ∆∆∆∆)

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CONFIDENTIAL - DO NOT DISTRIBUTE

I-TI-97020-MC5



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1. Introduction

The Yaskawa Varispeed-626MC5 inverter, a derivative of VS-616G series, is a compact and vespindle drive specially designed for machine tool application. The features of the MC5 inverter in

• 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 ManualS616-10) 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- a∆-windings (Figure 2.1). The base frequency of the Y-winding is lower than that of ∆-winding, providing higher torque at low speed.

Y-Winding (Y-Connection)

Low Speed, High Torque

∆∆∆∆-Winding ( ∆∆∆∆-Connection)

High Speed , Low Torque

X Y Z

U V W

U

V W

X-Y-Z

U

VWX

Y

Z

6 Lead Motor Winding

Figure 2.1 Y and ∆ Windings

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.

d (Fig- is

In contrast, the maximum speed of the ∆-winding is much higher than that of Y-winding (Figure 2.2)

By switching between the two winding connections, a wide constant power range can be obtaineure 2.3), beneficial for driving the spindle of a lathe or a milling machine. This type of applicationcalled the “Y/∆ winding change,” or simply “winding change.”

Figure 2.2

Y-Windingprovides hightorque at thelow speed.

∆-Winding coversthe high speedrange.

00

Power

Y-base

00 ∆∆∆∆-base

Power

Y-max.

∆∆∆∆-max.

Freq.

Freq.

Y-Winding

∆∆∆∆-Winding

winding changedone in this area

Figure 2.2 Performance Curves of Y and ∆ Windings

Winding change technology provides high torque and wideconstant power range with a relatively small size inverter.

0

∆-WindingY-Winding

Wide Constant Power Range:

A : B = up to 1:12 !!

Power

MotorSpeed

A BY-baseSpeed

∆∆∆∆-max.speed

0

hightorque atlow 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]tor 2 parameters [E3, E4, and E5]). For the winding change application, the motor parameters aV/f patterns are individually set for the two windings. The VS626MC5 is similar to a two-motor acation, except that the winding change control is performed “on-the-fly,” i.e., during operation. Anetic contactor is used to switch between the two windings. (The magnetic contactor must have tcontacts that can be directly driven by the inverter.)

Note: Although the MC5 can perform a winding changeover during cutting, this function is not sued by Yaskawa. Cutting performance cannot be guaranteed due to reliance on factors outside owa’s control, such as load inertia.

2.1 Winding Change Methods

The MC5 drive offers two different methods for winding change, internal winding change anternal winding change, namely.

External Winding Change Method

In this method, an external signal is given to one of the multi-function inputs (set as “80”Htrigger the winding changeover. Figure 2.4 illustrates a wiring example of this applicationthis case, the external signal is given from the CNC). Figure 2.5 on the next page illustratsequence of changing motor parameter for this method.

RST

7811

Change Winding

Common

CNC

3φ230V

UVW

MC5

9

10

MC Ansback

0V +24V

+24VDC Supply

1φ 230V

17 18

246

13

14

1516

X

179

11

HV-75AP3Magnetic Contactor

U Z

Dual WindingMotor

X V Y W

Figure 2.4 Sample Wiring for External Winding Change(Open Loop Vector Mode)

B1-02 = 4H1-05 = 80HH1-06 = 82HH2-01 = 41HA1-02 = 2E3-01 = 2

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Fout

RUN Command

Total base block time

During speed search

Motor 1 Motor 2

Minimum baseblock timeL2-03

2nd motorparameter

calculation time

Hz

0

V

Output Voltage

50%

0%

Torque Limit

64msec

Voltage recovery timeL2-04

The ramp time isdependent on theaccel timesetting.

SpdSrch Dec Timeb3-03

Note) When the closed loop vector control mode is selected, the torque reference increases from zero with64msec instead of 50% of torque limit for the open loop vector mode.

Figure 2.5 External Winding Change Sequence

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tend-r 1 pa-e input

P1-01

ally by P1-02). the

con-pe of /open

To use this method, the user must set “80”H to the multi-functional digital input which is ined to receive the winding changeover signal. This setting enables the drive to select Motorameters (E1 and E2) when the input is open and Motor 2 parameters (E4 and E5) when this closed. Note that when this method is used, the internal winding change parameters (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 internthe preset parameters, such as changeover frequency level (P1-01) and frequency width (Figure 2.6 illustrates this example. Do not set “80”H to the multi-function digital input wheninternal winding change is used.

In both the external and internal methods, the multi-function digital output terminal which isnected to the magnetic contactor must be set to either “1C”H or “41”H, depending on the tycontactor. This setting allows the drive to give a signal to the magnetic contactor to closethe contact for Y/∆ switching.

RST

811

3φ230V

UVW

MC5

26

0V +24V

+24VDC Supply

1φ 230V

17 18

246

13

14

1516

X

179

11

HV-75AP3Magnetic Contactor

U Z

Dual WindingMotor

X V Y W

Figure 2.6 Sample Wiring for Internal Winding Change(Flux Vector Mode)

B1-02 = 4H1-06 = 82HH1-03 = 41HP1-04 = 1A1-02 = 3E3-01 = 3

27PG-X2

Card(Option)

x PG

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c con-otor ntac-

2.2 Winding Selection Magnetic Contactor

In regard to the winding change application with the MC5 drive, use of a Yaskawa magnetitactor is recommended (Table 2.1, Figure 2.8). The contactor is specially designed for mwinding selection control and motor switch operation. The inverter directly controls the cotor switching function.

Table 2.1

Model Number HV-75AP3 HV-150AP3

Contact Arrangement Main Contact: 3NO3NC, Auxiliary Contact: 1NO

Rated Isolation Voltage 600V

Rated Energizing Current 75A (Continuous)87A (30 min. 33% ED)*

150A (Continuous)175A (30 min. 33% ED)*

Max. Breaking Current 200 A 400 A

Max. Operation Frequency(Switching Duty)

600 times/hour

Mechanical Life 5,000,000 times

Ratings of Applicable Magnetic Coils

200V 50/60 Hz, 220V 50/60 Hz, 230V 60 Hz

Ambient Temperature -10 to +55 °C (14 to 131 °F)

Humidity 10 to 95% RH (non-condensing)

Approximate Mass 2.5 kg 5.0 kg

Dimensions (H x W x D, mm) 115 x 160 x 93 164 x 192 x 107

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C for
The Yaskawa magnetic contactor requires a single phase 230V power supply and +24VDswitching signal. The +24VDC must be supplied by the user.
Status of Operation

Selective Signal Main Contacts Auxiliary Contacts Connection

13-14 1-2 3-4 5-6 7-8 9-10 11-12 15-16

+24V OPEN CLOSE OPEN Y

0V CLOSE OPEN CLOSE ∆

Figure 2.8 Yaskawa Magnetic Contactor for Winding Selection

Dimensions in mm

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ction alarm

ut

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f Y/-05).

al.

2.3 Magnetic Contactor Answer-back Failure Detection

Magnetic contactors commonly have an answer-back signal to feedback when the connechange is accomplished. The MC5 drive includes an option to check this signal and give anin the event of a magnetic contactor failure.

When the multi-function digital input is set to “81” or “82” (MC Ansback Input), the digital inpterminal 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 o∆ magnetic contactor does not change the state within the specified time limit (P1

Case 2) The magnetic contactor changes the state without issuing the triggering sign

W hen the motor parameter switching comm and is given and the auxiliary contact of Y/∆ magneticcontactor doesn’t change the state w ith in P1-03 time , the inverter w ill detect M C Answerback fa ilure.

P1-03 P1-03

M C Ansback Fault

M otor 1 M otor 2 M otor 1

M C Ansback off M C Ansback on M C Ansback off

DC 24V

P1-03M C Ansback Fault

M otor 1

M C Ansback off M C Ansback on

CASE 2

W ye connection

Delta connection

11

M ulti-functionInput

VS-626M C5

9

10

M C Ansback N.C.orM C Ansback N.O.

M ulti-digitaloutput

M otor 2 Selected

CASE 1

∆ Connection

Y Connection

When the motor parameter switching command is given and the auxiliary contact of Y/∆ magneticcontactor does not change the state within P1-03 time, the inverter detects MC Answerback failure.

Figure 2.9 Magnetic Contactor Answer-Back Failure Detection

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tings, cribe affect

Although use of the magnetic contactor answer-back failure detection is optional, Yaskawommends using this feature to protect the motor and/or inverter in the event of contactor

When a Yaskawa magnetic contactor (HV-75AP3 or HV-150AP3) is used, the setting shou“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 setand elimination of some parameters. (Refer to Appendix A.) Tables 3.1, 3.2 and 3.4 desthe modification in detail, whereas Table 3.3 describes the pre-existing parameters whichthe winding changeover performance.

Table 3.1 New Parameters in the MC5

Parameter # Name Description Unit Setting Range Default

E3-XX, E4-XX, E5-XX

Motor 2 Parameters Refer to Table 3.3

P1-01 Changeover FrequencyWinding change-over frequency from Y (low speed) winding to ∆ (high speed) winding

0.1Hz 0.0 ~ 400.0Hz 0.0Hz

P1-02 Frequency Width Hysterisis for change-over fre-quency. Change-over frequency from ∆ to Y = P1-01 - P2-02

0.1Hz 0.0 ~ 20.0Hz 5.0Hz

P1-03 Ansback Det Time Detection delay time setting for the magnetic contactor answer-back signal at winding change

0.01 sec 0.20 ~ 1.00 sec 0.20 sec

P1-04 Y-Winding Sel Selection of motor parameter sets (motor 1 or motor 2) for Y-wind-ing

— 0: Motor 1 for Y1: Motor 2 for Y

1

P1-05 ProgramMode@ Run Enable or disable MENU and ESC keys during operation

— 0: Disabled1: Enabled

1

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Table 3.2 Parameters with Additional (New) Settings

Parameter Additional (new) Setting Description/Remarks

B1-02(Run Source)

4: ∆/Y Seq. Must be selected for winding change application

L8-01(DB Resistor Protection)

1: 10% ED during RUN2: 3% ED3: 10% ED

When options 2 or 3 are selected, the braking transis-tor is always turned on when the DC bus voltage ex-ceeds the preset level, except during a fault condition.

H1-01 ~ H1~06(Multi function digital input)

80: Y/∆ Change Open: Motor 1 parameters are used Closed: Motor 2 parameters are used

Parameters P1-01 and P1-02 are disabled when 80H is selected.

81: MC Ansback N.C. Open: No ansback when MC is open Closed: Ansback when MC is closed

To use the magnetic contactor answer-back signal for the contactor fault detectionWhen Yaskawa HV-75AP or HV-150AP contactors are used, the setting is 82 (MC. Ansback N.O.)

82: MC Ansback N.O. Open: No ansback when MC is closed Closed: Ansback when MC is open

H2~01~H2-03(Multi function digital output)

40: Zero Speed 2 Closed: Zero speed condition except dur-

ing D/Y changeover

Setting this avoids the Zero Speed signal output dur-ing winding changeover

1C: Close Motor 2 Sel Open: Motor 1 is selected Close: Motor 2 is selected

External winding changeover signal selection.If “1C” is set, when the motor 1 parameters are se-lected, the signal is open. When the motor 2 param-eters are selected, the signal is closed. If “41” is set, the effect is the opposite of “1C” setting.41: Open Motor 2 Sel

Open: Motor 2 is selected Close: Motor 1 is selected

Table 3.3 Other Parameters Which Affect Winding Changeover Performance

Parameter #

Name Description Unit Setting Range Default

B3-03 Speed search deceleration time

See Figure 2.5 for detail

0.1 sec 0.0 ~ 10.0 sec 2.0 sec

L2-03 Minimum baseblock time (PwrL Baseblock t) 0.1 sec 0.0 ~ 5.0 sec Depends on inverter size

L2-04 Voltage recovery time (PwrL V/F Ramp t) 0.1 sec 0.0 ~ 2.0 sec 0.3 sec

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Q: Quick start (A1-01 = 2) B: Basic (A1-01 = 3)

A: Advanced (A1-01 = 4) X: Setting/Reading disabled

Table 3.4 Motor Parameters

Motor 1 Parameters

Motor 2 Parameters

(new parameters)

Description Parameter Access (Motor 1)

Parameter Access (Motor 2 )

V/f V/f w/ PG

O L V F V V/f V/f w/ PG

O L V FV

A1-02 E3-01 Control method selection Q Q Q Q A A A A

E1-01 — Input voltage setting Q Q Q Q —

E1-02 — Motor selection Q Q Q Q —

E1-03 — V/f pattern selection Q Q X X —

E1-04 E4-01 Max. frequency Q Q Q Q A A A A

E1-05 E4-02 Max. voltage Q Q Q Q A A A A

E1-06 E4-03 Base frequency Q Q Q Q A A A A

E1-07 E4-04 Mid. frequency Q Q A A A A

E1-08 E4-05 Mid voltage Q Q A A A A

E1-09 E4-06 Start frequency Q Q Q A A A A A

E1-10 E4-07 Start voltage Q Q A A A A

E1-11 — Mid frequency (2) A A A A —

E1-12 — Mid voltage (2) A A A A —

E1-13 — Base voltage A A Q Q —

E2-01 E5-01 Full load current at base frequency

A Q Q Q A A A A

E2-02 E5-02 Full load slip at base frequency

A A Q Q A A A A

E2-03 E5-03 No load current at base frequency

A A Q Q A A A A

E2-04 E5-04 Number of poles X Q X Q X A X A

E2-05 E5-05 Line to line resistance A A A A A A A A

E2-06 E5-06 Leakage inductance X X A A X X A A

E2-07 — Saturation coefficient 1 X X A A —

E2-08 — Saturation coefficient 2 X X A A —

E2-09 — Mechanical loss X X X A —

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pa-r 2 pa-ection

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“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 chantime. However, an over voltage (OV) fault may occur if the setting is too small. Yaskawaommends 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 moparameters. They are as follows:

Motor 1 Parameters Motor 2 Parameters

A1-02 : Motor 1 Control Method E3-01 : Motor 2 Control Method

E1-XX : Motor 1 V/f Pattern E4-XX : Motor 2 V/f Pattern

E2-XX : Motor 1 Set up E5-XX : Motor 2 Set up

Parameters for each of the Y- and ∆-windings can be set individually as motor 1 and motor 2 rameters for a winding change application. The setting ranges and default setting of motorameters are identical to the corresponding motor 1 parameters. To set E1~E5, refer to S4, “Auto-Tuning and Motor Parameter Adjustment”

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ng will OC) ds us-

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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 oproperly. 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 settiresult in the reduction of the overall winding changeover time. However, an overcurrent (fault caused by back EMF may occur if the setting value is too small. Yaskawa recommening the default setting.

Voltage Recovery Time (L2-04)

This parameter determines the duration of the voltage recovery time after base block at thing changeover. A larger setting allows the inverter to “ramp” the voltage at recovery. Howan overcurrent (OC) fault may occur if the setting value is too small. Yaskawa recommening the default setting.

DB Resistor Protection (L8-01)

This is the breaking resistor protection rating selection, as illustrated in Table 3.5.

Note: When L8-01 is set to 2 or 3, this software allows braking resistor to be turned on any time after thevoltage exceeds the level at which the braking transistor turns on, except during an inverter fault con

Winding Change-Over Frequency (P1-01)

This parameter is responsible for the winding change-over frequency from Y (low speed)ing to ∆ (high speed) winding when the automatic winding change is used. The P1-01 semust be smaller than the maximum frequency of the Y (low speed) winding.

Table 3.5 Braking Resistor Overheat Protection

L8-01 setting Display of setting Description

0 Not provided There is no braking resistor overheat protection.

1 10% ED during run The overheat protection for the 10% duty braking resistor is provided when the inverter is running.

2 3% ED The overheat protection for the 3% duty (YASKA-WA internal resistor ) braking resistor is provided whether or not the inverter is operating.

3 10% ED The overheat protection for the 10% duty braking resistor is provided whether or not the inverter is operating.

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Winding Change-Over Hysterisis (P1-02)

This parameter determines the winding change-over hysterisis; that is, the change-over frcy from ∆- (high speed) winding to Y- (low speed) winding when automatic winding changP1-01 ~ P1-02. Yaskawa recommends setting P1-02 so that the value of P1-01 ~ P1-02 ithe 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 peter is used only when one of the multi-function digital inputs (H1-01 ~ H1-06) is set to “81“82”.

Motor Parameter Selection (P1-04)

This parameter determines which of the two sets of motor parameters are assigned to Y-∆-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 parametersE4 and E5) are for ∆-winding.

“1”: Motor 2 parameters (E3, E4 and E5) are used for Y-winding, motor 1 parame(E1 and E2) are for ∆-winding.

Yaskawa recommends using the setting “1” for the following reason. At ∆0 (high speed) wind-ing, the motor’s maximum speed may be much higher than the base frequency (1:3 t 1:4 tly). In such a case, no-load voltage at such high speed operation may be higher than thabase speed. This requires a different V/f pattern setting for the base and maximum speedthe 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 driveinto the program mode during operation. The default setting is “0” (disabled).

“0”: Disabled -The operator key stroke (MENU and ESC) to enter the program mis 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 ESIf the winding changeover is attempted while the inverter is in the program mode, the motocoast to a stop. Setting P1-05 = “0” prevents this from occurring, but the user cannot go inprogram 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 performancethe motor. This is especially vital for the vector control modes (either open loop vector mode [wPG] or flux vector mode [with PG]).

The VS626MC5 drive has a built-in “auto-tune” feature for the vector modes (open loop vector anvector) to help the user set the motor parameters correctly for the optimum performance of the modrive in combination.

4.1 Tune-up Procedure

The following describes the step-by-step procedures for auto-tuning and adjusting the morameters

Step 1) Obtain motor data

Obtain the following data from the motor used (required to start auto-tuning and to set the pmotor 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 motor’s full load current. The inverter’s rated current (must be equal or larger than the motor’s full load current (A). Note that high speed spindtors are commonly high current, low voltage type, and in such a case, it may be necessaryup the inverter to match the motor current.

Step 3) Wiring

Wire the inverter, motor, magnetic contactor, 24VDC power supply, and encoder. (See fi2.4 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. Param-eter 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 (E2’s).

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pat-um

), then the

perly

4. Repeat the auto-tuning (#2 through #3)and record the resulting parameters (E2’s) 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 Mo-tor 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 (E2’s).

4. Repeat the auto-tuning (#2 through #3)and record the resulting parameters (E5’s) 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 terns (E1’s for Motor 1 and E4’s for Motor 2). This is especially important when the maximfrequency is higher than the base frequency. Adjust E1-05 and E4-02 (maximum voltageset the maximum frequency of the ∆-winding to both E1-04 and E4-01. It is essential to have 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 proat the desired frequency range. Adjust the parameters on Table 3.3 if necessary.

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to the

t correc-kawa

5. Troubleshooting

Table 5.1 shows the additional fault codes of VS-626MC5. Table 5.2 is a troubleshoot guidelineproblems 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 relevantive action. If the inspections and corrective actions do not solve the problem, contact your Yasrepresentative.

Table 5.1 Additional Fault Codes and Corrective Actions

Fault Code Description Check Point Corrective Action

OPE12

(Y/∆ Seq Fault)

One of the following conditions occurred:

1. Multi-function digital inputs are se-lected to “80” (Y/∆ Change) and “16” (Motor 2 Select) at the same time.

2. Multi-function digital inputs are se-lected to “81” (MC Ansback N.C.) and “82” (MC Ansback N.O.) at the same time.

3. Multi-function digital inputs are se-lected to “80” or P1-01 (Changeover Freq) is not equal to zero, but B1-02 (Run Source) is not set to 4 (Y/∆ Seq).

Check the parameter setting Correct the parameter setting

MCANS

(MC Ansback Fault)

One of the following conditions occurred:

1. Expected answer-back signal from the magnetic contactor is not received within the time specified by P1-03.

2. Magnetic contactor changed the wind-ing unexpectedly.

Wrong setting of H1 parame-ter (“81” or “82”)

Correct the parameter setting

Magnetic contactor is not en-ergized.

Apply power to the magnetic contactor

Loose wiring Correct wiring

Defective magnetic contactorReplace the magnetic contac-tor

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Table 5.2 Winding Change Related Failures and Corrective Actions

Fault Possible cause / Checkpoint Corrective Action

Motor does not change winding

Is the magnetic contact answerback fault detection used?

Use magnetic contactor answerback fault detection (see section 2.3)

Magnetic contactor is not energized. Apply power to the magnetic contactor

Loose wiring on the magnetic contactor Correct wiring

Defective magnetic contactor Replace the magnetic contactor

Wrong motor wiring Correct the wiring

Changeover trigger signal is not received (external winding change)

Correct the setting

Changeover frequency (P1-02) and/or hysterisis (P1-02) is not set correctly (in-ternal 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 wind-ing change

Avoid heavy cutting 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 wind-ing change

Avoid heavy cutting during winding change

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r

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 useprefers to the use internal winding change method. A Yaskawa magnetic contactor with answer-backwill be used. The user wants to use motor 1 parameters for ∆-winding and motor 2 parameters for Y-winding, 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 motor’s full load current at base speed is 58A and the inverter’s ratedcurrent must be at least this much. For the 200V class MC5 inverter, this is the CIMR-MC52015 (rated current is 64A).

Step 3. Wiring: Figure A.1 shows the wiring diagram required for this example.

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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

RST

811

3φ230V

UVW

MC5

9

10

0V +24V

+24VDC Supply

1φ 230V

17 18

246

13

14

1516

X

179

11

HV-75AP3

U Z

Dual WindingMotor

X V Y W

Figure A.1 Example 1 Wiring Diagram

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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


c. Auto-tuning was repeated successfully and the resultant motor parameters (E2) are asfollows below. Set the average values in the corresponding parameters.

Step 6. Auto-tune for motor 2 parameters (in this case, Y-winding) as follows:

a.) Select “Auto-Tuning” from the MENU


Rated Voltage = 200V (no load voltage at base freq. of Y-winding, assumed to be the same as ∆-winding)

Rated Current = 58A (full load amp at base freq. of ∆-winding, assumed to be the same as ∆-winding)

Parameter 1st Trial 2nd Trial 3rd Trial Average

E2-02 0.62Hz 0.64Hz 0.68Hz 0.65Hz

E2-03 35.2A 35.6A 35.5A 35.5A

E2-05 0.158Ω 0.157Ω 0.157Ω 0.157Ω

E2-07 0.47 0.47 0.48 0.47

E2-08 0.71 0.72 0.72 0.72

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Rated Frequency = 103.9 Hz (base freq. of Y-winding = 1.732 x base freq. of ∆-winding)

Rated Speed = 3031 rpm (base rpm of Y-winding =1.732 x base rpm of ∆-winding)

Number of Poles = 4

Select Motor = 2


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.

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)


E5-02 0.62Hz 0.64Hz 0.68Hz 1.14Hz

E5-03 35.2A 35.6A 35.5A 20.5A

E5-05 0.158Ω 0.157Ω 0.157Ω 0.292Ω

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The following table shows the resultant motor parameter setting. (Values appearing in bold-face type indicate that they are different from the default value).

Table A.1 Motor Parameters Determined for Example 1

∆ -Winding Y -Winding

Parameter No.

Setting Value Parameter No.

Setting Value Remarks

E1-01 230V — Inverter V

E1-04 266.7Hz E4-01 266.7Hz maximum Hz

E1-05 200V E4-02 200V maximum volt

E1-06 103.9Hz E4-03 60Hz base Hz

E1-07 3Hz E4-04 3Hz mid Hz

E1-08 12.6V E4-05 12.6V mid V

E1-09 0.5Hz E4-06 0.5Hz start Hz

E1-10 2.3V E4-07 2.3V start V

E1-11 0

—

mid Hz (2)

E1-12 0 mid V (2)

E1-13 200V base V

E2-01 58A E5-01 58A f/l Amp at base

E2-02 0.65Hz E5-02 1.14Hz f/l slip at base

E2-03 35.5A E5-03 20.5A n/l Amp at base

E2-04 4 — poles

E2-05 .157Ω E5-05 .292Ω line to line Ω

E2-06 17.2% E5-06 17.2% leak inductance

E2-07 0.47—

satur. coef. 1

E2-08 0.72 satur. coef 2

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r

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 usewould 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 per-formed 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 motor’s full load current at base speed is 86.3A for the ∆-winding and the inverter’s 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.

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)

RST

8 MCANS11 COM

3φ230V

MC5

26

0V +24V

+24VDC Supply

1φ 230V

17 18

246

13

14

1516

X

79

11

HV-75AP3

Figure A.2 Example 2 Wiring Diagram

27PG-X2Card(Option)

xPG

7 CHW

9

10

UVW

Z

XY

1024PPRAB

FromCNC

ToCNC

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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:



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


c.) Auto-tuning was repeated successfully and the resultant motor parameters (E2) are as follows. Set the average values in the corresponding parameters.


E2-02 0.64Hz 0.64Hz 0.66Hz 0.65Hz

E2-03 39.7A 39.7A 40.0A 39.8A

E2-05 0.077Ω 0.077Ω 0.075Ω 0.076Ω

E2-07 0.37 0.37 0.38 0.37

E2-08 0.62 0.65 0.64 0.64

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Step 6. Auto-tune for motor 2 parameters (in this case, Y-winding) as follows:



Rated Voltage = 128.4V (no load voltage at base freq. of Y-winding)

Rated Current = 74.8A (full load amp at base freq. of Y-winding)

Rated Frequency = 20.0Hz (base freq. of Y-winding)

Rated Speed = 564 rpm (base rpm of Y-winding, calculated from full load slip frequency and rated frequency)

Number of Poles = 4

Select Motor = 2


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.

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 bold-


E5-02 1.17 Hz 1.16 Hz 1.15 Hz 1.16 Hz

E5-03 21.8 A 21.8 A 21.9 A 21.8 A

E5-05 0.198 Ω 0.199 Ω 0.198 Ω 0.198 Ω

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face type indicate that they are different from the default value).

Step 8. Test run the motor and verify that the winding change is performed properly at the designatedfrequency. Adjust the parameters on table 3.3 if necessary.

Table A.2: Motor Parameters Determined for Example 2

∆ -Winding Y -Winding

Parameter No. Setting Value Parameter No. Setting Value Remarks

E1-01 230V Inverter V

E1-04 200.0Hz E4-01 200.0Hz maximum Hz

E1-05 129.6V E4-02 132.4V maximum volt

E1-06 33.3Hz E4-03 20Hz base Hz

E1-07 3Hz E4-04 3Hz mid Hz

E1-08 12.6 V E4-05 12.6 V mid V

E1-09 0.5 Hz E4-06 0.5 Hz start Hz

E1-10 2.3 V E4-07 2.3 V start V

E1-11 0 mid Hz (2)

E1-12 0 mid V (2)

E1-13 127.8 V base V

E2-01 86.3 A E5-01 74.8 A f/l Amp at base

E2-02 0.65 Hz E5-02 1.16 Hz f/l slip at base

E2-03 39.8 A E5-03 21.8 A n/l Amp at base

E2-04 4 poles

E2-05 0.076 Ω E5-04 .292 Ω line to line ΩE2-06 19.5 % E5-05 19.5 % leak induc-

tance

E2-07 0.37 satur. coef. 1

E2-08 0.64 satur. coef 2

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Appendix B: Parameter Modification List from G5 to MC5

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Documents

MC5 VS-626MC5 Spindle Inverter Supplemental … 3 of 31 MC5 VS-626MC5 Spindle Inverter Supplemental Manual Inverter Technical Information No. 97020 Date: 12/8/97 CONFIDENTIAL - DO