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Chapter 5
Maintenance Operations

5-1 Operation Selection During Option Error ...... 5-1
5-2 Cause and Countermeasure of Option Errors... 5-2
5-3 Warning Display ............................................... 5-3

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Summary of Contents for 3G3AX-PG

Page 1: ...Cat No I564 E1 01 USER S MANUAL 3G3AX PG Encorder Feedback Board ...

Page 2: ......

Page 3: ...fter reading this manual keep it handy for future reference zThis manual describes the specifications and functions of the product as well as the relations between them You should assume that anything not described in this manual is not possible with the product zIntended readers This manual is intended for Those with knowledge of electrical systems qualified electrical engineers or the equivalent...

Page 4: ...OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE OMRON DISCLAIMS ALL OTHER WARRANTIES EXPRESS OR IMPLIED LIMITATIONS OF LIABILITY OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL INDIRECT OR CONSEQUENTIAL DAMAGES LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS WHETHER SUCH CLAIM IS BASED ON CONTRACT WARRANTY NEGLIGENCE OR ...

Page 5: ...tended to imply that the uses listed may be suitable for the products Outdoor use uses involving potential chemical contamination or electrical interference or conditions or uses not described in this manual Nuclear energy control systems combustion systems railroad systems aviation systems medical equipment amusement machines vehicles safety equipment and installations subject to separate industr...

Page 6: ...at any time to confirm actual specifications of purchased products DIMENSIONS AND WEIGHTS Dimensions and weights are nominal and are not to be used for manufacturing purposes even when tolerances are shown PERFORMANCE DATA Performance data given in this manual is provided as a guide for the user in determining suitability and does not constitute a warranty It may represent the result of OMRON s te...

Page 7: ...ous injury due to an electric shock Wiring work must be carried out only by qualified personnel Not doing so may result in a serious injury due to an electric shock Do not touch the surface of the PG Board or terminals and do not remove the encoder wire or the PG Board while the power is being supplied Doing so may result in a serious injury due to an electric shock or fire Turn off the input powe...

Page 8: ...iring Do not drop or apply a strong impact on the product Doing so may result in damaged parts or malfunction Connect the PG Board to the Inverter tightly with the provided fixing screws Tighten securely the terminal screws for the encoder wire on the PG Board Tightening torque 0 9 N m 1 0 N m max Be sure to use the provided ferrite cores Fix the ferrite cores on the wire or take appropriate measu...

Page 9: ...cautions for Correct Use Rated Voltage Confirm that the power voltage for the encoder is the same as the rated voltage 5 V DC of the product Product Disposal Comply with the local ordinance and regulations when disposing of the product ...

Page 10: ... ordered Should you find any problems with the product immediately contact your nearest local sales representative or OMRON sales office Checking the Nameplate Checking the Model Checking the Accessories Accessories of the 3G3AX PG Board are shown below Fixing screws M3 x 8 2 Ferrite cores 2 D D C PG01 A 19208 Nameplate 3 G 3 A X P G 0 1 PG Board Serial number ...

Page 11: ... A manual revision code appears as a suffix to the catalog number located at the lower left of the front and back covers Revision code Revision date Changes and revision pages 01 April 2008 First printing Cat No I564 E1 01 Revision code ...

Page 12: ...bes the functional block diagram of the product Chapter 2 Design Describes the mounting method of the product terminal names and wiring Chapter 3 Operation Describes the parameters related to the product and precautions for operation Chapter 4 Functions Describes the parameter functions Chapter 5 Maintenance Operations Describes the causes and their countermeasures if the Inverter fails Chapter 6 ...

Page 13: ... Diagram 2 6 2 6 Switch Settings 2 8 2 7 Switch Setting Flow Chart 2 9 Chapter 3 Operation 3 1 Related Parameters 3 1 3 2 Precautions for Operation 3 8 Chapter 4 Functions 4 1 V2 Control Mode Selection 4 1 4 2 Sensor Vector Control speed control 4 2 4 3 Pulse Train Position Control Mode 4 6 4 4 Absolute Position High resolution Absolute Position Control Modes 4 15 Chapter 5 Maintenance Operations ...

Page 14: ...12 Contents ...

Page 15: ...Chapter 1 Overview 1 1 Overview 1 1 ...

Page 16: ...a pulse train position command input by detecting the rotation speed of the motor with an encoder and using the data for feedback PWM M EC Current control Torque limit Speed control Internal settings LAD Rotation speed detection Position detection 0 Hz signal Excessive speed deviation signal output Position control Orientation control 3G3AX PG Inverter EAP EAN EBP EBN EZP EZN EP5 EG5 AP AN BP BN D...

Page 17: ...Chapter 2 Design 2 1 Mounting the PG Board 2 1 2 2 Terminal Arrangement 2 2 2 3 Terminal Functions 2 3 2 4 Wiring 2 4 2 5 Connection Diagram 2 6 2 6 Switch Settings 2 8 2 7 Switch Setting Flow Chart 2 9 ...

Page 18: ...correctly with the two holes on the guideposts and the other two on the screw holes To mount the PG Board be sure to tightly fix it with the two provided fixing screws after putting in place the connector securely Otherwise the Inverter will not operate properly Board port 1 Board port 2 Fixing screw holes for the PG Board M3 screw The PG Board Guideposts for positioning the PG Board Guideposts fo...

Page 19: ...inal Arrangement The terminal arrangement on the PG Board is shown below TM1 TM2 DIP switch Connector to the Inverter EP5 EG5 EAP EAN EBP EBN EZP EZN SAP SAN SBP SBN AP AN BP BN SWENC DIP switch SWR TM1 terminal arrangement TM2 terminal arrangement ...

Page 20: ...rd pulse train Reverse pulse train Built in termination resistor can be set enabled or disabled using the DIP switch on the PG Board Built in termination resistance 150Ω 5V DC Receiver input Complies with RS 422 EAP EAN EBP EBN EZP EZN Encoder signal input A B Z Encoder signal input Photocoupler input Compatible with the rotary encoder of 5V DC line driver output type Output terminal AP AN BP BN E...

Page 21: ...uld work erroneously due to influ ence from the outside noise at that point Be careful of the relay amplifier wiring The encoder cable could be easily influenced by outside noise depending on the shielding method of the shield cable resulting in an Inverter failure Generally connect to the power supply ground of a signal line or to the ground for shielding To connect to the ground be careful of th...

Page 22: ...ver the shield coating they fail to work effectively causing the Inverter to mal function Be sure to fix the ferrite cores or take other appropriate measures so that they do not over lap the shield coating The shield wire connected to the terminal could become disconnected due to the weight of the ferrite cores Be sure to fix the ferrite cores or take other appropriate measures so that the shield ...

Page 23: ...ng length should be 20 m or longer by necessity use a relay amplifier that specifies 5 V line driver output FS FV FC Inverter control terminal Available to assign to multi function input terminals 1 to 8 EP5 EG5 EAP EAN EBP EBN EZP EZN M EC Motor with an encoder SAP SAN SBP SBN Pulse train position command POK ZS DSE Output terminal FW RV LAC PCLR Position deviation clear ORT CM1 Input terminal AP...

Page 24: ...of the Inverter and the common terminal common for the encoder signal and such peripheral devices as a sequencer Note 6 To connect the encoder signal line follow the illustration below for phase relations during the rotation of the motor Main circuit power cable Cross at right angles I O signal lines Control signals including STAT ORT LAC PCLR SAP SAN SBP SBN EAP EAN EBP EBN POK DSE ZS AP AN BP BN...

Page 25: ...der A and B phases are not connected OFF OFF Disconnection detection disabled when encoder A and B phases are not connected 2 ON Disconnection detection enabled when encoder Z phase is not connected OFF OFF Disconnection detection disabled when encoder Z phase is not connected SWR 1 1 ON Built in termination resistor between SAP and SAN 150 Ω enabled OFF OFF Built in termination resistor between S...

Page 26: ...and input be used Turn OFF the SWENC1 Turn ON the SWR1 and 2 Will disconnection detection of the encoder Z phase signal be enabled Turn ON the SWENC2 Turn ON the SWENC1 Turn OFF the SWENC2 Turn ON the SWR1 and 2 of the only one unit that is farthest from the master unit End Will the multiple units for pulse train position command inputs be connected in parallel YES NO NO NO NO YES YES YES ...

Page 27: ...Chapter 3 Operation 3 1 Related Parameters 3 1 3 2 Precautions for Operation 3 8 ...

Page 28: ...haracteristics selection 00 Constant torque characteristics VC 01 Special reduced torque characteris tics special VP 02 Free V f characteristics 03 Sensorless vector control SLV 04 0 Hz sensorless vector control 05 Sensor vector control V2 00 A076 PID feedback selection 00 FI 01 FV 02 RS485 communication 03 Pulse train frequency 10 Operation function output 00 A141 Operation frequency input A sett...

Page 29: ...input 6 selection 04 C007 Multi function input 7 selection 05 C008 Multi function input 8 selection 06 C021 Multi function output terminal P1 selection 21 ZS 0 Hz signal 22 DSE excessive speed deviation 23 POK position ready 00 C022 Multi function output terminal P2 selection 01 C023 Multi function output terminal P3 selection 03 C024 Multi function output terminal P4 selection 07 C025 Multi funct...

Page 30: ...01 to 9 999 10 00 to 65 53 Depends on the motor capacity Ω H032 Motor parameter L auto tuning data 0 01 to 99 99 100 0 to 655 3 Depends on the motor capacity mH H033 Motor parameter Io auto tuning data 0 01 to 99 99 100 0 to 655 3 Depends on the motor capacity A H034 Motor parameter J auto tuning data 0 001 to 9 999 10 00 to 99 99 100 0 to 999 9 1000 to 9999 Depends on the motor capacity kgm2 H050...

Page 31: ...mode selection 00 Mode 0 01 Mode 1 02 Mode 2 00 P014 Orientation stop position 0 to 4095 0 P015 Orientation speed setting Starting frequency to Max frequency Upper limit 120 0 5 00 Hz P016 Orientation direction setting 00 Forward side 01 Reverse side 00 P017 Position ready range setting 0 to 9999 1000 10000 5 Pulse P018 Position ready delay time setting 0 00 to 9 99 0 00 s P019 Electronic gear set...

Page 32: ... type 00 Digital Operator 01 Option 1 02 Option 2 00 P033 Torque reference input selection 00 Terminal FV 01 Terminal FI 02 Terminal FE 03 Digital Operator 00 P034 Torque reference setting 0 to 200 0 P035 Polarity selection at torque reference via FE 00 As per sign 01 Depends on the RUN direction 00 P036 Torque bias mode 00 Disabled 01 Digital Operator 02 Terminal FE 00 P037 Torque bias value 200 ...

Page 33: ...mmand 3 0 P064 Multi step position command 4 0 P065 Multi step position command 5 0 P066 Multi step position command 6 0 P067 Multi step position command 7 0 P068 Zero return mode 00 Low 01 Hi1 02 Hi2 00 P069 Zero return direction selection 00 Forward side 01 Reverse side 00 P070 Low speed zero return frequency 0 00 to 10 00 0 00 Hz P071 High speed zero return frequency 0 00 to 99 99 100 0 to Max ...

Page 34: ...74 Teaching selection 00 Multi step position command 0 P060 01 Multi step position command 1 P061 02 Multi step position command 2 P062 03 Multi step position command 3 P063 04 Multi step position command 4 P064 05 Multi step position command 5 P065 06 Multi step position command 6 P066 07 Multi step position command 7 P067 00 ...

Page 35: ...vibration or noise in the motor Check whether the phase sequence is correct if the motor does not accelerate normally or an In verter overload trip is observed in the test run If the waveform of phase A is 90 ahead of that of phase B in forward rotation the phase sequence can be said to be normal Note 1 In some cases monitor signal is not output from the MP terminal of Inverter if the Inverter run...

Page 36: ...parameter H024 H034 During deceleration Motor hunting occurs Reduce the speed response H005 Reduce motor parameter J from the set parameter H024 H034 During torque limit Insufficient torque occurs at low frequency during torque limit Set an overload limit level lower than the torque limit level b021 b041 to b044 Low frequency operation Rotation is not constant Increase motor parameter J from the s...

Page 37: ...r 4 Functions 4 1 V2 Control Mode Selection 4 1 4 2 Sensor Vector Control speed control 4 2 4 3 Pulse Train Position Control Mode 4 6 4 4 Absolute Position High resolution Absolute Position Control Modes 4 15 ...

Page 38: ...ve speed devia tion signal output Set a deviation level in speed deviation error detection level P027 When the deviation between real frequency and reference frequency exceeds the P027 set value the DSE signal turns on When 02 APR2 or 03 HAPR is selected in P012 the Inverter performs absolute position con trol with reference to the absolute position from its origin Parameter No Function name Data ...

Page 39: ...detected when the reverse command is activated the rotation direction is judged as being normal If sensor vector control cannot provide the desired characteristics adjust the motor parameters de pending on the phenomenon as shown in the table below Note 1 Make sure that the carrier frequency b083 is not lower than 2 1 kHz If the carrier frequency is at 2 1 kHz or lower the Inverter will not operat...

Page 40: ...tation regardless of the RUN direction When 01 Depends on the RUN direction is selected The torque bias signal polarity and torque bias direction vary depending on the RUN command direction Forward command Applies torque in the same direction as the torque bias Reverse command Applies torque in the opposite direction of the torque bias Parameter No Function name Data Default setting Unit P036 Torq...

Page 41: ...er No Function name Data Default setting Unit P033 Torque reference input selection 00 Input via terminal FV 01 Input via terminal FI 02 Input via terminal FE 03 Input via the Digital Operator 00 P034 Torque reference setting 0 to 200 Torque reference when P033 03 0 P035 Polarity selection at torque reference via FE 00 As per sign 01 Depends on the RUN direction 00 P039 Speed limit value in torque...

Page 42: ...TR terminal Torque reference input Torque bias Torque limit Torque reference Reference value for current control Speed control P control Speed monitor Speed limit value Speed detection value The speed control P control operates when a speed detection value exceeds the limit value ...

Page 43: ...ain position control mode 00 P013 Pulse train mode selection 00 Mode 0 pulse train with 90 phase difference 01 Mode 1 forward reverse command Pulse train 02 Mode 2 Forward pulse train Reverse pulse train P017 Position ready range setting 0 to 9999 1000 10000 Set a value equivalent to encoder 4 multiplication 5 P018 Position ready delay time setting 0 00 to 9 99 0 00 s P019 Electronic gear setting ...

Page 44: ...Forward Reverse command Pulse train Mode 2 Forward pulse train Reverse pulse train SAP SAN SBP SBN Pulse train input Pulse train input Detected pulses Time Forward Reverse SAP SAN SBP SBN Pulse train input Forward Reverse command Detected pulses Time Forward Reverse SAP SAN SBP SBN Forward pulse train input Reverse pulse train input Detected pulses Time Forward Reverse ...

Page 45: ...loop gain If an increased position loop gain causes hunting reduce the position loop gain 3 Make sure that the N D setting is within the range of 1 50 N D 20 N Electronic gear ratio numerator P020 D Electronic gear ratio denominator P021 Parameter No Function name Data Default setting Unit P019 Electronic gear setting position selection 00 Position feedback side FB 01 Position command side REF 00 ...

Page 46: ...90 phase difference Electronic gear setting position selection P019 01 REF Electronic gear ratio numerator P020 3000 Electronic gear ratio denominator P021 1024 2 2048 The following shows an example of the ratio of slave rpm to master rpm depending on the P019 to P021 settings Note that the same number of encoder pulses 1024 pulses should be set on both Inverters Electronic gear setting position s...

Page 47: ... the following data in the Inverter on the sub motor side Electronic gear setting position selection P019 01 REF Electronic gear ratio numerator P020 3000 Electronic gear ratio denominator P021 1024 2 2048 G Position loop gain ASR REF FB N D FFWG Electronic gear setting position 00 FB Position control feed forward gain G Position loop gain ASR REF FB N D FFWG Electronic gear setting position 01 RE...

Page 48: ...f encoder pulses P011 1024 Motor gear ratio numerator P028 10 Motor gear ratio denominator P029 100 In this case the orientation stop position is defined as 4096 divisions of the encoder s one rotation Note that the concept of the stop position is inverted from the description in Orientation stop po sition conceptual drawing page 4 14 Position Bias Function Set this function to apply position comm...

Page 49: ...ng positioning the Z pulse one rotation position signal is used as the reference signal Input Z pulse between EZP and EZN Position command variation Position feedback variation P024 Position control Speed feedback value Speed control A145 ADD terminal Position bias Speed bias Set with A146 Related functions A145 A146 Parameter No Function name Data Default setting Unit P011 Encoder pulses 128 to 9...

Page 50: ...me setting 4 After the remaining number of pulses reaches the position ready range setting P017 the Inverter outputs the POK signal after the position ready delay time setting P018 elapses The POK output remains until the ORT signal is turned OFF After positioning is completed the servo lock status remains until the RUN command is turned OFF Note 1 Do not set a high frequency for the orientation s...

Page 51: ...ber of divisions is fixed to 4096 regardless of the encoder s number of pulses The reference point is defined as the point where the pulse is input between EZP and EZN Below is the layout of the stop target position Positive phase connection Orientation stop position conceptual drawing Position of Z pulse Reference point 0 1024 3072 2048 Motor shaft viewed from motor shaft load side ...

Page 52: ...nction name Data Default setting Unit P012 V2 control mode selection 02 APR2 absolute position control mode 03 HAPR high resolution absolute position control mode 00 P023 Position loop gain 0 00 to 99 99 100 0 0 50 rad s P060 Multi step position command 0 Position range specification reverse side to Position range specification forward side 0 P061 Multi step position command 1 Position range speci...

Page 53: ...ition command 3 P063 04 Multi step position command 4 P064 05 Multi step position command 5 P065 06 Multi step position command 6 P066 07 Multi step position command 7 P067 00 C169 Multi step speed position determination time 0 to 200 10 ms 0 ms d029 Position command monitor 1073741823 to 1073741823 d030 Current position monitor 1073741823 to 1073741823 C001 to C008 Multi function inputs 1 to 8 se...

Page 54: ...n the position at power on is regarded as the origin po sition 0 When position command is set to zero position ready is set when the RUN command is turned ON In reset selection C102 select 03 trip reset only If reset selection C102 is not set to 03 turning ON the Inverter s reset terminal or RESET key clears the current position counter To operate the Inverter by using the current position counter...

Page 55: ...he terminal input is determined This prevents the transition status from being applied before it is determined You can adjust the determination time in multi step speed position determination time C169 If no input is made during the time set in C169 the data is determined after the set time elapses Note that the longer the determination time the slower the input response Position command CP3 CP2 C...

Page 56: ...when the SPD terminal is turned OFF during operation Speed Position switching With the position command set to 0 the Inverter shifts to the stop operation when the SPD terminal is turned OFF Hunting may occur depending on the position loop gain setting While the SPD terminal is turned ON the Inverter runs in the direction specified by the RUN com mand To shift from speed control to position contro...

Page 57: ... speed zero return frequency 5 The Inverter performs positioning when the ORL signal is turned OFF 1 The Inverter accelerates to the high speed zero return frequency according to the acceleration time setting 2 The Inverter runs at the high speed zero return frequency 3 The Inverter starts deceleration when the ORL signal is turned ON 4 The Inverter runs in reverse at the low speed zero return fre...

Page 58: ...eaching Function This function starts or stops the motor at a desired position and stores the current position in a de sired position command area Allocate 45 ORT to any of multi function inputs 1 to 8 C001 to C008 When V2 control mode selection P012 is set to 02 absolute position control or 03 high resolu tion absolute position control the relevant terminal serves as a teaching terminal Teaching ...

Page 59: ... is turned on when SON is allocated If the SON terminal is turned off during operation the Inverter goes into free run status When the SON terminal is turned on again the Inverter restarts according to the setting of free run stop se lection b088 This function cannot be simultaneously used with the preliminary excitation function 55 FOC If FOC and SON are both allocated to multi function inputs pr...

Page 60: ...oard to OFF encoder disconnection detection disabled Parameter No Function name Data Default setting Unit P055 Pulse train frequency scale 1 0 to 50 0 Set the input frequency at the maximum frequency 25 0 kHz P056 Pulse train frequency filter time constant 0 01 to 2 00 Set a filter time constant for pulse train input 0 10 s P057 Pulse train frequency bias amount 100 to 100 0 P058 Pulse train frequ...

Page 61: ...Chapter 5 Maintenance Operations 5 1 Operation Selection During Option Error 5 1 5 2 Cause and Countermeasure of Option Errors 5 2 5 3 Warning Display 5 3 ...

Page 62: ... an error Note Even if 01 has been selected in operation selection at option error the Inverter trips when an encoder disconnection error E60 E70 or 3G3AX PG connection error E69 E79 occurs Refer to 2 6 Switch Settings page 2 8 Parameter No Function name Data Default setting Changes dur ing operation Unit P001 Operation selection at option 1 error 00 Trip 01 Continues operation 00 P002 Operation s...

Page 63: ... without phase Z has been used Turn OFF the SWENC 2 on the PG Board Overspeed Detects if the motor rotation has ex ceeded Maximum frequen cy 2 Overspeed error detection level P026 3 Adjust the parameters of Kp and J relating to the speed control and reduce overshooting Positioning error Detects if the current position devia tion against the position command value exceeds 1 000 000 pulses during po...

Page 64: ...ngs other than the one mentioned below refer to the general purpose Inverter 3G3RX User s Manual Fault display Description Displays when the orientation speed setting P015 becomes larger than the maximum frequency A004 Check the orientation speed setting and the maximum frequency ...

Page 65: ...Chapter 6 Specifications 6 1 Product Specifications 6 1 ...

Page 66: ...mmand The pulse train can be input in three modes Mode 0 Pulse train with 90 phase difference Mode 1 Forward Reverse command Pulse train Mode 2 Forward pulse train Reverse pulse train The input mode depends on the Inverter setting Maximum input number of pulses 100k pulses s Electronic gear Pulse ratio A B A B 1 to 9999 can be set Available setting range 1 50 A B 20 Orientation Stop position 4096 ...

Page 67: ......

Page 68: ...ent or addition to the above warranty See http www omron247 com or contact your Omron representative for pub lished information 14 Limitation on Liability Etc OMRON COMPANIES SHALL NOT BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES LOSS OF PROFITS OR PRODUCTION OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS WHETHER SUCH CLAIM IS BASED IN CONTRACT WARRANTY NEGLIGENCE ...

Page 69: ... HEAD OFFICE Toronto ON Canada 416 286 6465 866 986 6766 www omron ca OMRON ELETRÔNICA DO BRASIL LTDA HEAD OFFICE São Paulo SP Brasil 55 11 2101 6300 www omron com br OMRON ELECTRONICS MEXICO SA DE CV HEAD OFFICE Apodaca N L 52 811 156 99 10 mela omron com OMRON ARGENTINA SALES OFFICE Cono Sur 54 11 4787 1129 OMRON CHILE SALES OFFICE Santiago 56 2206 4592 OTHER OMRON LATIN AMERICA SALES 56 2206 45...

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