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TRAINING SUMMER 03. Drives. OMRON-YASKAWA MOTION CONTROL. >> L7Z DIFFERENCE WITH FV. >> CIMR-L7Z OVERVIEW L7Z DIFFERENCE WITH FV HARDWARE FIRMWARE FUNCTIONS. >> CIMR-L7Z OVERVIEW. MAIN HARDWARE FEATURES. 200V and 400V versions 3.7Kw to 22Kw (Up to 55Kw in September)

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  1. TRAINING SUMMER 03 Drives OMRON-YASKAWA MOTION CONTROL

  2. >> L7Z DIFFERENCE WITH FV >> CIMR-L7ZOVERVIEW • L7Z DIFFERENCE WITH FV • HARDWARE • FIRMWARE FUNCTIONS OYMC L7Z training

  3. >> CIMR-L7Z OVERVIEW • MAIN HARDWARE FEATURES • 200V and 400V versions • 3.7Kw to 22Kw (Up to 55Kw in September) • V/F, Open Loop Vector and Closed Loop Vector Control methods • 8xDI, 1xAI, 4xDO (all relay), 3 Option ports : • IO expansion : Analog Input (AI-14B), Digital Input (DI-14H), Analog Output (AO-12), Digital Output (DO-02, DO-08) • Fieldbus :Profibus, DeviceNet, CANopen, Lonworks • PG Feedback : PG-X2, PG-B2 • Braking transistor built-in (Up to 18.5Kw) • Separate Control Power Supply terminal available for emergency rescue system. • New EMC filter “Bottom Plug” available • Pluggable control terminals. Easy maintenance of fan. Fan control from soft. • High nominal current (As FV) OYMC L7Z training

  4. >> CIMR-L7Z OVERVIEW • MAIN L7Z LIFT SOFTWARE FEATURES • Special LIFT sequence with Motor Brake, Contactor, and internal Run control • Specific parameter names. • High flexibility in the sequence behaviour selection (compatibility mode with FV) • Dual Torque compensation at start (Up/Down) in closed loop • Dual Feedforward Slip Compensation (motor/regen) in open loop • New errors • New lift oriented default values • New inertia compensation in closed loop • Added S-ramp for stop • Support for rescue operation with special alarm levels and control. • Simple to use Shortfloor function. OYMC L7Z training

  5. >> L7Z DIFFERENCE WITH FV • CIMR-L7ZOVERVIEW >> L7Z DIFFERENCE WITH FV • HARDWARE • FIRMWARE FUNCTIONS OYMC L7Z training

  6. >> L7Z DIFFERENCE WITH FV • MAIN DIFFERENCE WITH FV/G5 • New Static Autotune modes • Reduced size and reduced price • Improved performance (enhanced algorythms like DC braking, new functions) • New generation IGBTs. Lower voltage drop (reduced losses), smaller size. • Fan silent control when not working. • New DCCT current sensors. Faster response (1V/µs, FV was 8V/µs). Linearity • New generation capacitors with higher ripple current capacity, smaller size. • Better error handling and detection (GF is detected by specific slow circuitry (300 µs, OC is detected faster from the new DCCT in 8µs) • Same nominal rating as FV, although reduced duty cycle. • No RS-422 available in L7Z. RS-232 MEMOBUS is available. • Full 4 line LCD display • Of course : MANY NEW LIFT SOFTWARE FUNCTIONS OYMC L7Z training

  7. >> HARDWARE • CIMR-L7ZOVERVIEW • L7Z DIFFERENCE WITH FV >> HARDWARE • FIRMWARE FUNCTIONS OYMC L7Z training

  8. >> HARDWARE • STANDARD L7Z OYMC Labeling following Yaskawa naming • 3.7Kw to 55Kw now available OYMC L7Z training

  9. >> HARDWARE • L7Z WITH OPTIONAL LCD L7Z accepts PG option boards for Closed Loop Vector Pluggable terminal block OYMC L7Z training

  10. >> HARDWARE • HARDWARE SPECS OYMC L7Z training

  11. >> HARDWARE • CURRENT LIMITS AND SWITCHING FREQUENCY OYMC L7Z training

  12. Line Filter PG >> HARDWARE • POWER WIRING DC reactor to improve input power factor (Optional) Shielded wires Twisted-pair wires Braking Resistor unit (optional) U X Magnetic Contactor Short -circuit Bar Motor Fuse (+2) (-) B2 B1 U/T1 L1 3-phase power 380 to 480V 50/60Hz V/T2 IM L2 L3 W/T3 PE See emergency supply slide for other options P0 DC/DC Converter For option Input Voltage 48/96VDC For Battery Output Voltage For Control power supply P N0 OYMC L7Z training

  13. PG >> HARDWARE • CONTROL WIRING DI + Encoder Wiring (with PG) Forward run/stop S1 TA1 Reverse run/stop S2 Nominal speed S3 P Inspection Run S4 PG-X2 P Multi-function contact Inputs (Factory setting) (Option) Intermediate speed S5 Leveling speed S6 Shielded wires Not used S7 TA3 Hardware Baseblock BB Twisted-pair wires +24V 8mA TA2 A Pulse SC IP24V (24V) Pulse Monitor Output RS-422 Level (100m or less wiring) B Pulse CN5 (NPN setting) Z Pulse E(G) OYMC L7Z training

  14. M 1 M 2 >> Hardware • CONTROL WIRING AI + DO (relay outputs) Shielded wires E(G) M A Frequency setting adjustment Twisted-pair wires +V Fault contact Output 250VAC 1A or less 30VDC 1A or less Frequency setting power +15V 20mA M B 2KΩ M C External frequency reference Frequency setter 3 Master speed reference 0 to 10V 2 A1 0 to 10V 2KΩ 1 P AC Brake Command (Factory setting) 0V M 3 Multi-function Contact Output 250VAC 1A or less 30VDC 1A or less Communication and Control Cards (For Option) Contactor Control (Factory setting) M 4 2CN M 5 Inverter Ready (Factory setting) M 6 OYMC L7Z training

  15. >> HARDWARE • DETAIL ON CONTROL I/O LAYOUT AND CN5 NPN Internal Power supply (default) NPN External Power supply PNP Internal Power supply PNP External Power supply OYMC L7Z training

  16. >> HARDWARE • NEW BOTTOM-PLUG EMC FILTERS • New filters are being developed that provide CLASS A EMC filtering for 10m motor cable in compact size. • Available filters will be : • 18Amps for 3.7 –5.5kW • 35Amps for 7.5-11kW • 60Amps for 15-18.5kW • 100Amps for 22kW • Filters will be available for other inverters. • NOTE : Filter in image is a prototype OYMC L7Z training

  17. SoftCharge Resistor A A P ３ ＋ A ’ C R U S V ～ T W － B E D Control Power P ０ 200VClass(DC250V～300V) ＲＣＣ 400VClass(DC500V～600V) Minimum DC voltage 250V In both cases. Possible To use 220Vac UPS + rectifier N ０ E SX Battery　Operation Input SC setting 85 >> HARDWARE • EMERGENCY SUPPLY WIRING. USING BATTERY OYMC L7Z training

  18. >> FIRMWARE FUNCTIONS (FW1030) • CIMR-L7ZOVERVIEW • L7Z DIFFERENCE WITH FV • HARDWARE >> FIRMWARE FUNCTIONS (FW 1030) OYMC L7Z training

  19. DCInjection DCInjection zero servo zero servo S1-16 (200ms) brake open RUN Delay time delay time brake close delay time open delay Contactor S1-19 S1-06 S1-07 50ms speed Up/Down D/I Inverter Hardware BB (D/I) contactor confirmation D/I leveling D/I stop selected speed (D/I) Contactor Control D/O Internal Run Brake Control (D/O) t0 t1 t2 t3 t4 t5 t6 t7 t8 t9 t10 >> FIRMWARE FUNCTIONS (FW 1030) • THE CORE : THE LIFT SEQUENCE (I) Lift sequence without Torque compensation at start OYMC L7Z training

  20. >> FIRMWARE FUNCTIONS (FW 1030) • THE CORE : THE LIFT SEQUENCE (II) • Lift sequence without Torque compensation at start OYMC L7Z training

  21. >> FIRMWARE FUNCTIONS (FW 1030) • THE CORE : THE LIFT SEQUENCE (III) • Lift sequence without Torque compensation at start OYMC L7Z training

  22. Zero Speed Zero Speed Control Control RUN Delay (200ms) Brake Close delay time 50ms S1-16 S1-19 speed 300%torque S1-07 torque comp level at start Clear the torque comp Torque comp producing time S1-22 Up/Down D/I Inverter Hardware BB (D/I) contactor confirmation D/I leveling D/I stop selected speed (D/I) Contactor Control D/O Internal Run Brake Control (D/O) t0 t1 t2 t3 t4 t5 t6 t7 t8 t9 t10 >> FIRMWARE FUNCTIONS (FW 1030) • THE CORE : THE LIFT SEQUENCE (IV) • Lift sequence with Torque compensation at start (only FVC) • Selection is by setting analog input to Torque Comp. (e.g. H3-15=1) OYMC L7Z training

  23. >> FIRMWARE FUNCTIONS (FW 1030) • THE CORE : THE LIFT SEQUENCE (V) • Lift sequence with Torque compensation at start (only FVC) OYMC L7Z training

  24. >> FIRMWARE FUNCTIONS (FW 1030) • THE CORE : THE LIFT SEQUENCE (VI) • Lift sequence with Torque compensation at start (only FVC) OYMC L7Z training

  25. >> FIRMWARE FUNCTIONS (FW 1030) • THE CORE : THE LIFT SEQUENCE (VII) • Sequence parameters are in the new S1 menu. OYMC L7Z training

  26. >> FIRMWARE FUNCTIONS (FW 1030) • SOME SEQUENCE EXAMPLES (I) • Output current and brake output signal. We can identify the DC Injection perfectly.. OYMC L7Z training

  27. >> FIRMWARE FUNCTIONS (FW 1030) • SOME SEQUENCE EXAMPLES (II) • Here we can see Contactor Output (blue), brake output (brown) and Output current (green). OYMC L7Z training

  28. >> FIRMWARE FUNCTIONS (FW 1030) • SOME SEQUENCE EXAMPLES (III) • Here we can see a sequence example taken with SDC V2.1 … From top : • Run signal (Up) • Brake • Contactor • Frequency Output OYMC L7Z training

  29. >> FIRMWARE FUNCTIONS (FW 1030) • SPEED SELECTION (I) • THE SPEED PRIORITIES AND FV COMPATIBILITY MODE • The L7Z provides several sequence behaviour selection to allow FV update, old 2 speed systems update, new multispeed systems, etc… with minimum wiring. • Unfortunately, in FV compatibility mode some special functions related with the levelling speed selection are not possible in firmware 1030 (as the inverter is not aware of which is the levelling speed) : Short floor, feedforward slip, feedforward DC injection, etc. • TO GET MAXIMUM BENEFIT FROM Firmware 1030 use D1-18=1 or 2 !! • Also they provide increased sequence safety OYMC L7Z training

  30. DC DC Injection/ Injection/ zero servo zero servo speed Hardware BB Up/Down leveling no effect selected speed input is set DC DC Injection/ Injection/ zero servo zero servo speed Hardware BB Up/Down leveling speed leveling speed has priority selected speed >> FIRMWARE FUNCTIONS (FW 1030) • SPEED SELECTION (II) • PRIORITIES DEFINED AS FOLLOWS D1-18=1 is preferred type for safety : • D1-18 = 1 (high speed has priority) levelling STOPS. If levelling command is not configured, Up/Down STOPS. wires break = levelling • D1-18 = 2 (levelling has priority) levelling STOPS. If nominal command is not configured, Up/Down STOPS. wires break = nominal !!!!! OYMC L7Z training

  31. >> FIRMWARE FUNCTIONS (FW 1030) • SPEED SELECTION (III) • With D1-18=0, standard FV multifunction input values are available • With D1-18=1, New specific speed reference parameters with specific names are available. New multifunction values are available. OYMC L7Z training

  32. Inspection RUN DC DC (NO) Injection/ Injection/ zero servo zero servo speed speed Hardware BB Up/Down (D/I) Up/Down (D/I) Inspection RUN Inspection RUN base block base block MC closed (D/O) MC closed (D/O) Brake opened (D/O) Brake opened (D/O) >> FIRMWARE FUNCTIONS (FW 1030) • SPEED SELECTION. Inspection speed (IV) • The inspection speed has associated a specific typical inspection sequence Inspection RUN (NO) Hardware BB • RUN + Inspection speed terminal = start sequence. • The inverter coasts to stop during the inspection mode,. • The falling edge of the inspection RUN command or UP/DOWN commands triggers the contactor open command , the motor brake close command and the Baseblock. OYMC L7Z training

  33. >> FIRMWARE FUNCTIONS (FW 1030) • DECELERATION AND S-CURVE SETTINGS • C1-11 changes decel time from C1-02 to C1-08 only in decel section. C1-02 C1-01 C1-11 C1-08 • Additional S-Curve setting C2-05 for STOP. Very useful to modify stopping point without affecting deceleration ride quality. C2-03 C2-02 C2-04 C2-05 C2-01 OYMC L7Z training

  34. >> FIRMWARE FUNCTIONS (FW 1030) • NEW LIFT SEQUENCE FAULT MESSAGES • SE1 : Contactor feedback fault. If multifunction is set to 86 (Output Contactor feedback), then SE1 might appear : • CASE 1: Output contactor of output inverter kept closing before contactor closed command set. • CASE 2: Output contactor cannot be closed within the contactor close delay time. • CASE 3 :Output contactor is opened during inverter running. • SE2 : On brake release, the inverter checks if the motor current is higher than 25% of No-Load current. If not SE2 error is generated • SE3 : During RUN, the inverter checks if motor current is higher than 25% of No-Load current. If not, SE3 error is generated. OYMC L7Z training

  35. measure apply >> FIRMWARE FUNCTIONS (FW 1030) • FEEDFORWARD SLIP COMPENSATION (OLV / VF) (I) • After 1s at speed agree (nominal), the inverter makes an average of motor current (VF) or torque reference (OLV). This will be applied during levelling. • Only works with D1-18<>0 with firmware 1030 • The compesation differentiates regen and motoring. • Very, very useful in open loop for levelling accuracy. • New monitor U1-50 (slip comp. monitor) helps greatly to check how it works OYMC L7Z training

  36. >> FIRMWARE FUNCTIONS (FW 1030) • DC INJECTION (OLV / VF) (I) • DC Injection level (OLV and VF) and time (all methods) at Start and Stop can be set independently. • DC Injection times in FVC are zero speed hold times OYMC L7Z training

  37. ASR P,I ASR P,I C5-09 ASR Gain 3 C5-01 ASR Gain 1 C5-10　ASR I Time 3 C5-02 ASR I Time 1 C5-03 ASR Gain2 C5-03 ASR Gain2 C5-04　ASR I time 2 C5-04　ASR I time 2 0Hz 0Hz Speed(Hz) Speed(Hz) During Acceleration During Deceleration >> FIRMWARE FUNCTIONS (FW 1030) • 3 ASR (Automatic Speed Regulator) SETS (FVC) • L7Z allows selection of different ASR settings when starting, during top speed (E1-04 max freq. is the reference) and when stopping. This allows the most accurate settings. 50 ASR gain brake ASR gain levelling, opening zero speed 20 ASR gain top speed 0 OYMC L7Z training

  38. Internal RUN 300% torque Latch Torque comp.at start level >> FIRMWARE FUNCTIONS (FW 1030) • DWELL AT START FUNCTION • When S1-26 ( dwell speed reference ) is set , the Dwell at start function is activated. When the inverter starts, the inverter accelerates to S1-26 speed with C1-07 acceleration time. Once the motor speed exceeds the C1-11 frequency, the inverter will use the original acceleration. Dwell at start function C1-07 S1-26 • Original Dwell function (b6) is still available. Soft Starter Motor speed C1-11 Brake release OYMC L7Z training

  39. >> FIRMWARE FUNCTIONS (FW 1030) • INERTIA COMPENSATION (Speed feedforward) (FVC) • L7Z ads a feedforward term to the ASR control. When correctly tuned, overshoots due to inertia component of the machine are eliminated. • This becomes specially important as the gear ratio is reduced. • The tuning procedure is : • With balanced car, accelerate from zero to nominal speed with acceleration settings such that torque demand is continuous rated torque during acceleration. Measure the time and place in N5-02 OYMC L7Z training

  40. Speed Vs Vn Vn*0.4 Vl S2 Vj t 0 T1 T2 T1 T2 >> FIRMWARE FUNCTIONS (FW 1030) • SHORTFLOOR OPERATION • L7Z calculates estimated area (distance) from Vn to Vl with current parameters. • When levelling command is received, if actual speed is below 40% of Vn then the inverter keeps 40% reference for a calculated time to achieve the estimated area and reduce levelling time. The inverter keeps running at 40% of Vn reference until The S2 remaining area becomes Like S’ area. Speed Vn: nominal speed Vl: levelling speed T1:S-curve time at top T2:S-curve time at stop S = area Vstd VnX0.4 S s' s' t 0 T1 T2 OYMC L7Z training

  41. >> FIRMWARE FUNCTIONS (FW 1030) • NEW MONITORING FUNCTIONS • L7Z adds some other useful monitors. A group to check current behaviour during the car travel and a number of travels counter. In 1030 D1-18<>0. • LIMIT SWITCH INPUTS OYMC L7Z training

  42. >> FIRMWARE FUNCTIONS (FW 1030) • MULTIFUNCTION OUTPUTS • Door Open is already registered by other company, so we have to give a different name. OYMC L7Z training

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