Mitsubishi Electric 800 Series Instruction Manual

Plug-in option
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INVERTER
Plug-in option
FR-A8APS
INSTRUCTION MANUAL
EnDat interface
Orientation control
Encoder feedback control
Vector control
Position control
PRE-OPERATION INSTRUCTIONS
INSTALLATION AND WIRING
FR-A8APS FUNCTIONS
ORIENTATION CONTROL
ENCODER FEEDBACK CONTROL
VECTOR CONTROL
POSITION CONTROL FUNCTION
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  Summary of Contents for Mitsubishi Electric 800 Series

  • Page 1 INVERTER Plug-in option FR-A8APS INSTRUCTION MANUAL PRE-OPERATION INSTRUCTIONS EnDat interface INSTALLATION AND WIRING FR-A8APS FUNCTIONS Orientation control ORIENTATION CONTROL Encoder feedback control ENCODER FEEDBACK CONTROL Vector control VECTOR CONTROL Position control POSITION CONTROL FUNCTION...
  • Page 2 Thank you for choosing this Mitsubishi inverter plug-in option. This Instruction Manual provides handling information and precautions for use of this product. Incorrect handling might cause an unexpected fault. Before using this product, always read this Instruction Manual carefully to use this product correctly. Please forward this Instruction Manual to the end user.
  • Page 3  Additional instructions The following instructions must be also followed. If the product is handled incorrectly, it may cause unexpected fault, an injury, or an electric shock. Caution Transportation and mounting  Do not install or operate the plug-in option if it is damaged or has parts missing. ...
  • Page 4: Table Of Contents

    ─ CONTENTS ─ 1 PRE-OPERATION INSTRUCTIONS Unpacking and product confirmation.......................6 1.1.1 Product confirmation............................6 1.1.2 SERIAL number check ...........................7 Component names .............................8 2 INSTALLATION AND WIRING Pre-installation instructions ........................9 Installation procedure ..........................9 Wiring ................................12 Terminals..............................13 Encoder ..............................14 3 FR-A8APS FUNCTIONS 4 ORIENTATION CONTROL Wiring example ............................17 Terminals..............................18...
  • Page 5 Wiring examples ............................22 Setting procedure of vector control for motor with encoder ...............25 Vector control for PM motor with encoder.....................26 Offline auto tuning............................27 Encoder position tuning ..........................29 Specifications ............................32 7 POSITION CONTROL FUNCTION About position control ..........................33 Absolute position control ........................34...
  • Page 6: Pre-Operation Instructions Unpacking And Product Confirmation

    PRE-OPERATION INSTRUCTIONS Unpacking and product confirmation Take the plug-in option out of the package, check the product name, and confirm that the product is as you ordered and intact. This product is a plug-in option dedicated for the FR-A800 series inverter. 1.1.1 Product confirmation Check the enclosed items.
  • Page 7: Serial Number Check

    1.1.2 SERIAL number check The FR-A8APS can be used for the inverter models listed below with the following SERIAL number or later. Check the SERIAL number indicated on the inverter rating plate or package. Rating plate example    ...
  • Page 8: Component Names

    Component names Front view Rear view Terminal layout TST1 UP UN DT+ TST2 UP UN TST3 TST4 TST5 TST6 Symbol Name Description Refer to page Mounting hole Fixes the option to the inverter with screws, or installs spacers. Terminal block Connected with an encoder.
  • Page 9: Installation And Wiring Pre-Installation Instructions

    INSTALLATION AND WIRING Pre-installation instructions Check that the inverter's input power and the control circuit power are both OFF. Caution  With input power ON, do not install or remove the plug-in option. Otherwise, the inverter and plug-in option may be damaged. ...
  • Page 10 Do not insert the plug-in option to the connector 3. Connector 3 Mounting screw Spacer Spacer Connector 2 Connector 1 Spacer Spacer Mounting screw Mounting screw Insertion positions for screws and spacers INSTALLATION AND WIRING...
  • Page 11 NOTE • When mounting/removing the plug-in option, hold the sides of the option. Do not press on the parts on the option circuit board. Stress applied to the parts by pressing, etc. may cause a failure. • Caution must be applied to mounting screws falling off when removing and mounting the plug-in option. •...
  • Page 12: Wiring

    Wiring (1) Strip off the sheath of the signal cable from the encoder for the below length. If the length of the sheath peeled is too long, a short circuit may occur with neighboring wires. If the length is too short, wires might come off. Wire the stripped signal cable after twisting it to prevent it from becoming loose.
  • Page 13: Terminals

    (2) Loosen the terminal screw and insert the cable into the terminal. Screw size Tightening torque Cable size Screwdriver Small flat-blade screwdriver 0.22 Nm to 0.25 Nm 0.3 mm to 0.75 mm (Tip thickness: 0.4 mm/tip width: 2.5 mm) NOTE •...
  • Page 14: Encoder

    Encoder  Specifications Type EnDat 01/EnDat 21/EnDat 02/EnDat 22 Command set EnDat 2.1/2.2 Bit length 8192 (13 bits)/33554432 (25 bits) Measurement method Absolute measurement method only (Incremental signals are not supported.) Input power 4.5 to 5.5 V 300 mA The following table shows recommended encoders and cables. (as of April 2016.
  • Page 15: Fr-A8Aps Functions

    FR-A8APS FUNCTIONS  Parameter for detector Item FR-A8APS parameter Encoder rotation direction Pr.359 Number of detector pulses ― (Obtained via communication from the encoder) Encoder signal loss detection enable/disable selection Pr.376  Parameters related to the encoder pulse (Pr.353 to Pr.357, Pr.361, Pr.465 to Pr.494, Pr.1285 to Pr.1288) When the EnDat interface encoder with the encoder pulse number larger than 16384 is used, convert the pulse number using the following formula to find the value to be set in Pr.353 to Pr.357, Pr.361, Pr.465 to Pr.494, Pr.1285 to Pr.1288.
  • Page 16  Major functions list Function Function Vector control (speed control)   Deceleration check   Forward rotation output (Y30) signal/ Reverse  Vector control (torque control)  rotation output (Y31) signal/ Regenerative   status output (Y32) signal  Vector control (position control) ...
  • Page 17: Orientation Control

    ORIENTATION CONTROL Magnetic flux Vector Vector Vector Magnetic flux Magnetic flux This function is used with an encoder installed to the spindle of a machine tool, etc. to allow a rotary shaft to be stopped at the specified position (oriented). For the details of the parameters used for orientation control, refer to the Instruction Manual (Detailed) of the inverter.
  • Page 18: Terminals

    Terminals  Option FR-A8AX terminal Terminal Terminal name Description symbol Input the digital signal at the relay contact or open collector terminal. X0 to X15 Digital signal input terminal Using Pr.360, speed or position command is selected as the command signal entered. Used when a digital signal read timing signal is necessary.
  • Page 19: Specifications

    Specifications 1.5° Repeated positioning Depends on the load torque, moment of inertia of the load or orientaion, creep speed, position loop switching accuracy position, etc. Rotation speed of the EnDat interface encoder-mounted shaft Permissible speed The drive shaft and encoder-mounted shaft must be coupled directly or via a belt (with the speed ratio of 1:1) without any mechanical looseness or slip.
  • Page 20: Encoder Feedback Control

    ENCODER FEEDBACK CONTROL Magnetic flux Magnetic flux Magnetic flux Mount FR-A8APS to an FR-A800 series inverter to perform encoder feedback control under V/F control or Advanced magnetic flux vector control. This controls the inverter output frequency so that the motor speed is constant to the load variation by detecting the motor speed with the encoder to feed back to the inverter.
  • Page 21: Specifications

    Specifications 0.1% (100% means 3600 r/min) Speed variation ratio • Setting of speed feedback range Function • Setting of feedback gain • Setting of encoder rotation direction Maximum speed V/F control: 590 Hz, Advanced magnetic flux vector control: 400 Hz ENCODER FEEDBACK CONTROL...
  • Page 22: Wiring Examples

    VECTOR CONTROL When the FR-A8APS is installed on the FR-A800 series inverter, full-scale vector control operation can be performed using a motor with encoder. (For the details of vector control, refer to the Instruction Manual (Detailed) of the inverter.) Speed control, torque control, and position control are enabled under vector control for the induction motor. Speed control and position control are enabled under vector control for the PM motor.
  • Page 23  Torque control (With induction motor only) MCCB Inverter R/L1 Three-phase S/L2 AC power supply T/L3 Earth Forward rotation start (Ground) FR-A8APS Reverse rotation start DATA DATA Contact input common CLOCK CLOCK Encoder Speed limit command Frequency setting ∗1 potentiometer 1/2 W1 kΩ...
  • Page 24  Position control Positioning unit MELSEC-Q QD75P[ ]N/QD75P[ ] MCCB MELSEC-L LD75P[ ] Three-phase R/L1 Inverter AC power S/L2 supply T/L3 Earth (ground) STOP Forward stroke end Reverse stroke end FR-A8APS DATA Pre-excitation/servo on ∗3 DATA Clear signal ∗3 CLEAR CLOCK Pulse train ∗4...
  • Page 25: Setting Procedure Of Vector Control For Motor With Encoder

    Setting procedure of vector control for motor with encoder Follow the following procedure to change the setting for the vector control for the motor with an encoder. Set the applied encoder. (Pr.359) Set Pr.359 Encoder rotation direction in accordance with the encoder specification. Set the motor.
  • Page 26: Vector Control For Pm Motor With Encoder

    NOTE • For PM motors, after performing offline auto tuning and encoder position tuning, first perform PM parameter initialization. If parameter initialization is performed after setting other parameters, some of those parameters will be initialized too. (For the parameters to be initialized, refer to the Instruction Manual (Detailed) of the inverter.) Vector control for PM motor with encoder •...
  • Page 27: Offline Auto Tuning

    Offline auto tuning Vector Vector Vector • The offline auto tuning enables the optimal operation of a motor with encoder. Description Initial Setting Name value range PM motor Induction motor No offline auto tuning Performs offline auto tuning (without motor rotation) Performs offline auto tuning only for motor constant R1 (without Auto tuning setting/status motor rotation)
  • Page 28  Parameters in which the tuning results are set to after tuning (PM motor) Tuning items by Pr.96 (Pr.463) settings Name Description 90 (458) Motor constant (R1) Resistance per phase    92 (460) Motor constant (L1)/d-axis inductance (Ld) ...
  • Page 29: Encoder Position Tuning

    Encoder position tuning Vector Vector Vector • Encoder position tuning is required when a PM motor with an encoder is driven. The measured offset value between the motor home magnetic pole position and the encoder home position is stored. Only the encoder position tuning can be performed when offline auto tuning is not required, such as when the parameters for motor constant are set manually, or when offline auto tuning is already performed.
  • Page 30  Performing tuning POINT POINT • Before performing tuning, check the monitor display of the operation panel or parameter unit if the inverter is in the state ready for tuning. Turning ON the start command while tuning is unavailable starts the motor. •...
  • Page 31 • When encoder position tuning ends, press on the operation panel during PU operation. For External operation, turn OFF the start signal (STF signal or STR signal). This operation resets the encoder position tuning, and the PU's monitor display returns to the normal indication. (Without this operation, next operation cannot be started.) NOTE •...
  • Page 32: Specifications

    Specifications Speed control range 1:1500 (both driving/regeneration  0.01% (100% means 3000 r/min) Speed variation ratio Speed control Speed response 20 Hz (40 Hz during fast-response operation) Maximum speed 400 Hz Torque control range 1:50 10% Torque control Absolute torque accuracy ...
  • Page 33: Position Control Function About Position Control

    POSITION CONTROL FUNCTION About position control • In position control, speed commands, which are calculated to eliminate the difference between the command pulse (parameter setting) and the feedback pulse number, are output to rotate the motor. NOTE • For the details of the setting procedure and operations, refer to the Instruction Manual (Detailed) of the inverter. POSITION CONTROL FUNCTION...
  • Page 34: Absolute Position Control

    Absolute position control When the FR-A8APS is used, setting "1110" in Pr.419 Position command source selection enables storing of the position after the first home position return is completed for the point table positioning during position control by point tables. The home position return operation is not required at every power-ON.
  • Page 35 (2) Operation Example) Operation at power-ON Home position return (for the first-time positioning) Position at power-on Home position (for the second-time and Target position (stored) onward positioning) Positioning operation Positioning Operation First time After the home position return operation is performed (the home position data is retained), positioning starts. The home position return operation is not required regardless of the ON/OFF of the power supply.
  • Page 36 NOTE • Maximum possible position shift amount = (Encoder pulse number  (Maximum count of the multi-turn counter / 2) - Example) Encoder pulse number = 8192, multi-turn counter count = 4096 Maximum possible position shift amount = 16777215 (3) Warning Output is not shut off when a protective function is activated.
  • Page 37 MEMO...
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  • Page 39 REVISIONS *The manual number is given on the bottom left of the back cover. Print Date *Manual Number Revision May 2016 IB(NA)-0600661ENG-A First edition...
  • Page 40 INVERTER HEAD OFFICE: TOKYO BUILDING 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN IB(NA)-0600661ENG-A(1605) MEE Printed in Japan Specifications subject to change without notice.

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Fr-a8aps