YASKAWA AC Drive-Option Card

Line Driver Type PG

Installation Manual
Type PG-X3
To properly use the product, read this manual thoroughly and retain
for easy reference, inspection, and maintenance. Ensure the end user
receives this manual.

PG
PG-X3

MANUAL NO. TOBP C730600 37A

This Page Intentionally Blank
Table of Contents

1 PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 PRODUCT OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3 OPTION CARD COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 9
4 ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 10
5 RELATED PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
7 SPECIFICATIONS & WARRANTY INFORMATION . . . . . . . 26

Copyright © 2008 YASKAWA ELECTRIC CORPORATION

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted, in any form or by any means, mechanical, electronic, photocopying, recording, or
otherwise, without the prior written permission of Yaskawa. No patent liability is assumed with
respect to the use of the information contained herein. Moreover, because Yaskawa is constantly
striving to improve its high-quality products, the information contained in this manual is subject to
change without notice. Every precaution has been taken in the preparation of this manual.
Yaskawa assumes no responsibility for errors or omissions. Neither is any liability assumed for
damages resulting from the use of the information contained in this publication.

YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual 3
1 Preface

1 Preface
Yaskawa manufactures products used as components in a wide variety of industrial systems
and equipment. The selection and application of Yaskawa products remain the responsibility
of the equipment manufacturer or end user. Yaskawa accepts no responsibility for the way its
products are incorporated into the final system design. Under no circumstances should any
Yaskawa product be incorporated into any product or design as the exclusive or sole safety
control. Without exception, all controls should be designed to detect faults dynamically and
fail safely under all circumstances. All systems or equipment designed to incorporate a
product manufactured by Yaskawa must be supplied to the end user with appropriate
warnings and instructions as to the safe use and operation of that part. Any warnings
provided by Yaskawa must be promptly provided to the end user. Yaskawa offers an express
warranty only as to the quality of its products in conforming to standards and specifications
published in the Yaskawa manual. NO OTHER WARRANTY, EXPRESS OR IMPLIED, IS
OFFERED. Yaskawa assumes no liability for any personal injury, property damage, losses,
or claims arising from misapplication of its products.

◆ Applicable Documentation
This instruction manual has been written for the items listed below. Use this option card for
its intended purpose only.

Option Card
YASKAWA AC Drive-Option Card
Line Driver PG: PG-X3 Installation Manual (this book)
Document Number: TOBP C730600 37
PG-X3

Read this manual first.

It contains information required to install the option card and set up related drive
parameters.

Drive

Refer to the manual of the drive this option card is being used with.
The manual for the drive covers basic installation, wiring, operation procedures,
functions, troubleshooting, and maintenance information.
It also includes important information on parameter settings and how to tune the drive.
To obtain instruction manuals for Yaskawa products access these sites:
Europe: http://www.yaskawa.eu.com
Japan: http://www.e-mechatronics.com
Other areas: contact a Yaskawa representative.

4 YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual
1 Preface

◆ Registered Trademarks
• Company names and product names listed in this manual are the registered trademarks of
those companies.

◆ Supplemental Safety Information

Read and understand this manual before installing, operating or servicing this option unit.
The option unit must be installed according to this manual and local codes.
The following conventions are used to indicate safety messages in this manual. Failure to
heed these messages could result in serious or possibly even fatal injury or damage to the
products or to related equipment and systems.

DANGER
Indicates a hazardous situation, which, if not avoided, will result in death or serious
injury.

WARNING
Indicates a hazardous situation, which, if not avoided, could result in death or serious
injury.

CAUTION
Indicates a hazardous situation, which, if not avoided, could result in minor or moderate
injury.

NOTICE
Indicates an equipment damage message.

YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual 5
1 Preface

■ General Safety

General Precautions
• The diagrams in this section may include option units and drives without covers or safety shields to
illustrate details. Be sure to reinstall covers or shields before operating any devices. The option
board should be used according to the instructions described in this manual.
• Any illustrations, photographs, or examples used in this manual are provided as examples only and
may not apply to all products to which this manual is applicable.
• The products and specifications described in this manual or the content and presentation of the
manual may be changed without notice to improve the product and/or the manual.
• When ordering a new copy of the manual due to damage or loss, contact your Yaskawa
representative or the nearest Yaskawa sales office and provide the manual number shown on the
front cover.

DANGER
Heed the safety messages in this manual.
Failure to comply will result in death or serious injury.
The operating company is responsible for any injuries or equipment damage resulting
from failure to heed the warnings in this manual.

NOTICE
Do not expose the drive to halogen group disinfectants.
Failure to comply may cause damage to the electrical components in the option unit
Do not pack the drive in wooden materials that have been fumigated or sterilized.
Do not sterilize the entire package after the product is packed.

6 YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual
2 Product Overview

2 Product Overview
◆ About This Product
By installing this option card to a drive, the drive is able to read a feedback signal send from
a pulse generator (PG) attached to the motor. This PG signal lets the drive know about any
subtle variations in the load, and provides the drive with the data necessary for controlling
the output frequency to maintain constant speed with a high degree of accuracy.
This card can read a maximum input frequency sent from the PG of 300 kHz. Select a PG
with an output of maximum 300 kHz when operating at maximum speed.
This option card allows the user to connect a incremental encoder (PG) for motor speed
feedback to the drive and take advantage of the drive’s V/f with PG control mode, Closed
Loop Vector control mode, and Closed Loop Vector for PM motors to obtain more accurate
control and higher performance.

◆ Checking Package Contents

Table 1 Items Included with this Option Card
Package Lead Lines
Option Card Screws (M3) Manual (this book)
Contents (for grounding)

PG-X3
MANUAL

Number of
1 2 3 1
Items

• Inspect the Option Card for damage. If the Option Card appears damaged upon receipt,
contact the shipper immediately.
• Verify receipt of the correct model by checking the model number printed on the Name
plate of the Option Card. (see Figure 1)
• If you have received the wrong model or the Option Card does not function properly,
contact your supplier.

YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual 7
2 Product Overview

◆ Tools Required for Installation

A Phillips screwdriver PH1 (#1) is needed to install this option card.
Additionally a straight-edge screwdriver (blade depth: 0.4 mm, width: 2.5 mm) will be
needed to wire the terminal block.
Note: Other tools are required for preparing encoder cables.

8 YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual
3 Option Card Components

3 Option Card Components

◆ Option Card
Figure 1

C E

A G
PG-X3
F

Underside

A – Terminal block TB1 E – Model number

B – Ground terminal (installation hole) F – Installation hole
C – Jumper for PG power supply G – Connector (CN5)
voltage (CN3)
D – Terminal block TB2

Figure 1 Option Card

◆ Terminal Block
Figure 2

IP IG SG a+ a− b+ b− z+ z−
TB2

A+ A− B+ B− Z+ Z− SD FE
TB1

Figure 2 Terminal Block

YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual 9
4 Electrical Installation

4 Electrical Installation
◆ Safety Messages

DANGER
Electric Shock Hazard
Power to the drive must be shut off when installing this option card.
Even though the power has been shut off, voltage still remains in the drive’s DC bus. Wait
before removing the front cover once the drive has been turned off.
The CHARGE light on the drive will go out after voltage in the DC bus drops below 50 V,
at which point it is safe to remove the front cover.
Due to the risk of electric shock, be sure that all LEDs have gone out and that the DC bus
voltage has reached a safe level prior to performing any work on the drive.

WARNING
Electrical Shock Hazard
Do not allow unqualified personnel to perform work on the drive.
Failure to comply could result in death or serious injury.
Maintenance, inspection, and replacement of parts must be performed only by authorized
personnel familiar with installation, adjustment and maintenance of AC drives and
Option Cards.

10 YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual
4 Electrical Installation

NOTICE
Damage to Equipment
Observe proper electrostatic discharge procedures (ESD) when handling the option
unit, drive, and circuit boards.
Failure to comply may result in ESD damage to circuitry.
Never shut the power off while the drive is outputting voltage.
Failure to comply may cause the application to operate incorrectly or damage the drive.
Do not operate damaged equipment.
Failure to comply may cause further damage to the equipment.
Do not connect or operate any equipment with visible damage or missing parts.
Properly connect all pins and connectors.
Failure to comply may prevent proper operation and possibly damage equipment.

YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual 11
4 Electrical Installation

◆ Installing the Option Card

This option card can be inserted into the either the CN5-B or CN5-C connectors located on
the drive’s control board. If only one option card is connected to the drive, use the CN5-C
connector. If two option cards are connected, use both CN5-B and CN5-C.
See the drive manual for directions on removing the front cover.
1. Shut off power to the drive, wait the appropriate amount of time for voltage to
dissipate, then remove the operator and front cover.
2. Insert the CN5 connector on the option card into the matching CN5 connector on
the drive, then fasten it into place using one of the screws included with the option
card.
Connect one of the lead lines using one of the screws to the ground terminal.
Two separate lead lines have been included with the option card. Use the longer
one when the option card is plugged into connector CN5-C on the drive side. Use
the shorter one if it is plugged into connector CN5-B.
Note: There are only two screw holes on the drive for ground terminals. If three option cards are
connected, two of the lead lines will need to share the same ground terminal.
Figure 3

B F
G
C
J

D
K

L
H
I

A – Connector CN5-C G – Mounting screw

B – Connector CN5-B H – Lead line
C – Connector CN5-A I – Use wire cutters to create an
opening for cable lines
D – Drive grounding terminal (FE) J – Front cover
E – Insert connector CN5 here K – Digital operator
F – Option card L – Terminal cover

Figure 3 Installing the Option Card

12 YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual
4 Electrical Installation

3. Wire the option card to the terminal block on the option card.
For wiring instructions, see Connection Diagram on page 14.
In the drives CIMR-A†2A0004 to 0040 and 4A0002 to 0023 the PG cable might
need to be routed through the top cover to the outside. In this case cut out the
perforated openings at the left side of the drive top cover. Make sure no sharp
edges that can damage the cable remain.
In the drives CIMR-A†2A0056 to 0211 and 4A0031 to 0165 the PG cable can be
routed inside the drive.
Figure 4

A – Wires should pass through the B – Use the open space provided
access hold provided on the left inside the drive to route option
side of the front cover. card wiring.
(CIMR-A†2A0004 to 0040, 4A0002 (CIMR-A†2A0056 to 0211, 4A0031
to 0023) to 0165)

Figure 4 Wiring space

4. Place the front cover back onto the drive as it was before.
Note: 1. Take care when wiring the option card so that the front cover easily fits back onto the drive. Make sure
a cable is not caught between the front cover and the drive when putting the cover back on.
2. The drive will not be used as NEMA Type1 if there is any exposed wiring outside the enclosure.

YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual 13
4 Electrical Installation

◆ Connection Diagram
Refer to Figure 5 when wiring the terminal block on the option card.
• If using a single track encoder in the V/f with PG control mode, connect the pulse output
from the PG to the option card and set parameter F1-37 in the drive to 0. If using a two
track encoder, then connect the A and B pulse outputs on the PG to the option card and set
F1-37 to 1.
• If using a two track encoder for the Close Loop Vector control mode, connect pulse
outputs A and B from the encoder to the corresponding terminals on the option card.
• For a three track encoder, connect the A, B, and Z pulse outputs to the corresponding
terminals on the option card.
A detailed description of the option board terminals can be found in Terminal Functions on
page 16.
NOTICE: Make sure that jumper CN3 connects the IP terminals to set the correct voltage for the PG power
supply. If the wrong voltage is selected, the PG may not operate properly or may become damaged as a
result. Select the voltage level for the PG that is connected to the option card and motor. For more
information on the setting the power supply voltage, see Setting the Voltage for the PG Power Supplyon page16.
Figure 5

R/L1 U/T1
S/L2 V/T1 M
T/L3 W/T1

Drive TB1
PGX3 A+
A
B+
PG
B
Z+
Z
SD
NC
FE

CN3 TB2
IP12
IP5 IP
IG IG

SG
a+
CN5 A pulse monitor signal
a
b+
B pulse monitor signal
b
z+
Z pulse monitor signal
FE z

Lead line

twisted-pair shielded line

main circuit terminal control circuit terminal

Figure 5 Wiring the Option Card and PG

14 YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual
4 Electrical Installation

Take the following steps to prevent erroneous operation caused by noise interference:
• Use shielded wire for the signal lines.
• Keep all output wiring under 100 m.
• Make sure that control lines to the option card, main circuit wiring, and power lines are
separated from one another.
• The shield should be grounded on both the PG side as well as the drive side. If noise
problems arise in the PG signal, try grounding only one end of the signal line, or removing
the ground connection on both ends.
■ Interface Circuit
Figure 6

PGX3
A+,B+,Z+ A,B,Z PG
600 Ω
A,B,Z
26LS32 level a+,b+,z+ A,B,Z 26LS31 level

a,b,z
Monitor Signal
26LS31 level
SG

Figure 6 Interface Circuit

YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual 15
4 Electrical Installation

◆ Terminal Functions
Table 2 Terminal Functions
Terminal Terminal Function Description
Block
A+ A+ pulse signal input
A– A– inverse pulse input
B+ B+ pulse signal input • Inputs for the A, B, and Z pulses from the PG
B– B– inverse pulse input • Signal level matches RS-422
TB1
Z+ Z+ pulse signal input
Z– Z– inverse pulse input
SD NC pin (open) For use when cables shields should not be grounded
FE Ground Used for grounding shielded lines
IP PG power supply • Output voltage: 12.0 V ± 5% or 5.5 V ± 5%
IG PG power supply common • Max. output current: 200 mA <1>
SG Monitor signal common
a+ A pulse monitor signal
TB2 a– A pulse inverse monitor signal • Output signal for monitoring A, B, and Z pulses from
b+ B pulse monitor signal the PG
b– B pulse inverse monitor signal • Signal level matches RS-422
z+ Z pulse monitor signal
z– Z pulse inverse monitor signal
<1> A separate power supply is needed if the PG requires more than 200 mA to operate. To continue operating through
a momentary power loss, a back-up capacitor should be prepared.

◆ Setting the Voltage for the PG Power Supply

Jumper CN3 determines the voltage for the PG power supply. The voltage level is set by the
positioning the jumper as shown below.
NOTICE: Setting the incorrect voltage can damage the PG. Make sure the jumper is positioned properly to
supply the correct voltage for the PG being used.

Table 3 PG Power Supply Voltage (IP)

Voltage Level 5.5 V ± 5% (default) 12.0 V ± 5%

5.5 V 12 V 5.5 V 12 V
Jumper

16 YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual
4 Electrical Installation

◆ PG Signal Output and Option Card Settings

With a two or three track encoder the motor rotation direction is determined by the pulse that
leads. A PG signal with leading A pulse is considered as rotation in Forward direction
(counter-clockwise when from the load side).
NOTICE: Make sure that the option card and PG have been set correctly to ensure that the motor operates
as expected.
Figure 7

The A pulse leads, followed

by the B pulse displaced at 90 degrees

A pulse

B pulse

Time
Figure 7 Displacement of A and B Pulses
After connecting the PG outputs to the option card, the direction can be checked by
manually rotate the motor with the monitor on the drive.
If the monitor shows the forward direction as being the opposite of what you want, set
parameter F1-05/F1-32 to 1 to switch the direction of how the option card reads pulses from
the PG output.

◆ Wire Gauges and Tightening Torque

Wire gauge specifications are listed below in Table 4.
Yaskawa recommends using crimp terminals for easy of wiring and to ensure proper
connection. Crimp terminal specifications can be found in Table 5.
Table 4 Wire Gauges and Tightening Torque
Wiring Gauges with
Bare Cable
Crimp Terminals
Tightening Recom Recom
Terminal Screw Possible Possible
Signal Size Torque mended mended Wire Type
(Nxm) Gauges Gauges
mm2 Gauges mm2 Gauges
(AWG) mm2 (AWG) mm2
(AWG) (AWG)
A+, A–, B+, Stranded wire: Shielded
B–, Z+, Z–, 0.25 to 1.0 twisted pair,
SD, FE, IP, IG (24 to 17) 0.75 0.25 to 0.5 0.5 etc.
M2 0.22 to 0.25
Single line: (18) (24 to 20) (20)
a+, a–, b+, 0.25 to 1.5 Shielded line,
b–, z+, z–, SG (24 to 16) etc.

YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual 17
4 Electrical Installation

■ Crimp Terminals
Yaskawa recommends using CRIMPFOX ZA-3 by Phoenix Contact to crimp the terminal
ends.
NOTICE: Wire ends should be properly trimmed so no wire extends out from the crimp terminals.

Table 5 Crimp Terminal Sizes

Wire Gauge
L d1 d2
mm2 Model (mm) (mm) (mm) Manufacturer
(AWG)
0.25 (24) AI 0.25 - 6YE 10.5 0.8 2
0.34 (22) AI 0.34 - 6TQ 10.5 0.8 2 Phoenix Contact
d1 6 mm d2
L 0.5 (20) AI 0.5 - 6WH 14 1.1 2.5

◆ Wiring Procedure
When wiring the option card, wire ends should be prepared as shown in Figure 8. See Wire
Gauges and Tightening Torque on page 17 to make sure that the proper tightening torque is
applied to each terminal end.
Take particular precautions to ensure that each cable is properly connected, and that wire
covering has not been accidentally inserted into the terminals.
NOTICE: Insulation or tape may be required to ensure that shielded lines do not come into contact with
other wiring. Insufficient insulation may cause a short circuit that can damage the option card and the drive.

NOTICE: Follow the tightening torque specifications in this manual for all terminal screws. Failing to do so
may keep the drive from functioning properly and could damage the terminal block.
Figure 8

Shield Insulation

Option Card PG

Ground Terminal
FE/SD Shield shearth (Insulate with tape)
Figure 8 Treating Terminal Ends for Shielded Line
Figure 9

Terminal Loosen screw to

Avoid fraying wire stands insert wire.
block
when stripping insulation Blade depth of
from wire. 0.4 mm or less
Blade width of
2.5 mm or less
Strip length 5.5 mm Single wire or
stranded wire
Figure 9 Terminal Block Wiring

18 YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual
5 Related Parameters

5 Related Parameters
The following parameters are used to set up the drive for operation with a PG option card.
Set parameters as needed. Instructions on how to set parameters can be found in the
instruction manual for the drive the PG option card is connected to.
Table 6 Related Parameters
Connector Setting
No. Parameter Description Default
CN5-B CN5-C Range
F1-01 Sets the pulses to be read from the pulse 0 to
PG 1 Pulse Setting { 600
<1> generator. 60000
Sets the stopping method when the PG becomes
disconnected (PGo).
0: Ramp to stop (decelerates at time set to C1-
PG Feedback Loss
02)
F1-02 (PGo) Operation { { 0 to 3 1
1: Coast to stop
Selection
2: Fast Stop (decelerates at the time set to C1-
09)
3: Continue running
Sets the stopping method when overspeed is
detected.
0: Ramp to stop (decelerates at time set to C1-
PG Overspeed (oS) 02)
F1-03 { { 0 to 3 1
Operation Selection 1: Coast to stop
2: Fast Stop (decelerates at the time set to C1-
09)
3: Continue running
0: Ramp to stop (decelerates at time set to C1-
02)
PG Deviation (dEv) 1: Coast to stop
F1-04 { { 0 to 3 3
Operation Selection 2: Fast Stop (decelerates at the time set to C1-
09)
3: Continue running
0: Forward = A pulse leads
F1-05 PG 1 Rotation { 0, 1 0
1: Forward = B pulse leads
Sets the division ratio for the pulses output
from the PG encoder. Set as a three digit
number where x is the first digit, y is the second
digit, and z the third:
PG 1 Ratio for PG
F1-06 { (1 + x) 1 to 132 1
Pulse Monitor Ratio =
yz
When only the A pulse is read, this ratio is
1
disabled and pulses are set as to 1.
32

YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual 19
5 Related Parameters

Connector Setting
No. Parameter Description Default
CN5-B CN5-C Range
Sets the level for detecting overspeed (oS).
PG Overspeed (oS)
F1-08 { { Set as a percentage of the maximum output 0 to 120 115
Level
frequency.
Overspeed (oS) Sets the time required for the motor to exceed
F1-09 { { 0.0 to 2.0 <2>
Detection Time the the level set in F1-08 to trigger a fault.
Excessive Speed
Sets the degree of speed deviation to trigger a
Deviation
F1-10 { { dEv fault. Set as a percentage of the maximum 0 to 50 10
Detection (dEv)
output frequency.
Level
Excessive Speed
Deviation Sets the time required a speed deviation
F1-11 { { 0.0 to 10.0 0.5
Detection (DEv) situation to trigger a fault.
Time
F1-12 PG 1 Gear Teeth 1 {
Number of gear teeth between the PG and
<3> motor.
Pulses × 60 F1-13 (load side)
× 0 to 1000 0
F1-13 F1-01 F1-12 (motor side)
PG 1 Gear Teeth 2 {
<3>
A gear ratio of 1 will be used if any of these
parameters is set to 0.
PG Disconnect
Sets the time in seconds for PG disconnect to be
F1-14 (PGo) Detection { { 0.0 to 10.0 2.0
detected.
Time
Reverse Rotation 0: Disabled
F1-18 detection for PG 1 { n: Number of times a dv3 situation must be 0 to 10 10
(dv3) detected to trigger a fault.
Reverse Rotation 0: Disabled
F1-19 detection for PG 1 { n: Number of times a dv4 situation must be 0 to 5000 128
(dv4) detected to trigger a fault.
0: Disabled. No fault if the PG-X3 connection
PG 1 Hardware is lost.
F1-20 { 0, 1 1
Disconnect 1: Enabled. Fault trigger if PG-X3 connection is
lost.
PG 1 Option Card 0: A pulse detection
F1-21 { 0, 1 0
Function 1: AB pulse detection
Selects the connector for the PG option card
Motor 2 PG Card connected to motor 2.
F1-30 – – 0 to 1 1
Connector 0: CN5-C
1: CN5-B
F1-31 Sets the pulses to be read from the pulse
PG 2 Pulse Setting { 0 to 60000 1024
<1> generator.
0: Forward = A pulse leads
F1-32 PG 2 Rotation { 0, 1 0
1: Forward = B pulse leads

20 YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual
5 Related Parameters

Connector Setting
No. Parameter Description Default
CN5-B CN5-C Range
F1-33 Number of gear teeth between the PG and
<3>
PG 2 Gear Teeth 1 {
motor.
Pulses × 60 F1-33 (load side) 0 to
× 0
F1-34 F1-31 F1-34 (motor side) 1000
PG 2 Gear Teeth 2 {
<3>
A gear ratio of 1 will be used if any of these
parameters is set to 0.
Sets the division ratio for the pulses output
from the PG encoder. Set as a three digit
number where x is the first digit, y is the second
PG 2 Division digit, and z the third:
F1-35 Ratio for Pulse { (1 + x) 1 to 132 1
Ratio =
Monitor yz
When only the A pulse is read, this ratio is
1
disabled and pulses are set as to 1.
32
0: Disabled. No fault if the PG-X3 connection
PG 2 Hardware is lost.
F1-36 { 0, 1 1
Disconnect 1: Enabled. Fault trigger if PG-X3 connection is
lost.
PG 2 Option Card 0: A pulse detection
F1-37 { 0, 1 0
Function 1: AB pulse detection

<1> The number of output pulses for the PG can be calculated as follows:

Motor speed at maximum frequency output (min-1)

f
PG
(Hz) × PG rating (p/rev)
60
<2> Value changes according to the control mode selection in A1-02.
<3> Enabled only when using the V/f with PG control mode.

YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual 21
6 Troubleshooting

6 Troubleshooting
◆ Error Codes Displayed on the Drive Operator
The table below lists the various fault codes related to the option card and pulse generator.
Further detail on various faults can be found in the instruction manual for the drive.
• Make sure the PG cable is properly connected.
• Check the cables between the PG and the option card.
• Make sure the option card is properly installed to the drive.
Table 7 Fault Display
Digital Operator Display Fault Name
Speed Deviation (for Control Mode with PG)
dEv The deviation between the speed reference and speed feedback is greater than the
setting in F1-10 for longer than the time set to F1-11.
Cause Possible Solution
Load is too heavy. Reduce the load.
Acceleration and deceleration
Increase the acceleration and deceleration times (C1-01 through C1-08).
times are set too short.
The load is locked up. Check the machine.
Parameters are not set
Check the settings of parameters F1-10 and F1-11.
appropriately.
Motor brake engaged. Ensure the motor brake releases properly.
Digital Operator Display Fault Name
Z-phase Pulse Fall Detection
dv1
The motor turned one full rotation without the Z pulse being detected.
Cause Possible Solution
• Make sure the PG encoder is properly connected and shielded line is properly
PG encoder is not connected, not grounded.
wired properly, or is damaged. • If the problem continues after cycling power, then replace either the PG option
card or the PG encoder itself.
Digital Operator Display Fault Name
Z-phase Noise Fault Detection
dv2 The Z pulse is out of phase by more than 5 degrees for the number of times
specified in parameter F1-17.
Cause Possible Solution
Noise interference along the PG Separate the PG cable lines from the source of the noise (very possibly drive
cable. output wiring).
Rewire the PG encoder and maker sure all lines including shielded line are
PG cable is not wired properly.
properly connected.

22 YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual
6 Troubleshooting

PG option card or the PG If the problem continues after cycling power, then replace either the PG option
encoder is damaged. card or the PG encoder itself.
Digital Operator Display Fault Name
Inversion Detection
The torque reference and acceleration are in opposite directions from one another
dv3 (one is in reverse and the other is forward) while at the same time the speed
reference and actual motor speed differ by over 30% for the number of pulses set
to F1-18.
Cause Possible Solution
Set the value for Δθ to E5-11 as specified on the motor nameplate. Replacing the
The Z-pulse offset is not set
PG encoder or changing the application so that the motor rotates in reverse instead
properly to E5-11.
requires readjustment of the Z-pulse offset.
An external force on the load • Make sure the motor is rotating in the right direction.
side has caused the motor to • Look for any problems on the load side that might be causing the motor to rotate
move. in the opposite direction.
Noise interference along the PG
cable affecting the A or B pulse.
Rewire the PG encoder and maker sure all lines including shielded line are
PG encoder is disconnected, not properly connected.
wired properly, or the PG option
card or PG itself is damaged.
Rotational direction for the PG
encoder set to F1-05 is the
Make sure motor lines for each phase (U, V, W) are connected properly.
opposite of the order of the
motor lines.
Digital Operator Display Fault Name
Inversion Prevention Detection
Pulses indicate that the motor is rotating in the opposite direction of the speed
dv4 reference. Set the number of pulses to trigger inverse detection to F1-19.
Note: Disable inverse detection in applications where the motor may rotate in the
opposite direction of the speed reference. Setting F1-19 to 0 disables this feature.
Cause Possible Solution
• Set the value for Δθ to E5-11 as specified on the motor nameplate.
• If the problem continues after cycling power, then replace either the PG option
The Z-pulse offset is not set
card or the PG encoder itself. Replacing the PG encoder or changing the
properly to E5-11.
application so that the motor rotates in reverse instead requires readjustment of
the Z-pulse offset.
• Make sure the motor is rotating in the right direction.
Noise interference along the PG
• Look for any problems on the load side that might be causing the motor to rotate
cable affecting the A or B pulse.
in the opposite direction.
• Rewire the PG encoder and maker sure all lines including shielded line are
PG encoder is disconnected, not
properly connected.
wired properly, or the PG option
• If the problem continues after cycling power, then replace either the PG option
card or PG itself is damaged.
card or the PG encoder itself.

YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual 23
6 Troubleshooting

Digital Operator Display Fault Name

oFA00 Non-Compatible Option Card at CN5-A
Cause Possible Solution
Non-compatible option card
Use only compatible option cards. See note <1>.
connected to port CN5-A.
Digital Operator Display Fault Name

oFb00 Non-Compatible Option Card at CN5-B

Cause Possible Solution

Non-compatible option card
Use only compatible option cards. See note <1>.
connected to port CN5-B.
Digital Operator Display Fault Name

oFb01 Option Card Connection Error at CN5-B

Cause Possible Solution

Option card at port CN5-B was
Switch the power off and reconnect the option card.
changed during run.
Digital Operator Display Fault Name

oFC01 Option Card Connection Error at CN5-C

Cause Possible Solution

Option card at port CN5-C was
Switch the power off and reconnect the option card.
changed during run.
Digital Operator Display Fault Name
Control Method Selection Error
oPE06
Correct the setting for the control method.
Cause Possible Solutions
A control mode has been
selected that requires a PG
• Connect a PG option card.
option card to be installed, but
• Correct the value set to A1-02.
no PG encoder is installed (A1-
02 = 1, 3, or 7).
Digital Operator Display Fault Name
Overspeed
oS
The motor speed feedback exceeded the F1-08 setting.
Cause Possible Solution
• Increase the settings for C5-01 (Speed Control Proportional Gain 1) and reduce
C5-02 (Speed Control Integral Time 1).
Overshoot is occurring.
• If using a Closed Loop Vector mode enable Feed Forward Control and perform
Inertia Auto-Tuning.

24 YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual
6 Troubleshooting

Incorrect speed feedback scaling • Set H6-02 to the value of the speed feedback signal frequency when the motor
if terminal RP is used as speed runs at the maximum speed.
feedback input in V/f control • Adjust the input signal using parameters H6-03 through H6-05.
Incorrect PG pulse number has
• Check and correct parameter F1-01.
been set
Check the setting for the overspeed detection level and the overspeed detection
Inappropriate parameter settings.
time (F1-08 and F1-09).
Digital Operator Display Fault Name
PG Disconnect
PGo
Detected when no PG pulses received for a time longer than setting in F1-14.
Cause Possible Solutions
PG cable is disconnected. Reconnect the cable.
PG cable wiring is wrong. Correct the wiring.
PG encoder does not have
Make sure the correct power supply is properly connected to the PG encoder.
enough power.
Brake is holding the PG. Ensure the brake releases properly
Digital Operator Display Fault Name
PG Hardware Fault (detected when using a PG-X3 option card)
PGoH
PG cable has become disconnected.
Cause Possible Solutions
PG cable is disconnected. Reconnect the cable.

<1> Depending the type of option card, only a certain number of cards may be connected at the same time. Refer to
table below. More details can be found in the option card section of the drive instruction manual.

Table 8 Option Card Installation

Option Card Connector Number of Cards Possible
SI-C3, SI-N3, SI-P3, SI-S3, AI-A3,
CN5-A 1
DI-A3 <2>
PG-B3, PG-X3 CN5-B, C 2 <3>
DO-A3, AO-A3 CN5-A, B, C 1

<2> The AI-A3 and DI-A3 option can also be installed to option ports CN5-B and CN5-C, but are then used for
monitoring purposes only. Input levels are then displayed in U1-17, U1-21 to U1-23. Here, the option cards cannot
be used to set the frequency reference or replace the drive analog input with higher resolution inputs.
<3> If only one PG option card is connected to the drive, use the CN5-C connector. If two PG option cards are
connected, use both CN5-B and CN5-C.

YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual 25
7 Specifications & Warranty Information

7 Specifications & Warranty Information

◆ Specifications

Option Card PG-X3

Compatible Line driver
Pulse Generators Single track (A pulse), 2 track (A, B pulse) or 3 track (A, B, Z pulse)
PG Wiring Length 100 m max.
Output voltage: 12 V ± 5% or 5.5 V ± 5%
PG Power Supply
Max. Output Current: 200 mA
Compatible
V/f with PG, Closed Loop Vector, Closed Loop Vector for PM motors
Control Modes
Maximum Input
300 kHz
Frequency
Pulse Monitor Monitor for A, B, and Z pulse output
Output Matches RS-422 level
PG Disconnect
Software and hardware detection
Detection
Ambient
–10°C to 50°C
Temperature
Humidity 95% RH or less with no condensation
Storage
Temperature –20°C to 60°C allowed for short-term transport of the product

Area of Use Indoor (free of corrosive gas, airborne particles, etc.)

Altitude 1000 m or less

26 YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual
7 Specifications & Warranty Information

◆ Revision History
The revision dates and numbers of the revised manuals are given on the bottom of the back
cover.

MANUAL NO. TOBP C730600 37A

Published in Japan April 2009 08-7 1
Revision number
Date of Date of original
publication publication

Date of Rev.
Publication No Section Revised Content

July 2008 − − First edition

Addition: ‹ Connection Diagram
April 2009 1 Chapter 4
Instruction to counteract noise by grounding shielded lines

YASKAWA TOBP C730600 37A YASKAWA AC Drive-Option Card PG-X3 Installation Manual 27
YASKAWA AC Drive-Option Card
Line Driver Type PG
Installation Manual

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YASKAWA ELECTRIC CORPORATION

YASKAWA

In the event that the end user of this product is to be the military and said product is to be employed in any weapons systems or the manufacture
thereof, the export will fall under the relevant regulations as stipulated in the Foreign Exchange and Foreign Trade Regulations. Therefore, be sure
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Specifications are subject to change without notice for ongoing product modifications and improvements.
© 2008-2009 YASKAWA ELECTRIC CORPORATION. All rights reserved.

MANUAL NO. TOBP C730600 37A

Published in Japan April 2009 08-7 1
09-1