Fuji Electric OPC-LM1-PS1

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

This document describes the OPC-LM1-PS1 Option Card, an encoder interface card designed for installation in the Fuji FRENIC-Lift inverter. It facilitates vector control based on feedback signals from HEIDENHAIN rotary encoders (ECN1313 Endat2.1) or equivalent models.

Function Description

The OPC-LM1-PS1 option card enables precise motor control by integrating encoder feedback into the FRENIC-Lift inverter system. It supports vector control for permanent magnet synchronous motors, allowing for accurate speed and position management. The card processes incremental signals (two sinusoidal signals A and B with 2048 periods per revolution) and rotor position detection signals (two sinusoidal signals C and D with one period per revolution) from the encoder. It also provides a +5 VDC (±5%/300 mA) power supply for the encoder.

The card features various terminals for connecting to the encoder and a user controller. These include power supply (PO, CM), A and B phase input terminals (PA+, PA-, PB+, PB-), communication clock (CK+, CK-), communication data (DT+, DT-), and A and B phase pulse outputs (FPA, FPB). The communication clock and data terminals support RS-485 conforming for data transmission and reception. The pulse output terminals provide pulses with the same frequency as the A and B phase inputs, respectively, and are transistor outputs (open collector) with specific operation voltage and load current specifications.

A key feature of this option card is its support for magnetic pole position offset tuning, a crucial step before driving the motor. This tuning procedure involves setting specific function codes (C21, P01, F03, L31, P02, F04, F05, F42, P03, P07, P08, L01, L02, L36, L38) to match the motor and encoder characteristics. The tuning can be performed in different modes, including a mode for detecting wrong wiring (L03=2) and a mode for general tuning (L03=3). The tuning process helps ensure correct motor operation and stores the result in function code L04.

The card also supports unbalanced load compensation, which can be adjusted through function codes such as L05 (ACR P Constant), L06 (ACR I Constant), L65 (Unbalanced Load Compensation Operation), L68 (Unbalanced Load Compensation ASR P constant), L69 (Unbalanced Load Compensation ASR I constant), and L73 (Unbalanced Load Compensation APR Gain). These parameters help eliminate vibration and minimize rollback, especially during starting and stopping sequences. The document provides guidance on adjusting these parameters based on observed phenomena like rollback and vibration generation probability.

Important Technical Specifications

Applicable Inverter ROM Versions: Versions 0804, 0808, 1100 or later.
Encoder Compatibility: HEIDENHAIN ECN1313 or equivalent.
Encoder Power Supply: +5 VDC ±5%, Max. 300 mA.
Encoder Input Signals:
- Incremental: 2 sinusoidal signals A and B (sine and cosine) with 2048 periods per revolution.
- Rotor Position Detection: 2 sinusoidal signals C and D (sine and cosine) with one period per revolution.
Maximum Input Frequency: 50 kHz.
Differential Input Signal: PA(+) - PA(-), PB(+) - PB(-).
Pulse Output (FPA, FPB): Transistor output (Open collector), Max. 27 V (OFF level), Max. 2.0 V (ON level), Max. 50 mA (load current at ON), Max. 200µA (leakage current at OFF).
Maximum Wiring Length:
- Option card to encoder: 20 m.
- Option card (FPA, FPB) to user controller: 5 m.
Motor Control Method: Vector control.
Speed Control Range: 0 r/min to 1500 r/min.
Storage Temperature: -25 to 70°C.
Operating Temperature: -10 to 45°C.
Relative Humidity: 5 to 95% (non-condensing).
Altitude: 1,000 m max. (Derating factor applies above 1,000 m).
Vibration: 3 mm (Max. amplitude): 2 to 9 Hz, 9.8 m/s²: 9 to 20 Hz, 2 m/s²: 20 to 55 Hz, 1 m/s²: 55 to 200 Hz.
Terminal Block (TERM1) Plug Specifications:
- Tightening torque: 0.22 to 0.25 N-m.
- Screw size: M2.
- Bared wire length: 7 mm.
- Maximum wire size: AWG16.

Usage Features

The OPC-LM1-PS1 is designed for easy installation into the FRENIC-Lift inverter. The installation procedure involves removing the top cover of the inverter, inserting the option card by aligning its spacers and connector (CN1) with the corresponding holes and connector on the control circuit board, wiring the card, and then replacing the top cover. Visual checks are recommended to ensure firm insertion of the card.

The manual emphasizes safety precautions, including waiting at least five minutes after turning off power and checking for low DC link bus voltage before installation or wiring to prevent electric shock. It also warns against touching metallic parts of the connector or electronic components to avoid damage from static electricity or contamination.

For wiring, the encoder connection cable must be a HEIDENHAIN 17-pin cable with specific conductor sizes. Shielded wire is required, and the shield should be connected to the CM terminal of the option card. It is crucial to separate the option card wiring from other power lines to prevent noise-induced malfunctions.

The option card's functionality is configured through a series of function codes. The manual provides a detailed list of these codes, their names, and data settings, which are often dependent on the specific motor or elevator parameters. Proper setting of these codes is essential for correct operation and to avoid unexpected actions.

The magnetic pole position offset tuning procedure is critical for initial setup. It involves fixing the rotor (or allowing it to be free if fixing is not possible), confirming motor-inverter connection, and executing tuning via function code L03. The tuning process can be initiated through the Multi Function Key Pad (MFKP) in local mode or via remote mode. After tuning, the motor should be run at a low frequency (about 1 Hz) to verify normal operation. If issues arise, troubleshooting steps include checking function code configurations, wiring, and rotational direction matching.

Unbalanced load compensation settings are provided to fine-tune performance, particularly to mitigate vibration and rollback. The manual includes a table illustrating how different settings for L69, ASR I, and L73 (APR Gain) affect rollback and vibration generation probability, guiding users to achieve optimal performance. Timing adjustments for unbalanced load compensation are also detailed, ensuring proper synchronization with brake release and speed commands.

Maintenance Features

The manual provides clear guidelines for maintenance and inspection. It stresses the importance of waiting at least five minutes after turning off power and confirming the charge lamp is off before performing any inspection to prevent electric shock. Only authorized personnel are permitted to maintain, inspect, or replace parts of the option card. Modifying the option card is strictly prohibited.

A specific caution is given against performing a megger test (insulation resistance measurement) on the product.

For discarding the option card, it is noted that the card uses soldering lead and should be treated as industrial waste, adhering to environmental regulations.

The product comes with a guarantee term of one year after installation or two years after manufacturing, whichever expires first. However, the guarantee does not cover issues arising from incorrect usage, inappropriate repair, modification, use outside specified ranges, damage during transportation, or natural disasters.