Danfoss MCO 305 Operating guide

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Contents MCO 305 Operating Instructions

Contents

1 Introduction

1.1 Available Literature for VLT AutomationDrive, MCO 305 and MCT 10 Motion Control Tool

1.2 Symbols and Conventions

1.3 Abbreviations

2.1 High Voltage Warning

2.2 Safety Instructions

2.3 Before Commencing Repair Work

2.4 Avoid Unintended Start

2.5 Safe Stop of FC 302

2.6 General Warning

3 How to Install

3.1 How to Get Started

3.1.1 Initialisation to Default Settings 7

3.2 System Overview

3.2.1 Electrical Installation 10

3.2.2 MCO 305 Control Terminals 10

3 3 4 5 5 5 5 6 6

7 7

3.2.3 Terminal overview 11

3.2.4 Encoder Connections Examples 12

3.2.5 Virtual Master Connection 13

3.3 Commissioning Guide

3.4 Basic MCO Parameter Settings

3.4.1 Setting of Encoder Parameters 14

3.4.2 Setting of parameters for CANopen feedback encoder 14

3.4.3 Setting of parameters for CANopen Master encoder 15

3.4.4 Setting of Velocity Parameters 15

3.4.5 Setting of Home Parameters 15

3.4.6 Setting of Synchronization Parameters 15

3.5 Connecting and Testing the Encoder(s)

3.5.1 Execute the Encoder Test Program 16

3.5.2 Checking Master Encoder for Synchronizing Applications 16

3.5.3 Ending the Encoder Check 16

3.6 PID Controller Settings

3.6.1 Sample Program: Feed-forward Calculation 17

14 14

3.6.2 Influence to the Control Loop when Changing Parameters 17

3.7 Executing a Test Program

4 Optimizing the PID controller

4.1 How to Control Process Works

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19 19

Contents MCO 305 Operating Instructions

4.2 Significance and Influence of the Controller Parameters

4.3 PID Factors

4.3.1 Derivative Value for PID Control 21

4.3.2 Integral Factor: KINT 21

4.3.3 Limit Value for Integral Sum: KILIM 21

4.3.4 Velocity Feed-forward: FFVEL 21

4.3.5 Acceleration Feed-forward: FFACC 21

4.3.6 Sampling Time for PID Control: TIMER 21

4.3.7 PID Bandwidth 22

4.4 Optimizing your Controller Settings Step-by-Step

4.4.1 Ten Steps for Optimum Control 22

5 How to Install the Application

5.1 Download Application Program and Configuration

5.2 Backup and Restore

5.3 How to Connect and Run Multiple Frequency Converters

6 General Specifications

19 20

24 24 24 25

6.1 Protection and Features

6.2 Technical Data

6.3 Supply Voltage Overview

7 Troubleshooting

7.1 Warnings and Error Messages

7.2 APOSS Software Messages

8 Appendix

8.1 Parameter Lists

8.1.1 Application Parameters, Parameter Group 19-** 35

8.1.2 MCO Basics Settings, Parameter Group 32-** 36

8.1.3 MCO Advanced Settings, Parameter Group 33-** 38

8.1.4 MCO Data Readouts, Parameter Group 34-** 41

Index

26 26 27

28 28 33

35 35

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Introduction MCO 305 Operating Instructions

1 Introduction

1.1 Available Literature for VLT AutomationDrive, MCO 305 and MCT 10 Motion Control Tool

The MCO 305 Design Guide entails all technical information about the option board and customer design and applications.

The MCO 305 Command Reference completes the MCO 305 Design Guide with detailed description of all commands available for programming MCO 305.

The VLT AutomationDrive Operating Instructions provide the necessary information for getting the frequency converter up and running.

The VLT AutomationDrive Programming Guide provides complete descriptions of all parameters in the frequency converter.

The VLT AutomationDrive Design Guide entails all technical information about the frequency converter and customer design and applications.

The VLT AutomationDrive Profibus Operating Instructions provide the information required for controlling, monitoring and programming the drive via a Profibus fieldbus.

The VLT AutomationDrive DeviceNet Operating Instructions provide the information required for controlling, monitoring and programming the drive via a DeviceNet fieldbus.

The VLT AutomationDrive MCT- 10 Operating Instructions provide information for installation and use of the software on a PC.

Danfoss Drives technical literature is also available online at www.danfoss.com/drives.

CAUTION

Indicates a situation that may result in equipment or property-damage-only accidents.

NOTE

Indicates highlighted information that should be regarded with attention to avoid mistakes or operate equipment at less than optimal performance.

Approvals

Conventions

The information in this manual follows the system and uses the typographical features described below to the greatest extent possible:

Menus and Functions Menus and functions are printed italics, for

→

example:Controller

Commands and Parameters Commands and parameter names are written in capitals, for example: AXEND and KPROP; Parameters are printed in italics, for example: Proportional factor.

Parameter Options Values for use to select the parameter options are written in brackets, e.g. [3].

Parameters.

1 1

1.2

Symbols and Conventions

Symbols The following symbols are used in this manual.

WARNING

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

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices.

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Keys The names of keys and function keys are printed in brackets, for example the control key [Cntl] key, or just [Cntl], the [Esc] key or the [F1] key.

Introduction MCO 305 Operating Instructions

1.3 Abbreviations

Automatic Motor Adaptation AMA Direct Current DC Frequency Converter FC Local Control Panel LCP Master Unit MU Millisecond ms Minute min Motion Control Option MCO Motion Control Tool MCT Parameter par. Protective Extra Low Voltage PELV Position Control Loop PID Pulses per Revolution PPR Quad-counts qc Revolutions per Minute RPM Second sec. Switch normally closed nc Switch normally open no User Unit UU Volts V

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Safety Instructions and Gen... MCO 305 Operating Instructions

2.1 High Voltage Warning

MCO 305

Operating Instructions

Software version: 5.xx

These Operating Instructions can be used for the MCO 305 option board

with all FC 300 frequency converters with software version later than 5.xx.

The software version number can be seen from 15-43 Software Version for the frequency converter and in 15-61 Option SW Version for the MCO

305

2.1.1 High Voltage Warning

2 2

The voltage of the VLT AutomationDrive is dangerous whenever the converter is connected to mains. Incorrect fitting of the motor or VLT AutomationDrive may cause damage to the equipment, serious injury or death. Consequently, it is essential to comply with the instructions in this manual as well as local and national rules and safety regulations. At altitudes above 2km, please contact Danfoss Drives regarding PELV.

2.2 Safety Instructions

- Make sure the VLT AutomationDrive is properly connected to earth.

- Do not remove mains plugs or motor plugs while the VLT AutomationDrive is connected to mains.

- Protect users against supply voltage.

- Protect the motor against overloading according to national and local regulations.

- Motor overload protection is not included in the default settings. To add this function, set par. 1-90

Motor thermal protection to value ETR trip or ETR warning. For the North American market:

- ETR functions provide class 20 motor overload protection, in accordance with NEC.

- The earth leakage current exceeds 3.5 mA.

- The [OFF] key is not a safety switch. It does not disconnect the VLT AutomationDrive from mains.

2.3

Before Commencing Repair Work

1. Disconnect VLT AutomationDrive from mains.

2. Disconnect DC bus terminals 88 and 89.

3. Wait at least 4 minutes.

4. Remove motor plugs.

2.4 Avoid Unintended Start

While VLT AutomationDrive is connected to mains, the motor can be started/stopped using digital commands, bus commands, references or via the LCP.

- Disconnect the VLT AutomationDrive from mains whenever personal safety considerations make it necessary to avoid unintended start.

- To avoid unintended start, always activate the [OFF] key before changing parameters.

- Unless terminal 37 (safe stop) is turned off, an electronic fault, temporary overload, a fault in the mains supply, or lost motor connection may cause a stopped motor to start.

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Safety Instructions and Gen... MCO 305 Operating Instructions

2.5 Safe Stop of FC 302

The FC 302 can perform the Designated Safety Function Uncontrolled Stopping by removal of power (as defined by IEC 61800-5-2) or Stop Category 0 (as defined in EN 60204-1). It is designed and approved suitable for the requirements of Safety Category 3 according to EN 954/PLd according to ISO 13849-1. This functionality is called Safe Stop.

In order to install and use the Safe Stop function in accordance with the requirements of Safety Category 3 according to EN 954-1/PLd according to ISO 13849-1, the related information and instructions of the VLT AutomationDrive Design Guide MG.33.BX.YY must be followed! The information and instructions of Operating Instructions are not sufficient for a correct and safe use of the Safe Stop functionality.

2.6 General Warning

WARNING

Touching the electrical parts may be fatal – even after the equipment has been disconnected from mains. Also make sure that all voltage inputs have been disconnected, such as load-sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic back-up. Using VLT AutomationDrive (at and below 7.5kW): wait at least xx minutes. xx = The waiting time using the VLT AutomationDrive is different for different sizes: Please see period of waiting time xx in the VLT AutomationDrive Operating Instructions, MG.

33.AX.YY.

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How to Install MCO 305 Operating Instructions

3 How to Install

Manual initialisation

3.1 How to Get Started

Please consult the VLT AutomationDrive Operating Instructions for correct installation of VLT AutomationDrive, these instructions cover installation of MCO 305.

3.1.1 Initialisation to Default Settings

Initialize the frequency converter to default setting in two ways:

Recommended initialisation (via 14-22 Operation Mode)

Select 14-22 Operation Mode

2. Press [OK]

3. Select “Initialization”

4. Press [OK]

5. Cut off the mains supply and wait until the displays turns off.

6. Reconnect the mains supply – the frequency converter is now reset.

1. Disconnect from mains and wait until the display

2. Press [Status] – [Main Menu] – [OK] at the same

3. Reconnect mains supply while pressing the keys.

4. Release the keys after 5 sec.

5. The frequency converter is now programmed

NOTE

When carrying out manual initialization, serial communication and fault log settings are reset. All MCO 305 programs and arrays are deleted!

This method initializes all except:

15-00 Operating Hours 15-03 Power Up's 15-04 Over Temp's 15-05 Over Volt's

turns off.

time:

according to default settings.

NOTE

MCO 305 programs and arrays are not affected.

14-22 Operation Mode initialises all except: 14-50 RFI Filter 8-30 Protocol 8-31 Address 8-32 FC Port Baud Rate 8-35 Minimum Response Delay 8-36 Max Response Delay 8-37 Max Inter-Char Delay 15-00 - 15-05 Operating Data 15-20 - 15-22 Historic log 15-30 - 15-32 Fault log 33-90 X62 MCO CAN node ID 33-91 X62 MCO CAN baud rate

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How to Install MCO 305 Operating Instructions

3.2 System Overview

This is only relevant if the MCO 305 is delivered as an option for upgrading an existing VLT AutomationDrive. When ordered with the frequency converter, MCO 305 is preinstalled from factory. For retrofit, a mounting kit must be purchased.

There is a different mounting kit for different frames. MCO 305 is to be used in slot C0 but can be combined with another option in slot C1.

Mounting kit depending on frame Order no. Bookstyle A2 and A3 (40 mm for one C option) 130B7530 A2 and A3 (60 mm for C0 + C1 option) 130B7531 B3 (40 mm for one C option) 130B1413 B3 (60 mm for C0 + C1 option) 130B1414 Compact A5 130B7532 B, C, D, E and F (except B3) 130B7533

Do not mount the small fan for B4, C3, C4, D, E and F

Illustration 3.1 Bookstyle - A2, A3, B3

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How to Install MCO 305 Operating Instructions

Illustration 3.2 Compact - A5, B (except B3), C, D, E, F

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130BA248.11

130BT334.10

How to Install MCO 305 Operating Instructions

3.2.1 Electrical Installation

All control cables must be screened and the cable screen must be connected to earth at both ends. It is very important to use the correct cable for encoders to avoid noise problems, always follow the prescriptions of the encoder supplier. See also VLT AutomationDrive Design Guide (MG.

33.AX.YY) for more information regarding EMC correct cable installation.

3.2.2 MCO 305 Control Terminals

Frame size A2 and A3: Encoder and I/O terminal are located behind the C option terminal cover, see Illustration 3.3.

MCO CAN bus terminals and debug terminals (RS485) are located on the top of the c-option cover. If these connections are used cut out the plastic parts above the connectors and mount the cable relief

Frame size A5, B1 and B2: All MCO 305 terminals are located next to the VLT AutomationDrive control card. Remove the front cover to get access, see illustration.

MCO 305 control terminals are plug connectors with screw terminals; the terminal blocks are duplicated to enable use of the same MCO 305 in all frame sizes. See Illustration 3.5 to locate the terminal blocks:

Illustration 3.3 Location of Encoder and I/O Terminals

Illustration 3.4 Removing Front Cover

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X62

X55

X56

X57

X58

X59

X60

130BB794.10

How to Install MCO 305 Operating Instructions

MCO control terminals are plug connectors with screw

3.2.3

Terminal overview

terminals. Terminals X55, X56, X57, X58 and X59 are duplicated to be used for both bookstyle and compact frame size.

X55 = Encoder 2 X56 = Encoder 1 X57 = Digital inputs X58 = 24V DC supply X59 = Digital outputs X62 = MCO CAN Bus X60 = Debug connections (RS-485)

Illustration 3.5 Location of Terminal Blocks

Terminal block 1 is to be used with bookstyle and terminal

Terminal block

X55

Terminal block

X56

Terminal block

X57

Terminal number Descriptive Name Encoder 2

(Feedback) 1 +24V Supply 2 +8V Supply 3 +5V Supply 4 GND 5 A 6 A not 7 B 8 B not 9 Z / Clock

10 Z not / Clock not 11 DATA 12 DATA not

Terminal number Descriptive Name Encoder 1

(Master) 1 +24V Supply 2 N/A 3 +5V Supply 4 GND 5 A 6 A not 7 B 8 B not 9 Z / Clock

10 Z not / Clock not 11 DATA 12 DATA not

Terminal number Descriptive Name Digital inputs

1 Digital Input 2 Digital Input 3 Digital Input 4 Digital Input 5 Digital Input 6 Digital Input 7 Digital Input 8 Digital Input 9 Digital Input

10 Digital Input

block 2 with compact.

Terminal block

X58

Terminal number Descriptive Name Supply

1 +24V Supply 2 GND

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5V incremental encoder

2 3 12

130BA163.10

754 6 8 9 10 11

24V

8V 5V GND A A B B Z Z D D

How to Install MCO 305 Operating Instructions

Terminal block

X59

Terminal block

X60

Terminal block

X62

Terminal number Descriptive Name Digital

outputs 1 Digital Output/Input 2 Digital Output/Input 3 Digital Output 4 Digital Output 5 Digital Output 6 Digital Output 7 Digital Output 8 Digital Output

Terminal number MCO Debug (RS485)

Control Select 62 RxD/TxD - P 63 RxD/TxD - N 66 OV 67 +5V

CS is high when transmissions is active

Terminal number MCO CAN Bus

1 N/A 2 CAN - L 3 DRAIN 4 CAN - H 5 N/A

Illustration 3.7 5V Incremental Encoder (RS-422) Supplied by an External Power Source

Illustration 3.8 24V Absolute Encoder (SSI) Supplied by MCO 305

3.2.4 Encoder Connections Examples

Illustration 3.6 5V Incremental Encoder (RS-422) Supplied by MCO 305

Illustration 3.9 24V Absolute Encoder (SSI) Supplied by an External Power Source

NOTE

When external power supply is used, ensure the same potential between GND on external supply and encoder connections (4). This is to avoid common mode disturbances.

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How to Install MCO 305 Operating Instructions

3.2.5 Virtual Master Connection

When more than 2 MCO 305 master encoder interfaces are interconnected termination must be on (32-40 Encoder Termination = ON) at both ends of the bus. Termination must be off (32-40 Encoder Termination = OFF) in all other MCOs.

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How to Install MCO 305 Operating Instructions

3.3 Commissioning Guide

This guideline is only describing basic configuration and optimizing of MCO 305, before starting the following steps must be completed.

1. Basic commissioning of VLT AutomationDrive.

NOTE

VLT AutomationDrive must be optimized and have good control over the motor and application before commissioning MCO 305. Guidelines can be found in VLT AutomationDrive Operating Instructions (MG.33.AX.XX).

2. Install the PC software tools (MCT 10 Set-up Software)

3. Establish communication between PC and VLT AutomationDrive using USB, RS-485 or PROFIBUS DPV1.

Then follow these steps to set-up and optimize MCO 305.

1. Setting of basic MCO 305 parameters (groups 32-** and 33-**).

2. Connect and test encoder(s).

3. Optimize PID controller.

The MCT 10 Set-up Software will support you to set the parameters in LCP. For a detailed description of all parameters, please refer to 8 Appendix.

3.4.1 Setting of Encoder Parameters

Define the used type of feedback encoder in parameter group 32-0*. These defaults are set:

32-0* Encoder 2 - Feedback Default

32-00 Incremental Signal Type 32-01 Incremental Resolution 32-02 Absolute Protocol 32-03 Absolute Resolution 32-05 Absolute Encoder Data Length 32-06 Absolute Encoder Clock Frequency 32-07 Absolute Encoder Clock Generation 32-08 Absolute Encoder Cable Length 32-09 Encoder Monitoring

For CAN Encoders

32-14 Enc.2 node ID 32-15 Enc.2 CAN guard 33-91 X62 MCO CAN baud rate

[1] RS422 1024 [0] None 8192 25 262000 [1] On 0 [0] Off

127 [0] Off [20] 125 kbps

NOTE

Error 113 will show up right after power up if the VLT AutomationDrive is not ready. The VLT AutomationDrive is in the “Not ready” state when

- it has an alarm (trip),

- it is in hand mode, [Hand on] key,

- local LCP stop is activated, [OFF] key,

- there is no signal on input 37 safe stop (only FC

302).

Error 113 can only be reset using the ERRCLR command or with BREAK [Esc] in the PC software and only when the VLT AutomationDrive is in the “ready” state, which means none of the above may be true. The VLT AutomationDrive monitoring function can be switched off by selecting [0] in 33-82 Drive Status Monitoring.

Read the Safety Instructions before installing the frequency converter.

3.4 Basic MCO Parameter Settings

3.4.2 Setting of parameters for CANopen feedback encoder

In 32-00 Incremental Signal Type select the setting [3] “CAN encoder”.

In 32-01 Incremental Resolution set the resolution of the encoder.

In 32-14 Enc.2 node ID set the CAN ID of the encoder.

In 32-15 Enc.2 CAN guard activate or deactivate the guarding.

In 33-91 X62 MCO CAN baud rate set in the CAN bus baud rate.

The following parameters are only relevant for synchronizing applications when a master encoder signal is used. These defaults are set:

The following parameters must always be checked and if necessary adjusted. Depending on the requirements of the application it might be necessary to adjust other parameters as well. For the other parameters, use the default settings at first and then optimize the controller as needed at a later point in time with a Testrun.

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How to Install MCO 305 Operating Instructions

32-3* Encoder 1 - Master

32-30 Incremental Signal Type 32-31 Incremental Resolution 32-32 Absolute Protocol 32-33 Absolute Resolution 32-35 Absolute Encoder Data Length 32-36 Absolute Encoder Clock Frequency 32-37 Absolute Encoder Clock Generation 32-38 Absolute Encoder Cable Length 32-39 Encoder Monitoring 32-40 Encoder Termination

For CAN Encoders

32-44 Enc.1 node ID 32-45 Enc.1 CAN guard 33-91 X62 MCO CAN baud rate

[1] RS422 1024 [0] None 8192 25 262000 [1] On 0 [0] Off [1] On

127 [0] Off [20] 125 kbps

3.4.3 Setting of parameters for CANopen Master encoder

In 32-30 Incremental Signal Type select the setting [3] “CAN encoder”.

In 32-31 Incremental Resolution set the resolution of the encoder.

In 32-44 Enc.1 node ID set the CAN ID of the encoder.

In 32-45 Enc.1 CAN guard activate or deactivate the guarding.

In 33-91 X62 MCO CAN baud rate set in the CAN bus baud rate.

Setting of Velocity Parameters

3.4.4

Define 32-80 Maximum Velocity (Encoder), the Maximum Velocity of the shaft where the encoder is mounted in RPM.

32-8* Velocity & Acceleration

32-80 Maximum Velocity (Encoder) 32-81 Shortest Ramp

Default 1500

1.000

NOTE

For synchronizing application the setting of the follower drive must be at least the same as the maximum velocity of the master in order to be able to synchronize. For position synchronizing it must even be higher so that the follower drive can catch up lost position related to the master. All velocity commands (VEL, CVEL) are related to this value. Define 32-81 Shortest Ramp. That is the time from 0 to maximum velocity and from maximum velocity to 0. All acceleration and deceleration commands (ACC, DEC) are related to this value.

3.4.5 Setting of Home Parameters

Homing is not necessary in standard synchronization applications and applications using an absolute encoder. When using an incremental encoder the controller must be run to home after being switched on. During this process the reference switch defines the position at which 0 is located and how the VLT AutomationDrive functions during a home run: input depends on the application. Define 33-03 Velocity of Home Motion: Home speed is entered in % relative to the maximum speed of the frequency converter.

33-0* Home Motion Default

33-00 Force HOME 33-01 Zero Point Offset from Home Pos. 33-02 Ramp for Home Motion 33-03 Velocity of Home Motion 33-04 Behaviour during HomeMotion

[0] not forced 0 10 10 [0] Reverse + Index

3.4.6 Setting of Synchronization Parameters

The following parameters are only relevant for synchronizing applications:

33-10 Sync Factor Master

•

33-11 Sync Factor Slave

•

The Synchronizing Factors Master and Slave must be set according to the gear ratio between master and slave encoder.

Example: Both encoders have 1024 PPR, master is running 305 RPM and slave must run 1220 RPM.

33-10 Sync Factor Master 33-11 Sync Factor Slave

Alternative:

33-10 Sync Factor Master 33-11 Sync Factor Slave

The following parameters are only relevant when using synchronizing with marker correction (SYNCM):

33-15 Marker Number for Master

•

33-16 Marker Number for Slave

•

Marker Number for Master and Slave must be set according to the ratio between the number of marker signals from master and slave. A ratio of 1:1 means that each slave marker will be aligned with each master marker. A ratio of 2:1 means that each slave marker will be aligned with each second master marker.

= 305 and = 1220

= 1 = 4

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How to Install MCO 305 Operating Instructions

33-1* Synchronization Default

33-10 Sync Factor Master 33-11 Sync Factor Slave 33-15 Marker Number for Master 33-16 Marker Number for Slave 33-17 Master Marker Distance 33-18 Slave Marker Distance 33-19 Master Marker Type 33-20 Slave Marker Type

33-17 Master Marker Distance

•

33-18 Slave Marker Distance

•

When using the encoder zero pulse as marker signal the distance between 2 markers is the resolution (qc) of the encoder. When external marker signals are used, the marker distance can be measured by means of the program sample “Marker count”.

33-19 Master Marker Type

•

33-20 Slave Marker Type

•

Master marker signal: Input 5 Slave marker signal: Input 6 Marker signal type must be selected for master and slave: Default setting is [0] Encoder Z positive flank for both.

3.5

Connecting and Testing the Encoder(s)

1 1 1 1 4096 4096 [0] Enc. Z pos. [0] Enc. Z pos.

monitoring is activated in 32-39 Encoder Monitoring. Check the encoder connections by means of the test program: Select the file “Enc-S.m” via the MCT 10. APOSS and with that the file is opened automatically .

32-09 Encoder Monitoring and

3.5.1 Execute the Encoder Test Program

In the Development menu click on→ Execute to start the test program. Run the frequency converter forward for example in hand mode – [Hand on] key – then the position must count positive. If the position is counting negative, swap A and B channels from the encoder or two motor phases. If the motor is turned on by hand (the motor should not be connected!), test whether the encoder functions: the position is continuously registered in the communications window. For a full rotation you should receive 4 times the value of the resolution of the encoder, that means 2000 if the Encoder Counts per Revolution is 500.

Checking Master Encoder for

3.5.2 Synchronizing Applications

To check the master encoder change the test program: replace the command APOS by MAPOS in “Enc-S.m” and run the master forward then the master position must count positive as well. If the position is counting negative, swap A and B channels from the master encoder.

Ending the Encoder Check

3.5.3

NOTE

The controller and the motor must be able to be switched off at any time with an EMERGENCY STOP button. The motor must be able to turn completely freely so that a sudden jolt can not cause damage.

NOTE

If not yet connected, now is the time to connect and test the encoder. When using an absolute encoder, enter [0] in 32-00 Incremental Signal Type and in 32-02 Absolute Protocol the used type of encoder. Then enter the resolution in 32-03 Absolute Resolution.

WARNING

Turn off the power before connecting the encoder.

Each encoder channel (A, B, Z, and D) is monitored, open circuit as well as short circuit is detected. A green LED shows the status of each active channel, LED on means that the channel is ok. Monitoring if the channels are automatically enabled/disabled depending on the selected encoder type, e.g. A, B, and Z is monitored when an incremental encoder is selected. Additionally an alarm will be triggered if encoder

End the test of the encoder with the [Esc]-key and close the test program with File Close. A successful test of the encoder is a requirement for further starting up of operations. Repeat the test when using other encoders.

What to do, if … ?

....the encoder does not work?

This could be a result of incorrect cable installation. Measure the signals coming from the encoder and compare them to the values listed in the specifications. Check whether the connection was made according to the specification.

....the count is descending?

If the Count is Descending with an incremental encoder, exchange the feedback encoder track A by B and A/ by B/. If there is no counting in the display then check the wiring of the encoder.

3.6

PID Controller Settings

This is a quick guide to set-up the PID controller, further details can be found in the chapter “Optimizing the PID controller”.

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How to Install MCO 305 Operating Instructions

The following basic settings can be used in most applications with a 1024 PPR encoder connected directly to the motor shaft and maximum reference (3-03 Maximum Reference) is 1500 RPM:

32-60 Proportional factor 32-61 Derivative factor 32-62 Integral factor 32-65 Velocity Feed-Forward

Velocity Feed-forward (32-65 Velocity Feed-Forward) can also be calculated using the following formula:

Velocity Feed forward

Where:

- “envel” is encoder velocity in RPM at maximum

reference (3-03 Maximum Reference).

- eres” is the encoder resolution

(Incremental encoder: eres = 32-01 Incremental Resolution * 4. Absolute encoder: eres = 32-03 Absolute Resolution).

- “tsample” is PID sample time

(tsample = 32-69 Sampling Time for PID Control except with SYNCV where tsample = 32-70 Scan Time for Profile Generator).

The sample program “Feed-forward calculation” is making the above calculation and sets the parameters:

envel

62914560000 ×

eres

tsample

= 200 = 1000 = 5 = 10200

Sample Program: Feed-forward

3.6.1 Calculation

This program calculates basic settings for Velocity Feedforward and PID settings based on the following inputs: Encoder type (32-00 Incremental Signal Type and 32-02 Absolute Protocol), Encoder resolution (32-01 Incremental Resolution or 32-03 Absolute Resolution), Encoder velocity (par. 19-00), and Motion type (par. 19-00). These parameters must thus be set before starting the calculation. The program performs the following steps when setting input 1:

1. Check encoder type and resolution

2. Calculate PID sample time in order to get sufficient resolution

3. Check motion type and select sample time

4. Calculate Feed-Forward.

Parameters are updated when setting input 2. The updated parameters can be saved by setting input 3. New calculation is enabled by setting input 4.

Influence to the Control Loop when

3.6.2 Changing Parameters

The gain of the control loop changes when one or more of the following parameters is changed: Maximum reference, encoder resolution, and gearing between motor and encoder. When changing these parameters the following rules apply: Increased maximum reference = P and D factors as well as Feed-forward must be reduced. Higher encoder resolution = P and D factors as well as Feedforward must be reduced. Increase gear-ratio between motor and encoder (encoder turning slower) = P and D factors as well as Feedforward must be increased.

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How to Install MCO 305 Operating Instructions

Examples 32-60 32-61 32-62 32-65 1024 PPR encoder connected directly to the motor shaft and maximum reference 1500 RPM 4096 PPR encoder connected directly to the motor shaft and maximum reference 1500 RPM 1024 PPR encoder connected behind a 10:1 gearbox and maximum reference 1500 RPM 1024 PPR encoder connected directly to the motor shaft and maximum reference 3000 RPM

Further optimizing can easily be done by means of the graphical Test-run tool which is included in the APOSS editor this however implies that the motor/application can move.

200 1000 5 10200

50 250 5 2550

2000 10000 5 102000

100 500 5 5100

3.7 Executing a Test Program

Check the VLT AutomationDrive enable (terminal 37 = 24V) and check that the VLT AutomationDrive was not stopped via the LCP. Then increase 32-60 Proportional factor. (See 4 Optimizing the PID controller).

....the motor vibrates heavily?

If the motor vibrates, optimize the PID controller and adjust the other parameters of the controller: Reduce either 32-60 Proportional factor or increase 32-61 Derivative factor

....a "Tolerated Position Error is exceeded" is reported?

If the frequency converter stops due to a "Tolerated Position Error is exceeded" message it is possible to determine whether the frequency converter was rotating in the wrong direction by comparing the curves of the set and actual values. Check the connections of the motor or encoder. If the connections are correct, then it is necessary to increase the par. 32-67 Maximum Tolerated Position Error. (See Optimizing the PID controller.)

Now connect the motor to the VLT AutomationDrive, make sure that the motor can turn completely freely.

NOTE

The motor must be provided with an EMERGENCY STOP button.

Select the file “Move-S.m” via the VLT AutomationDrive. APOSS and with that the file is opened automatically. Click on Development and start the test program with → Execute or [F5]. The test is successful if the motor runs slowly back and forth and position 500 is registered. End the test with [Esc] and Close the File.

What to do, if … ?

....the motor sets off uncontrolled or vibrates heavily?

NOTE

Turn off the motor immediately with the EMERGENCY STOP button if it vibrates heavily or sets off uncontrolled.

....the motor sets off uncontrolled, but the encoder test

previously was successful, then decrease 32-60 Proportional factor. (See Optimizing the PID controller).

....the motor doesn't move?

If the motor doesn’t move at all, then the Proportional Factor of the PID filter is probably too low or the VLT AutomationDrive has not been enabled.

18 MG.33.K3.02 - VLT® is a registered Danfoss trademark

Optimizing the PID controll... MCO 305 Operating Instructions

4 Optimizing the PID controller

4.1 How to Control Process Works

How the Control Process Works

The Testrun explained in the chapter PC Software interface in the APOSS Online help can be used as a tool to optimize the MCO 305 controller settings, thereby optimizing system performance. To do that you only need to know a few things about the control scheme of MCO 305:

The APOSS position controller has two parts:

The Setpoint Generator interprets the various positioning commands in APOSS and generates a series of setpoint positions that eventually ends with the desired position. Normally, all positioning processes have a trapeze-shaped velocity curve. That means that after a phase of constant acceleration there is a phase with constant velocity and finally a phase with constant deceleration, which ends at the desired target position.

The PID controller receives the setpoint positions from the Setpoint Generator and in turn calculates the speed reference needed for the motor to follow the current setpoint position. By setting the PID control parameters you can directly influence to what degree and how quickly a deviation from a theoretical set path (as specified by the setpoint series) should be counteracted.

The following behavior indicate that the control parameters are not optimally adjusted:

4.2

Significance and Influence of the Controller Parameters

The PID control unit of the MCO 305 motion controller transfers the necessary output frequency via an internal speed reference to the VLT AutomationDrive. This set value is periodically recalculated with an interval of one millisecond (interval is programmable by the TIMER parameter). The MCO 305 is by default set with soft “fit for all” controller parameters.

4 4

- Frequency converter vibrates

- Frequency converter is loud

- Frequent occurrence of position errors

- Poor control accuracy

NOTE

The control parameters are load-dependent. Thus the frequency converter must be optimized under the actual conditions of use.

In exceptional cases it may be necessary to determine various sets of control parameters while working with heavily changing load conditions and to re-program them in subsequent application programs depending on the motion process.

MG.33.K3.02 - VLT® is a registered Danfoss trademark 19

Motor and

FC300

FFVEL

FFACC

KDER

Setpoint

generator

Position

Reference

KPROP

KINT

KILIM

BANDWIDTH











–

130BB809.10



Optimizing the PID controll... MCO 305 Operating Instructions

AP is the actual position (calculated from encoder feedback) in

qc (Quad Counts)

CP is the current position set point in qc CV is the velocity set point in qc/ms (position deviation) is

calculated by CP-AP

CA is the acceleration set point

The PID filter works according to the following formula:

1 = FFVEL * (Setpoint Velocity) 2 = FFACC * (Setpoint Acceleration) 3 = KPROP * (Position Deviation) 4 = KINT * (Sum of all previous Position Deviations) (limited by KILIM) 5 = KDER * (Difference of Position Deviation) 6 = 3 + 4 + 5 (Limited by BANDWIDTH)

NOTE

In SYNCV mode the PID controller is working with speed deviation instead of position deviation. Speed deviation is calculated by CV–AV. (AV is the Actual Velocity)

The controller in the MCO 305 utilizes two control strategies at the same time:

1. An open-loop feed-forward control. Since the asynchronous motor inherently has a good open loop performance the feed-forward control is a very important part of the controller in most

applications. Benefits from using feed-forwards control is a very fast and accurate response to changes in the setpoint reference.

2. A closed-loop PID control. The PID controller monitors the difference between the actual position and the setpoint position. Based on this information it calculates a control signal to minimize the position deviance. Thus the MCO is able to compensate for changes in load or friction. The PID controller is also necessary to compensate for any position deviance caused by inaccurate setting of the open-loop feedforward controller.

In short: The feed-forward control is used to handle changes in the setpoint reference (especially important in synchronization applications), while the PID control is used to handle changes in load conditions or inaccuracies of the feedforward control.

4.3 PID Factors

The32-60 Proportional factor is multiplied with the position deviance and the result is added to the control signal (the internal speed-reference to the VLT AutomationDrive). Since the calculated control signal is proportional to the position deviance (or error) this kind of control is called proportional control. The behavior of the proportional control is similar to that of a spring – the further the spring is extended the stronger the counter-force it produces.

20 MG.33.K3.02 - VLT® is a registered Danfoss trademark

Optimizing the PID controll... MCO 305 Operating Instructions

Influence of the Proportional Factor: KPROP too small large position deviation due to non-

compensatable load and frictional moment

KPROP larger quicker reaction, smaller steady-state

deviation, larger overshoot, lesser damping

KPROP too great heavy vibrations, instability

4.3.1 Derivative Value for PID Control

The 32-61 Derivative factor is multiplied with the derivative of the position deviance (the 'velocity' of the position deviance) and the result is added to the control signal. The behavior of the derivative control is similar to that of an absorber – the faster the absorber is extended the stronger the counterforce it produces. Thus using the Derivative Value increases damping in your system.

Influence of the Derivative Value: KDER small no effect KDER larger better dampening, lesser overshoot; if

KPROP is increased simultaneously: faster reaction to control deviation at the same level of vibration;

KDER too large heavy vibrations, instability

overall control signal (the internal speed-reference) is maxed out for long periods of time. This feature is also very helpful in applications where the power to the motor is turned off and on while the option card is controlling the VLT AutomationDrive. Cutting of power to the motor (by setting terminal 27 low) while little positioning deviance is present in the controller, could result in an enormous control signal being generated once the power is turned back on.

4 4

4.3.4 Velocity Feed-forward: FFVEL

The 32-65 Velocity Feed-Forward is a scaling factor that is multiplied with the derivative of the setpoint position (the velocity of the setpoint). The result of this operation is added to the overall control signal. This feature is especially useful in applications where there is a good correlation between the control signal (the VLT AutomationDrive speed reference), and the speed of the motor. This is indeed the case with most applications.

NOTE

The scaling of the FFVEL parameter is dependent on the correct setting of the Maximum Reference (3-03 Maximum Reference) as well as the32-80 Maximum Velocity (Encoder) and 32-01 Incremental Resolution.

4.3.2 Integral Factor: KINT

The sum of all error is calculated every time the control signal is updated. The 32-62 Integral factor is then multiplied with the sum of all positioning errors and added to the overall control signal. Thus in case that steady-state position errors occurs in your application, make sure to use the integral part of the controller. Steady-state errors will be leveled out as the summed error increases over time until the control signal eventually matches the load. It is possible to set a limit for the control signal generated by the integral part of the controller (anti-windup).

Influence of the Integral factor: KINT very small steady-state position deviance is very

slowly regulated to zero

KINT larger faster regulation towards zero steady-state

position deviance, larger overshoot

KINT too large heavy vibrations, instability

4.3.3 Limit Value for Integral Sum: KILIM

The32-63 Limit Value for Integral Sum sets a limit for the control signal generated by the integral part of the controller. This helps to prevent the so called "wind-up" problem which typically occurs in applications where the

4.3.5 Acceleration Feed-forward: FFACC

The 32-66 Acceleration Feed-Forward is multiplied with the 2nd derivative of the setpoint position (the acceleration of the setpoint) and the result is added to the control signal. This feature should be used to compensate for the torque used to accelerate/decelerate the system inertia.

NOTE

Scaling of the Acceleration Feed-forward factor is depending on the setting of the Shortest Ramp. Increase 32-66 Acceleration Feed-Forward accordingly when decreasing 32-81 Shortest Ramp and vice versa.

4.3.6 Sampling Time for PID Control: TIMER

For particularly slow systems, slow down the entire control system by entering multiples of 1 ms as the sampling time. However, it is important to remember that such a change influences all the control parameters! Therefore, normally you should not deviate from the value of 1 ms in 32-69 Sampling Time for PID Control.

MG.33.K3.02 - VLT® is a registered Danfoss trademark 21

Optimizing the PID controll... MCO 305 Operating Instructions

4.3.7 PID Bandwidth

A Bandwidth of 1000 means that the set value is being executed 100%, thus Derivative, Proportional and Integral Factors are effective as defined. But if operating a system which could be jeopardized by vibrations, for example, a crane with a heavy load then you can limit the bandwidth in which the PID controller should function.32-64 PID Bandwidth of 300 makes a limitation of 30% possible. The

build-up of a vibration is thus prevented since the control is only moved to with 30% of the calculated set value. However, then it is necessary also to use the feed-forward part of the controller in order to achieve the corresponding control.

Par. # Typical Settings 3-03 32-80 32-00 32-01 32-81

4.4 Optimizing your Controller Settings

as well as encoder type and resolution in 32-00 Incremental

Signal Type and 32-01 Incremental Resolution, and 32-81 Shortest Ramp. If these settings change again

at a later point, the controller may need optimizing again.

Maximum Reference Max. Velocity (Encoder) Incremental Signal Type Incremental Resolution Incremental Resolution

Set 32-67 Max. Tolerated Position Error to a very high value e.g. 1000000 to avoid getting the error 108 during the following tests.

32-80 Maximum Velocity (Encoder), the

1500,000 1500 [1] RS422 1024

1.000

Step-by-Step

NOTE

Before adjusting the controller parameters it is important to determine which controller behavior is to be achieved.

NOTE

The drive elements must never be operated outside of the technical specifications. Thus the maximum acceleration is determined by the “weakest” drive element.

- “Stiff” axis: the fastest reaction possible is mainly

influenced by the Proportional Factor. You can judge the results on the basis of the velocity graph.

- Damping of vibrations is mainly influenced by the

Derivative Value. The results can best be assessed in the velocity graph.

- Temporary (static) deviations in position are mainly

reduced by the Integral Factor and can best be judged on the basis of the positioning graph.

For best results use the functions in the Tune Oscilloscope for this purpose; these help you to evaluate and optimize the PID controller on the basis of graphs of the set and actual curves. However, it is recommended only to change one value at a time and subsequently determining the improvement with a Testrun. Click on Controller → Parameter → Axis and select the frequency converter, of which you are currently adjusting the settings.

4.4.1

Ten Steps for Optimum Control

The following procedure will optimize your controller settings in most applications:

1. Make sure that you have specified correct values

for VLT AutomationDrive 3-03 Maximum Reference,

To avoid damaging the system, make sure to set 32-67 Max. Tolerated Position Error within the limits of the system, because the position error monitoring is not active with extremely high values.

3. Optimize the Velocity Feed-forward control: Click on Execute Testrun and Start a testrun with following parameter settings:

32-6* PID-Controller

32-60 Proportional factor 32-61 Derivative factor 32-65 Velocity Feed-Forward 32-66 Acceleration Feed-Forward

View the velocity profiles: If the Actual Velocity profile is lower than the Commanded Velocity profile, increase Velocity Feed-forward and → Start the testrun again. Of course if the Actual Velocity profile is Commanded Velocity you should decrease Velocity Feed- forward. Run successive test runs until the two velocity profiles shown in the Testrun graph have the same maximum value. Velocity Feed-forward is now optimized, save the current value.

4. In systems with large inertia and/or rapid changes in the reference velocity it is a good idea to use and optimize the Acceleration Feed-forward control (make sure the inertial load is connected when optimizing this parameter): Execute a Testrun with KPROP=0, KDER=0, KINT=0, FFACC=0, and FFVEL at the optimized value found above. Use the highest possible acceleration setting. If 32-81 Shortest Ramp is adjusted properly an acceleration value of 100 and a deceleration value of 100 should be sufficient. Start out with a low setting of Acceleration Feed-forward approx. 10.

higher than the specified

0 0 100 0

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Optimizing the PID controll... MCO 305 Operating Instructions

View the velocity profiles: If during acceleration the actual velocity is constantly lower than the reference velocity profile, then set a higher value of Acceleration Feed-forward and → Start the Testrun again. Run successive test runs until the two velocity profiles shown in the Testrun graph have similar rampup and ramp-down curves. Acceleration Feed-forward is now optimized, save the current value.

32-6* PID-Controller

32-60 Proportional factor 32-61 Derivative factor 32-62 Integral factor 32-65 Velocity Feed-Forward 32-66 Acceleration Feed-Forward

0 0 0 result of step 3 10

5. Next step is finding the maximum stable value of the Proportional Factor in the PID controller. Execute a Testrun with KPROP=0, KDER=0, KINT=0. Set FFVEL and FFACC at the optimized values found above. View the velocity profile. If the velocity profile is not oscillating then increase the Proportional Factor. Run successive testruns until the actual velocity profile is oscillating mildly. Decrease this "mildly" unstable Proportional Factor value to about 70 %. Save this new value.

32-6* PID-Controller

32-60 Proportional factor 32-61 Derivative factor 32-62 Integral factor 32-65 Velocity Feed-Forward 32-66 Acceleration Feed-Forward

KPROP 0 KDER 0 KINT 0 FFVEL result of step 3 FFACC result of step 4

6. In order to dampen the oscillations created by the Proportional part of the controller, the Derivative Value should now be optimized. Start a Testrun with KINT=0 and KDER=200. Set FFVEL, FFACC and KPROP at the optimized values found above. Run successive test runs with increasing values of the Derivative Value. At first the oscillations will gradually reduce. Stop increasing Derivative Value when the oscillations begin to increase. Save the last value of Derivative.

32-6* PID-Controller

32-60 Proportional factor 32-61 Derivative factor 32-62 Integral factor 32-65 Velocity Feed-Forward 32-66 Acceleration Feed-Forward

KPROP result of step 5 KDER 200 KINT 0 FFVEL result of step 3 FFACC result of step 4

7. In any system that requires a zero steady-state error, the Integral part of the controller must be

used. Setting this parameter though is a trade-off between achieving zero steady-state error fast (which is good) and increasing overshoot and oscillations in the system (which is bad). If you are using the Integral part of the PID controller, remember to reduce the 32-63 Limit Value for Integral Sum as much as possible (without losing the Integral Factor effect of course) in order to reduce oscillations and overshoot as much as possible.

Reduce the 32-64 PID Bandwidth as much as possible. With a properly optimized open-loop control Bandwidth could be reduced to as little as 6 or 12 % (60 – 120).

Set the 32-67 Max. Tolerated Position Error back to normal e.g. 20,000.

10.

Once the Testrun is concluded, then → Save the new parameters as the user parameters. Thus, these parameters are saved in the controller and in the future will be used for all programs.

What to do if....

....there is a tendency towards instability?

In the event of a strong tendency towards instability reduce 32-60 Proportional factor and 32-61 Derivative factor again, or reset 32-62 Integral factor.

....stationary precision is required?

If stationary precision is required, increase 32-62 Integral factor.

....the tolerated position error is exceeded?

If the test run is constantly interrupted with the message “position error” set 32-67 Max. Tolerated Position Error – within the tolerable limits – as large as possible. If the position error occurs during the acceleration phase that suggests that the set acceleration cannot be achieved under the existing load conditions. Increase 32-67 Max. Tolerated Position Error or determine a Maximum Acceleration suitable for the entire system. If position errors do not occur until after the acceleration phase and they can be delayed but not eliminated by increasing 32-67 Max. Tolerated Position Error, this suggests that the Maximum Velocity (RPM) chosen is too high. Determine a maximum velocity suitable for the entire system.

....the maximum acceleration is not achieved?

In general, the technical data for a frequency converter are only valid for a freely rotating axle end. If the frequency converter is carrying a load the maximum acceleration is reduced. The theoretical maximum acceleration will also not be achieved if, for example, the PID controller output is too small, or the FC 300/motor is not sized correctly and therefore does not provide enough energy for peak consumption during acceleration.

4 4

MG.33.K3.02 - VLT® is a registered Danfoss trademark 23

How to Install the Applicat... MCO 305 Operating Instructions

5 How to Install the Application

3. When copy is completed, paste the drive in-to a

5.1 Download Application Program and Configuration

Follow these steps to create and download MCO 305 program and configuration using MCT 10 and APOSS

1. Open MCT 10.

2. Open the folder “Project – Drive – MCO 305 – programs”.

3. Right click in the right hand view and select:

a. “Import program file” if using an existing program

“outside” the project file or,

b. “New MCO 305 program” when writing a new

program. Right click the program file and double click or right click and select “Edit”. Program editor will open.

4. Repeat step 3 if more programs are required.

5. One program must be set as Autostart program: Right click the program file and select “Set as Autostart”.

6. Open the folder “Project – Drive – MCO 305 – Arrays”.

7. Right click on the file and select “Import” or “Edit”.

8. Right click on the MCO 305 folder in the tree structure in the left-hand view of MCT 10 and select “Write to drive”.

9. “Write MCO 305 Program Source Files to the Drive” must be ticked if it should be possible to read the program from the frequency converter.

Now parameters and MCO 305 data is stored in the project file, restore by the following steps:

Now both parameters and MCO 305 data is restored in the drive.

Backup and Restore via LCP

Both parameters and MCO 305 data can be stored in the LCP and thus restored from the LCP to another frequency converter. Use the following steps to back-up parameters data in the LCP:

Now parameters and MCO 305 data is stored in the LCP, restore by the following steps:

Now both parameters and MCO 305 data are restored in the frequency converter.

project folder.

4. Save the project.

1. Open the project file with MCT 10 Set-up Software.

2. Go on-line with the drive via the Network folder.

3. Open the project folder, Right click on the drive folder and select “Write to drive”.

Select “All to LCP” [1] in 0-50 LCP Copy.

Select “File from MCO to LCP” [4] in 0-50 LCP Copy.

Select “All from LCP” [2] in 0-50 LCP Copy.

Select “File from LCP to MCO” [5] in 0-50 LCP Copy.

5.2

Backup and Restore

All parameters and MCO 305 data can be read out and stored in an MCT 10 project and thus restored to the frequency converter.

NOTE

MCO 305 programs can only be read-out when they have be downloaded including source code!

Use the following steps to back-up parameters and data by PC:

1. Go on-line with the drive via the Network folder.

2. Right click on the drive folder and select copy. “Include programs” must be ticked.

24 MG.33.K3.02 - VLT® is a registered Danfoss trademark

How to Install the Applicat... MCO 305 Operating Instructions

5.3 How to Connect and Run Multiple Frequency Converters

Use MCT 10 Networking or start APOSS directly by clicking on the application's icon. This stand-alone operation mode allows APOSS to switch frequency converters or connect to multiple frequency converters. In stand-alone mode, all file and parameter handling is done via APOSS. Thus the File menu also provides the functions for File → New, → Open, and → Save As. The Settings menu allows selecting the interface.

Run programs in several frequency converters If you want to load the program into several controllers, link the program with the corresponding VLT AutomationDrive and click on → Execute. If you want to load a different program in each controller, open a different edit window for each VLT AutomationDrive, then open the desired program file and connect it to the VLT AutomationDrive with → Select Controller. Then start each program, one after the other, with → Execute.

5 5

MG.33.K3.02 - VLT® is a registered Danfoss trademark 25

General Specifications MCO 305 Operating Instructions

6 General Specifications

1) Selected in parameter 5-00 Digital I/O mode. The digital

6.1 Protection and Features

inputs are galvanic isolated from the internal electronics and can be sourced by an external 24V power supply.

- All inputs, outputs and supply voltages are protected against short circuit.

- All inputs, outputs and supply voltages are galvanic isolated from high voltages such as mains supply and motor voltage (PELV).

- Encoder signals are monitored during operation and standstill.

- Customer specific application programs can be copy protected.

- All MCO 305 parameters including user defined application parameters are accessible via the VLT AutomationDrive LCP.

- MCO 305 can be combined with other VLT AutomationDrive options e.g. PROFIBUS and DeviceNet interface.

- All digital inputs and outputs are galvanic isolated from the internal electronics and can be sourced from an external 24V power supply.

6.2

Technical Data

Type Plug connectors with screw

terminals. Maximum cross section, rigid wire Maximum cross section, flexible wire Maximum cross section, wire with enclosed core Minimum cross section

Table 6.1 Connection Terminals

of programmable digital inputs 10

Number Terminal block X57 Terminal number 1, 2, 3, 4, 5, 6, 7, 8, 9, 10 Logic Voltage level 0 - 24V DC Voltage level, logic.0. PNP < 5V DC Voltage level, logic.1. PNP > 10V DC Voltage level, logic.0. NPN > 19V DC Voltage level, logic.1. NPN < 14V DC Maximum voltage on input 28V DC

1.5mm2 / AWG 16

0.08mm2 / AWG 28

PNP or NPN ¹

Number of programmable digital outputs Terminal block X59 Terminal number Driver type Push/Pull Logic Voltage level 0 - 24V DC Max. output current (sink or source) with

internal power supply (total ) Max. output current (sink or source) with external power supply (per output)

Table 6.3 Digital Outputs

8 (6)

11, 21, 3, 4, 5, 6, 7, 8

PNP or NPN

40mA

100mA

1) Terminals X59-1 and X59-2 can be programmed as input, 33-60 Terminal X59/1 and X59/2 Mode.

2) Selected in 5-00 Digital I/O Mode.

Number of digital outputs which can be used as digital inputs Terminal block X59 Terminal number 1, 2 Logic

Voltage level 0 - 24V DC Voltage level, logic.0. PNP < 10V DC Voltage level, logic.1. PNP > 17V DC Voltage level, logic.0. NPN > 13V DC Voltage level, logic.1. NPN < 6V DC Maximum voltage on input 28V DC

Table 6.4 Combined Digital Inputs/Outputs

PNP or NPN

1) Terminals X59-1 and X59-2 can be programmed as input, 33-60 Terminal X59/1 and X59/2 Mode.

2) Selected in 5-00 Digital I/O Mode.

Terminal block Terminal number 1, 2 Maximum load 65mA

Table 6.5 24V DC Supply Output

X58

The internal 24V power supply can be disconnected via parameter 33-85, an external 24V power supply must then be connected to X58-1 and X58-2.

Table 6.2 Digital Inputs

26 MG.33.K3.02 - VLT® is a registered Danfoss trademark

General Specifications MCO 305 Operating Instructions

General specifications: Number of encoder inputs 2 Terminal block X55 and X56 Terminal number 5, 6, 7, 8, 9, 10, 11, 12 Input impedance Maximum voltage on inputs 5V DC Cable type Screened cable with a twisted pair of

Table 6.6 Encoder Inputs

Incremental encoder type RS422/TTL Maximum frequency 410kHz Phase displacement between A and B 90°± 30° Maximum cable length

Table 6.7 Incremental Encoder Specifications

Absolute encoder type SSI Data coding Gray Data length 12 – 32 bit Clock frequency Maximum cable length

120Ω

wires for each encoder channel

300m

78kHz – 2MHz

150m

Sample time of position PID loop Positioning accuracy Synchronizing accuracy

Table 6.11 Control Characteristics

1ms

± 1 increment ¹ ± 1 increment ¹

1) This is the static accuracy; dynamic accuracy depends on many “external” factors such as encoder resolution, moment of inertia, mechanical backlash and elasticity.

Program memory size 100 Kbytes Maximum number of application programs 90 Average command execution time 0.3ms Maximum reaction time on interrupt input ms

Table 6.12 Application Program

6.3 Supply Voltage Overview

Table 6.8 Absolute Encoder Specifications

1) Always observe specifications/limitations prescribed by the encoder supplier.

2) 150m cable is possible up to 500kHz clock frequency, above 500kHz cable length must be limited further.

Number of encoder outputs Terminal block X56 Terminal number 5, 6, 7, 8, 9, 10, 11, 12 Signal type RS422 Maximum frequency 410kHz Maximum number of slaves 31 (more with repeater) Maximum cable length 400m

Table 6.9 Encoder Output

Number of supply voltages Terminal block X55 and X56 Terminal number 1, 2, 3, 4 24V, max. load 8V, max. load 5V, max. load

250mA

400mA

Table 6.10 Encoder Voltage Supply

1) This is maximum load when only one supply voltage is used; when 2 or 3 supply voltages are used simultaneously the load must be reduced accordingly. The following must be observed: load24V + load8V + load5V 6W and load8V + load5V 2W.

2) 8V is only available at terminal block X55.

MG.33.K3.02 - VLT® is a registered Danfoss trademark 27

Troubleshooting MCO 305 Operating Instructions

7 Troubleshooting

You can find brief information on the error messages in the

7.1 Warnings and Error Messages

All messages are shown in the LCP display of the VLT AutomationDrive in short and in the APOSS software in plain text.

Error no. LCP display Error text

102 Too many CAN objects There are no more CAN objects available (CANINI). 103 Illegal axis num. Axis not in system. 105 Error not reset Error not cleared. 106 Home not done Failed to move to HOME position. 107 Home vel. zero Home velocity 0

108 Position error Position error. 109 Index not found Index pulse (encoder) not found. 110 Unknown com. Unknown command. 111 SW end limit Software end limit activated. 112 Unknown param. Illegal parameter number. 113 FC not enabled VLT Error Status 114 Too many loops. Too many nested loops. 115 Par. save failed INLONG command got an illegal string 116 Param. memory Parameters in memory are corrupted. 117 Progr. Memory Programs in memory are corrupted. 118 Reset by CPU Reset by CPU. 119 User abort User abort. 121 No more SDO chn Number of SDO channels exceeded. 125 HW end limit Limit switch activated. 149 Too many inter. Too many interrupt functions. 150 No ext. 24V External supply is missing. 151 Too many gosub Too many nested GOSUB commands 152 Too many return Too many RETURN commands. 154 D. out overload Digital output overloaded. 155 LINK failed LINKGPAR failed. 156 Illegal double arg. A floating point function was called with an invalid argument. 160 Internal Intr. error Interrupt happened, but interrupt address is no longer valid. 162 Memory error Error in verifying 170 Too many DIM arrays Too many DIM arrays defined. 171 Array too small Array too small 175 Out of array mem. No more memory space for the new array defined by DIM. 176 Array size wrong Array size does not correspond to the size of the existing array. 179 Waitndx timeout Timeout while waiting for index. 184 Too many ontime Too many ONTIME or ONPERIODS interrupts. 187 Out of memory Not enough memory for variables 188 CAN guarding error A guarding error happened. 189 CAN send-receive error CAN send or receive error. 190 Memory locked Memory locked 191 Illegal cam array Illegal curve array in SETCURVE. 192 Encoder error Encoder error 193 Stack overflow Stack overflow: Too many local variables or nested function calls. 194 Out of dyn. mem Out of dynamic memory.

table or detailed information in the following section. The tables contain the messages in numerical order. Letters following a % sign represent variables which can be used in plain text at the corresponding locations.

28 MG.33.K3.02 - VLT® is a registered Danfoss trademark

Troubleshooting MCO 305 Operating Instructions

Error no. LCP display Error text

195 Too many testindices Too many test indices in data logging command. 196 Code too old Code is too old for the current firmware. 198 Limit sw. violation rong direction after limit switch tripped and error reset. 199 Internal MCO fault Internal MCO fault

Error 102 Too many CAN objects have been used and there are no more CAN objects available. The optional error information (see Error History) is used as follows:

CN_TIMEOUT -2 // timeout of CAN commands when sending or reading telegrams NO_HARDWARE -6 // no CAN hardware present NO_MEMORY -7 // no more entries available (mailboxes or lists) NO_CANMEMORY -10 // no more mailboxes available for define command NO_MOBJ -11 // the demanded mailbox is not available CN_CANERROR -12 // a CAN bus error is detected (low level bus error) CN_MOBJ_DIRERR -13 // direction of mailbox is wrong (try to read a write box or vice versa) NO_USER -33 // return value for sdo state (SDOSTATE).

SDO_ABORT -50 // has to be higher than the CN_ error messages SDO_ID_NOT_IN_USE -33 // return value for sdo state (SDOSTATE ) SDO_SEG_ARRAY_TOO_SMALL -51 SDO_SEG_TOGGLE_ERROR -52 SDO_SEG_TOO_MUCH_DATA -53 SDO_SEG_NOT_ENOUGH_DATA -54 SDO_SEG_ARRAY_WRITE_ERROR -55

7 7

GUARD_ERROR_NOT_OPERATIONAL -101 GUARD_ERROR_TOGGLE -102 GUARD_ERROR_MODULE_NOT_RESPONSE -103 GUARD_ERROR_NO_MODULE -104

Error 103 Illegal axis number An attempt has been made to find an axis which does not exist in the controller. Check to see if the program axis command has an invalid number or a general axis command (...X(*)).

Error 105

Error 108 Position error HOME was executed with HOME_VEL set to zero. The distance between the set and the real position was greater than the Maximum Tolerated Position Error defined in 32-67 Max. Tolerated Position Error. Causes:

Error not reset An attempt has been made to execute a motion command, although an actual error message has not been cleared.

Error 106 Home not done Failed to move to HOME position. According to the axis 33-00 Force HOME, a forced move to the machine zero-point is demanded, before other motion commands can be executed. This move to the machine zero-point has not been executed.

Error 107 Home velocity zero An attempt was made to execute the HOME command but the motor is set to 0 in 33-03 Velocity of Home Motion.

- Mechanically blocked or overloaded frequency converter,

32-67 Max. Tolerated Position Error too small,

- commanded speed greater than VLT AutomationDrive 4-13 Motor Speed High Limit [RPM] and 3-03 Maximum Reference,

- commanded acceleration too great,

32-60 Proportional factor too small, or

- VLT AutomationDrive not enabled.

MG.33.K3.02 - VLT® is a registered Danfoss trademark 29

Troubleshooting MCO 305 Operating Instructions

Error 109 Index not found At reference or index search, the encoder index pulse could not be found within a motor rotation. Causes:

- An encoder without an index pulse has been used,

- index pulse not connected,

- index pulse incorrect (all three channels must have a simultaneous low), or

32-01 Incremental Resolution (ENCODER) is set too low.

Error 110 Unknown command Cause is a Communication or program error. The program must be re-compiled and re-loaded.

Error 111

Software end limit A motion command will cause or has caused the software end limit to be activated. Identification of attainment of software limit at a motion in the speed mode will only be made after the current position is identical to the software limit switch. Starting with MCO 5.00 it is possible to clear a software limit error and then drive in the opposite direction. If you try again to move in the wrong direction, then a new error is generated. Handling of hardware limit switches is the same as software limit switches. That means that the error you can clear and drive in the opposite direction. But if you try to move in the wrong direction, then the error 198 occurs. In positioning mode, it is known before motion start that the target position lies outside the path. In this case, the movement will not be executed and the error message can be cleared. The control unit will be switched off and the frequency converter must be manually moved back to within the admissible area, or the monitoring of the software limit switch must be temporarily de-activated via 33-43 Negative

Software End Limit Active and 33-44 Positive Software End Limit Active. Only then is it possible to clear the error.

Limit switches and reference switches allow the usage of any input. That means not only 1..8 are supported but also larger numbers as well as virtual inputs or outputs.

NOTE

Using virtual inputs as limit switches is dangerous because it eliminates the direct connection between the limit switch and the controller. That may introduce a time delay (or other failure scenarios) which will limit the controller’s ability to respond quickly to the switch. Software-limit error handling a up MCO 5.00: A Software-Limit error can not be cleared: The control unit will be switched off and the frequency converter must be manually moved back to within the admissible area, or the monitoring of the software limit switch must be temporarily de-activated in 33-43 Negative Software End Limit Active and 33-44 Positive Software End Limit Active. Only then is it possible to clear the error.

Error 112 Unknown parameter An attempt has been made to change a parameter (SET or SETVLT command), which does not exist.

Error 113 FC not enabled VLT Error Status: VLT AutomationDrive is not ready but the PID controller is active. The FC status word (Bit 09 and Bit 11) is monitored every 20ms when the PID controller is active. The VLT AutomationDrive is in the “Not ready” state when:

- it has an alarm,

- it is in local mode,

- local LCP stop is activated.

Error 114 Too many loops Too many nested LOOP commands exist in the executed program.

Error 115 Parameter save failed The INLONG command got an illegal string. It has been used to read a long value from serial line. If the string which arrives does not represent a valid number then this error will be released.

Error 116 Parameters memory are corrupted The parameters in EPROM are no longer correct because of

- EEPROM defective or

- power outage while saving.

NOTE

Re-initialize the parameter with 14-22 Operation Mode and then overwrite these parameters again with your own application parameters. Otherwise motion programs which require application parameters will no longer function correctly. In Stand-alone-Mode you could also use Controller → Parameters →Reset.

30 MG.33.K3.02 - VLT® is a registered Danfoss trademark

Troubleshooting MCO 305 Operating Instructions

Error 117 Programs in memory are corrupted The program data stored in EPROM cannot be found or are no longer correct because of

- EEPROM defective or

- power outage while saving.

have to do a 3-finger reset to reset all para¬me¬ters to their defaults (ex factory) and to delete all user programs, arrays, and application parameters. Afterwards re-load the programs and parameters. This corresponds to a Reset → Complete in the APOSS menu. In Stand-alone-Mode delete the EPROM with Controller → Memory → Delete EPROM and then re-load the programs and parameters.

Error 118 Reset by CPU The processor has been stopped and a re-set has automatically been executed (watchdog). Causes could be

- Short term voltage drop,

- voltage peak, or

- short circuit.

Error 119 User abort The Autostart program has been aborted by the user. Or the [CANCEL] key was pressed during switching on and a Master Reset triggered.

Error 121 No more SDO channels If a SDOREAD or SDOWRITE is used with a negative index, then the command returns immediately and stores the running SDO in a channel. It is freed when the result is read. There is a maximum of 5 channels.

Error 125 Limit switch activated A motion command has caused an axis limit switch to be activated. Through activation of an end limit switch, the controller (depending on 33-40 Behaviour at End Limit Switch) is automatically switched off and the frequency converter must be manually moved out of this position, before the error message can be cleared. The behavior in case of hard and software limit switches has been improved starting with MCO 5.00: It is possible to clear a Software-Limit error and then drive in the opposite direction. If you try again to move in the wrong direction, then a new error is generated. Handling of hardware limit switches is now the same as software limit switches. That means that you can clear the error and drive in the opposite direction. But if you try to move in the wrong direction, then the error 198 occurs.

Limit switches and reference switches allow the usage of any input. That means not only 1..8 are supported but also larger numbers as well as virtual inputs or outputs.

NOTE

Error 149 Too many interrupt functions More interrupt functions than the maximum possible number were used. Permitted are:

32 ON INT 32 ON STATBIT 32 ON COMBIT 10 ON PARAM 20 ON posint GOSUB: ON APOS, ON IPOS, ON MAPOS, ON MCPOS, ON MIPOS

Error 150 No external 24V External supply is missing.

Error 151 Too many nested GOSUB commands In the program exists too many calls from one subroutine to another subroutine. The error usually occurs when there is a recurrent reference to one of the sub-programs in a subprogram. Avoid too many (10 is maximum) opposing subroutine calls, and avoid subroutines which call themselves (re-cursive subroutine procedures).

Error 152 Too many RETURN commands There are either more RETURN than corresponding GOSUB commands in the program, or there is a direct jump from a subroutine with a GOTO command. Only one RETURN is allowed per sub-program. It is always better to jump to the beginning of a sub-program and then to jump with IF… to a previously defined label.

Error 154 D. out overload Digital output overloaded.

Error 155 LINK failed LINKGPAR command failed.

Error 156 Illegal double argument Mathematical error: Illegal arguments for one of the “double” function, that means, a floating point function was called with an invalid argument. For example sqrt got a negative number or asin or acos were called with an argument bigger than 1. Double functions are available starting with MCO

5.00.

7 7

MG.33.K3.02 - VLT® is a registered Danfoss trademark 31

Troubleshooting MCO 305 Operating Instructions

Error 160 Internal interrupt error Interrupt happened, but interrupt address is no longer valid. (Internal error which should not ever happen.)

Error 162 Memory error Error in verifying: After saving something in the EPROM (a program or parameters) an error was detected during verification. Delete the EPROM with a 3-finger reset and try to save the program or parameters again. In Stand-alone Mode you can use → Controller → Memory → Delete EPROM instead of the 3-finger reset. If this is not successful please call the technical service department.

Error 170 Too many DIM arrays

The definition of an array in a DIM command does not correspond to an already existing array in the MCO 305. Cause might be that the fields are from older SYNCPOS/ APOSS programs. The current program has other definitions. Either adapt the APOSS program to the correct array size or delete the old arrays, e.g. in Stand-alone Mode with Controller → Memory → Delete EPROM or use the command Controller → Reset → Arrays.

NOTE

Remember to follow the recommendations concerning saving programs and parameters before deleting the EPROM.

Error 183 Invalid argument This command error signals that an TESTSTOP command contained an invalid argument. Or a compiler error in other commands like invalid parameter value, format, or range. (Internal error, which should not occurred.)

Error 184 Too many ONTIME Too many interrupts (ON TIME or ON PERIOD commands) were used within the program. A maximum of 12 of these ON TIME and/or ON PERIOD commands are allowed within one program.

Error 187 Out of memory Not enough memory for variables: When the APOSS program is started the space for the necessary variables is reserved dynamically. This space is now no longer available. You may have selected a maximum number of variables which is too high. Reduce the maximum number in Settings → Compiler (Standard = 92). Or the memory available is occupied with programs or arrays. Delete the programs with Controller → Programs → Delete all or delete both the programs and arrays, i.e. by deleting the entire memory with Controller → Memory → Delete EPROM..

Remember to follow the recommendations concerning saving programs and parameters before deleting the EEPROM.

Error 171 Array too small An attempt was made to describe an array element that is located outside of the defined array limits. Cause might be an error in the APOSS program. Array sizing does not agree with the space required (e.g. due to an incorrectly programmed loop). Or the array is too small for the number of test drives triggered by TESTSTART. Check loop variables.

Error 175 Out of array memory There is no more memory space for the new array defined by a DIM command.

Error 176 Array size wrong The size in a DIM command does not correspond to the size of the existing array. Either delete existing arrays or correct the DIM command.

Error 179 Waitndx timeout Timeout while waiting for index: The command WAITNDX was executed and the timeout listed was exceeded. The timeout is probably too short or the index impulse could not found (see also Error 109).

Error 188 CAN guarding error A guarding error happened. This happens either when requesting guarding messages from slaves or if guarding is done by a master. In both cases it is caused by a time out. In the additional error information it could be seen if it was an error caused by a master guarding (-34). The additional error information (see Error History) is used as it is shown in error 102.

Error 189 CAN send or receive error. This error is a send or receive error caused by a SDOREAD or SDOWRITE, by a CANIN or CANOUT or by an IN or OUT command using CAN I/O. The optional error information either contains the CAN ID which produced the error (IN, OUT, SDO, …) or the object number (handle) which was used (CANIN, CANOUT).

Error 190 Memory locked The program memory is write-protected and cannot be altered. This means that auto recognition can neither be set nor deleted and programs can neither be saved nor deleted. Equally, → RAM save and → Delete EPROM will not be executed.

32 MG.33.K3.02 - VLT® is a registered Danfoss trademark

Troubleshooting MCO 305 Operating Instructions

Error 191 Illegal cam array An incorrect or old array is defined in the DIM instruction for SETCURVE. An old array may exist if the zbc (or cnf) file with all parameters and arrays has not been loaded into the CAM-

Editor.

An incorrect array could be caused by the following:

- It was not created by the curve editor.

- Previous version of a curve editor. Such an array must first be converted by the current CAMEditor (→ load and save).

- Or the order of the arrays in the DIM instruction does not match the order in the zbc (or cnf) file. Refer to the number of the array in the title bar of the CAM-Editor in this respect.

Error 192 Encoder error Error from encoder monitoring: open or short circuit in accordance with the displayed LED.

An error will be indicated even if no encoder is connected.

Error 193 Stack overflow Internal error. Dynamic stack overflow caused by too many local variables or to many nested function calls. Increase the stack size in Settings → Compiler.

Error 194 Out of dynamic memory There is not enough dynamic memory for the requested data log (TESTSETP). Either TESTSTART demands too much dynamic memory or is called repeatedly.

Error 195 Too many testindices The data logging command (TESTSETP) contained too many indices. There is an actual limit of 20.

Error 196 Code too old The compiler which produced the program code was too old for this firmware. Please use a newer APOSS.

Error 198 Limit sw. violation After reaching the limit switch and clearing the error there was the attempt to move again into wrong direction.

Error 199 Internal MCO fault If such an error should occur, please contact your dealer and report the error number displayed to the technical service department.

7.2

APOSS Software Messages

The APOSS software messages are arranged in alphabetical order. Letters following a % sign represent variables which can be used in plain text at the corresponding locations.

Compilation error(s): program not saved!

A file is always compiled first and then saved. If you want to save the program, for example in the menu Controller → Save program and a syntax error is found during compilation this message will be displayed. Start the → Syntax Check in the menu Development, correct the syntax error and then save the program.

Connection to ... already exists . . . Connection to %d already exists [%s] - change to Window?

When opening a new window, or when trying to connect a window with a controller that is already linked to a window.

Yes: The controller is disconnected from the old window

No: The controller stays connected to the old window. The

Connector pin is not valid Connector %d pin %d is not valid in line %d column %d

An illegal combination or a pin number which cannot be set is used with the OUT command.

Controller is executing a program or command!

When the controller is executing a command or program it is not available for additional commands. You have to Break the new command and re-start it once the previous command has been completely.

Error in array part of file

When re-saving a configuration (e.g. Controller → Parameters → Restore from file) the computer recognizes that the data in the array area is formatted incorrectly. In order to be able to save a file, the following conditions must be fulfilled:

- Identical software versions,

- same configuration (e.g. same number of axes),

- in the case that arrays have already been inputted,

7 7

and linked to the new window.

new window is not linked to a controller.

these must match the ones that are to be saved in terms of type and size.

MG.33.K3.02 - VLT® is a registered Danfoss trademark 33

Troubleshooting MCO 305 Operating Instructions

Error in axis parameter part of file

When re-saving a configuration (e.g. Controller → Parameters → Restore from file) the computer recognizes that the data in the area of the axis parameters is formatted incorrectly. The parameter number and the sequence must be correct and numbering must be continuous. In order to be able to save a file, the following conditions must be fulfilled:

- Identical software versions, that provides same number and order of the parameters,

- same configuration (e.g. same number of axes).

Error in global parameter part of file

When re-saving a configuration (e.g. Controller → Parameters→ Restore from file) the computer recognizes that

the data in the area of the global parameters is formatted incorrectly. In order to be able to save a file, the following conditions must be fulfilled:

- Identical software versions, that provides same number and order of the parameters,

- same configuration (e.g. same number of axes).

Lost connection to ...

If the VLT AutomationDrive is turned off or the plug is pulled, etc. the window is disconnected from the VLT AutomationDrive and the lost connection is registered.

Timeout: no reply from FC

The VLT AutomationDrive does not answer; check the connection.

34 MG.33.K3.02 - VLT® is a registered Danfoss trademark

Appendix MCO 305 Operating Instructions

8 Appendix

Conversion index

8.1 Parameter Lists

The parameters are determined by parameter numbers. We recommend using the alphabetical overview as a guide; then you will be able to find detailed information very quickly

This number refers to a conversion figure used when writing or reading by means of a frequency converter. Please see for all conversion indices the VLT AutomationDrive Design Guide, MG.33.BX.YY.

using the number or the link.

Conversion index 0

Changes during operation

“TRUE” means that the parameter can be changed, while the

Conversion factor 1

Data type frequency converter is in operation. “FALSE” means that the frequency converter must be stopped before a change can be made.

4-Set-up

“1-Set-up”: Data value will be the same in all set-ups.

Please see for all data types the VLT AutomationDrive Design

Guide, MG.33.BX.YY.

Data type Description Type 2 Integer 8 Int8 3 Integer 16 Int16 4 Integer 32 Int32 5 Unsigned 8 Uint8 6 Unsigned 16 Uint16 7 Unsigned 32 Uint32

8.1.1 Application Parameters, Parameter Group 19-**

8 8

Par. No. # Parameter name Parameter description Default setting Changes

during

operation 19-0* Application Parameters 19-00 Application parameters 0 'TRUE' … TRUE 19-89 Application parameters 0 TRUE 19-9* Read-only Application Parameters 19-90 Application parameter 90 0 read only 1 set-up 0 Int32 19-91 Application parameter 91 0 read only 1 set-up 0 Int32 19-92 Application parameter 92 0 read only 1 set-up 0 Int32 19-93 Application parameter 93 0 read only 1 set-up 0 Int32 19-94 Application parameter 94 0 read only 1 set-up 0 Int32 19-95 Application parameter 95 0 read only 1 set-up 0 Int32 19-96 Application parameter 96 0 read only 1 set-up 0 Int32 19-97 Application parameter 97 0 read only 1 set-up 0 Int32 19-98 Application parameter 98 0 read only 1 set-up 0 Int32 19-99 Application parameter 99 0 read only 1 set-up 0 Int32

4-set-up Conversion

index

Type

MG.33.K3.02 - VLT® is a registered Danfoss trademark 35

Appendix MCO 305 Operating Instructions

8.1.2 MCO Basics Settings, Parameter Group 32-**

Par. No. # Parameter name Parameter

description

Default setting Changes

during

4-set-up Conver-

sion index

Type

operation

32-0* Encoder 2 - Slave 32-00 ENCODERTYPE Incremental Signal

Type

32-01 ENCODER Incremental

Resolution 32-02 ENCODER ABSTYPE Absolute Protocol [0] None TRUE 1 set-up Uint8 32-03 ENCODER ABSRES Absolute

Resolution 32-04 ENCODERBAUD Absolute Encoder

Baudrate X55 32-05 ENCODERDATLEN Absolute Encoder

Data Length 32-06 ENCODERFREQ Absolute Encoder

Clock Frequency 32-07 ENCODER CLOCK Absolute Encoder

32-08 ENCODER DELAY Absolute Encoder

32-09 ENCODER

MONITORING

32-10 POSDRCT Rotational

32-11 POSFACT_N User Unit

32-12 POSFACT_Z User Unit

32-13 ENCCONTROL Enc.2 Control 0 TRUE 2 set-ups Uint8 32-14 Enc.2 node ID 127 TRUE 2 set-ups Uint8 32-15 Enc.2 CAN guard [0] Off TRUE 2 set-ups Uint8 32-3* Encoder 1 - Master 32-30 MENCODER TYPE Incremental Signal

32-31 MENCODER Incremental

32-32 MENCODER ABSTYPE Absolute Protocol [0] None TRUE 1 set-up Uint8 32-33 MENCODER ABSRES Absolute

32-34 MENCODERBAUD Absolute Encoder

32-35 MENCODER DATLEN Absolute Encoder

32-36 MENCODER FREQ Absolute Encoder

32-37 MENCODER CLOCK Absolute Encoder

32-38 MENCODER DELAY Absolute Encoder

32-39 MENCODER

MONITORING

Clock Generation

Cable Length

Encoder

Monitoring

Direction

Denominator

Numerator

Type

Resolution

Baudrate X56

Data Length

Clock Frequency

Clock Generation

Cable Length

Encoder

Monitoring

[1] RS422 'TRUE' 1 set-up Uint8

1024 PPR TRUE 1 set-up Uint32

8192 PPR TRUE 1 set-up Uint32

[4] 9600 TRUE 1 set-up

25 Bit TRUE 1 set-up Uint8

262.000 kHz TRUE 1 set-up Uint32

[1] On TRUE 1 set-up Uint8

0 TRUE 1 set-up Uint16

[0] Off TRUE 1 set-up Uint8

[1] No action TRUE 1 set-up Uint8

1 TRUE 1 set-up Uint32

[1] RS422 TRUE 1 set-up Uint8

1024 PPR TRUE 1 set-up Uint32

8192 PPR TRUE 1 set-up Uint32

[4] 9600 TRUE 1 set-up

25 Bit TRUE 1 set-up Uint8

262.000 kHz TRUE 1 set-up Uint32

[1] On TRUE 1 set-up Uint8

0 TRUE 1 set-up Uint16

[0] Off TRUE 1 set-up Uint8

36 MG.33.K3.02 - VLT® is a registered Danfoss trademark

Appendix MCO 305 Operating Instructions

Par. No. # Parameter name Parameter

description

Default setting Changes

during

4-set-up Conver-

sion index

Type

operation

32-40 MENCODER TERM Encoder

Termination 32-43 MENCCONTROL Enc.1 Control 0 TRUE 2 set-ups Uint8 32-44 Enc.1 node ID 127 TRUE 2 set-ups Uint8 32-45 Enc.1 CAN guard [0] Off TRUE 2 set-ups Uint8 32-5* Feedback Source 32-50 Source Slave [2] Enc2 TRUE 1 set-up 32-52 Source Master [1] Enc1 TRUE 1 set-up 32-6* PID-Controller 32-60 KPROP Proportional Factor 30 TRUE 1 set-up 0 Uint32 32-61 KDER Derivative Value for

PID Control 32-62 KINT Integral Factor 0 TRUE 1 set-up 0 Uint32 32-63 KILIM Limit Value for

Integral Sum 32-64 BANDWIDTH PID Bandwidth 1000 TRUE 1 set-up 0 Uint16 32-65 FFVEL Velocity Feed-

forward 32-66 FFACC Acceleration Feed-

forward 32-67 POSERR Maximum

Tolerated Position

Error 32-68 REVERS Reverse Behavior

for Slave 32-69 TIMER Sampling Time for

PID control 32-70 PROFTIME Scan Time for

Profile Generator 32-71 REGWINMAX Size of the Control

Window

(Activation) 32-72 REGWINMIN Size of the Control

Window (Deacti-

vation) 32-73 KILIMTIME Integral limit filter

time 32-74 POSERRTIME Position error filter

time 32-8* Velocity & Acceleration 32-80 VELMAX Maximum Velocity

(Encoder) 32-81 RAMPMIN Shortest Ramp 1 s TRUE 1 set-up Uint32 32-82 RAMPTYPE Ramp Type 0 TRUE 1 set-up Uint8 32-83 VELRES Velocity Resolution 100 TRUE 1 set-up Uint16 32-84 DFLTVEL Default Velocity 50 TRUE 1 set-up Uint16 32-85 DFLTACC Default

Acceleration 32-86 JERKMIN Acc. up for limited

jerk 32-87 JERKMIN2 Acc. down for

limited jerk

[1] On TRUE 1 set-up Uint8

0 TRUE 1 set-up 0 Uint32

1000 TRUE 1 set-up 0 Uint16

0 TRUE 1 set-up 0 Uint32

0% TRUE 1 set-up 0 Uint32

20000 qc TRUE 1 set-up Uint32

[0] Reversing TRUE 1 set-up Uint8

1 ms TRUE 1 set-up Uint16

[1] 1 ms TRUE 1 set-up Uint8

0 qc TRUE 1 set-up Uint32

0 ms TRUE 2 set-ups int16

1500 RPM TRUE 1 set-up Uint32

50 TRUE 1 set-up Uint16

100 ms TRUE 2 set-ups Uint32

0 ms TRUE 2 set-ups Uint32

8 8

MG.33.K3.02 - VLT® is a registered Danfoss trademark 37

Appendix MCO 305 Operating Instructions

Par. No. # Parameter name Parameter

description

Default setting Changes

during

4-set-up Conver-

sion index

Type

operation

32-88 JERKMIN3 Dec. up for limited

jerk 32-89 JERKMIN4 Dec. down for

limited jerk

0 ms TRUE 2 set-ups Uint32

8.1.3 MCO Advanced Settings, Parameter Group 33-**

Par. No. # Parameter

name

33-0* Home Motion 33-00 HOME_FORCE Force HOME [0] not forced 'TRUE' 1 set-up Uint8 33-01 HOME_OFFSET Zero Point Offset

33-02 HOME_RAMP Ramp for Home

33-03 HOME_VEL Velocity of Home

33-04 HOME_TYPE Behavior during

33-1* Synchronization 33-10 SYNCFACTM Synchronization

33-11 SYNCFACTS Synchronization

33-12 SYNCPOSOFFS Position Offset for

33-13 SYNC ACCURACY Accuracy Window for

33-14 SYNCVELREL Relative Slave

33-15 SYNCMARKM Marker Number for

33-16 SYNCMARKS Marker Number for

33-17 SYNCMPULSM Master Marker

33-18 SYNCMPULSS Slave Marker

33-19 SYNCMTYPM Master Marker Type [0] Enc. Z pos. TRUE 1 set-up Uint8 33-20 SYNCMTYPS Slave Marker Type [0] Enc. Z pos. TRUE 1 set-up Uint8 33-21 SYNCMWINM Master Marker

33-22 SYNCMWINS Slave Marker

33-23 SYNCMSTART Start Behavior for

33-24 SYNCFAULT Marker Number for

33-25 SYNCREADY Marker Number for

Parameter description

from Home Position

Motion

Home Motion

Factor Master (M:S)

Factor Slave (M:S)

Synchronization

Position Synchronization

Velocity Limit

Master

Slave

Distance

Tolerance Window

Synchronization

Fault

Ready

Default setting Changes

during

4-set-up Conver-

sion index

Type

operation

0 qc TRUE 1 set-up Int32

10 TRUE 1 set-up Uint16

10 TRUE 1 set-up Int16

[0] Reverse + Index TRUE 1 set-up Uint8

1 TRUE 1 set-up Int32

0 qc TRUE 1 set-up Int32

1000 qc TRUE 1 set-up Int32

0% TRUE 1 set-up Uint8

1 TRUE 1 set-up Uint16

4096 TRUE 1 set-up Uint32

0 TRUE 1 set-up Uint32

[0] Start Funct. 1 TRUE 1 set-up Uint16

10 TRUE 1 set-up Uint16

1 TRUE 1 set-up Uint16

38 MG.33.K3.02 - VLT® is a registered Danfoss trademark

Appendix MCO 305 Operating Instructions

Par. No. # Parameter

name

Parameter description

Default setting Changes

during

4-set-up Conver-

sion index

Type

operation

33-26 SYNCVFTIME Velocity Filter 0 ms TRUE 1 set-up 0 Int32 33-27 SYNCOFFTIME Offset Filter Time 0 ms TRUE 1 set-up Uint32 33-28 SYNCMFPAR Marker Filter Config-

uration

33-29 SYNCMFTIME Filter Time for Marker

Correction

33-30 SYNCM

MAXCORR 33-31 SYNCTYPE Synchronization Type [0] Standard TRUE 1 set-up Uint8 33-32 SYNCFFVEL Feed Forward Speed

33-33 SYNCVFLIMIT Velocity Filter

33-34 SYNCSFTIME Slave Marker Filter

33-4* Limit Handling 33-40 ENDSWMOD Behavior at End Limit

33-41 NEGLIMIT Negative Software

33-42 POSLIMIT Positive Software End

33-43 SWNEGLIMACT Negative Software

33-44 SWPOSLIMACT Positive Software End

33-45 TESTTIM Time in Target

33-46 TESTVAL Target Window Limit

33-47 TESTWIN Size of Target

33-5* I/O Configuration 33-50 I_FUNCTION_1 Terminal X57/1

33-51 I_FUNCTION_2 Terminal X57/2

33-52 I_FUNCTION_3 Terminal X57/3

33-53 I_FUNCTION_4 Terminal X57/4

33-54 I_FUNCTION_5 Terminal X57/5

33-55 I_FUNCTION_6 Terminal X57/6

33-56 I_FUNCTION_7 Terminal X57/7

33-57 I_FUNCTION_8 Terminal X57/8

33-58 I_FUNCTION_9 Terminal X57/9

Maximum Marker Correction

Adaptation

Window

time

Switch

End Limit

Limit

End Limit Active

Limit Active

Window

Value

Window

Digital Input

[0] Marker Filter 1 TRUE 1 set-up Uint8

0 ms TRUE 1 set-up Int32

[0] Off TRUE 1 set-up Uint32

0 TRUE

0 qc TRUE

0 TRUE

[0] Call error handler TRUE 1 set-up Uint8

-500000 qc TRUE 1 set-up Int32

500000 qc TRUE 1 set-up Int32

[0] Inactive TRUE 1 set-up Uint8

0 ms TRUE 1 set-up Uint8

1 qc TRUE 1 set-up Uint16

0 qc TRUE 1 set-up Uint16

[0] no function TRUE 1 set-up Uint8

8 8

MG.33.K3.02 - VLT® is a registered Danfoss trademark 39

Appendix MCO 305 Operating Instructions

Par. No. # Parameter

name

Parameter description

Default setting Changes

during

4-set-up Conver-

sion index

Type

operation

33-59 I_FUNCTION_10 Terminal X57/10

Digital Input

33-60 IOMODE Terminal X59/1 and

X59/2 Mode

33-61 I_FUNCTION_11 Terminal X57/11

Digital Input

33-62 I_FUNCTION_12 Terminal X57/12

Digital Input

33-63 O_FUNCTION_1 Terminal X59/1

Digital Output

33-64 O_FUNCTION_2 Terminal X59/2

Digital Output

33-65 O_FUNCTION_3 Terminal X59/3

Digital Output

33-66 O_FUNCTION_4 Terminal X59/4

Digital Output

33-67 O_FUNCTION_5 Terminal X59/5

Digital Output

33-68 O_FUNCTION_6 Terminal X59/6

Digital Output

33-69 O_FUNCTION_7 Terminal X59/7

Digital Output

33-70 O_FUNCTION_8 Terminal X59/8

Digital Output 33-8* Global Parameters 33-80 PRGPAR Activated Program

Number 33-81 Power-up State Power-up State [1] Motor on TRUE 1 set-up Uint8 33-82 STATUS

MONITORING 33-83 ERRCOND Behavior after Error [0] Coast TRUE 1 set-up Uint8 33-84 ESCCOND Behavior after Escape [0] Contr. Stop TRUE 1 set-up Uint8 33-85 EXTERNAL24V MCO Supplied by

33-9* MCO Port Settings 33-90 X62 MCO CAN node

33-91 X62 MCO CAN baud

33-94 X62 MCO RS485

33-95 X62 MCO RS485

Drive Status Monitoring

External 24VDC

rate

serial termination

serial baud rate

[0] no function TRUE 1 set-up Uint8

[0] Output 'FALSE' 1 set-up Uint8

[0] no function TRUE 1 set-up Uint8

-1 TRUE 1 set-up 0 Uint8

[1] On TRUE 1 set-up 0 Uint8

[0] No TRUE 1 set-up Uint8

127 N/A TRUE 2 set-ups Uint8

[20] 125 Kbps TRUE 2 set-ups Uint8

[0] Off TRUE 2 set-ups Uint8

[2] 9600 Baud TRUE 2 set-ups Uint8

40 MG.33.K3.02 - VLT® is a registered Danfoss trademark

Appendix MCO 305 Operating Instructions

8.1.4 MCO Data Readouts, Parameter Group 34-**

Par. No. # Parameter

Name

Parameter description Default

setting

Changes

during

4-Setup Conver-

sion Index

Type

operation

34-0* PCD Write Parameters 34-01 PCD 1 Write to MCO 1 set-up Uint16 34-02 PCD 2 Write to MCO 1 set-up Uint16 34-03 PCD 3 Write to MCO 1 set-up Uint16 34-04 PCD 4 Write to MCO 1 set-up Uint16 34-05 PCD 5 Write to MCO 1 set-up Uint16 34-06 PCD 6 Write to MCO 1 set-up Uint16 34-07 PCD 7 Write to MCO 1 set-up Uint16 34-08 PCD 8 Write to MCO 1 set-up Uint16 34-09 PCD 9 Write to MCO 1 set-up Uint16 34-10 PCD 10 Write to MCO 1 set-up Uint16 34-2* PCD Read Parameters 34-21 PCD 1 Read from MCO 1 set-up Uint16 34-22 PCD 2 Read from MCO 1 set-up Uint16 34-23 PCD 3 Read from MCO 1 set-up Uint16 34-24 PCD 4 Read from MCO 1 set-up Uint16 34-26 PCD 6 Read from MCO 1 set-up Uint16 34-27 PCD 7 Read from MCO 1 set-up Uint16 34-28 PCD 8 Read from MCO 1 set-up Uint16 34-29 PCD 9 Read from MCO 1 set-up Uint16 34-30 PCD 10 Read from MCO 1 set-up Uint16 34-4* Inputs & Outputs 34-40 Digital Inputs 1 set-up Uint16 34-41 Digital Outputs 1 set-up Uint16 34-5* Process Data Unit 34-50 Actual Position UU 1 set-up Int32 34-51 Commanded Position UU 1 set-up Int32 34-52 Actual Master Position qc 1 set-up Int32 34-53 Slave Index Position UU 1 set-up Int32 34-54 Master Index Position qc 1 set-up Int32 34-55 Curve Position 1 set-up Int32 34-56 Track Error UU 1 set-up Int32 34-57 Synchronizing Error UU 1 set-up Int32 34-58 Actual Velocity UU/s 1 set-up Int32 34-59 Actual Master Velocity qc/s 1 set-up Int32 34-60 Synchronizing Status 1 set-up Int32 34-61 Axis Status 1 set-up Int32 34-62 Program Status 1 set-up Int32 34-7* Diagnosis Readouts 34-70 MCO Alarm Word 1 'FALSE' 1 set-up Uint32 34-71 MCO Alarm Word 2 FALSE 1 set-up Uint32

8 8

MG.33.K3.02 - VLT® is a registered Danfoss trademark 41

Index MCO 305 Operating Instructions

Index

Abbreviations........................................................................................... 4

Absolute Encoder Specifications.................................................... 27

Acceleration Feed-forward:.............................................................. 21

Application

Parameters, Parameter Group 19-**......................................... 35

Program............................................................................................... 27

Approvals................................................................................................... 3

Available Literature For VLT AutomationDrive, MCO 305 And

MCT 10 Motion Control Tool...... 3

General

Specifications.................................................................................... 26

Warning................................................................................................. 6

High Voltage Warning........................................................................... 5

How

To Connect And Run Multiple Frequency Converters........ 25

To Control Process Works............................................................. 19

To Get Started...................................................................................... 7

To Install The Application............................................................. 24

Backup And Restore Via LCP............................................................. 24

Basic MCO Parameter Settings........................................................ 14

Before Commencing Repair Work.................................................... 5

Checking Master Encoder For Synchronizing Applications........

Combined Digital Inputs/Outputs................................................. 26

Commissioning Guide........................................................................ 14

Connecting And Testing The Encoder (s).................................... 16

Connection Terminals......................................................................... 26

Control Characteristics....................................................................... 27

Conventions.............................................................................................. 3

Derivative Value For PID Control.................................................... 21

Digital

Inputs................................................................................................... 26

Outputs................................................................................................ 26

Download Application Program And Configuration............... 24

Incremental Encoder Specifications.............................................. 27

Influence To The Control Loop When Changing Parameters.....

Integral Factor:...................................................................................... 21

KILIM.......................................................................................................... 21

KINT........................................................................................................... 21

KPROP....................................................................................................... 20

Limit Value For Integral Sum:........................................................... 21

Manual Initialisation............................................................................... 7

MCO

305 Control Terminals.................................................................... 10

Advanced Settings, Parameter Group 33-**.......................... 38

Basics Settings, Parameter Group 32-**................................... 36

Data Readouts, Parameter Group 34-**................................... 41

Mechanical Installation Of The Option In The VLT Automation-

Drive...... 8

Electrical Installation........................................................................... 10

Encoder

Connections Examples................................................................... 12

Inputs................................................................................................... 27

Output.................................................................................................. 27

Voltage Supply.................................................................................. 27

Ending The Encoder Check............................................................... 16

Execute The Encoder Test Program............................................... 16

FFACC....................................................................................................... 21

FFVEL......................................................................................................... 21

42 MG.33.K3.02 - VLT® is a registered Danfoss trademark

Optimizing

The PID Controller........................................................................... 19

Your Controller Settings Step-by-Step..................................... 22

PID

Bandwidth.......................................................................................... 22

Controller Settings........................................................................... 16

Filter...................................................................................................... 20

Proportional Factor.............................................................................. 20

Protection And Features.................................................................... 26

Index MCO 305 Operating Instructions

Restore...................................................................................................... 24

Safe Stop Of FC 302................................................................................ 6

Safety Instructions.................................................................................. 5

Sample Program: Feed-forward Calculation.............................. 17

Sampling Time For PID Control:...................................................... 21

Setting

Of Encoder Parameters.................................................................. 14

Of Home Parameters...................................................................... 15

Of Synchronization Parameters.................................................. 15

Of Velocity Parameters................................................................... 15

Significance And Influence Of The Controller Parameters..........

Software Version..................................................................................... 5

Stationary Precision Is Required?.................................................... 23

Supply Voltage Overview.................................................................. 27

Symbols...................................................................................................... 3

Technical Data....................................................................................... 26

Terminal Overview............................................................................... 11

Test Program.......................................................................................... 18

The

Maximum Acceleration Is Not Achieved?............................... 23

Motor Doesn't Move?..................................................................... 18

Motor Sets Off Uncontrolled........................................................ 18

Tolerated Position Error Is Exceeded?...................................... 23

There Is A Tendency Towards Instability?.................................... 23

TIMER........................................................................................................ 21

Tolerated Position Error Is Exceeded............................................. 18

Unintended Start..................................................................................... 5

Velocity Feed-forward:....................................................................... 21

MG.33.K3.02 - VLT® is a registered Danfoss trademark 43

Danfoss MCO 305 Operating guide

Specifications and Main Features

Frequently Asked Questions

User Manual