Danfoss MCO 305 Operating guide

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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