Danfoss MCO 351 Operating guide

MAKING MODERN LIVING POSSIBLE

Operating Instructions

Positioning Controller MCO 351

VLT® AutomationDrive FC 301/302

www.danfoss.com/drives

Contents Operating Instructions

Contents

1 Introduction

1.1 Purpose of the Manual

1.2 Additional Resources

1.3 Overview

1.3.1 Software Version 4

1.4 Approvals

1.5 Disposal

2 Safety

2.1 Safety Symbols

2.2 Safety Warnings

2.3 Functional Safety

3 Mechanical Installation

4 Electrical Installation

4.1 MCO 350/351 Control Terminals

4.1.1 Enclosure Types A2 and A3 10

4 4 4 4

5 5

6 6 6 7

10 10

4.1.2 Enclosure Types A5, B1, and B2 10

4.2 Frequency Converter Control Card Terminals

4.3 Wiring Diagram

4.4 MCO Option Card Terminals

4.4.1 X55 Feedback Encoder Input 14

4.4.2 X56 Master Encoder Input/Virtual Master Output 14

4.4.3 X57 Digital Input 14

4.4.4 X58 24 V DC Supply 15

4.4.5 X59 Digital Outputs 15

4.4.6 X62 MCO-CAN 15

4.5 Description of Terminals

4.5.1 Frequency Converter Control Card Terminals 16

4.5.2 MCO Digital Inputs Terminal (X57) 17

4.5.3 MCO Digital Outputs Terminal (X59) 17

4.5.4 MCO Encoder Connection 18

4.5.4.1 Encoder Connection Examples 18

4.6 Fieldbus Interface

11 13 14

4.6.1 Introduction 20

4.6.2 Data Layout 20

5 Commissioning

5.1 Safety Instructions

23 23

Contents Operating Instructions

5.2 Basic Parameters Set-up

5.3 Basic Set-up

5.4 PID Settings

5.5 Description of Application Parameters

5.5.1 19-** Application Parameters 24

5.6 MCO Basic Settings

5.6.1 32-0* and 32-1*, Encoder 2 Parameters 29

5.6.2 32-3* and 32-4*, Encoder 1 Parameters 31

5.6.3 32-5* Feedback Source 33

5.6.4 32-6* and 32-7*, PID-Controller Parameters 34

5.6.5 32-8* Velocity & Acceleration 36

5.7 MCO Advanced Settings

5.7.1 33-0* Home Motion 38

5.7.2 33-4* Limit Handling 38

5.7.3 33-8*, Global Parameters 40

5.7.4 33-9*, MCO Port Settings 40

5.8 MCO Data Readouts

23 23 23 24

5.8.1 34-0*, PCD Write Parameters 41

5.8.2 34-2*, PCD Read Parameters 41

5.8.3 34-4*, Inputs and Outputs 41

5.8.4 34-5*, Process Data 41

6 Application Examples

6.1 Homing

6.2 Touch Probe Positioning

6.3 Brake Control

6.4 Hardware End Limit

6.5 Software Limits

6.6 Index Positioning

6.7 Quick Bus Positioning

7 Diagnostics

7.1 Troubleshooting

7.2 Error Messages

42 42 42 42 43 43 43 44

45 45 46

8 Appendix

8.1 Abbreviations and Conventions

8.2 Glossary of Key Terms

8.3 Positioning

8.3.1 Positioning Table 50

8.3.2 Positioning Templates 51

48 48 48 50

Contents Operating Instructions

8.3.2.1 Example of Index Positioning via Fieldbus 51

8.3.2.2 Example of Index Positioning via Quick Bus 51

Index

Introduction Operating Instructions

1 Introduction

1.1 Purpose of the Manual

These Operating Instructions provide information for safe installation and commissioning of the VLT® Positioning

Controller MCO 351. The Operating Instructions are intended for use by qualified personnel. Read and follow the Operating Instructions to use the product safely and professionally, and pay particular attention to the safety instructions and general warnings. Keep these Operating Instructions available with the MCO 351 at all times.

Compliance with the information in these Operating Instructions is a prerequisite for:

Trouble-free operation

•

Recognition of product liability claims

•

Therefore, read the Operating Instructions before working with the MCO 351.

VLT® is a registered trademark.

1.2 Additional Resources

1.3

Overview

The VLT® Positioning Controller MCO 351 is for use with the FC 300 series frequency converters. The control card option expands the functional properties of the frequency converter in positioning applications. It is user-friendly,

enabling the set-up of all parameters via the VLT AutomationDrive Local Control Panel (LCP) or via the VLT

MCT 10 Set-up Software.

The module is available as an option card for field installation or as a built-in option in all VLT® AutomationDrives.

It is available with and without conformal coating.

As the MCO 351 is a standard product with fixed functional properties, no additional application programming is required.

The positioning controller can handle most positioning applications with vertical as well as horizontal movements. The option is suited for applications with an overall control system, for example a PLC.

Resources available to understand advanced frequency converter and MCO functions and programming:

VLT® AutomationDrive FC 301/FC 302 Operating

•

Instructions

VLT® AutomationDrive FC 301/FC 302 Design

•

Guide

VLT® AutomationDrive FC 301/FC 302

•

Programming Guide Motion Control Option MCO 305 Operating

•

Instructions Motion Control Option MCO 305 Design Guide

•

Supplementary publications and manuals are available from Danfoss. See www.danfoss.com/BusinessAreas/DrivesSo-

lutions/Documentations/VLT+Technical+Documentation.htm

for listings.

The main features are:

Direct positioning via fieldbus

•

Relative, absolute, and touch probe positioning

•

32 fixed positions (64 via fieldbus)

•

End limit handling (software and hardware)

•

Mechanical brake handling

•

Error handling

•

Jog speed/manual operation

•

Home function

•

Auto PID calculation

•

Software Version

1.3.1

Refer to parameter 19-90 Type/Version for the software version number.

Introduction Operating Instructions

1.4 Approvals

NOTICE

The T7 (525-690 V) frequency converters are not certified for UL.

1.5 Disposal

Equipment containing electrical components can not be disposed of together with domestic waste. It must be separately collected with electrical and electronic waste according to local and currently valid legislation.

Safety

Operating Instructions

2 Safety

2.1 Safety Symbols

The following symbols are used in this document:

WARNING

Indicates a potentially hazardous situation which could result in death or serious injury.

CAUTION

Indicates a potentially hazardous situation which could result in minor or moderate injury. It may also be used to alert against unsafe practices.

NOTICE

Indicates important information, including situations that may result in damage to equipment or property.

2.2 Safety Warnings

WARNING

HIGH VOLTAGE

Frequency converters contain high voltage when connected to AC mains input power. Failure to perform installation, start up, and maintenance by qualified personnel could result in death or serious injury.

Installation, start up, and maintenance must be

•

performed by qualified personnel only.

WARNING

UNINTENDED START

When the frequency converter is connected to AC mains, DC power supply, or load sharing, the motor may start at any time. Unintended start during programming, service, or repair work can result in death, serious injury, or property damage. The motor can start by means of an external switch, a serial bus command, an input reference signal from the LCP or LOP, via remote operation using MCT 10 software, or after a cleared fault condition. To prevent unintended motor start:

Disconnect the frequency converter from the

•

mains. Press [Off/Reset] on the LCP before

•

programming parameters. Ensure that the frequency converter, motor, and

•

any driven equipment is fully wired and assembled when the frequency converter is connected to AC mains, DC power supply, or load sharing.

WARNING

DISCHARGE TIME

Frequency converters contain DC link capacitors that can remain charged even when AC mains is disconnected. To avoid electrical hazards, remove AC mains from the frequency converter before doing any service or repair and wait the amount of time specified in Table 2.1. Failure to wait the specified time after power has been removed before doing service or repair on the unit could result in death or serious injury.

Voltage [V]

200–240 0.25–3.7 kW 5.5–37 kW 380–480 0.25–7.5 kW 11–75 kW 525–600 0.75–7.5 kW 11–75 kW 525–690 N/A 11–75 kW High voltage may be present even when the warning indicator lights are off.

Table 2.1 Discharge Time

Minimum waiting time (minutes)

4 15

Safety Operating Instructions

NOTICE

Installation at high altitudes:

380–500 V: Enclosure A, B, and C: At altitudes

•

above 2 km, contact Danfoss regarding PELV. 380–500 V: Enclosure D, E, and F: At altitudes

•

above 3 km, contact Danfoss regarding PELV. 525–690 V: At altitudes above 2 km, contact

•

Danfoss regarding PELV.

2.3 Functional Safety

Safe Torque Off is an option. To run Safe Torque Off, additional wiring for the frequency converter is required.

Refer to VLT® Frequency Converters Safe Torque Off Operating Instructions for further information.

2 2

Mechanical Installation Operating Instructions

3 Mechanical Installation

This chapter is only relevant if the MCO 350/351 is delivered as an option for upgrading an existing VLT

AutomationDrive. When ordered with the frequency converter, MCO 350/351 is pre-installed. For retrofit, purchase a mounting kit.

There is a different mounting kit for different enclosures. Use MCO 350/351 in slot C0 or combine it with another option in slot C1.

Mounting kit depending on enclosure Order no.

Bookstyle Enclosure

A2 and A3 (40 mm for 1 C option) 130B7530 A2 and A3 (60 mm for C0 + C1 option) 130B7531 B3 (40 mm for 1 C option) 130B1413 B3 (60 mm for C0 + C1 option) 130B1414

Compact Enclosure

A5 130B7532 B, C, D, E, and F (except B3) 130B7533

Table 3.1 Mounting Kits

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

Illustration 3.1 Bookstyle Enclosure – A2, A3, B3

Mechanical Installation Operating Instructions

3 3

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

130BA248.11

130BT334.10

Electrical Installation Operating Instructions

4 Electrical Installation

Refer to the safety warnings in chapter 2 Safety before installing the MCO.

Screen all control cables and connect the cable screen to ground at both ends to avoid EMC problems. Always

follow the instructions of the encoder supplier. See also

VLT

AutomationDrive FC 301/FC 302 0.25-75 kW Design

Guide for more information regarding cable installation.

4.1 MCO 350/351 Control Terminals

4.1.1 Enclosure Types A2 and A3

Encoder and I/O terminal are located behind the C option terminal cover, see Illustration 4.1.

MCO CAN bus terminals and debug terminals (RS-485) are 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.

Enclosure Types A5, B1, and B2

4.1.2

All MCO 350/351 terminals are located next to the VLT AutomationDrive control card. Remove the front cover to get access. See Illustration 4.2.

MCO control terminals are plug connectors with screw terminals. Terminals X55, X56, X57, X58, and X59 are duplicated to be used for both bookstyle and compact enclosure type. See Illustration 4.3 to locate the terminal blocks.

Illustration 4.1 Location of Encoder and I/O Terminals

Illustration 4.2 Removing the Front Cover

X62

X55

X56

X57

X58

X59

X60

130BB794.10

Electrical Installation Operating Instructions

4.2

Frequency Converter Control Card Terminals

The terminals on the VLT® AutomationDrive control card are allocated for the MCO 351.

Do not change the following parameters for I/O settings:

Parameters 5-10 to 5-15 set to [0] No operation

•

(default setting) Parameters 3-15, 3-16 and 3-17 set to [0] No

•

function (default setting) Parameter 6-50 set to [52] MCO 0–20 mA

•

4 4

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

Illustration 4.3 Location of Terminal Blocks 1 and 2

Illustration 4.4 FC 300 Terminals

Technical data on these terminals can be found in the VLT® AutomationDrive FC 301/FC 302 Design Guide.

Use terminal block 1 with bookstyle and terminal block 2 with compact.

Electrical Installation Operating Instructions

Digital inputs

12 +24 V OUT 13 +24 V OUT 18 Reference index bit 0 19 Reference index bit 1 27 Enable (error clear in digital control mode) 29 Reference index bit 4

32 Reference index bit 3 33 Reference index bit 2 20 COM D in 37 Safe Torque Off (STO)

Table 4.1 Digital Inputs

Relay 1:

Mechanical brake (normally open)

Relay 2:

Mechanical brake monitoring (normally closed)

Analog input:

53 ±10 V-In Manual jog positive 54 ±10 V-In Manual jog negative 55 Common for analogue inputs

Supply voltage:

12, 13 +24 V Out 20 Common for digital inputs (common with X55/4-X56/4X58/2)

FC300

Reference index Bit 1

Enable (error clear in dig. control mode)

Reference index Bit 4

Reference index Bit 3

Reference index Bit 2

Touchprobe pos. locked

Manual Jog positive

Reset Touchprobe pos.

Go to Home position

Latch new index

Homing completed

Reference pos. reached

Reference index Bit 0

Reference index Bit 1

Reference index Bit 2

Reference index Bit 3

Reference index Bit 4

+24 V DC out

+8 V DC out

+5 V DC out

COM

+24 V DC out

+8 V DC out

+5 V DC out

COM

CLK

/CLK

DATA

/DATA

Analog Output

Analog Inputs

S201, S202 = O

MCO 351

Relay

Mains

Motor

X56

Encoder 1

X55

Encoder 2

+24 V OUT

Reference index Bit 0

COM D in Safe torque o (STO)

COM A in

+10 V OUT

Quickstop

Manual Jog negative

COM A out

Touchprobe switch

Positive HW limit switch

Negative HW limit switch

Home reference switch

Go to target position

Reset Home ag

+24 V supply

COM

Error occured

53 54

8 9

Digital Inputs

X57 Digital Inputs

X58 24 V DC Supply

X59 Digital Outputs

01 Brake Supply

Brake Brake COM

TTL SSI SINCOS

CLK

/CLK

DATA

/DATA

SIN

REFSIN

COS

REFCOS

1 2

130BD658.10

Electrical Installation Operating Instructions

4.3 Wiring Diagram

4 4

Illustration 4.5 Wiring Diagram

NOTICE

Input 29 is not available in FC 301. Therefore only 16 positions can be selected via digital inputs in FC 301.

130BD653.10

1 2 3 4 5 7

116

8 10

130BD653.10

1 2 3 4 5 7

116

8 10

1 2 3 4 5 7 96 8 10

130BD655.10

Electrical Installation Operating Instructions

X56 Master Encoder Input/Virtual

4.4 MCO Option Card Terminals

4.4.2 Master Output

Technical data on these terminals can be found in the Motion Control Option MCO 305 Operating Instructions.

4.4.1 X55 Feedback Encoder Input

Pin number TTL encoder SSI encoder

1 +24 V DC Supply +24 V DC Supply 2 +8 V DC Supply +8 V DC Supply 3 +5 V DC Supply +5 V DC Supply

Pin number TTL encoder SSI encoder SinCos encoder

1 +24 V DC

Supply 2 +8 V DC Supply +8 V DC Supply +8 V DC Supply 3 +5 V DC Supply +5 V DC Supply +5 V DC Supply 4 GND GND GND 5 A - +SIN 6 A not - REFSIN 7 B - +COS 8 B not - REFCOS 9 Z CLK 10 Z not CLK not 11 - DATA 12 - DATA not -

Illustration 4.6 X55 Feedback Encoder Input

+24 V DC

Supply

+24 V DC

Supply

4 GND GND 5 A 6 A not 7 B 8 B not 9 Z CLK 10 Z not CLK not 11 - DATA 12 - DATA not

Illustration 4.7 X56 Master Encoder Input/Virtual Master Output

X57 Digital Input

4.4.3

Pin number

1 Touch probe switch 2 Positive hardware limit switch 3 Negative hardware limit switch 4 Home switch 5 Go to target position 6 Reset home flag 7 Reset touch probe position 8 Quick stop 9 Go to home position 10 Latch new reference position index number

Illustration 4.8 X57 Digital Inputs

Description

1 2

130BD656.10

1 2 3 4 5 76 8

130BD657.10

3 4 5

130BD672.10

Electrical Installation Operating Instructions

4.4.4 X58 24 V DC Supply

Pin number

1 +24 V 2 COM

Illustration 4.9 X58 24 V DC Supply

4.4.5

Description

X59 Digital Outputs

X62 MCO-CAN

4.4.6

Pin number Description

1 – 2 CAN_L (CAN low) 3 Drain 4 CAN_H (CAN high) 5 –

Illustration 4.11 X62 MCO CAN

4 4

Pin number

1 Homing completed 2 Reference position reached 3 Error 4 Reference index bit 0 5 Reference index bit 1 6 Reference index bit 2 7 Reference index bit 3 8 Reference index bit 4

Illustration 4.10 X59 Digital Outputs

Description

Electrical Installation

Operating Instructions

4.5 Description of Terminals

4.5.1 Frequency Converter Control Card Terminals

Connector Terminal Designation Description Inputs

Relay 01

Relay 02

Analogue I/O

RS-485

12, 13 +24 V OUT 24 V (+1, –3 V) power supply

Max. load: VLT® AutomationDrive FC 301: 130 mA VLT® AutomationDrive FC 302: 200 mA

18 Reference index bit 0 (LSB) Reference position index number bit 0 (least significant bit). Not used in

fieldbus mode. 19 Reference index bit 1 Reference position index number bit 1. Not used in fieldbus mode. 20 COM D IN Ground for 24 V – common with 39, 55, X55/4, X56/4, and X58/2 27 Enable (error clear in digital

control mode)

29 Reference index bit 4 (msb) Reference position index number bit 4 (most significant bit). Not used in

32 Reference index bit 3 Reference position index number bit 3. Not used in fieldbus mode. 33 Reference index bit 2 Reference position index number bit 2. Not used in fieldbus mode. 37 Safe Torque Off (STO) Safe input. Used for STO. 01 COM Relay 01 Common terminal for Relay 01. 02 Connect to electro-mechanical

brake NO

03 NC Normal Closed 04 COM Relay 02 Common terminal for Relay 02. 05 Brake activated NC Normal Closed Relay 02 is closed to indicate an activated electrome-

06 NO Normal Open 39 COM A OUT Ground for analog output. Common with 20 and 55. 42 Touch probe position locked in This analog output delivers either 0 mA (not locked in) or 20 mA (locked

50 +10 V OUT Power supply for manual JOG inputs (terminal 53 and 54).

53 ±10 V-In Manual jog positive When high (above 5 V), the drive travels with jogging speed (parameter

54 ±10 V-In Manual jog negative When high (above 5 V), the drive travels with jogging speed (parameter

55 COM A IN Ground for analogue inputs. Common with 20 and 39. 61 Shield

68 RxTx+ A control card switch is provided for termination resistance. 69 RxTx–

To enable operation, this input must be maintained at high in both

digital control mode and fieldbus control mode.

Digital control mode: Errors are cleared on the rising edge. Must be 0 V

for at least 1 ms to guarantee edge detection.

fieldbus mode. Not available in VLT® AutomationDrive FC 301.

Normal Open Relay 01 is open (brake activated) during power off and

start-up of the FC 300. It is always open after a Quick Stop procedure or

with an error situation. Relay 01 only closes with motion procedures or if

specified in parameter 19-09 Automatic Brake Control.

chanical brake. It is open to indicate a deactivated electromechanical

brake. Not used in fieldbus control mode.

in) at a maximum of 500 Ω.

Maximum 15 mA.

19-16) and ramp (parameter 19-17) in the positive direction. When low

(below 5 V), the drive ramps down and stops if no other motion

procedure is activated. Jog positive has higher priority than jog negative.

Not used in fieldbus mode by default. Can be enabled via parameter

19-31 Digital Jog in field Bus mode.

19-16) and ramp (parameter 19-17) in the negative direction. When low

(below 5 V), the drive ramps down and stops if no other motion

procedure is activated. Not used in fieldbus mode by default. Can be

enabled via parameter 19-31 Digital Jog in field Bus mode.

Integrated RC-filter for cable screen. Only for connecting the screen

when experiencing EMC problems.

Table 4.2 Control Card Terminals

+ 40 hidden pages