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	4
1.1 Purpose of the Manual	4
1.2 Additional Resources	4
1.3 Overview	4
1.3.1 Software Version	4
1.4 Approvals	5
1.5 Disposal	5
2 Safety	6
2.1 Safety Symbols	6
2.2 Safety Warnings	6
2.3 Functional Safety	7
3 Mechanical Installation	8
4 Electrical Installation	10
4.1 MCO 350/351 Control Terminals	10
4.1.1 Enclosure Types A2 and A3	10
4.1.2 Enclosure Types A5, B1, and B2	10
4.2 Frequency Converter Control Card Terminals	11
4.3 Wiring Diagram	13
4.4 MCO Option Card Terminals	14
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	16
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	20
4.6.1 Introduction	20
4.6.2 Data Layout	20
5 Commissioning	23
5.1 Safety Instructions	23

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Contents	Operating Instructions

5.2 Basic Parameters Set-up	23
5.3 Basic Set-up	23
5.4 PID Settings	23
5.5 Description of Application Parameters	24
5.5.1 19-** Application Parameters	24
5.6 MCO Basic Settings	29
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	38
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	41
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	42
6.1 Homing	42
6.2 Touch Probe Positioning	42
6.3 Brake Control	42
6.4 Hardware End Limit	43
6.5 Software Limits	43
6.6 Index Positioning	43
6.7 Quick Bus Positioning	44
7 Diagnostics	45
7.1 Troubleshooting	45
7.2 Error Messages	46
8 Appendix	48
8.1 Abbreviations and Conventions	48
8.2 Glossary of Key Terms	48
8.3 Positioning	50
8.3.1 Positioning Table	50
8.3.2 Positioning Templates	51

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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	52

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Introduction	Operating Instructions

1	1	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

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/DrivesSolutions/Documentations/VLT+Technical+Documentation.htm for listings.

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.

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

1.3.1 Software Version

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

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Introduction	Operating Instructions
1.4 Approvals				1	1

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.

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Safety	Operating Instructions

2 Safety

2 2

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]	Minimum waiting time (minutes)
		4	15
	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

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Safety Operating Instructions

NOTICE

Installation at high altitudes:

•	380–500 V: Enclosure A, B, and C: At altitudes	2	2
	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.

2.3Functional 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.

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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®

3 3 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

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Mechanical Installation	Operating Instructions

3 3

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

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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

4 4 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.

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4.1.2 Enclosure Types A5, B1, and B2

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.

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Illustration 4.2 Removing the Front Cover

Illustration 4.1 Location of Encoder and I/O Terminals

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Electrical Installation

2 X62

1

X55

X56

X57

X58

X59

Operating Instructions

X60		<![if ! IE]> <![endif]>130BB794.10	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	4	4
	(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

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.

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				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
4		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-X56/4- X58/2)

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Operating Instructions

4.3 Wiring Diagram

+24 V OUT					12
+24 V OUT					13
Reference index Bit 0																																	18
Reference index Bit 1																												19
Enable (error clear in dig. control mode)																										27
Reference index Bit 4																												29
Reference index Bit 3																												32
Reference index Bit 2																												33
COM D in																											20
Safe torque o (STO)																											37
COM A out																																39
Touchprobe pos. locked																												42
+10 V OUT
																																50
Manual Jog positive																																				53
Manual Jog negative
					54
COM A in					55
Touchprobe switch
																													1
Positive HW limit switch																													2
Negative HW limit switch
																													3
Home reference switch
																													4
Go to target position
																													5
Reset Home ag
																													6
Reset Touchprobe pos.
																															7
Quickstop
																															8
Go to Home position
																															9
Latch new index																															10
+24 V supply																																1
COM																																2
Homing completed																																		1
Reference pos. reached
					2
Error occured																																			3
Reference index Bit 0																																		4
Reference index Bit 1																																			5
Reference index Bit 2																																			6
Reference index Bit 3																																		7
Reference index Bit 4																														8

FC300

91

L1

Mains

92

L2

93

L3

PE

PE

Digital

96

U

97

V

Inputs

Motor

98

W

99

PE

Relay

01

Brake Supply

02

Brake

Brake COM

Analog

01

03

Output

Relay

04

05

Analog

02

06

Inputs

S201, S202 = O

MCO 351

TTL

SSI

SINCOS

1

+24 V DC out

2

+8 V DC out

3

+5 V DC out

X57

X55

4

COM

5

A

SIN

Digital

Encoder 2

6

/A

REFSIN

Inputs

7

B

COS

8

/B

REFCOS

9

Z

CLK

10

/Z

/CLK

11

DATA

X58

12

/DATA

24 V DC

Supply

1

+24 V DC out

2

+8 V DC out

3

+5 V DC out

4

X59

COM

X56

5

Digital

A

Outputs

Encoder 1

6

/A

7

B

8

/B

9

Z

CLK

10

/Z

/CLK

11

DATA

12

/DATA

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.

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<![endif]>130BD658.10

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4 4

Electrical Installation	Operating Instructions

4.4 MCO Option Card Terminals

Technical data on these terminals can be found in the

Motion Control Option MCO 305 Operating Instructions.

4.4.1 X55 Feedback Encoder Input

1	2	3	4	5	6	7	8	9 10 11 12	<![if ! IE]> <![endif]>130BD653.10

Pin number	TTL encoder	SSI encoder	SinCos encoder
1	+24 V DC	+24 V DC	+24 V DC
	Supply	Supply	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

4.4.2X56 Master Encoder Input/Virtual Master Output

1	2	3	4	5	6	7	8	9 10 11 12	<![if ! IE]> <![endif]>130BD653.10

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
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

	4.4.3	X57 Digital Input									<![if ! IE]> <![endif]>130BD655.10
	1	2	3	4	5	6	7	8	9	10

Pin	Description
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

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4.4.4 X58 24 V DC Supply

1	2	<![if ! IE]> <![endif]>130BD656.10

Pin Description number

1+24 V

2COM

Illustration 4.9 X58 24 V DC Supply

4.4.5 X59 Digital Outputs

1	2	3	4	5	6	7	8	<![if ! IE]> <![endif]>130BD657.10

4.4.6 X62 MCO-CAN

1	2	3	4	5	<![if ! IE]> <![endif]>130BD672.10

4 4

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

Illustration 4.11 X62 MCO CAN

Pin	Description
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

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Electrical Installation	Operating Instructions

4.5 Description of Terminals

4.5.1 Frequency Converter Control Card Terminals

				Connector	Terminal	Designation	Description
				Inputs	12, 13	+24 V OUT	24 V (+1, –3 V) power supply
							Max. load:
							VLT® AutomationDrive FC 301: 130 mA
4		4
							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	To enable operation, this input must be maintained at high in both
						control mode)	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.
					29	Reference index bit 4 (msb)	Reference position index number bit 4 (most significant bit). Not used in
							fieldbus mode. Not available in VLT® AutomationDrive FC 301.
					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.
				Relay 01	01	COM Relay 01	Common terminal for Relay 01.
					02	Connect to electro-mechanical	Normal Open Relay 01 is open (brake activated) during power off and
						brake NO	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.
					03	NC	Normal Closed
				Relay 02	04	COM Relay 02	Common terminal for Relay 02.
					05	Brake activated NC	Normal Closed Relay 02 is closed to indicate an activated electrome-
							chanical brake. It is open to indicate a deactivated electromechanical
							brake. Not used in fieldbus control mode.
					06	NO	Normal Open
				Analogue I/O	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
							in) at a maximum of 500 Ω.
					50	+10 V OUT	Power supply for manual JOG inputs (terminal 53 and 54).
							Maximum 15 mA.
					53	±10 V-In Manual jog positive	When high (above 5 V), the drive travels with jogging speed (parameter
							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.
					54	±10 V-In Manual jog negative	When high (above 5 V), the drive travels with jogging speed (parameter
							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.
					55	COM A IN	Ground for analogue inputs. Common with 20 and 39.
				RS-485	61	Shield	Integrated RC-filter for cable screen. Only for connecting the screen
							when experiencing EMC problems.
					68	RxTx+	A control card switch is provided for termination resistance.
					69	RxTx–

Table 4.2 Control Card Terminals

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