ABOUT THE SHAFT SYNCHRONIZATION APPLICATION MANUAL
Congratulations for choosing the Smooth Control provided by Vacon NX Frequency Converters!
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9.1 Closed loop parameters (ID’s 612 to 621)................................................................................ 91
9.1.1 Note on use of permanent magnet motors (“AC brushless” motors)..........................91
9.2 Parameters of motor thermal protection (ID’s 704 to 708):.................................................... 92
9.3 Parameters of stall protection (ID’s 709 to 712):..................................................................... 92
9.4 Fieldbus control parameters (ID’s 850 to 859) ........................................................................ 92
10. Shaft synchronization application specific fault codes..................................................... 93
11. COMMISSIONING of shaft synchronization application .................................................... 93
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introduction vacon • 5
shaft synchronization application
(Software APFIFF11 V1.13 or higher)
Select the Shaft Synchronization Application in menu M6 on page
S6.2.
1. INTRODUCTION
The Shaft Synchronization Application provides Position synchronization control of a follower drive
to a master position signal, with the ability to control the synchronization ratio online via fieldbus,
parameter or by digital trim +/- input. The drive requires feedback from an encoder or resolver. The
master position signal comes from an incremental encoder or a single phase pulse generator and is
read using the OPT-A7 board if the follower drive employs an induction motor or the OPT-BC board
if the motor is of a PM synchronous type.
The application offers general purpose functionality support also for independent speed or torque
control when the shaft synchronization mode is not enabled.
Specific application features:
• Synchronization commands: enable sync. mode, engage/release, freeze and reference
speed are all controlled from digital inputs or fieldbus control register
• Ratio range -4 to +4 in steps of 1/65536 can be controlled by parameter or fieldbus in RUN
mode
• Programmable trim inputs +/- and trim ratio change parameter for temporary ratio change
from digital inputs
• Programmable ratio change ramp
• Programmable engage/ release ramp
• Digital or relay outputs for “Ratio change” and “Synchronization engaged”
• Phasing from standstill or during running (offset of follower position)
• Mechanical brake control
Other general purpose features:
• Induction motor identification
• PM motor rotor angle identification
• All digital and analogue inputs and outputs are freely programmable
• Analogue input signal range selection, with automatic adjustment
• Supervision of two frequency thresholds
• Supervision of torque limit
• Supervision of reference limit
• Second ramp and S-shape ramp programming
• Programmable start/stop and reverse logic
• DC-braking at start and stop
• Programmable U/f curve and switching frequency
• Fully programmable motor thermal and stall protection
• Input and output phase supervision
• Joystick with programmable hysteresis
NOTE: The Shaft Synchronization application creates a rigid electrical coupling between master and
follower(s) axis. The application is not suitable if there is a rigid mechanical coupling
between master and follower(s).
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1
6 • vacon introduction
1.1 Requirements
− NXP frequency converter with control board type VB00561 (“nxp2” type) or newer.
− NXP00002V155 system software package (NXP00002V160 for the support of single phase master
pulse reference).
− Double encoder board OPTA7 for induction motor with HTL incremental encoder for closed loop
control. The second encoder channel is used for master pulse reference.
− Resolver board OPTBC for permanent synchronous motor with resolver feedback for closed loop
control. The second encoder channel is used for master pulse reference.
− Application license key is needed for shaft synchronization functions (based on power unit serial
number)
However there is a 2 week trial time without charge. It is always possible to run the drive in
multi-purpose mode without the license key.
1.2 Trial Time period
Trial time is very useful for test and evaluation. If FC has to be replaced during a weekend there is 2
weeks trial time for free and during that time a new license can be ordered from Vacon.
After loading the application it will be possible to run in Shaft synchronization mode without license
key for 2 weeks (336 h)
STEPS IN TRIAL PERIOD
1. A warning F72 with the text “Trial time” will appear on the display (until <24 hours left) at
every run request
2. When only 24 hours is left of trial time the warning F73 “<24 hours left” is triggered and
remains on all the time when FC is in run in shaft synchronization mode.
3. When trial time has expired and the drive will trip with F72 Error: “TrialTimeOver”
NOTE: Drive will trip in run mode!
4. A monitoring value V1.23 on the keypad shows Trial time left (h). The trial time starts from
336 h and counts down to 0.
NOTE: The trial time counter is counting when the shaft synchronization is enabled by digital input
or from fieldbus.
rising edge
in shaft synchronization mode.
1
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control i/o vacon • 7
J
2. CONTROL I/O
Reference potentiometer,
1…10 kΩ
mA
READY
RUN
220
VAC
OPT-A1
Terminal Signal Description
1 +10V
2 AI1+ Analogue input, voltage range
3 AI1- I/O Ground Ground for reference and controls
4 AI2+
5 AI2-
6 +24V Control voltage output Voltage for switches, etc. max 0.1 A
7 GND I/O ground Ground for reference and controls
8 DIN1 Start forward
9 DIN2 Start reverse
10 DIN3 Shaft Synchronization Enable
11 CMA Common for DIN 1—DIN 3 Connect to GND or +24V
12 +24V Control voltage output Voltage for switches (see #6)
13 GND I/O ground Ground for reference and controls
14 DIN4 Synch. Mode BIT0
15 DIN5 Synch. Mode BIT1
16 DIN6 Free
17 CMB Common for DIN4—DIN6 Connect to GND or +24V
18 AOA1+
19 AOA120 DOA1 Digital output
OPT-A2
21 RO1
22 RO1
23 RO1
24 RO2
25 RO2
26 RO2
Reference output Voltage for potentiometer, etc.
ref
0—10V DC
Analogue input, current range
0—20mA
(programmable)
(programmable)
(programmable)
(programmable)
(programmable)
(programmable)
Output frequency
Analogue output
READY
Relay output 1
Relay output 2
FAULT
Voltage input frequency reference
Current input frequency reference
Contact closed = start forward
Contact closed = start reverse
Contact closed = Enabled
Contact closed = Engage Synchronization
Contact closed = Freeze follower speed
Programmable
Programmable
Range 0—20 mA/R
Programmable
Open collector, I≤50mA, U≤48 VDC
Note: See jumper selections below.
More information in the product's
User's Manual.
umper block X3:
CMA and CMB grounding
CMB connected to GND
CMA connected to GND
CMB isolated from GND
CMA isolated from GND
CMB and CMA
internally connected together,
isolated from GND
= Factory default
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2
8 • vacon connection of signals between master and follower
3. CONNECTION OF SIGNALS BETWEEN MASTER AND FOLLOWER DRIVE (OPT-A7)
NOTE: To eliminate the risk of electrical noise, use only double shielded twisted pair cable for
connections.
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3
jumper setting on the opt-a7 board vacon • 9
4. JUMPER SETTING ON THE OPT-A7 BOARD
The X5 jumper selects which channel is sent to the repeater outputs (connections17-20)
On the Master drive OPT-A7 the channel 1 (DIC) has to be sent to repeater outputs.
If there are more than one follower normally channel 2 (DID) is to be sent from follower(s) to
follower(s). Then all drives will follow master drive.
See the Option board manual UD00741 for more information.
Master drive can have any software application. Follower is regulating based on incoming encoder
channel 2 pulses.
COMMISSIONING NOTE:
Always check in option board menu (M7) that master pulses are coming to encoder channel 2
on the follower OPT-A7 board (or OPT-BC if resolver board is used).
Pulses per revolution for follower channel 2 (P7.3.1.4 Enc 2 Pulse/rev for OPT-A7) should
normally be set equals to Master encoder pulses/rev.
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4
10 • vacon "terminal to function" (ttf) programming principle
5. “TERMINAL TO FUNCTION” (TTF) PROGRAMMING PRINCIPLE
The programming principle of the input and output signals in the Multipurpose Control Application
as well as in the Pump and Fan Control Application (and partly in the other applications) is different compared to the conventional method used in other Vacon NX applications.
In the conventional programming method,
have a fixed input or output that you define a certain function for. This application, however, use the
Terminal to Function Programming method (TTF)
the other way round: Functions appear as parameters which the operator defines a certain
input/output for. See
Warning
on page 11.
5.1 Defining an input/output for a certain function on keypad
Connecting a certain input or output with a certain function (parameter) is done by giving the parameter an appropriate value. The value is formed of the
(see the product's User's Manual) and the
Function name
AI Ref Faul/Warn
DigOUT:B.1
Slot Terminal number
Terminal type
Example: You want to connect the digital output function
2.3.3.7) to the digital output DO1 on the basic board OPT-A1 (see the product's User's Manual).
First find the parameter 2.3.3.7 on the keypad. Press the
mode. On the
value line
, you will see the terminal type on the left (DigIN, DigOUT, An.IN, An.OUT)
and on the right, the present input/output the function is connected to (B.3, A.2 etc.), or if not connected, a value (0.#).
When the value is blinking, hold down the
and signal number. The program will scroll the board slots starting from 0 and proceeding from A
to E and the I/O selection from 1 to 10.
Once you have set the desired value, press the
READY
I/Oterm
AI Ref Faul/WarnAI Ref Faul/WarnA I Ref Faul/Warn
DigOUT :0.0
DigOUT :0.0
Function to Terminal Programming Method (FTT),
in which the programming process is carried out
Board slot
respective signal number
READY
I/Oterm
Reference fault/warning
Menu button right
Browser button up
Enter button
READY
I/Oterm
on the Vacon NX control board
, see below.
(parameter
once to enter the edit
or
down
to find the desired board slot
once to confirm the change.
READ Y
I/Oterm
DigOUT :B.1
you
enter
5
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"terminal to function" (ttf) programming principle vacon • 11
s
s
5.2 Defining a terminal for a certain function with NCDrive programming tool
If you use the NCDrive Programming Tool for parametrizing you will have to establish the connection between the function and input/output in the same way as with the control panel. Just pick the
address code from the drop-down menu in the
Value
column (see the Figure below).
Figure 1. Screenshot of NCDrive programming tool; Entering the address code
Be ABSOLUTELY sure not to connect two functions to one and same
!
WARNING
Note: The
input
output
operation.
, unlike the
in order to avoid function overruns and to ensure flawless
output
, cannot be changed in RUN state.
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5
12 • vacon "terminal to function" (ttf) programming principle
5.3 Defining unused inputs/outputs
All unused inputs and outputs must be given the board slot value 0 and the value 1 also for the terminal number. The value 0.1 is also the default value for most of the functions. However, if you want
to use the values of a digital input signal for e.g. testing purposes only, you can set the board slot
value to 0 and the terminal number to any number between 2…10 to place the input to a TRUE state.
In other words, the value 1 corresponds to 'open contact' and values 2 to 10 to 'closed contact'.
In case of analogue inputs, giving the value 1 for the terminal number corresponds to 0% signal
level, value 2 corresponds to 20%, value 3 to 30% and so on. Giving value 10 for the terminal number
corresponds to 100% signal level.
On the next pages you will find the lists of parameters within the respective parameter groups. The
parameter descriptions are given on pages 32 to 85.
Column explanations:
Code = Location indication on the keypad; Shows the operator the present param. number
Parameter = Name of parameter
Min = Minimum value of parameter
Max = Maximum value of parameter
Unit = Unit of parameter value; Given if available
Default = Value preset by factory
Cust = Customer’s own setting
ID = ID number of the parameter
= On parameter code: Parameter value can only be changed after the FC has been
stopped.
= Apply the Terminal to Function method (TTF) to these parameters (see chapter 3)
6.1 Monitoring values (Control keypad: menu M1)
The monitoring values are the actual values of parameters and signals as well as statuses and
measurements. Monitoring values cannot be edited.
See the product's User's Manual for more information.
Code Parameter Unit ID Description
V1.1 Output frequency Hz 1 Output frequency to motor
V1.2 Frequency reference Hz 25
V1.3 Motor speed rpm 2 Motor speed in rpm
V1.4 Motor current A 3
V1.5 Motor torque % 4 In % of Motor nominal torque
V1.6 Motor power % 5 Motor shaft power
V1.7 Motor voltage V 6
V1.8 DC link voltage V 7
V1.9
V1.10 Motor temperature
V1.11
V1.12
V1.13 DIN1, DIN2, DIN3 15 Digital input statuses
V1.14 DIN4, DIN5, DIN6 16 Digital input statuses
V1.15 Analog Iout MA 26 AOA1
V1.16 Torque reference
V1.17 Actual ratio*2^16 1700 Actual synch. ratio
V1.18 Position error
V1.19 Encoder 1 Freq
V1.20 Encoder 2 Freq
V1.21 Pole pair number
V1.22 ID Run Status
V1.23 Trial time left
V1.24 Accum Space Error
G1.25 Multimonitoring items
Unit temperature
Analogue input 1
Analogue input 2
°C
%
V/mA
V/mA
%
u
Hz
Hz
h
u
1701 Psotion error in user unit
1124
1803
Frequency reference to motor
control
8 Heatsink temperature
9 Calculated motor temperature
13 AI1
14 AI2
18
Shaft Frequency filtered
Master encoder frequency
53
Calculated pole pair number
58
based on given motor data
Status of ID run made
49
Hours left of trial time
67
Displays accumulated position
error when follower not
running in synch. mode.
Displays three selectable
monitoring values
Table 2. Monitoring values
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Jogging speed selected for
frequency reference (cc)
Closed cont.=Mode 2 is used
Open cont.=Mode 1 is used
See par 2.6.1, 2.6.12
Enable shaft synchronization
control mode (software
license required)
Disabled = multi-purpose
control mode
Reference speed/Freeze
follower speed request input
Trim input for increasing of
ratio in run mode
Trim input fordecreasing of
ratio in run mode
Hardware feedback from
mechanical brake.
cc = closing contact
oc = opening contact
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P2.3.8.6 Brake reaction time 0 10,00 s 0,10 1544 Physical reaction time
P2.3.8.7
P2.3.8.8 Brake close delay 0 10,00 s 0,00 1541
Mechanical brake
used
Close Frequency
limit
0 1 0 1550
0 P2.1.6 1,00 1539
0 = Not used
1 = Mechanical brake
used
Current limit for brake
open enable
Frequency limit for
brake open in open loop
Frequency limit for
brake open in closed
loop
Delay time for brake
open
Frequency limit for
closing the brake
Closing delay after close
frequency limit is
reached.
P2.5.18.16 KpF1 spd thresldP2.5.18.17 P2.1.2 Hz 2,00
P2.5.18.17 KpF0 spd thresld0,00 P2.5.18.16Hz 1,00
P2.5.18.18 %Kp spd reg @ F00 100 % 50
P2.5.18.19 Stop State Flux 0,0 150,0 % 100,0
P2.5.18.20 Flux Off Delay -1 32000 s 0
Magnetizing time
at start
0-speed time at
start
0-speed time at
stop
Start-up torque
FWD
Start-up torque
REV
Current control
P gain
0,000 60,000 s 0,0
0 32000 ms 100
0 32000 ms 100
–300,0 300,0 s 0,0
–300,0 300,0 s 0,0
0,00 100,00 % 40,00
628
615
616
621
633
634
617
1555
1556
1557
1401
1402
Table 18. Motor control parameters, G2.5
0=Not used
1=Torque memory
2=Torque reference
3=Start-up torque fwd/rev
Frequency threshold for
transition to normal speed
regulator gain
Frequency threshold for
transition to low speed
regulator gain
Speed regulator gain at
low speed, as a percentage of normal gain
(P2.5.18.2)
Stop state magnetization
current in % of nominal
magnetizing current
Maximum time for stop
state magnetization
6.6.1 PMSM settings (Control keypad: Menu M2 G2.5.19)
Code Parameter Min Max Unit DefaultCust ID note
P2.5.19.1 Motor type 0 1 0 650
P2.5.19.2 FluxCurrent Kp 0 32000 500
P2.5.19.3 FluxCurrent Ti 0 1000 ms 50
P2.5.19.4
P2.5.19.5 EnableRsIdentific0 1 1
P2.5.19.6 ModIndexLimit 0 200 100
PMSMShaft
Position
0 65535 0
0=Asynchronous motor
1=PMS Motor
Gain for flux current
651
control
Integral time for flux
652
control
Low word of encoder
649
angle corresponding to
the shaft 0 position
Enable Rs identification
654
during DC brake at start
Modulaton index limit at
655
field weakening point
Table 19. Parameters for permanent magnet synchronous motor, G2.5.19
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Threshold for position
error during
synchronization
0=Read
1=Ignore
0=Enabled
1=Disabled
Allowed difference
between output
frequency and the
encoder feedback
frequency
If freq. difference is
higher than ID1735 in this
time the lock fault is
triggered
Only for Vacon personnel.
Possibility to change
parameters in run state
when this parameter is
set to 1.
Table 20. Protections, G2.6
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6.8 Fieldbus parameters (Control Keypad: Menu M2 G2.7)
Code Parameter Min Max Unit Default Cust ID Note
P2.7.1
P2.7.2
P2.7.3
P2.7.4
P2.7.5
P2.7.6
P2.7.7
P2.7.8
SHAFT SYNCHRONIZATION SPECIFIC PARAMETERS (See separate description)
P2.7.9
P2.7.10
P2.7.11
P2.7.12
P2.7.13Free signal selection 0 8 7
Fieldbus data out 1
selection
Fieldbus data out 2
selection
Fieldbus data out 3
selection
Fieldbus data out 4
selection
Fieldbus data out 5
selection
Fieldbus data out 6
selection
Fieldbus data out 7
selection
Fieldbus data out 8
selection
Fieldbus data out
1_2 selection
Synch. ratio register
selection
Synch. control
register selection
Torque reference
selection
0 10000 0
0 10000 0
0 10000 1703
0 10000 4
0 10000 5
0 10000 6
0 10000 7
0 10000 37
0 10000 1702
0 7 0
0 8 1
0 8 6
1740
1741
1742
1680
1681
Choose monitoring data
852
with parameter ID
Choose monitoring data
853
with parameter ID
Choose monitoring data
854
with parameter ID
Choose monitoring data
855
with parameter ID
Choose monitoring data
856
with parameter ID
Choose monitoring data
857
with parameter ID
Choose monitoring data
858
with parameter ID
Choose monitoring data
859
with parameter ID
Choose 32-bit monitoring
data with parameter ID.
See separate description.
Selection of PD in channels for ratio register.
Occupies 2 PD in
channels !
Selection of PD in channel for synchronization
control register. See
table 39.
Select PD in channel for
Torque reference
Select PD in channel for
Free Signal. Can be used
for Torque or Current
limit. See G2.2.4.