Danfoss VLT 5000 FLUX, VLT 5000 Operating guide
Operating Instructions
Positioning Controller
VLT® 5000
VLT® 5000 FLUX
Positioning Controller
Table of contents
Safety regulations _______________________________________________________________ 3
Introduction____________________________________________________________________ 4
Hardware ........................................................................................................................................................................ |
5 |
VLT control card terminals......................................................................................................................................... |
5 |
Technical data............................................................................................................................................................. |
5 |
Option card terminals.................................................................................................................................................. |
5 |
Supply voltages........................................................................................................................................................... |
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Encoder monitor ......................................................................................................................................................... |
7 |
Option card layout ...................................................................................................................................................... |
8 |
Technical Data .............................................................................................................................................................. |
10 |
Description of the electrical and field bus interface ___________________________________ 12
Electrical interface VLT ............................................................................................................................................... |
12 |
Option card MK3A ................................................................................................................................................... |
14 |
Option card MK3C ................................................................................................................................................... |
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Option card MK3B (secondary position feedback for absolute encoders when using VLT 5000 Flux)................... |
15 |
Option card MK3D (primary position feedback)...................................................................................................... |
16 |
Field bus interface......................................................................................................................................................... |
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Data layout................................................................................................................................................................ |
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Description of the available parameters_____________________________________________ 20
Special LCP functions................................................................................................................................................... |
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Description of parameters ............................................................................................................................................. |
21 |
An application example!_________________________________________________________ 35
Wiring diagram ............................................................................................................................................................. |
36 |
Basic set-up................................................................................................................................................................... |
36 |
Parameter settings ......................................................................................................................................................... |
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Troubleshooting _______________________________________________________________ 41
Frequently asked questions ........................................................................................................................................... |
41 |
Appendix _____________________________________________________________________ 44
Binary selection of reference positions using digital control ........................................................................................ |
44 |
Binary selection of reference positions using fieldbus control...................................................................................... |
44 |
Glossary of key terms ................................................................................................................................................... |
46 |
Index ............................................................................................................................................................................. |
48 |
MG.50.P3.02 - VLT is a registered Danfoss trademark |
1 |
Positioning Controller
Positioning Controller for
VLT 5000 and VLT 5000Flux
Software Version 2.1X
Software Version number: See Parameter 779.
2 |
MG.50.P3.02 - VLT is a registered Danfoss trademark |
Positioning Controller
The voltage of the frequency converter is dangerous whenever the equipment is connected to mains. Incorrect installation of the motor or the frequency converter may cause damage to the equipment, serious personal injury or death. Consequently, the instructions in this manual, as well as national and local rules and safety regulations, must be complied with.
Safety regulations
1.The VLT frequency converter must be disconnected from mains if repair work is to be carried out. Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs.
2.The [STOP/RESET] key on the control panel of the frequency converter does not disconnect the equipment from mains and is thus not to be used as a safety switch.
3.Correct protective earthing of the equipment must be established, the user must be protected against supply voltage, and the motor must be protected against overload in accordance with applicable national and local regulations.
4.The earth leakage currents are higher than 3.5 mA.
5.Protection against motor overload is not included in the factory setting. If this function is desired, set parameter 128 to data value ETR trip or data value ETR warning.
Note: The function is initialized at 1.16 x rated motor current and rated motor frequency.
For the North American market: The ETR functions provide class 20 motor overload protection in accordance with NEC.
6.Do not remove the plugs for the motor and mains supply while the frequency converter is connected to mains. Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs.
7.Please note that the frequency converter has more voltage inputs than L1, L2 and L3, when load sharing (linking of DC intermediate circuit) and external 24 V DC have been installed.
Check that all voltage inputs have been disconnected and that the necessary time has passed before repair work is commenced.
Warning against unintended start
1.The motor can be brought to a stop by means of digital commands, bus commands, references or a local stop, while the frequency converter is connected to mains.
If personal safety considerations make it necessary to ensure that no unintended start occurs, these stop functions are not sufficient.
2.While parameters are being changed, the motor may start. Consequently, the stop key [STOP/RESET] must always be activated, following which data can be modified.
3.A motor that has been stopped may start if faults occur in the electronics of the VLT frequency converter, or if a temporary overload or a fault in the supply mains or the motor connection ceases.
Warning:
Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains. Also make sure that other voltage inputs have been disconnected, such as external 24 V DC, load sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic back-up.
Using VLT 5001-5006 220 and 500 V units: wait at least 4 minutes
Using VLT 5008-5500 220 and 500 V units: wait at least 15 minutes
Using VLT 5001-5005 550-600 V units: wait at least 4 minutes
Using VLT 5006-5022 550-600 V units: wait at least 15 minutes
Using VLT 5027-5250 550-600 V units: wait at least 30 minutes
MG.50.P3.02 - VLT is a registered Danfoss trademark |
3 |
Positioning Controller
Introduction
The Positioning Controller is an application option for the VLT 5000 and VLT 5000 Flux Series. It is based on the SyncPos option card.
The positioning controller can be used in a wide range of applications where a frequency converter is used for positioning. The controller holds information of up to 32 (64 in field bus mode) fixed positions. Relative positions can be added to each other by triggering a new relative positioning command when the controller is already executing a relative positioning command.
Full field bus support is now included meaning starting and stopping etc can be done via bus.
In field bus mode a “quickbus” mode is introduced to enable writing a target position directly. Hence an unlimited number of positions can be reached.
Positions are defined either relative to a fixed home position (absolute positions) or relative to other positions, or relative to a movable “touch probe” sensor.
An advanced mechanical brake controller is included. It is strongly advised to use this brake function as suppose to the VLT mechanical brake handler.
If absolute encoders must be used for positioning feedback in conjunction with VLT 5000 Flux this is now possible. Encoder input MK 3B can be programmed as option feedback input allowing the feedback encoder input MK 3D to be used for VLT 5000 Flux.
The encoder(s) connected can now hardware wise be monitored for open or short-circuits.
Last but not least VLT manual run mode is introduced. It is selected via parameter 711.
This manual consists of the following parts:
Hardware
Description of the electrical interface
Description of the available parameters
An application example!
Troubleshooting
Appendix
4 |
MG.50.P3.02 - VLT is a registered Danfoss trademark |
Positioning Controller
Hardware
VLT control card terminals
The terminals on the control card are allocated for positioning controller functions the following parameter settings should therefore not be changed in positioning mode (set-up 1):
Digital inputs 16, 17, 18, 19, 27, 29, 32 and 33
Parameters 300–303 and 305–307 are set to ”No operation” (default setting), then the inputs are ignored by the control card but used as inputs to the positioning controller.
Analogue inputs 53, 54 and 60
Parameters 308, 311 and 314 are set to ”No operation”, then the inputs are ignored by the control card but used as inputs to the positioning controller.
Digital/analogue outputs 42 and 45 (VLT 5000)
Parameters 319 and 321 are set to:
OPTION 0 … 20 mA [91] analogue output (default setting)
Digital outputs 26 and 46 - Analogue outputs 42 and 45(VLT 5000 Flux)
Parameters 319 and 321 are set to:
OPTION 0 … 20 mA [90] analogue output (default setting)
Parameters 341 and 355 are set to:
OPTION digital |
[90] digital output |
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(default setting) |
Technical data
Technical data on the control card terminals can be found in the VLT 5000 design guide.
Option card terminals
There are two encoder interfaces, which are covering the following functions:
•Primary Feedback encoder input
•Secondary encoder input
There are 8 digital inputs, 8 digital output and terminals for 5 V and 24 V supply. The functions and
technical data of the terminals are described in the following. |
B1 |
Z1 |
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Z1 |
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Terminal |
A1 |
A1 |
B1 |
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Incremental input |
A in |
A in |
B in |
B in |
Z in |
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Z in |
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Absolute input |
Clk out |
Clk out |
Data in |
Data in |
Not used |
Not used |
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Fig. 1 |
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Terminal |
A2 |
A2 |
B2 |
B1 |
Z2 |
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Z2 |
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Incremental input |
A in |
A in |
B in |
B in |
Z in |
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Z in |
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Absolute input |
Clk out |
Clk out |
Data in |
Data in |
Not used |
Not used |
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Fig. 2 |
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MG.50.P3.02 - VLT is a registered Danfoss trademark |
5 |
Positioning Controller
Terminal description
There are 4 terminal blocks, 2 with 10 poles and 2 with 8 poles. (See figure below)
MK3A |
Digital Inputs |
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MK3B |
Secondary feedback |
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I1 |
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I2 |
I3 |
I4 |
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I5 |
I6 |
I7 |
I8 |
24V |
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COM |
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5V |
COM |
A1 |
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A1 |
B1 |
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B1 |
Z1 |
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Z1 |
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MK3C |
Digital Outputs |
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MK3D |
Primary feedback |
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O1 |
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O2 |
O3 |
O4 |
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O5 |
O6 |
O7 |
O8 |
24V |
COM |
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5V |
COM |
A2 |
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A2 |
B2 |
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B2 |
Z2 |
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Z2 |
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Supply voltages
The option card is supplied by the internal 24 V DC supply of VLT 5000, but as the available power is limited it can be necessary to use an external 24 V DC supply.
The 24 V DC supply of VLT 5000 can supply a total of 420 mA including the load on the control card (terminal 12, 13 and output 42 and 45 + 26 and 46 for VLT 5000 Flux).
The 5 V output on the option card is generated from the 24 V supply. The maximum power on the 5 V side is 5 V * 280 mA = 1.4 W, this corresponds to app. 60 mA on the 24 V side.
When an external 24 V DC voltage source is used the internal 24 V supply from the control card must be disconnected, this is done by opening switch 1.1 and 1.2
Each digital input on the option card takes 8 mA. Each digital output on the option card can supply up to 0.7 A (external 24V-supply) depending on the load. The load from the 24 V supply (internal or external) can be calculated as follows:
8 mA * number of digital inputs
+
Load on digital outputs (mk3 C, O1 – O8)
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load on 5 V supply (mk3 B/D, 5 V/com)
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Load on control card
(24 V supply, terminal 12/13 and outputs, terminal 42/45, 26/46)
6 |
MG.50.P3.02 - VLT is a registered Danfoss trademark |
Positioning Controller
Encoder monitor
Both encoder interfaces are equipped with a monitoring circuit that can detect open circuit as well as short circuit of each encoder channel. Each encoder channel has a LED showing the status: Green light means ok, no light means fault.
Zero channel monitoring can be switched off by means of switch 1.4, this is necessary when using incremental encoders without Zero channel or absolute encoders. Switch 1.4 disables monitoring of both Zero channels. If disabling of only one of the two Zero channels is required (e.g. when using incremental Flux feedback encoder and absolute option feedback encoder) the unused Zero channel input must be connected to 5V/common as shown below.
An encoder fault will only result in an ”Option error” 92 if encoder monitoring is activated via parameter 713.
Note: Monitoring of the secondary feedback encoder is disabled when switch 1.3 is ”OFF”.
MG.50.P3.02 - VLT is a registered Danfoss trademark |
7 |
Positioning Controller
Option card layout
Option card layout showing the position of connectors and dip switch.
Encoder monitor secondary input,
channel A, B and Z:
LED off = Short or open circuit LED green = Ok.
5V monitor: LED off = no 5V
LED Green = 5V ok.
CPU monitor:
LED must flash at 1 Hz to indicate a running CPU system
Encoder monitor primary input,
channel A, B and Z:
LED off = Short or open circuit LED green = Ok.
SW 1.1: Connect(ON)/disconnect(OFF) 24 V from control card (see description of supply voltages). SW 1.2: Connect(ON)/disconnect(OFF) 24 V common from control card.
SW 1.3: Connect(ON)/disconnect(OFF) termination resistor for secondary encoder. Note: When OFF the secondary encoder monitor is disabled.
SW 1.4: Switch Z-channel encoder monitor ON/OFF for both encoder inputs.
Default setting of switch 1.1. - 1.4 is ON.
8 |
MG.50.P3.02 - VLT is a registered Danfoss trademark |
Positioning Controller
MG.50.P3.02 - VLT is a registered Danfoss trademark |
9 |
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Positioning Controller |
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Technical Data |
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Terminals: |
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Type.............................................................................................................. |
Plugs with screw connections |
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Maximum cable size ...................................................................................................... |
1.3 mm2 (AWG 16) |
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Digital inputs, MK3A: |
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Terminal designations ....................................................................................................................... |
I1 – I8 |
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Voltage level ............................................................................................ |
0 – 24 V DC (PNP positive logic) |
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Voltage threshold logical “0” ................................................................................................ |
.......... 5 V DC |
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Voltage threshold logical “1” ................................................................................................ |
........ 10 V DC |
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Maximum voltage .......................................................................................................................... |
28 V DC |
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Input impedance .................................................................................................................................. |
4 kΩ |
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Min. pulse duration (ON INT)........................................................................................................... |
1 msec |
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Galvanic isolation: All digital inputs are galvanically isolated by means of optocouplers, |
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but with the same common as the digital outputs. |
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Digital outputs, MK3C: |
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Terminal designations ................................................................................................................... |
O1 – O8 |
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Voltage level ............................................................................................................................ |
0 – 24 V DC |
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Maximum load ........................................................................................ |
0.7A (with external power supply) |
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Update rate...................................................................................................................................... |
1 msec |
Galvanic isolation: All digital outputs are galvanically isolated by means of optocouplers, but with the same common as the digital inputs.
External 24 V DC supply:
(see VLT 5000 manual)
Encoder input 1, MK3B (secondary):
Terminal designations .......................................................................................... |
A1, A1, B1, B1, Z1, Z1. |
Incremental: |
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Signal level ........................................................................................................................... |
5 V differential |
Signal type ..................................................................................................................... |
Linedriver, RS 422 |
Input impedance ............................................................................................. |
120 Ω (Dip switch 1.3 = ON) |
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> 24 kΩ (Dip switch 1.3 = OFF) |
Maximum frequency ...................................................................................... |
220 kHz (at 50 % duty cycle) |
Phase displacement between A and B.......................................................................................... |
90° ±30° |
Absolute: |
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Signal level ........................................................................................................................... |
5 V differential |
Signal type ............................................................................................................................................. |
SSI |
Data coding ................................................................................................................................ |
Gray code |
Data length ......................................................................................................................................... |
25 bit |
Parity.................................................................................................................................................... |
none |
Clock frequency.................................................................................................................. |
105 or 260 kHz |
Protocol ............................................................................................................................................... |
Gray |
Maximum positions per revolution....................................................................................................... |
8192 |
Maximum number of revolutions ......................................................................................................... |
4096 |
10 |
MG.50.P3.02 - VLT is a registered Danfoss trademark |
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Positioning Controller |
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Encoder input 2, MK3D (primary) |
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Terminal designations ......................................................................................... |
A2, A2 , B2, B2 , Z2, Z2 |
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Incremental: |
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Signal level ........................................................................................................................... |
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5 V differential |
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Signal type ...................................................................................................................... |
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Linedriver, RS422 |
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Input impedance ................................................................................................................................ |
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120 Ω |
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Maximum frequency ...................................................................................... |
220 kHz (at 50 % duty cycle) |
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Phase displacement between A and B.......................................................................................... |
90° ±30° |
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Absolute: |
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Signal level ........................................................................................................................... |
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5 V differential |
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Signal type ............................................................................................................................................. |
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SSI |
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Protocol ...................................................................................................................................... |
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Gray code |
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Data length ......................................................................................................................................... |
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25 bit |
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Parity.................................................................................................................................................... |
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none |
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Clock frequency.................................................................................................................. |
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105 or 260 kHz |
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Maximum positions per revolution....................................................................................................... |
8192 |
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Maximum number of revolutions ......................................................................................................... |
4096 |
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Encoder cable:
Cable type... |
Twisted pair and screened. Note: Please observe the prescriptions of the encoder supplier |
Cable length................................................................. |
Observe the prescriptions of the encoder supplier. |
Absolute encoder is tested ok up to 150 meter cable at 105 kHz clock and 100 m at 260 kHz clock.
(Tested with TR electronic encoder type CE-65 M 8192*4096 and appropriate cable prescribed by TR electronic.)
Maximum allowed time delay between clock and data signal measured at the controller terminals...........
................................................................................................................................ 105 kHz clock = 9µsec
............................................................................................................................ 260 kHz clock = 3.5 µsec
MG.50.P3.02 - VLT is a registered Danfoss trademark |
11 |
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Positioning Controller |
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Description of the electrical and field bus interface |
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Electrical interface VLT |
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Terminal |
Designation |
Description |
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24V power supply for switches etc. maximum load 200 mA |
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12 |
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24V DC |
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24V power supply for switches etc. maximum load 200 mA |
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13 |
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24V DC |
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Reference position index number bit 0 (least significant bit). |
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16 |
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Reference index Bit 0 |
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(LSB) |
Not used in field bus mode. |
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Reference position index number bit 1. |
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Reference index Bit 1 |
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Not used in field bus mode. |
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Reference position index number bit 2. |
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18 |
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Reference index Bit 2 |
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Not used in field bus mode. |
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Reference position index number bit 3. |
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19 |
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Reference index Bit 3 |
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Not used in field bus mode. |
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Ground for 24V is normally bridged with Terminal 39, but can be |
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20 |
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GND |
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set to “OFF” by means of Switch SW 4 on the control card. |
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Errors are cleared on the rising edge (must be “0” min. 1 ms. to |
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27 |
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Reset / ENABLE (error |
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clear) |
guarantee edge detection). Not used in field bus mode. |
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To enable operation, this input must be maintained at “1” in |
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either digital control mode or field bus control mode. |
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Reference position index number bit 4 (most significant bit). |
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29 |
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Reference index Bit 4 |
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(MSB) |
Not used in field bus mode. |
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While this input is high the drive executes the homing sequence. |
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32 |
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Go to HOME position |
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While this input is high no position or jog operations are carried |
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out. Any homing sequence is interrupted by a low state on this |
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input. |
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Not used in field bus mode. |
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Active on the rising edge (must be “0” min. 1 ms. to guarantee |
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33 |
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LATCH new reference |
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position index number |
edge detection): |
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Latches reference position index number specified on terminal |
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16, 17, 18, 19, 29 into memory. Digital output MK3C 4 – 8 is |
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changed to mirror the new reference index specified when using |
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digital input control. |
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Not used in field bus mode. |
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12 |
MG.50.P3.02 - VLT is a registered Danfoss trademark |
Positioning Controller
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Terminal |
Designation |
Description |
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Common terminal for Relay 01-03. |
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01 |
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COM; 240V AC/2A |
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Normal Open |
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02 |
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Connect to electro |
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mechanical brake |
Relay 01-03 is open (brake activated) during power off, and |
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NO |
start-up of the VLT 5000. It is always open after a “Quick Stop” |
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procedure or in connection with an error situation. Relay 01-03 |
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only closes in connection with motion procedures or if specified |
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in P715. |
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Normal Closed |
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03 |
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NC |
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Common terminal for Relay 04-05. |
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04 |
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COM; 50V AC/1A; 75V |
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DC/1A |
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Normal Closed |
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05 |
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Brake activated |
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NC |
Relay 04-05 is closed to indicate an activated electromechanical |
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brake. It is open to indicate a deactivated electromechanical |
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brake. |
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Not used in field bus control mode. |
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A high “1” signal is present when a rising edge has been |
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26 |
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Touch probe position |
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locked in (VLT 5000 |
detected on digital input 1 (terminal MK3A) and a target position |
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Flux only) |
is fixed in memory. |
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A low signal is present when no target position has yet been |
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determined. |
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Not used in field bus mode. |
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Ground for analogue inputs/outputs is normally bridged with |
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39 |
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GND |
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Terminal 20, but can be set to “OFF” by means of Switch SW 4 |
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on the control card. |
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A high “1” signal is present when a rising edge has been |
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42 |
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Touch probe position |
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locked in (VLT 5000 |
detected on digital input 1 (terminal MK3A) and a target position |
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Process only) |
is fixed in memory. |
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A low signal is present when no target position has yet been |
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determined. |
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Not used in field bus mode. |
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This output toggles continually as long as the program is active. |
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45 |
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Watchdog output in |
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(VLT 5000 Process |
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only) |
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This output toggles continually as long as the program is active. |
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46 |
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Watchdog output in |
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(VLT 5000 Flux only) |
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Power supply for manual JOG inputs (terminal 53 and 54) |
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50 |
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10V DC 17mA |
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± 10V-In |
When high (above 5V), the drive will travel with jogging speed |
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53 |
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Manual jog positive |
(P723) and ramp (P724) in the positive direction. |
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When low (below 5V), the drive will ramp down and stop if no |
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other motion procedure is activated. |
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Jog positive has higher priority than Jog negative |
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Not used in field bus mode. |
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MG.50.P3.02 - VLT is a registered Danfoss trademark |
13 |
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Positioning Controller |
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Terminal |
Designation |
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Description |
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± 10V-In |
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When high (above 5V), the drive will travel with jogging speed |
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54 |
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Manual jog negative |
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(P723) and ramp (P724) in the negative direction. When low |
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(below 5V), the drive will ramp down and stop if no other motion |
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procedure is activated. |
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Not used in field bus mode. |
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± 20mA-In |
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Not used |
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60 |
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Option card MK3A |
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Terminal |
Designation |
Description |
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Interrupt triggered on the rising edge. If this signal goes high |
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1 |
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Touch probe switch |
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input |
when no touch probe target position is currently locked (VLT 5000 |
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Process: terminal 42 low, VLT 5000 Flux: terminal 26 low), a new |
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touch probe target position is calculated and locked in memory. |
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Interrupt triggered on the falling edge. Triggers a HW limit error |
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2 |
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Positive HW limit |
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switch input |
and the drive is stopped according to P725. |
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Interrupt triggered on the falling edge. Triggers a HW limit error |
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3 |
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Negative HW limit |
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switch input |
and the drive is stopped according to P725. |
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Active high. Marks the HOME position in the application. |
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4 |
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HOME reference |
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switch input |
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Active high. Upon activation the drive goes to the specified target |
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5 |
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Go to the referenced |
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target position |
position. A low signal interrupts any positioning sequence. |
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Not used in field bus mode. |
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Active high. This input clears the home flag. This allows the user |
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6 |
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Reset home flag |
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to perform a second homing sequence. |
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Not used in field bus mode. |
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Active high. This input clears the touch probe position flag. The |
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7 |
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Reset touch probe |
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position |
reset is necessary to carry out a touch probe positioning |
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command to a new target position. |
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Not used in field bus mode. |
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Active low. This input activates the Quick Stop function. The drive |
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8 |
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Quick stop |
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is stopped according to the setting of P725. After that the |
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electromechanical brake is always activated when the “Quick |
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stop” input is activated regardless of the P715 setting. |
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9 |
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24V DC |
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10 |
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COM |
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14 |
MG.50.P3.02 - VLT is a registered Danfoss trademark |
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Positioning Controller |
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Option card MK3C |
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1 |
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Homing completed |
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Active high. This output is always high if an absolute encoder is |
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specified in P713 |
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Active high. This output is set when the target position is reached |
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2 |
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Referenced position |
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reached |
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according to the setting of P746. |
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Active high. This output is set every time an error occurs. It is |
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3 |
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Error occurred |
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cleared every time a successful error clear is carried out. This |
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output will remain high as long as the Power recovery function is |
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selected (P736) and active. |
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Active high. Mirror of the currently locked-in reference index bit 0. |
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4 |
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Reference index bit 0 |
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Not used in field bus mode. |
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Active high. Mirror of the currently locked-in reference index bit 1. |
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5 |
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Reference index bit 1 |
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Not used in field bus mode. |
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Active high. Mirror of the currently locked-in reference index bit 2. |
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6 |
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Reference index bit 2 |
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Not used in field bus mode. |
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Active high. Mirror of the currently locked-in reference index bit 3. |
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7 |
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Reference index bit 3 |
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Not used in field bus mode. |
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Active high. Mirror of the currently locked-in reference index bit 4. |
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8 |
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Reference index bit 4 |
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Not used in field bus mode. |
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9 |
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24V DC |
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10 |
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COM |
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Option card MK3B (secondary position feedback for absolute encoders when using VLT 5000 Flux)
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Encoder supply |
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1 |
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5V DC |
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Encoder supply |
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2 |
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COM |
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Incremental encoder |
Absolute encoder |
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A-track |
Clock out |
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3 |
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A1 |
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A-track inverted |
Clock out inverted |
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4 |
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/A1 |
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B-track |
Data in |
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5 |
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B1 |
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B-track inverted |
Data in inverted |
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6 |
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/B1 |
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Zero-track |
Not used |
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7 |
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Z1 |
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Zero-track inverted |
Not used |
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8 |
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/Z1 |
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|
MG.50.P3.02 - VLT is a registered Danfoss trademark |
15 |
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