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........................................................................................................................................................... 6

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................................................................................................................................................... 15

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.........................................................................................................................................................17

Data layout................................................................................................................................................................ 17

Description of the available parameters_____________________________________________ 20

Special LCP functions...................................................................................................................................................20

Description of parameters............................................................................................................................................. 21

An application example!_________________________________________________________ 35

Wiring diagram............................................................................................................................................................. 36

Basic set-up................................................................................................................................................................... 36

Parameter settings.........................................................................................................................................................38

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: For the North American market: The ETR functions provide class 20 motor overload protection in

6. Do not

7. Please note that the frequency converter has more voltage inputs than L1, L2 and L3, when load sharing

1. The motor can be brought to a stop by means of digital commands, bus commands, references or a

2. While parameters are being changed, the motor may start. Consequently, the stop key

3. A motor that has been stopped may start if faults occur in the electronics of the VLT frequency

The function is initialized at 1.16 x rated motor current and rated motor frequency.

accordance with NEC.

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.

(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

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.

must always be activated, following which data can be modified.

converter, or if a temporary overload or a fault in the supply mains or the motor connection ceases.

[STOP/RESET]

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

(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.

Terminal A1 Incremental input A in in A B in in B Z in in Z Absolute input Clk out out Clk Data in inData Not used Not used

Fig. 1

Terminal A2 Incremental input A in in A B in in B Z in in Z Absolute input Clk out out Clk Data in inData Not used Not used

Fig. 2

A1 B1 B1 Z1 Z1

A2 B2 B1 Z2 Z2

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

MK3B Secondary feedback

I1 I2 I3 I4 I5 I6 I7 I8 24V

COM 5V COM A1

MK3C Digital Outputs

MK3D Primary feedback

O1 O2 O3 O4 O5 O6 O7 O8 24V COM 5V COM A2

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) + load on 5 V supply

(mk3 B/D, 5 V/com) + 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 s

stem

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

Positioning Controller

Technical Data

Terminals:

Type..............................................................................................................Plugs with screw connections

Maximum cable size......................................................................................................1.3 mm

Digital inputs, MK3A:

Terminal designations .......................................................................................................................I1 – I8

Voltage level............................................................................................0 – 24 V DC (PNP positive logic)

Voltage threshold logical “0”............................................................................................................5 V DC

Voltage threshold logical “1”..........................................................................................................10 V DC

Maximum voltage .......................................................................................................................... 28 V DC

Input impedance..................................................................................................................................4 kΩ

Min. pulse duration (ON INT)...........................................................................................................1 msec

Galvanic isolation: All digital inputs are galvanically isolated by means of optocouplers, but with the same common as the digital outputs.

Digital outputs, MK3C:

Terminal designations ...................................................................................................................O1 – O8

Voltage level............................................................................................................................0 – 24 V DC

Maximum load ........................................................................................0.7A (with external power supply)

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:

Signal level ...........................................................................................................................5 V differential

Signal type.....................................................................................................................Linedriver, RS 422

Input impedance.............................................................................................120 Ω (Dip switch 1.3 = ON)

...................................................................................................................> 24 kΩ (Dip switch 1.3 = OFF)

Maximum frequency......................................................................................220 kHz (at 50 % duty cycle)

Phase displacement between A and B..........................................................................................90° ±30°

Absolute:

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

(AWG 16)

10 MG.50.P3.02 - VLT is a registered Danfoss trademark

Positioning Controller

Encoder input 2, MK3D (primary)

Terminal designations .........................................................................................A2, A2, B2, B2 , Z2, Z2

Incremental:

Signal level ...........................................................................................................................5 V differential

Signal type......................................................................................................................Linedriver, RS422

Input impedance................................................................................................................................120 Ω

Maximum frequency......................................................................................220 kHz (at 50 % duty cycle)

Phase displacement between A and B..........................................................................................90° ±30°

Absolute:

Signal level ...........................................................................................................................5 V differential

Signal type.............................................................................................................................................SSI

Protocol ......................................................................................................................................Gray code

Data length .........................................................................................................................................25 bit

Parity....................................................................................................................................................none

Clock frequency.................................................................................................................. 105 or 260 kHz

Maximum positions per revolution.......................................................................................................8192

Maximum number of revolutions.........................................................................................................4096

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

Positioning Controller

Description of the electrical and field bus interface

Electrical interface VLT

Terminal Designation Description

12 24V DC 13 24V DC 16 Reference index Bit 0

(LSB)

17 Reference index Bit 1

18 Reference index Bit 2

19 Reference index Bit 3

20 GND

27 Reset / ENABLE (error

clear)

29 Reference index Bit 4

(MSB)

24V power supply for switches etc. maximum load 200 mA 24V power supply for switches etc. maximum load 200 mA Reference position index number bit 0 (least significant bit).

Not used in field bus mode. Reference position index number bit 1. Not used in field bus mode. Reference position index number bit 2. Not used in field bus mode. Reference position index number bit 3. Not used in field bus mode. Ground for 24V is normally bridged with Terminal 39, but can be

set to “OFF” by means of Switch SW 4 on the control card. Errors are cleared on the rising edge (must be “0” min. 1 ms. to

guarantee edge detection). Not used in field bus mode. To enable operation, this input must be maintained at “1” in

either digital control mode or field bus control mode. Reference position index number bit 4 (most significant bit). Not used in field bus mode.

32 Go to HOME position

33 LATCH new reference

position index number

While this input is high the drive executes the homing sequence. While this input is high no position or jog operations are carried out. Any homing sequence is interrupted by a low state on this input.

Not used in field bus mode. Active on the rising edge (must be “0” min. 1 ms. to guarantee

edge detection): Latches reference position index number specified on terminal

16, 17, 18, 19, 29 into memory. Digital output MK3C 4 – 8 is changed to mirror the new reference index specified when using digital input control.

Not used in field bus mode.

12 MG.50.P3.02 - VLT is a registered Danfoss trademark

Positioning Controller

Terminal Designation Description

01 COM; 240V AC/2A 02 Connect to electro

mechanical brake NO

03 NC 04 COM; 50V AC/1A; 75V

DC/1A

05 Brake activated

26 Touch probe position

locked in (VLT 5000 Flux only)

Common terminal for Relay 01-03. Normal Open

Relay 01-03 is open (brake activated) during power off, and start-up of the VLT 5000. It is always open after a “Quick Stop” procedure or in connection with an error situation. Relay 01-03 only closes in connection with motion procedures or if specified in P715.

Normal Closed Common terminal for Relay 04-05.

Normal Closed Relay 04-05 is closed to indicate an activated electromechanical

brake. It is open to indicate a deactivated electromechanical brake.

Not used in field bus control mode. A high “1” signal is present when a rising edge has been

detected on digital input 1 (terminal MK3A) and a target position is fixed in memory.

A low signal is present when no target position has yet been determined.

39 GND

42 Touch probe position

locked in (VLT 5000 Process only)

45 Watchdog output in

(VLT 5000 Process only)

46 Watchdog output in

(VLT 5000 Flux only)

50 10V DC 17mA 53

± 10V-In

Manual jog positive

Not used in field bus mode. Ground for analogue inputs/outputs is normally bridged with

Terminal 20, but can be set to “OFF” by means of Switch SW 4 on the control card.

A high “1” signal is present when a rising edge has been detected on digital input 1 (terminal MK3A) and a target position is fixed in memory.

A low signal is present when no target position has yet been determined.

Not used in field bus mode. This output toggles continually as long as the program is active.

This output toggles continually as long as the program is active.

Power supply for manual JOG inputs (terminal 53 and 54) When high (above 5V), the drive will travel with jogging speed

(P723) and ramp (P724) in the positive direction. When low (below 5V), the drive will ramp down and stop if no

other motion procedure is activated. Jog positive has higher priority than Jog negative Not used in field bus mode.

MG.50.P3.02 - VLT is a registered Danfoss trademark 13

Terminal Designation Description

Positioning Controller

± 10V-In

Manual jog negative

± 20mA-In

When high (above 5V), the drive will travel with jogging speed (P723) and ramp (P724) in the negative direction. When low (below 5V), the drive will ramp down and stop if no other motion procedure is activated.

Not used in field bus mode. Not used

Option card MK3A

Terminal Designation Description

1 Touch probe switch

input

2 Positive HW limit

switch input

3 Negative HW limit

switch input

4 HOME reference

switch input

Interrupt triggered on the rising edge. If this signal goes high when no touch probe target position is currently locked (VLT 5000 Process: terminal 42 low, VLT 5000 Flux: terminal 26 low), a new touch probe target position is calculated and locked in memory.

Interrupt triggered on the falling edge. Triggers a HW limit error and the drive is stopped according to P725.

Active high. Marks the HOME position in the application.

5 Go to the referenced

target position

6 Reset home flag

7 Reset touch probe

position

8 Quick stop

9 24V DC

10 COM

Active high. Upon activation the drive goes to the specified target position. A low signal interrupts any positioning sequence.

Not used in field bus mode. Active high. This input clears the home flag. This allows the user

to perform a second homing sequence. Not used in field bus mode. Active high. This input clears the touch probe position flag. The

reset is necessary to carry out a touch probe positioning command to a new target position.

Not used in field bus mode. Active low. This input activates the Quick Stop function. The drive

is stopped according to the setting of P725. After that the electromechanical brake is always activated when the “Quick stop” input is activated regardless of the P715 setting.

14 MG.50.P3.02 - VLT is a registered Danfoss trademark

Option card MK3C

Positioning Controller

1 Homing completed

2 Referenced position

reached

3 Error occurred

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

Active high. This output is always high if an absolute encoder is specified in P713

Active high. This output is set when the target position is reached according to the setting of P746.

Active high. This output is set every time an error occurs. It is cleared every time a successful error clear is carried out. This output will remain high as long as the Power recovery function is selected (P736) and active.

Active high. Mirror of the currently locked-in reference index bit 0. Not used in field bus mode. Active high. Mirror of the currently locked-in reference index bit 1. Not used in field bus mode. Active high. Mirror of the currently locked-in reference index bit 2. Not used in field bus mode. Active high. Mirror of the currently locked-in reference index bit 3. Not used in field bus mode. Active high. Mirror of the currently locked-in reference index bit 4. Not used in field bus mode.

9 24V DC

10 COM

Option card MK3B (secondary position feedback for absolute encoders when using VLT 5000 Flux)

1 2

3 4 5 6 7 8

5V DC COM

A1 /A1 B1 /B1 Z1 /Z1

Encoder supply Encoder supply

Incremental encoder Absolute encoder

A-track Clock out A-track inverted Clock out inverted B-track Data in B-track inverted Data in inverted Zero-track Not used Zero-track inverted Not used

MG.50.P3.02 - VLT is a registered Danfoss trademark 15

+ 35 hidden pages