Danfoss VLT 6000 HVAC Operating guide

Download

Syncronising Controller MCO 350 Operating Instructions

Contents

1. Safety Regulation

Approvals 5

Symbols 5

Disposal Instruction 5

High Voltage 6

Safety Instructions 6

Avoid Unintended Start 7

Safe Stop of FC 300 7

Safe Stop Installation (FC 302 and FC 301 - A1 enclosure only) 9

IT Mains 9

2. Introduction

Function Description 11

Introduction 11

Speed Synchronisation 11

Position Synchronisation (angle synchronisation) 11

Marker Synchronisation

Mechanical Brake Control 12

Tips and Tricks for Synchronisation Tasks 12

Introduction 12

Example 12

Calculation with Insufficient Numerical Values 13

Example with Corrected Numerical Values 13

Hardware 14

VLT Control Card Terminals 14

Technical Data 14

Introduction 14

Option Card Terminals 14

Encoder Monitor 16

Option Card Layout 16

General Technical Data 17

Example of Encoder Interface connections 19

Description of Terminals 20

Standard RS 485-Interface 22

MCO 350 Terminal X57 22

MCO 350 Terminal X59 23

Description of Fieldbus Interface 23

Data Layout 23

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Contents

Syncronising Controller MCO 350 Operating

Instructions

3. Programming

Description of Parameters 27

4. Synchronisation

Speed Synchronisation 47

SyncStart 47

Function Diagrams for Speed Synchronisation 47

SyncStart 47

Up/Down Factor 48

Hold Function 49

Gear Changing 50

Changing the Gear Ratio with an Analogue Value 51

Application Examples - Admixture 51

Setting the Parameters 52

How to Check the Motor Connection 54

How to Test the Incremental Encoders 54

How to Optimise the Controller 55

How to Programme Synchronisation 56

Starting Synchronisation 58

Stopping Synchronisation 58

Fine Setting of the Gear Ratio 58

Switching to Another Gear Ratio 58

Error Procedure 58

Position Synchronisation 58

Position Synchronisation (angle synchronisation) 58

Function Diagrams for Position Synchronisation 60

SyncStart to a Stationary Master 60

SyncStart to a Running Master 60

Position Displacement with a Running Master 61

Application Example - Embossing Patterns on Mould 61

Description of Terminals and Terminal Configuration 62

Setting the Parameters 63

How to Check the Motor Connection 64

How to Test the Incremental Encoders

How to Optimise the Controller 65

How to Programme Synchronisation 66

Operation and Operating Functions 68

Marker Synchronisation - Function Diagrams for Marker Synchronisation 69

Marker Synchronising 69

SyncStart to a Running Master after Power ON 70

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

Marker Correction during Operation 71

Application Example - Packaging 71

Terminals and Terminal Configuration 72

Setting the Parameters 72

How to Check the Motor Connection 74

How to Test the Incremental Encoders 75

How to Optimise the Controller 75

How to Programme Synchronisation 77

Operation and Operating Functions 79

Contents

5. Appendix

Messages and Error Reference 81

Warnings and Error Messages 81

Errors 82

Parameter Overview 86

Glossary of Key Terms 96

Index

100

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

1. Safety Regulation

Syncronising Controller MCO 350 Operating

Instructions

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

1. Safety Regulation

1.1.1. Approvals

1.1.2. Symbols

Symbols used in these Operating Instructions.

NB!

Indicates something to be noted by the reader.

Indicates a general warning.

Indicates a high-voltage warning.

∗ Indicates default setting

1.1.3. Disposal Instruction

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

The FC 300 AutomationDrive DC link capacitors remain charged after power has been disconnected. To avoid electrical shock hazard, disconnect the FC 300 from the mains before carrying out maintenance. When using a PM-motor, make sure it is disconnected. Before doing service on the frequency converter wait at least the amount of time indicated below:

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

1. Safety Regulation

FC 300 380 - 500 V 0.25 - 7.5 kW 4 minutes

11 - 22 kW 15 minutes 30 - 75 kW 15 minutes 90 - 200 kW 20 minutes 250 - 400 kW 40 minutes 525 - 690 V 37 - 250 kW 20 minutes 315 - 560 kW 30 minutes

Syncronising Controller MCO 350 Operating

Instructions

MCO 350 Synchronising Controller for

VLT AutomationDrive FC 30x

Operating Instructions Software version: 1.1x

These Operating Instructions can be used for all MCO 350 Synchronising Controller for VLT AutomationDrive FC 30x frequency converters with software version 1.1x. The software version number can be seen from parameter 19-92.

1.1.4. High Voltage

The voltage of the frequency converter is dangerous whenever the frequency converter is connected to mains. Incorrect installation or operation of the motor or frequency converter may cause damage to the equipment, serious personal injury or death. The instructions in this manual must consequently be observed, as well as applicable local and national rules and safety regulations.

Installation in high altitudes

At altitudes above 2 km, please contact Danfoss Drives regarding PELV.

1.1.5. Safety Instructions

• Make sure the FC 300 is properly connected to earth.

• Do not remove mains plugs or motor plugs while the FC 300 is connected to mains.

• Protect users against supply voltage.

• Protect the motor against overloading according to national and local regulations.

• Motor overload protection is not included in the default settings. To add this function, set parameter 1-90 North American market: ETR functions provide class 20 motor overload protection, in accordance with NEC.

• The earth leakage current exceeds 3.5 mA.

• The [OFF] key is not a safety switch. It does not disconnect the FC 300 from mains.

Motor thermal protection

to value

ETR trip

ETR warning

. For the

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

1.1.6. General Warning

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 loadsharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic back-up. Using VLT Shorter time is allowed only if indicated on the nameplate for the specific unit.

Leakage Current

The earth leakage current from the FC 300 exceeds 3.5 mA. To ensure that the earth cable has a good mechanical connection to the earth connection (terminal 95), the cable cross section must be at least 10 mm separately.

Residual Current Device

This product can cause a D.C. current in the protective conductor. Where a residual current device (RCD) is used for extra protection, only an RCD of Type B (time delayed) shall be used on the supply side of this product. See also RCD Application Note MN.90.GX.02. Protective earthing of the FC 300 and the use of RCD's must always follow national and local regulations.

AutomationDrive FC 300: wait at least 15 minutes.

1. Safety Regulation

or 2 times rated earth wires terminated

1.1.7. Before Commencing Repair Work

1. Disconnect the frequency converter from mains

2. Wait for discharge of the DC-link. See period of time on the warning label.

3. Disconnect DC bus terminals 88 and 89

4. Remove motor cable

1.1.8. Avoid Unintended Start

While FC 300 is connected to mains, the motor can be started/stopped using digital commands, bus commands, references or via the Local Control Panel (LCP).

• Disconnect the FC 300 from mains whenever personal safety considerations make it necessary to avoid unintended start.

• To avoid unintended start, always activate the [OFF] key before changing parameters.

• An electronic fault, temporary overload, a fault in the mains supply, or lost motor connection may cause a stopped motor to start. FC 300 with Safe Stop (i.e. FC 301 in A1 enclosure and FC 302) provides protection against unintended start, if the Safe Stop Terminal 37 is on low voltage level or disconnected.

1.1.9. Safe Stop of FC 300

The FC 302, and also the FC301 in A1 enclosure, can perform the safety function

(As defined by IEC 61800-5-2) or

Off

Stop Category 0

Safe Torque

(as defined in EN 60204-1).

FC 301 A1 enclosure: When Safe Stop is included in the drive, position 18 of Type Code must be either T or U. If position 18 is B or X, Safe Stop Terminal 37 is not included! Example: Type Code for FC 301 A1 with Safe Stop: FC-301PK75T4Z20H4TGCXXXSXXXXA0BXCXXXXD0

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

1. Safety Regulation

It is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1. This functionality is called Safe Stop. Prior to integration and use of Safe Stop in an installation, a thorough risk analysis on the installation must be carried out in order to determine whether the Safe Stop functionality and safety category are appropriate and sufficient. In order to install and use the Safe Stop function in accordance with the requirements of Safety Category 3 in EN 954-1, the related information and instructions of the FC 300 Design Guide MG.33.BX.YY must be followed! The information and instructions of the Operating Instructions are not sufficient for a correct and safe use of the Safe Stop functionality!

Syncronising Controller MCO 350 Operating

Instructions

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

1.1.10. Safe Stop Installation (FC 302 and FC 301 - A1 enclosure only)

To carry out an installation of a Category 0 Stop (EN60204) in conformance with Safety Category 3 (EN954-1), follow these instructions:

1. The bridge (jumper) between Terminal 37 and 24 V DC must be removed. Cutting or breaking the jumper is not sufficient. Remove it entirely to avoid short-circuiting. See jumper on illustration.

2. Connect terminal 37 to 24 V DC by a short-circuit protected cable. The 24 V DC voltage supply must be interruptible by an EN954-1 Category 3 circuit interrupt device. If the interrupt device and the frequency converter are placed in the same installation panel, you can use a regular cable instead of a protected one.

3. Unless the FC302 itself has protection class IP54 and higher, it must be placed in an IP 54 enclosure. Consequently, FC301 A1 must always be placed in an IP 54 enclosure.

1. Safety Regulation

Illustration 1.1: Bridge jumper between terminal 37 and 24 VDC

The illustration below shows a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN 954-1). The circuit interrupt is caused by an opening door contact. The illustration also shows how to connect a non-safety related hardware coast.

Illustration 1.2: Illustration of the essential aspects of an installation to achieve a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN 954-1).

1.1.11. IT Mains

Par. 14-50 the RFI filter to ground. If this is done it will reduce the RFI performance to A2 level.

RFI 1

can on FC 102/202/302 be used to disconnect the internal RFI capacitors from

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

2. Introduction

Syncronising Controller MCO 350 Operating

Instructions

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

2. Introduction

The synchronising Controller is an application option for VLT Automation Drive FC 301 and 302.

The application option consists of two parts:

• synchronising controller part

• Test Run part

2.2. Function Description

2.2.1. Introduction

The synchronising controller can be used in any application where a drive is to operate synchronously with a master drive. The synchronising controller acts as an electronic shaft. The gear ratio is freely selectable and can also be changed during operation. The speed or the position is automatically and accurately controlled based on encoder feedback signals from both the master drive and the slave drives.

For synchronous operation of two or more drives you can use:

• Speed synchronisation

• Position synchronisation or

• Marker synchronisation

2.2.2. Speed Synchronisation

This is the simplest type of synchronisation. It can be used to compensate for speed differences, where it is not necessary to compensate for position errors.

The speed synchronisation between master and slave is done at maximum acceleration. To obtain optimum control the slave drive should therefore be set for a quicker acceleration speed than that of the master drive.

2.2.3. Position Synchronisation (angle synchronisation)

This is the electronic shaft ensuring a constant angle position ratio between master and slave drives. In case of a position deviation the slave drive is automatically accelerated to a speed level that is sufficient for regaining its position to the master drive (I-control like).

2.2.4. Marker Synchronisation

Marker synchronisation is an extended position control. Apart from ensuring a constant angle position between master and slave drives, marker synchronisation provides the option of using either an additional sensor or the zero track of the incremental encoder to compensate for any deviations between master and slave that may occur during operation. Using marker synchronisation the slave is position synchronised until the markers is reached and then the control compensates for the position difference between master marker and slave marker. This type of control is used where precision cannot be achieved by using a motor mounted encoder. That could be because of gearbox slack or other disturbance like belt elongation etc. that are not directly measurable. Similarly, with marker synchronisation, the slave drive does not need to be brought into the start position of the master drive at initial start-up, as this is affected automatically by marker correction.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating

2. Introduction

2.2.5. Mechanical Brake Control

The synchronising controller has a 24 V DC digital output (Output 4) and a relay output (Relay 1) to control an electromechanical brake; this is very useful in applications when a motor (shaft) must be kept in the same position for a longer time. This is usually the case in hoisting applications. The brake output will be active (low) in case of an error and when synchronisation is stopped, that means whenever motor control is switched off. The brake signal can be delayed when switched on and off in two individual parameters (par. 19-21

). Please note that the brake output is kept low in VLT mode (when input 8 is high). That

Delay

means the brake must be opened for example by means of the VLT mechanical brake function in set-up 2.

Brake on Delay

and par. 19-22

2.3. Tips and Tricks for Synchronisation Tasks

2.3.1. Introduction

When configuring the drives to be synchronised please keep in mind that the ratios should be of integer size. When using gear it is also important to know the number of teeth of the various gear stages (ask the gear manufacturer) as gears are normally set up with infinite gear ratios. When calculating the ratios between master and slave you must either use the figure PI for both of them or not use PI at all.

Instructions

Brake off

2.3.2. Example

A master drive with a 4-pole motor and an incremental encoder of 1024 increments/revolution works on a 2-stage gear. i is specified to be 30.33. At the gear output, a belt ratio of 40:20 is placed, driving a conveyor belt on the drive side with a diameter of 102mm. Via a 3-stage gear (i is specified to be 46,54) the slave drive is connected to an 8-toothed chain conveyor with a tooth pitch of 200mm.

Illustration 2.1: Calculation Example

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

2.3.3. Calculation with Insufficient Numerical Values

The master/slave gear ratio (numerator to denominator) is now calculated as follows:

2. Introduction

Master side = increments * i1 * i2 * power take off =

1024

incr x

Slave side = increments * i1 * power take off =

This gives a ratio of:

That gives a numerical value of 48,460995 for the numerator and 29,7856 for the denominator. Note: It is only possible to enter integer values. The most serious error: The master expression contains the value Pi, an infinite number sequence. Even with small numerical values for master and slave, the effect would always be that the drives drifted apart, as the Numerator: Denominator expression can never be an integer.

Another error arises from the gear ratios given, as the master drive was specified with a value of i = 30.33. The correct ratio is easily found by recalculating the individual numbers of teeth. The gear is a 2-stage gear; the first stage is formed from two pinions, 126 to 27, and the second stage from two pinions, 117 to 18.

The ratio is calculated as:

30.33

48, 460995

29, 7856

126x117

102

mm x

=30,33

= 48, 460995

1024

incr x

46.54

200

= 29, 7856

The specified value of 30.33 thus deviates by 0.1 ‰.

This may appear small; if this error is related to the encoder resolution, however, it will be seen that even this error is serious.

From the example it can be seen that it is important to maintain the exact values of the gear stages and to ensure that the data include Pi either for both drives or for none of them.

2.3.4. Example with Corrected Numerical Values

Master side: Gear 1st stage 126/27 2nd stage 117/18; belt ratio 40/20; drive shaft 100 mm Slave side: Gear 1st stage 97/10, 2nd stage 43/11, 3rd stage 27/22; effective diameter of the sprocket wheel 510mm

1024

Master side:

Slave side:

To remove Pi from the equations, substitute both equations into the combined formula:

1024

Masterside

Slaveside

Incr x

Incr x97x

11x22x510xπ

1024

126x117x20

18x40x102xπ

43x27

Incr x

126x117x20

18x40x102xπ

1024

Incr x

11x22x510xπ

97x43x27

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

2. Introduction

1024

Incr x

18x40x1024

126x117x20x510xπx10x11x22

Incr x97x

43x27x102

Syncronising Controller MCO 350 Operating

Instructions

Reduce by Pi and 1024 incr.:

Reduce further:

7x5x54x11x22x117

97x43x27

This gives a ratio of

This is an absolute value, as it contains no infinite number sequences and no rounded values.

4954950 3040659

126x117x20x510x10x11x22

18x40x97x43x27x102

2.4. Hardware

2.4.1. VLT Control Card Terminals

The terminals on the control card are allocated for synchronising controller functions the following parameter settings should therefore not be changed in synchronising mode (set-up 1):

Digital inputs 18, 19, 27, 32 and 33 Parameters 510–515 are set to control card but they are used as inputs for the synchronising controller.

No operation

(default setting), then the inputs are ignored by the

Analogue inputs 53, 54 Parameters 315, 316 and 317 are set to card but they are used as inputs to the synchronising controller.

Digital/analogue outputs 42 Parameters 650 are set to:

MCO 0 … 20 mA [52] analogue output

2.5. Technical Data

2.5.1. Introduction

Technical data on the control card terminals can be found in the VLT Automation Drive FC 300

Design Guide.

2.5.2. Option Card Terminals

There are two encoder interfaces, which coveers the following functions:

• Feedback encoder input

• Master encoder input / virtual master output

No function

, then the inputs are ignored by the control

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

2. Introduction

Terminal X55

Terminal Number Descriptive Name

Encoder 2 (Feedback)

1 + 24 V Supply 2 + 8 V Supply 3+ 5 V Supply 4 GND 5A 6 A not 7B 8 B not 9Z / Clock 10 Z / Clock not 11 Data 12 Data not

There are 2 digital input/output terminal blocks, 10 inputs and 8 outputs. (See figure below)

Terminal X57

Terminal Number Descriptive Name

Digital Inputs

1Digital Input 2 Digital Input 3Digital Input 4 Digital Input 5Digital Input 6 Digital Input 7Digital Input 8 Digital Input 9Digital Input 10 Digital Input

Terminal Number Descriptive Name

1 + 24 V Supply 2 NC 3+ 5 V Supply 4 GND 5A 6 A not 7B 8 B not 9Z / Clock 10 Z / Clock not 11 Data 12 Data not

Terminal Number Descriptive Name

1Digital Output 2 Digital Output

3Digital Output 4 Digital Output 5Digital Output 6 Digital Output 7Digital Output 8 Digital Output

Terminal X56

Encoder (Master)

Terminal X59

Digital Output

Terminal X58

Terminal Number Descriptive Name

24 V Supply

1 + 24 V Supply 2 GND

There are 2 digital input/output terminal blocks, 10 inputs and 8 outputs. (See figure below)

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

2. Introduction

Syncronising Controller MCO 350 Operating

Instructions

2.5.3. 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. An encoder fault will result in an ”Option error” 192 if encoder monitoring is activated via parameter 3239 (master) and 3209 (slave).

2.5.4. Option Card Layout

MCO 350 control terminals are plug connectors with screw terminals; the terminal blocks are duplicated to enable use of the same MCO 350 in all frame sizes. See illustration to locate the terminal blocks:

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

(1) is used with frame sizes A2 and A (2) is used with frame sizes A5, B1 and B2 X55 = Encoder 2 X56 = Encoder 1 X57 = Digital inputs X58 = 24VDC supply X59 = Digital outputs

2.5.5. General Technical Data

− All inputs, outputs and supply voltages are protected against short circuit.

− All inputs, outputs and supply voltages are galvanic isolated from high voltages such as mains

supply and motor voltage (PELV).

− Encoder signals are monitored during operation and standstill.

− All MCO 350 parameters including user defined application parameters are accessible via the

FC 300 Local Control Panel.

− MCO 350 can be combined with other FC 300 options, namely PROFIBUS and DeviceNet interface.

− All digital inputs and outputs are galvanic isolated from the internal electronics and can be sourced from an external 24V power supply.

2. Introduction

Connection Terminals: Maximum cross section, rigid wire 1.5 mm2/AWG 16 Maximum cross section, flexible wire 1.5 mm2/AWG 16 Maximum cross section, wire with enclosed core 1.5 mm2/AWG 16 Minimum cross section 0.082/AWG 28

Digital inputs: Number of programmable digital inputs 10 Terminal block X57 Terminal number 11),21),3,4,5,6,7,8,9,10 Logic PNP or NPN Voltage level 0 - 24 V DC Voltage level 0 - 24 V DC Voltage level, logic '0' PNP < 5 DC Voltage level, logic'1' PNP > 10 V DC Voltage level, logic '0' NPN Voltage level, logic '1' NPN Maximum voltage on input 28 V DC

> 19 V DC < 14 V DC

1) ) Selected in parameter 5-00 Digital I/O mode. The digital inputs are galvanic isolated from the internal electronics and can be sourced by an external 24V power supply.

Digital outputs: Number of programmable digital outputs 8 (6) Terminal block X59 Terminal number 11), 21),3,4,5,6,7,8 Driver type push/pull Logic PNP or NPN Voltage level 0 - 24 V DC Max. output current (sink or source) with internal power supply (total Σ) 40 mA Max. output current (sink or source) with external power supply (per output) 100 mA

Terminals X59-1 and X59-2 can be programmed as input, parameter 33-60.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

2. Introduction

Syncronising Controller MCO 350 Operating

Instructions

Combined Digital Inputs/Outputs: Number of digital outputs which can be used as digital inputs 2 Terminal block X59 Terminal number 1,2 Logic PNP or NPN Voltage level 0 - 24 V DC Voltage level 0 - 24 V DC Voltage level, logic '0' PNP < 10 V DC Voltage level, logic'1' PNP > 17 V DC Voltage level, logic '0' NPN > 13 V DC Voltage level, logic '1' NPN < 6 V DC Maximum voltage on input 28 V DC

1) Terminals X59-1 and X59-2 can be programmed as input, parameter 33-60.

2) Selected in parameter 5-00 Digital I/O mode.

24 V DC Supply Output Terminal block X58 Terminal number 1,2 Maximum load 65 mA

The internal 24V power supply can be disconnected via parameter 33-85, an external 24V power supply must then be connected to X58-1 and X58-2.

Encoder Inputs Number of encoder inputs 2 Terminal block X55 and X56 Terminal number 5,6,7,8,9,10,11,12 Input impedance 120Ω Maximum voltage on inputs 5 V DC Cable type Screened cable with a twisted pair of wires for each encoder channel Incremental encoder type RS422/TTL Maximum frequency 410 kHz Phase displacement between A and B 90°±30° Maximum cable length 300 m Absolute encoder type SSI Data coding Gray Data length 12 - 37 bit Clock frequency 78 kHz - 2 MHz Absolute encoder type SSI Maximum cable length 150 m

1) Always observe specifications/limitations prescribed by the encoder supplier.

2) 150 m cable is possible up to 500 kHz clock frequency, above 500 kHz cable length must be limited further.

Encoder Output Number of encoder outputs 1 Terminal block X56 Terminal number 5,6,7,8,9,10,11,12 Signal type RS 422Ω Maximum frequency 410 kHz Maximum number of slaves 31 (more with repeater) Maximum cable length 400 m

Encoder Output Number of supply voltages 3 Terminal block X55 and X56 Terminal number 1,2,3,4

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

2. Introduction

24 V, max load 250 mA 8 V, max load 250 mA 5 V, max load 400 mA Absolute encoder type SSI Maximum cable length 150 m

1) This is maximum load when only one supply voltage is used; when 2 or 3 supply voltages are used simultaneously the load must be reduced accordingly. The following must be observed: load24V + load8V + load5V ≤ 6W and load8V + load5V ≤ 2W.

2) 8 V is only available at terminal block X55.

2.6. Example of Encoder Interface connections

1) 2)

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

2. Introduction

2.7. Description of Terminals

I/O Number Designation Description

12 24 V DC 24V power supply for switches etc. 13 24 V DC 24V power supply for switches etc. 18 Disable Resync The Resync function (to be enabled by param

19 Home run Starts the homing. 20 GND Ground for 24 V. 27 Reset/Enable Error reset on rising edge. To enable opera-

32 Test run reverse Test run; Program 1:

Speed/Pos - Synchronous operation; Program 2:

Syncronising Controller MCO 350 Operating

Instructions

1924) can be temporarily disabled by setting this input to 1

tion, this input must be switched to “1”. “0” = motor coast.

Test run reverse at the speed defined in Parameter 19-01

In velocity synchronous mode (P. 1901 = 0, 3, 6 or 7) the gear ratio and thus the velocity of the slave can be changed by the value specified in parameter 1912. In position synchronous and marker synchronous operation (P. 1901 = 1, 2, 4 or 5), the position offset of the slave can be changed by the value specified in Parameter 1912. The sign of the value in parameter 1912 selects the offset type to be absolute or relative. Absolute offset means that the fixed offset of parameter 1912 is changed and this offset is executed when restarting synchronisation. Relative offset means that the actual slave position is displaced but the fixed offset of parameter 1912 is unchanged. This again means that the actual slave position is maintained when restarting synchronisation. Relative offset is useful when always changing the offset in the same direction as this would give a very high fixed offset when using absolute offset. This high fixed offset would then be executed when restarting synchronisation and the min. or max. limit of parameter 1912 would eventually be reached.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

I/O Number Designation Description

33 Test run forward Test run; Program 1:

Speed/Pos + Synchronous operation; Program 2:

01 COM; 240V AC/2A Relay output 1: 02 Electromechanical

brake: NO

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

DC/1A

05 NO 06 NC 39 GND Ground for analogue inputs/outputs. 42 Slave/Master velocity The output value is scaled to maximum slave

50 10V DC 15mA Power supply for reference value potentiome-

53 0 - 10V In Serves as reference input for the virtual mas-

54 0 - 10V In Serves as numerator for the gear ratio if “6” or

2. Introduction

Test run forward at the speed defined in Parameter 1901

In velocity synchronous mode (P. 1901 = 0, 3, 6 or 7) the gear ratio and thus the velocity of the slave can be changed by the value specified in parameter 19-12. In position synchronous and marker synchronous operation (par. 19-01 = 1, 2, 4 or 5), the position offset of the slave can be changed by the value specified in Parameter 1912. The sign of the value in parameter 1912 selects the offset type to be absolute or relative. Absolute offset means that the fixed offset of parameter 19-12 is changed and this offset is executed when restarting synchronisation. Relative offset means that the actual slave position is displaced but the fixed offset of parameter 19-12 is unchanged. This again means that the actual slave position is maintained when restarting synchronisation. Relative offset is useful when always changing the offset in the same direction as this would give a very high fixed offset when using absolute offset. This high fixed offset would then be executed when restarting synchronisation and the min. or max. limit of parameter 1912 would eventually be reached.

Relay 1 is open (brake activated) during power off, and start-up of the frequency converter. Afterwards the brake-control depends on the selected Sync mode.

Relay output 2: Function can be configured by means of Parameter 540.

velocity (parameter 32-80); The output can be selected between slave or master velocity by means of parameter 19-25

ter

ter if “0“ is selected in Parameter 19-16.

“7” is selected in parameter 19-01.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

2. Introduction

2.7.1. Standard RS 485-Interface

I/O Number Designation Description

61 Ground RS 485 Not used 68 RS 485-P Not used 69 RS 485-N Not used

2.7.2. MCO 350 Terminal X57

I/O Number Designation Description

1 I1 - Sync-Start Start and stop of synchronisation. Input

2 I2 - Take over gear ratio Activates the gear ratio selected at Ter-

3 I3 - Start/Stop virtual master Test run; Program 1: Start test run

4 I4 - Hold The drive is held at a programmable

5 I5 - Master marker input When using external marker signal for

6 I6 - Slave marker input When using external marker signal for

7 I7 - Measuring of the master marker

interval

Home switch Synchronous operation; Program

8 I8 - measuring of the slave marker

interval

I8 - VLT mode selection Synchronous operation; Program

9 10

Gear ratio 2 Gear ratio 2

Syncronising Controller MCO 350 Operating

Instructions

1 must be toggled if synchronisation was interrupted by an error or by input 27 (motor coast). Behaviour at stop can be selected via parameter 1901.

minals 9 and 10.

with virtual master. Synchronous op- eration; Program 2: The virtual master is accelerated up to the set pulse frequency, or stopped, with the set ramp time.

(parameter 1903) speed, or the current speed (parameter 1902 = 1). Synchronous control is not activated.

the master drive it must be connected to this input.

the slave drive it must be connected to this input.

Test run; Program 1:

Measuring of the master marker interval is started.

If a home position is to be attained, the home switch must be connected here. The signal must show a rising edge

Test run; Program 1:

Measurement of the slave marker interval is started.

Switches the VLT to normal frequency converter operation. The settings for this operating mode are to be made in Parameter set-up 2. Refer to the VLT Automation Drive Product Manual. Gear ratio least significant bit Gear ratio most significant bit

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

2.7.3. MCO 350 Terminal X59

I/O Number Designation Description

1 O1 - READY Ready, i.e. for the number of marker signals that were

2 O2 - FAULT Fault, i.e. for the number of marker signals that were

3 O3 - ACCURACY The drive runs within the tolerance specified in Param-

4 O4 - Brake control This output can be used to control a mechanical brake.

5 O5 - Saving This output stays high while saving is in progress. The

6 O6 - Drive running Signal “1” when the drive is running. 7 O7 - Home reached If the data value “1” was chosen in Parameter 3300, this

8 O8 - Ready, no error The synchronising controller is ready for operation.

2. Introduction

specified in Parameter 3325, the slave drive has run within the tolerance (Accuracy).

specified in Parameter 3324, the slave drive has run outside the tolerance (Accuracy). OR when the number of marker signals have been missing when marker monitor is activated in parameter 1923.

eter 3313.

“0” means that the brake must be closed (braking) “1” means that the brake must be open (not braking)

saving is initiated by Parameter 1900, Input 4 or fieldbus bit 4.

output shows “1” when homing is completed.

2.8. Description of Fieldbus Interface

NB!

This section is only relevant if the VLT is equipped with a Field bus interface (option) as well as the synchronising controller.

The synchronising controller can be controlled via the digital/analogue inputs or via field bus. The control source can be selected individually for test-run and synchronising in the parameters 1919 (test-run) and 1920 (synchronising). There can only be one control source at a time meaning that the digital/analogue inputs are inactive when Field bus is selected as control source and visa versa. The only exception is input 27, which is always stop/enable also when Field bus is selected as control source. In synchronising mode three signals are only available as digital inputs even when Field bus is selected as control source that is the marker signals for marker synchronisation and the Home switch. This is because these signals are too time-critical for Field bus control. Status signals are always available on the digital/analogue outputs but they are only available via Field bus when Field bus is selected as control source.

2.8.1. Data Layout

Control and status signals are transferred via the so-called process data channel (PCD) of the various fieldbus interfaces. The telegram structure and the available number of data words depends on the Fieldbus used, please refer to the manual of the Fieldbus option in use for further details. The below example is based on the layout of a PROFIBUS telegram, the so-called PPO:

Example using PROFIBUS PPO type 5:

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

2. Introduction

Fieldbus Control Signals Fieldbus [word.bit]

1.1 Not used Start of synchronisation 1

1.2 Not used Take over gear ratio 2

1.3 Start/stop virtual master Start/stop virtual master 3

1.4 Not used Save gear-settings (only

1.5 Not used VLT-mode 8

1.6 Not used Gear-ratio select LSB 9

1.7 Not used Gear-ratio select MSB 10

1.8 Not used Start homing 19

1.9 Reset/enable Reset/enable 27

1.10 Not used Hold 29

1.11 Not used Speed/position - 32

1.12 Not used Speed/position + 33

1.13 Measuring master marker

1.14 Measuring slave marker

1.15 Test-run left Not used 32

1.16 Test-run right Virtual master negative di-

2 Virtual master reference* Virtual master reference* 53

Syncronising Controller MCO 350 Operating

Instructions

Test Run synchronising Corresponding Input

possible when stopped!)

Not used 7

distance

Not used 8

distance

rection

*) Only when par. 19-16 = 2.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

Fieldbus Status Signals Fieldbus [word.bit]

1.1 Not used Ready 1

1.2 Not used Fault 2

1.3 Not used Accuracy 3

1.5 Saving Saving 5

1.6 Running Running 6

1.7 Not used Home reached 7

1.8 Ready, no error Ready, no error 8 2 Track error Track error Par. 19-93 (testrun)/

3 Not used synchronising error Par. 19-93 4 Not used Status of synchronisation Par. 34-60 5 Slave speed Slave speed Par. 19-94 6 Master speed Master speed Par. 19-95

Test Run synchronising Corresponding Output/Parame-

2. Introduction

ter

Par. 19-96 (synchronising)

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

3. Programming

Syncronising Controller MCO 350 Operating

Instructions

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

3. Programming

3.1. Description of Parameters

3. Programming

19-00 Store data

Option: Function:

Here you can save the gear-ratio data permanently in the EEPROM

[0] no function

[1] Gear data is being

saved

19-01 Test run; Program 1

Option: Function:

19-01 Synchronous operation; Program 2

Option: Function:

While saving, the value remains “1“; when saving is finished, the value automatically reverts to “0“. At the same time, during saving, Output O5 “Saving“ is set to “1“. Saving is not possible during operation, but only in the stopped state.

Test run speed: Specify here the speed at which the test runs are to be carried out. The speed is specified as a percentage of the maximum speed defined in par. 32-80.

Type of operation: Select here the type of operation of the synchronising Controller

[0] Speed synchronising

[1] Position synchronising

[2] Marker synchronising

[3] Speed synchronising with motor coast after stop

[4] Position synchronising with motor coast after stop

[5] Marker synchronising with motor coast after stop

[6] . Speed synchronising with motor coast after stop and setting of

gear ratio via analogue input 54

[7] Speed synchronising with setting of gear ratio via analogue in-

put 54.

With the selections “0” - “2” and “7” the motor is always controlled keeping the actual position when stopping synchronisation (input 1 = “0”).

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

3. Programming

19-02 Test run; Program 1

Option: Function:

[0] If “0“ is set, the slave drive is brought to the speed set in par.

[1] If “1“ is set, the actual speed is maintained. While these signals

Syncronising Controller MCO 350 Operating

Instructions

Test run acceleration: Specify here the acceleration for the test run as a percentage of the maximum acceleration. 100 % means that the drive accelerates with the minimum ramp specified in par. 32- 8 1 . 5 0 % m e a ns that the drive only proceeds with half the acceleration, i.e. the acceleration takes twice as long as with the minimum ramp specified in par. 32-81.

Synchronous operation; Program 2: Hold function:

If the contact at Terminal 29 is closed, the slave drive is disengaged, i.e. it no longer runs in synchrony with the master.

19-03.

are present, the current Hold speed can be changed by means of Inputs 32 and 33.

19-03 Test run; Program 1

Option: Function:

Test run distance: Specify the distance for the test run in quad

counts.

Synchronous operation; Program 2: Hold speed: If Hold function “0“ was selected, enter here the

speed as a percentage of the maximum speed (par. 32-80).

19-04 Test run, program 1: synchronising type (Sync type)

Option: Function:

This parameter is used to specify the type of synchronisation used when optimising the PID controller for synchronisation by means of the virtual master.

[0] Speed synchronising Select “0” if speed synchronising should be used in synchronous

mode

[1] Position synchronis-

ing

Select “1” if position or marker synchronising should be used in synchronous mode.

Synchronous operation; Program 2: Delta hold speed: Specify the percentage by which the hold

speed is to change when Input 32 or 33 is activated during Hold mode.

19-05 Test run, program 1: Activate feed forward and PID calculation (FFVEL calc.)

Option: Function:

This parameter is used to trigger automatic calculation of the optimal value for velocity feed forward (par. 32-65) as well as PID sample time (par. 32-69), proportional factor (par. 32-60) and derivative factor (par. 32-61).

[0] No action

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

3. Programming

[1] Activate calculation of

velocity feed forward (par. 3265)

[2] Activate calculation of velocity feed forward (par. 32-65), PID

The parameter value is automatically reset to “0” when the calculation is done.

NB!

If any of the above mentioned parameters are changed the calculation must be repeated.

The calculation is based on the following parameters that must be set before the calculation is started: Par. 32-00/32-02 “Slave encoder type”,

Par. 3201/3203 “Slave encoder resolution”, Par. 32-80 “encoder velocity” Par. 32-69 “PID sample time”.

sample time (par. 32-69), Proportional factor (par. 32-60) and derivative factor (par. 32-61). The calculations are based on the following parameters that must be set before the calculation is started: Par. 32-00/32-02 “Slave encoder type”, Par. 32-01/32-03 “Slave encoder resolution”, Par. 32-80 “Maximum velocity”,

Synchronous operation; Program 2: Gear ratio no.: Select the number of the gear ratio that you want to edit in parameters 19-06

to 19-10.

19-06 Gear ratio numerator

Option: Function:

Enter the numerator for the gear ratio selected in par. 19-05. Ensure that the gear ratio matches the marker ratio.

19-07 Gear ratio denominator

Option: Function:

Enter the denominator for the gear ratio selected in par. 19-05. Ensure that the gear ratio matches the marker ratio.

19-08 Slave marker quantity

Option: Function:

Enter the number of slave markers for the marker ratio. Ensure that the gear ratio matches the marker ratio.

MG.33.Q1.02 - VLT

NB!

This parameter is only used in marker synchronising mode (par. 19-01 = 2 or 5).

is a registered Danfoss trademark

3. Programming

19-09 Master marker quantity

Option: Function:

19-10 Fixed offset

Option: Function:

Syncronising Controller MCO 350 Operating

Instructions

Enter the number of master markers for the marker ratio. Ensure that the marker ratio matches the gear ratio.

NB!

This parameter is only used in marker synchronising mode (par. 1901 = 2 or 5).

Enter the position offset. This makes it possible to compensate for differences in the placing of the encoder or markers. Input is in quad counts.

Offset_slave

19-11 Step time

Option: Function:

Enter the time after which

• with the Hold function activated and the presence of

• in the engaged state, without Hold, the next change of

Input is in milliseconds.

19-12 Step Length

Option: Function:

Enter the step value for changing the position offset in quad counts. Par. 19-10 is changed accordingly. The sign of this parameter selects the offset type when changing the offset via the position + and - inputs:

A positive value selects absolute offset (see Input 32/33). A negative value selects relative offset (see Input 32/33).

NB!

Offset is related to the master position. Offset related to the slave position can be calculated as follows:

O ffest x Parameter

one of the signals at Terminal 32 or 33, a change in speed takes place;

the slave position takes place.

Parameter

19 − 06

19 − 07

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

19-13 Slave speed factor

Option: Function:

19-14 Master speed factor

Option: Function:

3. Programming

Enter here the factor by which the slave speed must be scaled, so that the desired value is displayed. The following formula applies for calculation of the factor:

400

Factor

Example: Resolution 1024 PPR, desired display 100 at 15001/ min

Factor

Enter here the factor by which the master speed must be scaled, so that desired value is displayed. The formula for calculation of the factor is:

Factor

Set

1500

min

Set

x Slaveencoder_resolution

xDisplay_value

400x1024

60x100

400

x Slaveencoder_resolution

xDisplay_value

Incr

Rev

. .

= 102400

19-15 synchronising error display factor

Option: Function:

Enter the factor by which the error must be scaled, so that the desired value is displayed. The formula for calculation of the factor is:

Speed synchronisation: The factor should be 100, the synchronising error is then displayed in RPM related to the slave.

Position synchronisation:

400

Factor

Example: Resolution 1024 PPR, user unit is 100 mm/revolution

Factor

19-16 Virtual master reference value

Option: Function:

Select the type of reference value for the virtual master.

[0] reference value signal 0.. *10V via Terminal 53,

Set

xSlaveencoder_resolution

U ser unit

400x1024

100

= 4096

[1] reference value can be set via par. 310 subindex 1.

[2] reference value is set via Field bus (PCD 2). +/- 1000 corre-

sponds to maximum virtual master velocity (par. 1918).

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

3. Programming

19-17 Virtual master acceleration

Option: Function:

Syncronising Controller MCO 350 Operating

Instructions

Enter here the acceleration for the virtual master in Hz/s.

Virtual master acceleration =

Pulsfrequenz Hz

t s

Example: The virtual master must correspond to an encoder with 1024 inc/rotation. The maximum speed of 25 encoder rotations per second must be attained in 1 second.

Virtual master acceleration =

1024

19-18 Virtual master maximum speed

Option: Function:

Enter here the maximum speed of the virtual master in Hz.

Virtual master maximum speed =

Increments

Rev

Example: The maximum virtual master signal must correspond to an incremental encoder with 1024 inc/rotation at a rotational speed of 50 rotations/s.

Virtual master maximum speed =

1024

Incr

Rev

= 25600

Rev

= 51200 1

19-19 Control source test run (Contr. testrun)

Option: Function:

This parameter is used to select the control source in test run mode (par. 33-80 = “1”). There can only be one control source at a time: Digital inputs or field bus control word. Only exception is input 27 which is always stop also with field-bus control.

When digital control is selected status signals are updated on the digital outputs, when field bus control is selected status signals are updated on digital outputs as well as field bus.

[0] Digital Inputs “0” means that all control commands are activated via the digital

inputs according to the description of the terminals.

[1] Fieldbus “1” means that all control commands are activated via the field

bus control word according to the description of field bus control.

NB!

The new control source selected in this parameter is not active before next power up (power cycle).

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

19-20 Control source synchronising (Contr. synchron)

Option: Function:

[0] Digital Inputs means that all control commands are activated via the digital

[1] Fieldbus means that all control commands are activated via the field bus

3. Programming

This parameter is used to select the control source in synchronising mode (par. 33-80 = “2”). There can only be one control source at a time: Digital inputs or field bus control word. Only exception is input 27 which is always stop also with field-bus control.

When digital control is selected status signals are updated on the digital outputs, when field bus control is selected status signals are updated on digital outputs as well as field bus.

inputs according to the description of the terminals.

control word according to the description of field bus control.

NB!

The new control source selected in this parameter is not active before next power up (power cycle).

19-21 Brake on delay (Brake on delay)

Range: Function:

This parameter is used to specify the delay time between closing the mechanical brake (output 4) and disabling motor control (motor coast). This is necessary to avoid loosing the load because of the reaction time of the mechanical brake.

[0...5000 msec.] The value must be set according to the reaction time of the me-

chanical brake.

19-22 Brake off delay (Brake off delay)

Range: Function:

This parameter is used to specify the delay time between activating motor control and opening the mechanical brake (output

4). This is necessary to avoid loosing the load because of the reaction time of the mechanical brake.

[0...5000 msec.] The value must be set according to the reaction time of the me-

chanical brake.

19-23 Marker monitor

Option: Function:

This parameter specifies the behaviour when markers are missing in Marker synchronising mode (par. 1901 = 2 or 5)

[0] Output 2 Fault is set when “not accuracy” for x number of markers (x =

par. 33-24).

[1] Output 2 Fault is set when “not accuracy” for x number of markers (x =

par. 33-24) OR when x number of markers are missing.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

3. Programming

[2] Output 2 Fault is set when “not accuracy” for x number of markers (x =

19-24 Resync.

Option: Function:

[0] Inactive

[1] Active

Syncronising Controller MCO 350 Operating

Instructions

par. 33-24) and Output 2, fault is set and the error handler is called when x number of markers are missing.

NB!

This function can only be used if marker windows are used (par. 33-22 and 33-21).

With resync active synchronisation will remain active while the slave is stopped (Input 1 and/or Input 27 = 0). The actual synchronising error will be corrected with the set velocity and acceleration when restarting synchronisation.

19-25 Select Analogue output 42

Option: Function:

[0] Slave speed

[1] Master speed

19-92 Software version number

Option: Function:

The software version of the synchronising controller is displayed here.

19-93 Test run; Program 1

Option: Function:

Track error“: The track error is displayed in quad counts. Synchronous operation; Program 2: “Sync-error”: The syn-

chronisation error is displayed with the value calculated in par. 19-15.

19-94 Slave speed (read only)

Option: Function:

The slave speed is displayed with the value calculated in par. 19-13.

19-95 Master speed (read only)

Option: Function:

The master speed is displayed with the value calculated in par. 19-14.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

19-96 Track error (read only)

Option: Function:

32-00 Incremental Signal Type (Slave)

Option: Function:

[0] None Choose if an absolute encoder is used

[1] RS422 (TTL/Line driv-

er)

[2] Sinusoidal 1 Vpp Choose if 1 V peak to peak analog incremental encoder is used.

32-01 Incremental Resolution (Slave)

Option: Function:

3. Programming

“Track-error”: The synchronisation error is displayed with the value calculated in par. 19-15.

Enter the pulses per revolution

32-02 Absolute Protocol (Slave)

Option: Function:

[0] None choose if an incremental encoder is used.

[1] SSI.

[2] SSI with filter choose if the encoder signal is unstable.

32-03 Absolute Resolution (Slave)

Option: Function:

Enter the positions per revolution.

32-05 Absolute Encoder Data Length (Slave)

Option: Function:

Enter the number of data bits of the connected absolute encoder.

32-06 Absolute Encoder Clock Frequency (Slave)

Option: Function:

Enter the clock frequency according to the encoder manufacturer specifications.

32-07 Absolute Encoder Clock Generation (Slave)

Option: Function:

Off Clock signal is not generated.

On Clock signal is generated, this is most commonly used.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

3. Programming

32-08 Absolute Encoder Cable Length (Slave)

Option: Function:

32-09 Encoder Monitoring (Slave)

Option: Function:

32-10 Direction of rotation

Option: Function:

[1] standard, position is counting positive when the drive is running

Syncronising Controller MCO 350 Operating

Instructions

Enter the cable length of the encoder, please note that 300 meters is the maximum.

Off No monitoring of encoder hardware.

On Monitoring of encoder hardware, open- or short-curcuit will

generate error 192.

forward.

[3] position is counting negative when the drive is running forward.

[2] as “1”, but with opposite sign of the reference to the drive. This

can be used as alternative to swapping two motor phases if direction of motor rotation is wrong.

[4] as “3”, but with opposite sign of the reference to the drive. This

can be used as alternative to swapping two motor phases if direction of motor rotation is wrong.

32-30 Incremental Signal Type (Master)

Option: Function:

[0] None choose if an absolute encoder is used

[1] RS422 (TTL/Line driv-

er).

[2] Sinusoidal 1 Vpp choose if 1 V peak to peak analog incremental encoder is used.

32-31 Incremental Resolution (Master)

Option: Function:

Enter the pulses per revolution.

32-32 Absolute Protocol (Master)

Option: Function:

[0] None choose if an incremental encoder is used.

[1] SSI.

[2] SSI with filter choose if the encoder signal is unstable.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

32-33 Absolute Resolution (Master)

Option: Function:

32-35 Absolute Encoder Data Length (Master)

Option: Function:

32-36 Absolute Encoder Clock Frequency (Master)

Option: Function:

32-37 Absolute Encoder Clock Generation (Master)

Option: Function:

Off Clock signal is not generated.

3. Programming

Enter the positions per revolution.

Enter the number of data bits of the connected absolute encoder.

Enter the clock frequency according to the encoder manufacturer specifications.

On Clock signal is generated, this is most commonly used.

32-38 Absolute Encoder Cable Length (Master)

Option: Function:

Enter the cable length of the encoder, please note that 300 meters is the maximum.

32-39 Encoder Monitoring (Master)

Option: Function:

Off No monitoring of encoder hardware.

On Monitoring of encoder harware, open- or short-curcuit will gen-

erate O.ERR_192.

32-40 Encoder Termination (Master)

Option: Function:

If only one encoder is connected then select “ON”, for all other configurations select “OFF”

32-60 P-portion of the synchronising controller

Option: Function:

Setting: see Examples.

32-61 D-portion of the synchronising controller

Option: Function:

Setting: see Examples.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

3. Programming

32-62 I-portion of the synchronising controller

Option: Function:

32-63 Limitation for I-portion

Option: Function:

32-64 Band width for PID controller

Option: Function:

32-65 Velocity feed forward

Option: Function:

Syncronising Controller MCO 350 Operating

Instructions

Setting: see Examples.

32-66 Acceleration feed forward

Option: Function:

Setting: see Examples.

32-67 Maximum track error

Option: Function:

Enter here the maximum track error. This is the permitted error between the calculated position and the feedback position. If the value is exceeded, the drive stops and displays the error message: O.ERR_108 “Position error“. The value should be set higher than the permitted tolerance range ACCURACY in par. 33-13. Input in quad counts.

32-68 Reversing behaviour

Option: Function:

[0] means that the slave drive may always reverse, e.g. after over-

shooting the target position.

[1] the slave drive may only reverse when the master is reversing.

[2] the slave drive may never reverse.

32-69 PID-sample time

Option: Function:

The parameter is setting the sample time of the control algorithm. The value should be increased if:

• The pulse frequency is very low, e.g. 1 to 2 quad

MG.33.Q1.02 - VLT

counts per sample time (you need at least 10 to 20 quad counts per sample time).

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

32-80 Maximum speed

Option: Function:

3. Programming

• The system is very slow and heavy (high inertia). Controlling systems with 1 ms can make big motors vibrate.

The correct value can be calculated automatically, see test run par. 19-05.

NB!

The parameter setting has direct influence on the PID loop; if for example the Sample time is doubled, the P-portion (par. 32-60) also has the double effect.

Enter here the maximum speed of the slave drive, measured at the slave encoder in revolutions per minute.

32-81 Minimum ramp

Option: Function:

Enter here the minimum possible ramp in which the slave drive can accelerate from 0 to the speed specified in par. 3280. This is input in milliseconds.

33-00 Home_Force

Option: Function:

If this param is set to 1, a home has to be carried out before sync can start

33-02 Home acceleration

Option: Function:

Specify here the acceleration for the homing as a percentage of the maximum acceleration. 100% means that the drive accelerates with the minimum ramp specified in par. 32-81. 50% means that the drive only proceeds with half the acceleration, i.e. the acceleration takes twice as long as the minimum ramp specified in par. 32-81.

33-03 Velocity of Home Motion

Option: Function:

In % of the Maximum Velocity 3280

33-04 Synchronous operation; Program 2

Option: Function:

[0] The homing only has to be carried out after power up

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

3. Programming

[1-3] The homing has to be carried out before every sync start.

33-13 Synchronous operation; Program 2

Option: Function:

33-14 Synchronous operation; Program 2

Option: Function:

Syncronising Controller MCO 350 Operating

Accuracy: This parameter specifies that maximum master – slave position deviance, this is used to control the accuracy output (O 3). The accuracy output will only be “1” if the actual master – slave position deviance is within this value. In velocity synchronisation (par. 19-01 = 0, 3, 6 or 7) the value must be set in RPM (Rounds Per Minute) in all other modes it must be set in quad counts. With a negative value in this parameter the synchronising error (par. 19-93) is shown with a sign otherwise the synchronising error is unsigned.

M-S tolerance speed: Specify here the tolerated speed deviation between master and slave while synchronising. The following apply here:

Slave must catch up:

mitted speed or at the speed: master speed + master speed * M-S tolerance speed / 100, whichever of the two is lowest.

Slave must slow down:

master speed - master speed * M-S tolerance speed / 100. If the M-S tolerance speed value is set to 50, the slave will not travel more slowly than half the master speed.

The slave can travel at the maximum per-

The slave travels at the minimum speed:

Instructions

33-17 Marker interval at the master

Option: Function:

Enter here the interval between two markers at the master drive in quad counts. If this value is not known, it can be determined during the test run. For procedure, see as described in the section “Testing the incremental encoders“ in the Loading belt, Marker synchronisation, application example.

33-18 Marker interval at the slave

Option: Function:

Enter here the interval between two markers at the slave drive in quad counts. If this value is not known, it can be determined during the test run. For procedure, see description in the section “Testing the incremental encoders“ in the packaging application example.

NB!

This parameter is only used in marker synchronising mode (par. 19-01 = 2 or 5).

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

3. Programming

NB!

This parameter is only used in marker synchronising mode (par. 19-01 = 2 or 5).

33-19 Master marker type

Option: Function:

[0] rising edge of the zero

track

[1] falling edge of the

zero track

[2] rising edge at I5

[1] falling edge of the

zero track

[3] falling edge at I5

33-20 Slave marker type

Option: Function:

[0] rising edge of the zero

track

[1] falling edge of the

zero track

[2] rising edge at I6

[1] falling edge of the

zero track

[3] falling edge at I6

Select here the type of marker signal for the master drive

Select here the type of marker signal for the slave drive

NB!

This parameter is only used in marker synchronising mode (par. 19-01 = 2 or 5).

NB!

This parameter is only used in marker synchronising mode (par. 19-01 = 2 or 5).

33-21 Marker window master

Option: Function:

Enter how large the permitted tolerance for the occurrence of the marker is. The factory setting “0” means all markers are used. At every other setting only those markers are accepted which are within the window. Example: Marker interval = 30000 and marker window = 1000. Only markers with an interval of 29000 to 31000 is accepted.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

3. Programming

Syncronising Controller MCO 350 Operating

Instructions

NB!

This parameter is only used in marker synchronising mode (par. 19-01 = 2 or 5).

33-22 Marker window slave

Option: Function:

NB!

This parameter is only used in marker synchronising mode (par. 1901 = 2 or 5).

33-23 Marker synchronous operation

Option: Function:

[0] last marker pulse, i.e. the slave synchronises to the last detected

marker pulse. This is achieved by accelerating to this position.

[1] next marker pulse: The slave waits for the next marker pulse

and synchronises to it.

[2] once the master speed is reached marker correction to next fol-

lowing markers take place(may catch up slow down).

[3] same as “0” but after master speed is reached.

[4] same as “1” but after master speed is reached.

[5] once the master speed is reached marker correction to closest

marker take place.

If 1000 is added to the previous choices the fixed offset is not executed before the marker correction has taken place.

NB!

This parameter is only used in marker synchronising mode (par. 19-01 = 2 or 5).

33-24 Marker quantity FAULT

Option: Function:

Enter when a FAULT signal (O2) must be set. Input the number of marker pulses, i.e. a setting of 10 means that ACCURACY must be low for 10 marker pulses before the FAULT signal is set.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

3. Programming

In position synchronisation (par. 19-01 = 1 or 4) only the slave marker is used; in marker synchronisation (par. 19-01 = 2 or 5) both slave and master marker must be detected before counting.

33-25 Marker quantity READY

Option: Function:

Enter when a READY signal (O1) must be set. Enter the number of marker pulses, i.e. a setting of 10 means that ACCURACY must be present for 10 marker pulses before the READY signal is set.

In position synchronisation (par. 19-01 = 1 or 4) only the slave marker is used; in marker synchronisation (par. 19-01 = 2 or 5) both slave and master marker must be detected before counting.

33-26 Velocity filter

Option: Function:

In speed synchronisation it is recommended to set a filter time based on resolution. This is to avoid speed fluctuation at low speed or when using low resolution of encoders. Please see following table:

Encoder Resolution

250 39500 500 19500 1000 9500 2000 4500 2500 3500 4096 1900 5000 1400

Filter Time Value

For all other types of synchronisation: Changing the sign of the filter value enables the use of filtering the other types of synchronisation. This means that unstable position or marker synchronisation can be smoothened.

33-80 Selection of the Operation Mode

Option: Function:

[1] [2]

34-40 Input status (read only)

Option: Function:

Test run synchronisation

MG.33.Q1.02 - VLT

This parameter is showing the actual status of the 10 digital inputs (I1 - I10) on X 57 as a binary code.

is a registered Danfoss trademark

3. Programming

34-50 Slave position (read only)

Option: Function:

34-52 Master position (read only)

Option: Function:

Syncronising Controller MCO 350 Operating

Instructions

Input 3, 7 and 8 high Par 3440 = 11000100 Input 1 and 3 high Par 3440 = 101

Table 3.1: Example:

The slave position is displayed in quad counts.

The master position is displayed in quad counts.

34-56 Track error (read only)

Option: Function:

This parameter indicates the actual PID error during synchronisation

34-60 Status of synchronisation

Option: Function:

The following status flags are defined for position and marker synchronisation. The flags are not updated when using speed synchronisation:

Flag: Decimal value Bit

SYNCREADY 1 0 SYNCFAULT 2 1 SYNCACCURACY 4 2 Only marker synchronisation: Master marker HIT 8 3 Slave marker HIT 16 4 Master marker Error 32 5 Slave marker Error 64 6

The flags are reset when restarting synchronisation (SyncStart).

SYNCACCURACY

Each millisecond it is checked if the actual position deviance between master and slave is smaller than par. 33-13(accuracy), if this is true the SYNCACCURACY flag is set (1), otherwise the flag is reset. (0).

SYNCFAULT / SYNCREADY

For every marker pulse it is checked whether the SYNCACCURACY flag is present or not. If it is not present the fault counter

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

3. Programming

is increased and the ready counter set to 0, if it is present the ready counter is increased and the fault counter set to 0.

If the ready counter is higher than the value set in par. 33-25 (marker quantity ready) then the flag SYNCREADY is set, if not the flag is reset.

If the fault counter is higher than the value in par. 33-24 (marker quantity fault) the flag SYNCFAULT is set (1), if not the flag is reset (0).

Marker HIT flags:

The marker HIT flags are set (1) after detecting n marker pulses (n = par. 19-08 and 19-09).

Marker error flags:

It is checked at each n marker pulse (n = par. 19-08 or 19-09) whether the distance between the actual marker position and the last registered marker position is lower than 1.8 times the value of par. 33-18 or 33-17. If this is not true, then the associated flag is set. (1). When using marker windows (par. 33-22 and 33-21) it is checked whether a marker is detected within the window. If no marker is detected the error flag is set (1).

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

4. Synchronisation

Syncronising Controller MCO 350 Operating

Instructions

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

4. Synchronisation

4.1. Speed Synchronisation

4.1.1. SyncStart

When closing the SyncStart contact (Terminal I1), the slave drive accelerates with minimum ramp time to the speed of the master drive, taking the gear ratio into account. When I1 is opened, the slave drive ramp or coast to stop. Stop behaviour is selected in par. 19-01.

4. Synchronisation

Illustration 4.1: Figure 10: SyncStart with speed synchronisation

4.2. Function Diagrams for Speed Synchronisation

4.2.1. SyncStart

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

4. Synchronisation

Syncronising Controller MCO 350 Operating

Instructions

Illustration 4.2: Figure 10: SyncStart with speed synchronisation

4.2.2. Up/Down Factor

After the slave has been synchronised to the speed of the master by means of SyncStart (Terminal I1), the gear ratio can be changed during operation. By means of Inputs 33 Speed+ / Up-factor, or 32 Speed- / Down-factor, the gear ratio can be changed by the value set in par. 19-12

. This change affects only the slave factor. For more sensitive adjustment of the gear ratio,

width

the gear ratio digits should be extended and a small step width should be selected. If one of the two inputs is on longer than the time defined in par. 19-11 cuted. Example: Gear ratio i = 22:43 If the step width is equal to 1, the first upward step will result in i = 22:44, which represents almost 3 %. It would be better to set the ratio as i = 2200:4300. Then the upward step will result in i = 2200:4301, which represents a change of approx. 0.03 %.

step time

step

, a further step will be exe-

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

4. Synchronisation

Illustration 4.3: Up/down factor with speed synchronisation

4.2.3. Hold Function

The Hold function operates the slave drive in closed loop speed control at a speed independent of the master. With par. 19-02 speed set in par. 19-03 or whether it is to maintain current speed. For the duration of the Hold signal, the speed of the master is no longer taken into account; the master can even stop without this having any effect on the slave drive. While the Hold function is activated you can change the speed with inputs 32 and 33. The speed is changing according to the settings in par. 19-04

hold speed

and par. 19-12

Hold function

Step width

you can choose whether the slave is to run at a fixed

Delta

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

4. Synchronisation

Syncronising Controller MCO 350 Operating

Instructions

Illustration 4.4: Hold speed

4.2.4. Gear Changing

During synchronous operation, it is possible to switch between 4 fixed gear ratios, set in par. 19-05 to 19-07. The fixed gear ratios are selected at terminals 9 and 10:

Input 9 Input 10 Gear Ratio no.

0 0 0 01 1 1 0 2 11 3

To activate the new ratio you must activate input I2. The newly set gear ratio is attained with the minimum possible ramp.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

4. Synchronisation

Illustration 4.5: Changing the gear ratio in speed synchronisation

4.2.5. Changing the Gear Ratio with an Analogue Value

As an alternative the gear ratio can be set via analogue input 54 with a +/- 10V signal, this function is active when synchronising type 6 or 7 is selected in parameter 1901. The gear ratio denominator is taken from the setting in gear 0. The gear ratio numerator is set by input 54, 5V corresponds to 500. If you e.g. have set up 500 for masterfactor in gear 0, this would give a gear ratio of 1:1.

4.3. Application Examples - Admixture

A feed screw conveyor pump leads substance 1 to a nozzle adding substance 2. For different end products it must be possible to select different mixing ratios (ratio 1 = 1:1; ratio 2 = 1:1.12; ratio 3 = 1:1.2; ratio 4 = 1:1.21). During operation it must be possible manually to make slight adjustments of the selected mixing ratio.

Description of terminals and terminal configuration

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

4. Synchronisation

Syncronising Controller MCO 350 Operating

Instructions

4.3.1. Setting the Parameters

For this work it is recommended to have the description of parameters at hand. See the

AutomationDrive Programming Guide.

NB!

It is very important that the frequency converter is optimised for the motor before optimising the synchronising controller:

1. Record the motor data and perform an AMA (Automatic Motor Adaptation) if possible.

2. Start programming the synchronisation functions.

MG.33.Q1.02 - VLT

VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

Parameter No. 303

Maximum reference: Set the frequency for a value that is about 10% higher than the maximum value of par. 32-80.

Example:

Motor

7.5kW,14601/

speed of the application approx

Nom

Parameter No. 416

Torque limit for motor mode: Set for maximum. – Choose a lower value, if special safety precautions are necessary.

Parameter No. 417

Torque limit for regenerative operation: Set for maximum. – Choose a lower value, if special safety precautions are necessary.

Application

Nom

1.1 =

min at

50Hz,

. 1800 1/

Hz x

1800

1460

min

H z maximum ref.value

min

4. Synchronisation

Parameter No. 33-80

Record “1” to start the test program.

Parameter No. 33-26

This parameter configures the velocity filter for speed synchronisation. Since speed synchronisation is based on speed a small fluctuation in master speed, when running at low speed, can have an effect on the pid loop control. Hence this filter will even out the effect.

Cmdvel = Old_Cmdvel + (Actvel – Old_Cmdvel) * ms/tau_filt

Cmdvel = set velocity

Old_Cmdvel = last set velocity

Actvel = actual velocity of master

ms = sample time (parameter 32-69)

tau_filt = filter time constant

For standard encoders the following table can be used:

Encoder Resolution

250 39500 256 38600 500 19500 512 19000 1000 9500 1024 9300 2000 4500 2048 4400 2500 3500 4096 1900 5000 1400

Tau_filt (ms)

Parameter No. 32-00/32-02

Record the type of slave encoder. Factory default is incremental encoder.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

4. Synchronisation

Parameter No. 32-01/32-03

Record the resolution of the slave encoder.

Parameter No. 32-30/32-32

Record the type of master encoder. Factory default is incremental encoder.

Parameter No. 32-31/32-33

Record the resolution of the master encoder.

Parameter No. 32-10

Record “No action” for clockwise rotation of both master and slave. Record “User units reversed” if the slave is to run in the opposite direction.

Parameter No. 32-80

Record maximum RPM measured at the slave encoder.

Parameter No. 32-81

Minimum ramp: Set the time in Ms for the slave drive to accelerate from standstill to maximum speed (par 3280). This value is important as this setting highly affects the control accuracy!

Syncronising Controller MCO 350 Operating

Instructions

Parameter No. 32-82

Ramp type: Record “0” for linear ramp and “1” for s-ramp. NOTE: S-ramp requires higher acceleration torque.

Parameter No. 32-68

Reversing behaviour: Record “0” if reversing is allowed, “1” if the slave must always follow the direction of the master or “2” if reversion is not allowed.

4.3.2. How to Check the Motor Connection

When the above parameters have been programmed, check the motor connection as follows:

1. Remove all signals to terminals 18-33 and I1-I10.

2. Press [Hand On] button on the LCP

3. Set the reference to a low value with the arrow keys (25 to 50 rpm). Please note that the motor may now turn!

4. Press the [Off] button on the LCP to stop again. If the motor rotates in the wrong direction then exchange the motor phases.

4.3.3. How to Test the Incremental Encoders

When you have tested the motor speed direction you test the incremental encoder connection as follows: 1. 2. 3.

1. Remove all signals to terminals 18-33 and I1-I10.

2. Select parameter 34-50. The current actual position is then displayed.

3. Rotate the slave drive motor shaft manually in the forward direction. Now the display shows an ascending count of the slave position. If the count is descending, exchange the slave encoder track A by B and A/ by B/. If there is no counting in the display then check the wiring of the encoder.

Follow the same procedure when testing the master encoder but use par. 34-52 for read-out of the master position. Remember to push [Auto On] to return to normal control.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

4.3.4. How to Optimise the Controller

synchronisation is obtained via two main elements of the controller: Velocity feed forward and the PID controller.

NB!

Before starting the optimising procedures it is important to select the right type of synchronisation in parameter 1904, in this example it must be “0” for velocity synchronisation. Please always have the necessary degree of accuracy in mind, you could go on optimising for a long time, but it might not be necessary to have a 100% accuracy in the application you are dealing with.

First step is to optimise velocity feed forward this can be done via the automatic calculation function: Velocity feed forward calculation is activated by setting parameter 19-05 to “1”, remember to make the required parameter settings according to the description of par. 19-05 before starting the calculation. The calculation is done when the value of par. 19-05 returns to “0”.

Velocity feed forward can also be optimised manually by the following procedure:

1. Set par. 32-64 PID bandwidth to “0”.

2. Set par. 32-67 maximum track error to a high value (e.g. 1,000,000).

3. Set par. 32-65 velocity feed forward to 100.

4. Start test-run with virtual master with a known velocity via input 3 = 1.

5. Increase parameter 3265 while watching master and slave velocity (press [Status] to get the velocity readouts). You have found the optimal velocity feed forward when slave velocity is approximately equal to the master velocity.

6. Stop test-run by input 3 = 0.

7. Reset parameter 3267 to the original value.

8. Reset parameter 3264 to 1000.

4. Synchronisation

Second step is to optimise the PID controller, a good starting point can be found be means of

the automatic calculation function: By setting par. 19-05 to “2” velocity feed forward calculation is activated as well as calculation of PID sample time and P/D factors, remember to make the required parameter settings according to the description of par. 19-05 before starting the calculation. The calculation is done when the value of par. 19-05 returns to “0”.

Using the test run functions can optimise the PID factors further: There is two types of test run available: Positioning where the slave drive moves a specific distance and synchronising with virtual master where the slave follows the virtual master in position or spe e d . Ge n era l ly i t is b e t te r t o u se test run with virtual master as that comes closer to the operating conditions in synchronising mode (program 2).

For test run with positioning the following parameters must be set:

Parameter No. 19-01

Test run speed: Record the speed as a percentage of the maximum speed of parameter 3280.

Parameter No. 19-02

Test run acceleration: record the acceleration time in per cent. 100% is minimum acceleration. 50% is half as fast as minimum acceleration, the ramp time will thus be twice as long.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

4. Synchronisation

Parameter No. 19-03

Test run distance: Record the distance (quad counts) for the drive to run during optimisation.

Then use the following procedure:

1. Close the contacts at terminal 32 (clockwise/forward direction) or terminal 33 (counter-

2. Increase the P-portion (par. 3260). After each change you should make a test run to find

3. Now set the D-portion (parameter 3261) to 5 times the value of parameter 3260.

4. If a lower synchronising error is required the I-portion (parameter 3262) can be set to a

For test run with virtual master the following parameters must be set:

Parameter No. 19-16

Virtual master reference: Select the reference source for setting the velocity of the virtual master. “0” is analogue input 53, “1” is parameter 310 sub-index 0 and “2” is Fieldbus PCD 2.

Syncronising Controller MCO 350 Operating

Instructions

clockwise/reverse). During the test the last value of the first display line will indicate the track error (PID error). After the test run is completed you can see the maximum track error (PID error) in the display.

the right setting. If the drive becomes unsteady or if a message is given about overvoltage or over-current, then reduce the value in parameter 3260 to about 70-80% of the set value.

low value e.g. 10 but be careful a too high value will course overshoot and instability.

Parameter No. 19-17

Virtual master acceleration: Set the acceleration of the virtual master in encoder pulses per sec-

ond

Parameter No. 19-18

Virtual master maximum speed: Set the maximum velocity of the virtual master in encoder pulses per second.

Then use the following procedure:

1. Disconnect the master encoder from the synchronising controller (X56). Start test run with virtual master by activating input 3. During test run you can read the track error in the last value of the first display line. At stop the maximum track error during the test run is read out. Because velocity synchronisation is selected (parameter 1904 = 0) the track error is velocity deviance between master and slave.

2. If more accurate and dynamic control is required the P-portion (parameter 3260) must be increased. If the slave becomes unstable the value must be reduced to by approximately 25%.

3. Now set the D-portion (parameter 3261) to 5 times the value of parameter 3260

4. If a lower synchronising error is required the I-portion (parameter 3262) can be set to a low value e.g. 10 but be careful a too high value will course overshoot and instability.

The optimised values are automatically saved.

4.3.5. How to Programme Synchronisation

Change the value of parameter 33-80 to “2”. This will start the synchronisation application program. To do the synchronisation programming use the following parameters:

Parameter No. 19-01

Type of operation: Record “0” or “3” for speed synchronisation.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

Parameter No. 19-02

Hold function: Specify how the drive is to react when Input 29 is activated . “Hold” switches the drive from master synchronisation to a fixed frequency. Choose “0” to use the frequency set in par. 1903 and “1” to use the current frequency.

Parameter No. 19-03

Hold speed: Set here, as a percentage of the maximum speed, the speed at which the drive should move when you activate Hold and the value “0“ was selected in Parameter 1902.

Parameter No. 19-04

Delta hold speed: Set here the step width by which the hold speed is to be changed upwards or downwards by activating Terminals 32 + 33.

Parameter No. 19-05

Gear ratio No.: Record the number of the gear ratio that is to be displayed in Parameters 1906 to

1907. Then you set the values required in Parameters 1906 to 1908. Follow the same procedure for the next gear ratio(s).

Parameter No. 19-06

Gear ratio numerator: Record the numerator value of the gear ratio. That is the encoder pulses of the slave drive. To make fine adjustment possible by means of inputs 32 and 33 a ratio of for example 7:16 must be programmed as 7000:16000.

4. Synchronisation

Parameter No. 19-07

Gear ratio denominator: Enter here the denominator value of the gear ratio. This value corresponds to the master pulses.

Parameter No. 19-11

Step time: In Hold mode, the next frequency change and, in synchronisation mode, the next change of the counter factor of the gear ratio, is carried out after this time, on the presence of one of the signals at terminal 32 or 33. The time input is in milliseconds.

Parameter No. 19-12

Step width: In speed synchronisation, the gear ratio numerator is changed by this amount, if one of the terminals 32 or 33 is closed.

Parameter No. 19-13

Slave speed factor: Record the factor by which the slave speed must be multiplied, so that it can be displayed. Use the following formula:

400

Factor

set

xSlaveencoder_resolution

xDisplay_value

Example:

Factor

Resolution

min

400x1024

100

1500

Incr

Rev

= 102400

1024

increments,desired display

Parameter No. 19-14

Master speed factor: Record the factor by which the master speed must be multiplied, so that it can be displayed. Use the following formula:

100at1500 1

Factor

set

400

xMasterencoder_resolution

xDisplay_value

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

4. Synchronisation

Parameter No. 19-15

Synchronising error display factor: This factor must be 100, the synchronising error is then displayed in RPM related to the slave.

The settings are automatically saved.

4.4.1. Starting Synchronisation

Synchronisation with the master is achieved by closing the SyncStart contact (I1); the drive accelerates the maximum permitted acceleration to the speed of the master (calculated by means of the gear ratio).

4.4.2. Stopping Synchronisation

When the SyncStart contact (I1) is opened, the slave is stopped at the permitted acceleration.

4.4.3. Fine Setting of the Gear Ratio

Fine setting of the gear ratio can now be undertaken by means of Inputs 32 + 33. This setting is only temporary, i.e. the fine setting data will be lost as soon as the VLT is disconnected from the mains. If the setting is to be saved, a Store operation must be carried out by closing the Store contact (I4) or by means of Parameters 1900 before the VLT is switched off.

Syncronising Controller MCO 350 Operating

Instructions

4.4.4. Switching to Another Gear Ratio

4.4.5. Error Procedure

Errors of tracking, over current etc. make the drive stop and the Ready output (O8) is reset. Reset is done with Input 27 or fieldbus bit 1.9. Reset is also possible with the [Reset] key of the local control panel of the drive.

In case the drive has stopped because of earth fault or short-circuit, please cycle the power to the drive from the mains before you reset!

4.5. Position Synchronisation

4.5.1. Position Synchronisation (angle synchronisation)

The position controller adjusts the slave drive position or angle to the master.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

Illustration 4.6: Control behaviour with position synchronisation

4. Synchronisation

It appears from the diagram that the control accuracy depends on the master acceleration and on the speed deviation between slave and master. A typical application for this type of synchronising could be the replacement of a mechanical shaft. Or mixing controls where a mixing rate is required.

The following example shows how embossing patterns on moulds is controlled. This application requires accurate position control.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating

4. Synchronisation

4.6. Function Diagrams for Position Synchronisation

4.6.1. SyncStart to a Stationary Master

If the slave is synchronised to a stationary master drive, the slave will remain stationary. However, if a fixed offset is defined for the activated gear ratio, the slave travels to the extent of this offset during synchronisation.

Instructions

Illustration 4.7: synchronising to a stationary master

4.6.2. SyncStart to a Running Master

If synchronisation is effected to a running master, the slave drive first makes up the deviation of distance then it proceeds synchronously with the master. Any Offset setting is taken into account.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

4. Synchronisation

Illustration 4.8: synchronising to a running master

4.6.3. Position Displacement with a Running Master

If one of the Inputs 32 or 33 is activated during synchronous travel, the actual position in relation to the master is displaced by the value set in Parameter 1910. If the displacement is positive, the slave accelerates in order to travel the necessary distance in order then again to travel synchronously to the master at the speed determined via the gear ratio. If the displacement is negative, the slave decelerates in order to attain the necessary distance to then again travel synchronously with the master at the speed determined via the gear ratio.

Illustration 4.9: Position displacement

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating

4. Synchronisation

4.7.1. Application Example - Embossing Patterns on Mould

Moulds of two different kinds and lengths are embossed with a pattern. The conveyor belt operator changes the position of the pattern by means of two buttons. Each of the two incremental encoders has a zero track for marker synchronisation.

4.7.2. Description of Terminals and Terminal Configuration

Instructions

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

4.7.3. Setting the Parameters

4. Synchronisation

For this work it is recommended to have the description of parameters at hand. See the

VLT

Automation Drive Operating Instructions.

NB!

It is very important that the VLT is optimised for the motor before optimising the synchronising controller:

1. Record the motor data and perform an AMA (Automatic Motor Adaptation) if possible.

2. Start programming the synchronisation functions.

Parameter No. 303

Maximum reference: Set the frequency for a value that is about 10% higher than the maximum value of par.32-80. Example: Motor 7.5 kW, 1460 1/min at 50 Hz, speed of the application approx. 1800 1/min

Nom

=62

Parameter No. 416

Torque limit for motor mode: Set for maximum. – Choose a lower value, if special safety precautions are necessary.

Application

Nom

1, 1 =

Hz Maximum ref.value

Hz x

1460

1800

min

1, 1

Parameter No. 417

Torque limit for regenerative operation: Set for maximum. – Choose a lower value, if special safety precautions are necessary.

Parameter No. 33-80

Record “1” to start the test program.

Parameter No. 33-26

When performing position synchronisation this parameter is used to insert a filter to compensate for an oscillating master signal. If, for example, the master is experiencing shock loads the pid loop of the synchronising controller will have a tendency to oscillate as well. A negative value must be entered. Example: If a filter factor of –100000 (100 ms) is used the correction is balanced within: 1000/ (filter factor *10)= 1 second.

Parameter No. 32-00/32-02

Record the slave encoder type. “0” represents the incremental encoder.

Parameter No. 32-01/32-03

Record the resolution of the slave encoder.

Parameter No. 32-30/32-32

Record the master encoder type. “0” represents the incremental encoder.

Parameter No. 32-31/32-33

Record the resolution of the master encoder.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

4. Synchronisation

Parameter No. 32-10

Record “No action” for clockwise rotation of both master and slave. Record “User units reversed” if the slave is to run in the opposite direction.

Parameter No. 32-80

Record maximum RPM measured at the slave encoder.

Parameter No. 32-81

Minimum ramp: Set the time in ms for the slave drive to accelerate from standstill to maximum speed (par 3280). The value is important, as this setting highly affects the control accuracy!

Parameter No. 32-82

Ramp type: Record “0” for linear ramp and “1” for s-ramp. Note: S-ramp requires higher acceleration torque

Parameter No. 32-67

Maximum track error: Record the value that is to generate “Track error” indication in the display, if exceeded. Input is in quad counts.

Syncronising Controller MCO 350 Operating

Instructions

Parameter No. 32-68

Reversing behaviour: Record “0” if reversing is allowed, “1” if the slave must always follow the direction of the master or “2” if reversing is not allowed.

The settings are automatically saved.

4.7.4. How to Check the Motor Connection

When the above parameters have been programmed, check the motor connection as follows:

Remove all signals to terminals 18-33 and I1-I10

Press [Hand On] button on the LCP.

Set the reference tor a low value with the arrow kkeys (25 to 50 rpm). Please note that the motor may now turn

Press the [Off] button on the LCP to stop again. If the motor rotates in the wrong direction then exchange the motor phases.

4.7.5. How to Test the Incremental Encoders

After testing the motor speed direction, test the incremental encoder connection as follows:

1. Remove all signals to terminals 18-33 and I1-I10.

2. Select parameter 3450. The current actual position is then displayed.

3. Rotate the slave drive motor shaft manually in the forward direction. Now the display shows an ascending count of the slave position.

4. If the count is descending, exchange the slave encoder track A by B and A/ by B/.

5. If there is no counting in the display then check the wiring of the encoder.

Follow the same procedure when testing the master encoder but use parameter 34-52 for readout of the master position. Remember to push [Auto On] to return to normal control.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

4.7.6. How to Optimise the Controller

Synchronisation is obtained via two main elements of the controller: Velocity feed forward and the PID controller.

NB!

Before starting the optimising procedures it is important to select the right type of synchronisation in parameter 1904, in this example it must be “1” for position synchronisation. Please always have the necessary degree of accuracy in mind, you could go on optimising for a long time, but it might not be necessary to have a 100% accuracy in the application you are dealing with.

First step is to optimise velocity feed forward this can be done via the automatic calculation function: Velocity feed forward calculation is activated by setting parameter 1905 to “1”, remember to make the required parameter settings according to the description of par. 1905 before starting the calculation. The calculation is done when the value of par. 1905 returns to “0”.

Velocity feed forward can also be optimised manually by the following procedure:

Set parameter 3264 PID bandwidth to “0”.

Set parameter 3267 maximum track error to a high value (e.g. 1.000.000).

Set parameter 3265 velocity feed forward to 100.

Start test-run with virtual master with a known velocity via input 3 = 1.

Increase parameter 3265 while watching master and slave velocity (press [DISPLAY/ STATUS] to get the velocity readouts). The optimal velocity feed forward has been identified when the slave velocity is approximately equal to the master velocity.

Stop test-run by input 3 = 0.

Reset parameter 3267 to the original value.

Reset parameter 3264 to 1000.

Second step is to optimise the PID controller, a good starting point can be found be means of the automatic calculation function: By setting parameter 1905 to “2” velocity feed forward calculation is activated as well as calculation of PID sample time and P/D factors, remember to make the required parameter settings according to the description of par. 1905 before starting the calculation. The calculation is done when the value of par. 1905 returns to “0”.

4. Synchronisation

Using the test run functions optimises the PID factors further: Two types of test runs are available: Positioning where the slave drive moves a specific distance and synchronising with virtual master where the slave follows the virtual master in position or spe e d . Ge n era l ly i t is b e t te r t o u se test run with virtual master as that comes closer to the operating conditions in synchronising mode (program 2).

For test run with positioning the following parameters must be set:

Parameter No. 1901

Test run speed: Record the speed as a percentage of the maximum speed of parameter 3280.

Parameter No. 1902

Test run acceleration: record the acceleration time in per cent. 100% is minimum acceleration. 50% is half as fast as minimum acceleration, the ramp time will thus be twice as long.

Parameter No. 1903

Test run distance: Record the distance (quad counts) for the drive to run during optimisation.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

4. Synchronisation

Then use the following procedure:

1. Close the contacts at terminal 32 (clockwise direction) or terminal 33 (counter-clockwise).

2. Increase the P-portion (par. 3260). After each change you should make a test run to find

3. Now set the D-portion (parameter 3261) to 5 times the value of parameter 3260.

4. If a lower synchronising error is required the I-portion (parameter 3262) can be set to a

For test run with virtual master the following parameters must be set:

Parameter No. 19-16

Virtual master reference: Select the reference source for setting the velocity of the virtual master. “0” is analogue input 53, “1” is parameter 310 sub-index 0, “2” is Fieldbus PCD 2.

Syncronising Controller MCO 350 Operating

Instructions

During the test the last value of the first display line will indicate the track error (PID error). After the test run is completed you can see the maximum track error (PID error).

the right setting. If the drive becomes unsteady or if a message is given about overvoltage or over-current, then reduce the value in parameter 3260 to about 70-80% of the set value.

low value e.g. 10 but be careful a too high value will course overshoot and instability

Parameter No. 19-17

Virtual master acceleration: Set the acceleration of the virtual master in encoder pulses per sec-

ond

Parameter No. 19-18

Virtual master maximum speed: Set the maximum velocity of the virtual master in encoder pulses per second.

Then use the following procedure:

1. Start test run with virtual master by activating input 3. During test run you can read the track error in the last value of the first display line. At stop the maximum track error during the test run is read out.

2. If more accurate and dynamic control is required the P-portion (parameter 3260) must be increased. If the slave becomes unstable the value must be reduced to by approximately 25%.

3. Now set the D-portion (parameter 3261) to 5 times the value of parameter 3260

4. If a lower synchronising error is required the I-portion (parameter 3262) can be set to a low value e.g. 10 but be careful a too high value will course overshoot and instability.

The settings are automatically saved.

4.7.7. How to Programme Synchronisation

Change the value of parameter 33-80 to “2”. This will start the synchronisation program of VLT. To do the synchronisation programming you use the following parameters:

Parameter No. 19-01

Type of operation: Record “1” or “4” for position synchronisation.

Parameter No. 33-00

Home function, used together with par 30-04: Specify the start function of the drive: “0” Homerun not forced “1” Home run must be carried out before the first start of synchronisation

Parameter No. 33-02

Home acceleration: Set the acceleration (% of minimum acceleration) for homing.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

Parameter No. 30-03

Home speed: Set the speed (% of maximum speed) at which Homing is to be made. Positive values for clockwise rotation, negative values for counter-clockwise rotation.

Parameter No. 30-04

Home force function: 0 = The homing only has to be carried out after power up 1-3 = The homing has to be carried out before every sync start

Parameter No. 33-13

Accuracy: Record a value (quad counts) for a tolerance within which the slave position may deviate from the position of the master. With a negative value the synchronising error (parameter 1993) show the error with a sign.

Parameter No. 33-24

Marker quantity Fault: Inaccuracy: Record the number of marker signals to generate a Fault signal.

Parameter No. 33-25

Marker quantity Ready: Accuracy: Record the number of marker signals to generate a Ready signal.

4. Synchronisation

Parameter No. 19-05

Gear ratio No.: Record the number of the gear ratio that is to be displayed in Parameters 1906 to

1907. First set the number of the gear ratio, then the necessary values for this gear ratio can be set in Parameters 1906 and 1907. The next gear ratio is then selected in Parameter 1905 and the same procedure is repeated.

Parameter No. 19-06

Gear ratio numerator: Enter here the numerator value of the gear ratio. The value corresponds to the encoder pulses of the slave drive. To make fine adjustment possible by means of inputs 32 and 33 a ratio of for example 7:16 must be programmed as 7000:16000.

Parameter No. 19-07

Gear ratio denominator: Record the denominator value of the gear ratio. This value corresponds to the master pulses.

Parameter No. 19-10

Fixed Offset: Record a fixed position offset for the selected gear ratio (quad counts). You use this value to specify the position deviation between slave and master. During operation you can change the value by means of inputs 32 and 33. Note: Offset is related to the master position. Offset related to the slave position can be calculated as follows:

O ffset_slave

Parameter No. 19-11

Step time: Record the delay in ms from one frequency change to another (hold mode) and from one gear ratio numerator factor change to another (synchronisation mode) when there is a signal on terminal 32 or 33.

O ffset x Par

Par

. 738

. 739

Parameter No. 19-12

Step width: Record a value to specify the position displacement between slave and master.

Parameter No. 19-13

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

4. Synchronisation

Slave speed factor: Record the factor by which the slave speed must be multiplied, so that the desired value is displayed. To calculate the value use the following formula:

Factor

Example:

Resolution 1024 increments, desired display 100 at 15001/min

Syncronising Controller MCO 350 Operating

Instructions

400

Set

x Slaveencoder_resolution

xDisplay_value

1500

Factor

Parameter No. 19-14

Master speed factor: Record the factor by which the master speed must be multiplied, so that the desired value is displayed. To calculate the value use the following formula:

Factor

Parameter No. 19-15

Synchronisation error display factor: Record the factor by which the error must be multiplied, so that the desired value is displayed. To calculate the value use the following formula:

Factor

400x1024

min

100

400

Set

x Slaveencoder_resolution

xDisplay_value

400

x Slaveencoder_resolution

xDisplay_value

Incr

Rev

. .

= 102400

The settings are automatically saved.

4.7.8. Operation and Operating Functions

After all values have been set as described and the controller has been optimised for the application, Parameter 3004 Home function is set to the value of “2”. The drive can now be operated normally.

Home run

As parameter 33-00 is set to “1” and parameter 33-04 is set to “2” homing must be carried out before each start. To start homing the contact at Terminal 19 is closed. The slave drive then travels to the home switch and stops there. If the reversing procedure is set to “0”, the slave travels back to the start of the home switch; otherwise, the offset arising from disabling reversing is added to the fixed offset.

Starting synchronisation

Preferably, the master is first similarly brought into its start position and the slave activated by means of I1 (SyncStart), then the master is started. This produces optimum synchronisation. The slave can, of course, also be started by, e.g. a start signal from the master, although in that case it should be noted that the delay of the start signal can be prolonged by the scan time of e.g. the PLC. Attention should be paid to the accuracy of the start signal. Hence, it is better to start the slave drive when the master is in position. The position of the master, plus the value of the fixed offset, is the synchronisation position to which the slave drive will travel at the maximum permitted acceleration when started. It may happen here that the slave drive travels faster than the master, as the slave drive needs to catch up with the master position.

Stopping synchronisation

On opening the SyncStart contact (I1), the slave is stopped at the permitted acceleration. Because Home force function is set at “2”, a new start is only possible after a renewed Home run.

Fine setting of the position

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

As soon as the slave drive is in position synchronisation to the master, a displacement of this position can be effected by means of Inputs 32 + 33. Offset is related to the master position. Offset related to the slave position can be calculated as follows:

4. Synchronisation

O ffset_slave

Switching to another gear ratio

During synchronisation, a new gear ratio can be selected at Inputs 9 and 10. The gear ratio is then activated by means of Input (I2). The slave will then proceed at the permitted acceleration to this new gear ratio. The offset is related to the first gear ratio after SyncStart. Therefore a stop and then start must be performed if the offset must relate to the latest gear ratio it the gear ratio has been changed.

Error procedure

Errors of tracking, over current etc. make the drive stop. The Ready output (O8) is set low. Reset is done with Input 27 or fieldbus bit 1.9. Reset is also possible with of the [Reset] button on the local control panel of the drive.

O ffset x Par

In case the drive has stopped because of earth fault or short-circuit, disconnect the drive from the mains before resetting!

Par

.19− 06

.19− 07

4.8. Marker Synchronisation - Function Diagrams for Marker Synchronisation

4.8.1. Marker Synchronising

Using Marker synchronising the start position is not predefined. The Marker will alter the position during operation, as required. Marker synchronising is for example used to compensate for any undesired slip.

Illustration 4.10: Control behaviour with marker synchronisation

It appears from the diagram that the control accuracy depends on the master acceleration and on the speed deviation between slave and master.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

4. Synchronisation

The following example shows the use of marker synchronisation to compensate for friction slip that can arise from dropping a box onto Conveyor belt 1. By means of marker correction in the form of object recognition, the slave belt is controlled so that the product will always be placed right in the middle of the box, even if the box itself is not centrally positioned in its conveyor compartment.

Syncronising Controller MCO 350 Operating

Instructions

Illustration 4.11: Conveyor belt with marker synchronisation

4.8.2. SyncStart to a Running Master after Power ON

If the slave is synchronised to a running master drive, the slave automatically synchronises its position to the master. After at least one slave marker and one master marker have been detected, the marker compensation comes into effect.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

4. Synchronisation

Illustration 4.12: Initial start-up with marker synchronisation

4.8.3. Marker Correction during Operation

During operation, marker correction is always carried out when the markers is detected. This ensures optimum synchronisation, no matter whether the gear ratios are not accurate or there is a slip.

Illustration 4.13: Marker correction during operation

4.9. Application Example - Packaging

This example is a conveyor belt with cardboard boxes of low weight and different lengths. To ensure that the components to be packed are placed right in the middle of the boxes you must use synchronisation with marker correction. The grab belt is controlled by position synchronisation

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

4. Synchronisation

and as soon as one of the two markers is recognised, the grab belt is either moved forward to the conveyor belt position or slowed down. It is also possible for the operator to change the position by means of two push buttons.

4.9.1. Terminals and Terminal Configuration

Syncronising Controller MCO 350 Operating

Instructions

Wiring diagram - conveyor belt regulation

4.9.2. Setting the Parameters

For this purpose it is recommended to have the parameter descriptions at hand. See the

Automation Drive FC 300 Operating Instructions.

MG.33.Q1.02 - VLT

VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

NB!

It is very important that the VLT is optimised for the motor before optimising the synchronising controller. First, record the motor data and perform an AMA (Automatic Motor Adaptation) if possible. Then start programming the synchronisation functions

Parameter No. 303

Maximum reference: Set the frequency for a value that is about 10% higher than the maximum value of parameter 32-80. Example: Motor 7.5kW, 1460 1/min at 50Hz, speed of the application approx. 1800 1/min

Nom

=62

Parameter No. 33-80

Record “1” to start the test program.

Application

Nom

1.1 =

H z maximum ref.value

Hz x

1460

1800

min

4. Synchronisation

1.1

Parameter No. 33-26

Parameter No. 32-00/32-02

Record the slave encoder type. “0” represents an incremental encoder.

Parameter No. 32-01/32-03

Record the resolution of the slave encoder.

Parameter No. 32-30/32-32

Record the master encoder type. “0” represents an incremental encoder.

Parameter No. 32-31/32-33

Record the resolution of the master encoder.

Parameter No. 32-10

Direction of rotation: Record “1” for clockwise rotation of the slave. Record “-1” if the slave is to run in the opposite direction.

Parameter No. 32-80

Record maximum RPM measured at the slave encoder.

Parameter No. 32-81

Minimum ramp: Set the time in ms for the slave drive to accelerate from standstill to maximum speed (par. 3280). Consider the value carefully as this setting will highly affect the control accuracy!

Parameter No. 32-82

Ramp type: Record “0” for linear ramp and “1” for s-ramp. NOTE: S-ramp requires higher acceleration torque.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

4. Synchronisation

Parameter No. 32-67

Maximum track error: Record the value that is to generate “Track error” indication in the display, if exceeded.

Parameter No. 32-68

Reversing procedure: Record “0” if reversing is allowed, “1” if the slave must always follow the direction of the master or “2” if reversing is not allowed.

Parameter No. 33-20

Slave marker type: As external marker signals are used, you can set the type of edge triggering of the external marker signal; “2” for a positive edge, “3” for a negative edge.

Parameter No. 33-18

Slave marker interval: Record the interval between two marker signals of the slave. Input of the interval is in quad counts. If the interval is not known, it can also be determined during the test run.

Parameter No. 33-19

Master marker type: As external marker signals are used, you can set the type of edge triggering of the external marker signal here; “2” for a positive edge, “3” for a negative edge.

Syncronising Controller MCO 350 Operating

Instructions

Parameter No. 33-17

Master marker interval: Record the interval between two marker signals of the master. Input of the interval is in quad counts. If the interval is not known, it can also be determined during the test run.

Parameter No. 19-01

Test run speed: Record the speed at which you want to carry out the optimisation run. Record the speed as a percentage of the speed in Parameter 3280.

Parameter No. 19-02

Test run acceleration: Record the acceleration for the test run in percent of the minimum acceleration time. 100% represents the minimum acceleration, 50% is half as fast as minimum acceleration; the ramp time is thus twice as long.

Parameter No. 19-03

Test run distance: Record the distance (quad counts) for the drive to travel during optimisation.

4.9.3. How to Check the Motor Connection

After programming the above parameters, check the motor connectio n as follows:

1. Remove all signals to terminals 18-33 and I1-I10.

2. Press [Hand On] button on the LCP.

3. Set the reference to a low value with the arrow keys (25 to 50 rpm).

4. Press the [Off] button on the LCP to stop again. If the motor rotates in the wrong direction then exchange the motor phases.

How to test the incremental encoders When you have tested the motor speed direction you test the incremental encoder connection as follows: 1. Remove all signals to terminals 18-33 and I1I10. 2. Select parameter 3450. The current actual position is then displayed, 3. Rotate the slave drive motor shaft manually in the forward direction. Now the display shows an ascending count of the slave position. If the count is descending, exchange the slave encoder track A by B and A/ by B/. If there is no counting in the display then check the wiring of the encoder. Follow the same

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

procedure when you test the master encoder but use parameter 3452 for read-out of the master position. Remember to push [Auto On] to return to normal control.

4.9.4. How to Test the Incremental Encoders

After testing the motor speed direction, test the incremental encoder connection as follows:

1. Remove all signals to terminals 18-33 and I1-I10.

2. Select parameter 34-50. The current actual position is then displayed

Follow the same procedure when testing the master encoder but use parameter 34-52 for readout of the master position. Remember to push [Auto On] to return to normal control.

4.9.5. How to Optimise the Controller

4. Synchronisation

Synchronisation is obtained via two main elements of the controller: Velocity feed forward and the PID controller.

NB!

Velocity feed forward can also be optimised manually by the following procedure:

1. Set parameter 3264 PID bandwidth to “0”.

2. Set parameter 3267 maximum track error to a high value (e.g. 1.000.000).

3. Set parameter 3265 velocity feed forward to 100.

4. Start test-run with virtual master with a known velocity via input 3 = 1.

5. Increase parameter 3265 while watching master and slave velocity (press [DISPLAY/ STATUS] to get the velocity readouts). You have found the optimal velocity feed forward when slave velocity is approximately equal to the master velocity.

6. Stop test-run by input 3 = 0.

7. Reset parameter 3267 to the original value.

8. Reset parameter 3264 to 1000.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

4. Synchronisation

Using the test run functions can optimise the PID factors further: There is two types of test run available: Positioning where the slave drive moves a specific distance and synchronising with virtual master where the slave follows the virtual master in position or speed. Generally it is better to use test run with virtual master as that comes closer to the operating conditions in synchronising mode (program 2).

For test run with positioning the following parameters must be set:

Parameter No. 19-01

Test run speed: Record the speed as a percentage of the maximum speed of parameter 3280.

Parameter No. 19-02

Test run acceleration: record the acceleration time in per cent. 100% is minimum acceleration. 50% is half as fast as minimum acceleration, the ramp time will thus be twice as long.

Parameter No. 19-03

Test run distance: Record the distance (quad counts) for the drive to run during optimisation.

Then use the following procedure:

1. Close the contacts at terminal 32 (clockwise direction) or terminal 33 (counter-clockwise).

2. Increase the P-portion (par. 3260). After each change you should make a test run to find

3. Now set the D-portion (parameter 3261) to 5 times the value of parameter 3260.

4. If a lower synchronising error is required the I-portion (parameter 3262) can be set to a

For test run with virtual master the following parameters must be set:

Syncronising Controller MCO 350 Operating

Instructions

During the test the last value of the first display line will indicate the track error (PID error). After the test run is completed you can see the maximum track error (PID error).

the right setting. If the drive becomes unsteady or if a message is given about overvoltage or over-current, then reduce the value in parameter 3260 to about 70-80% of the set value.

low value e.g. 10 but be careful a too high value will course overshoot and instability

Parameter No. 19-16

Virtual master reference: Select the reference source for setting the velocity of the virtual master. “0” is analogue input 53, “1” is parameter 310 sub-index, “2” is Fieldbus PCD 2.

Parameter No. 19-17

Virtual master acceleration: Set the acceleration of the virtual master in encoder pulses per sec-

ond

Parameter No. 19-18

Virtual master maximum speed: Set the maximum velocity of the virtual master in encoder pulses per second.

Then use the following procedure:

2. If more accurate and dynamic control is required the P-portion (parameter 3260) must be increased. If the slave becomes unstable the value must be reduced to by approximately 25%.

3. Now set the D-portion (parameter 3261) to 5 times the value of parameter 3260.

4. If a lower synchronising error is required the I-portion (parameter 3262) can be set to a low value e.g. 10 but be careful a too high value will course overshoot and instability.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

If the interval between two marker signals at the slave is not known, this interval can now be measured. To do this, the contact at the Slave marker search input (I8) is closed. The slave drive now rotates at the set test run speed. With each master signal, the interval can be read off in Parameter 3318. If the marker search is stopped by opening the Slave marker search contact (I8), an average of all the marker intervals is taken, and this is entered as the value in Parameter 3318. Similarly, the intervals between the marker signals of the master drive are measured by means of the Master marker search input (I7). To do this, it is necessary to start the master. The intervals are continuously displayed in Parameter 3317. After opening the Master marker search contact (I7), the calculated average of all the measurements is again entered as the final result in Parameter 3317.

4. Synchronisation

The settings are automatically saved.

4.9.6. How to Programme Synchronisation

Change the value of parameter 33-80 to “2”. This will start the synchronisation application program.

Use the following parameters to programme the synchronisation:

Parameter No. 19-01

Type of operation: Record “2” or “5” for marker synchronisation.

Parameter No. 33-23

Marker synchronisation behaviour: Specify here how the slave drive is to react while synchronising to the master marker. “0” means the last marker pulse of the master - the slave synchronises to the last master marker pulse already registered - it catches up. “1” means the next master marker pulse - the slave waits for the next master marker and synchronises to it - the slave slows down. “2” means that the slave uses the nearest master marker - it decides for itself whether to catch up or slow down.

Parameter No. 33-13

Accuracy: Record a value (quadcounts) for a tolerance within which the slave position may deviate from the position of the master.

Parameter No. 33-24

Marker quantity Fault: Inaccuracy: Record the number of market signals to generate a Fault signal.

Parameter No. 33-25

Marker quantity Ready: Accuracy: Record the number of marker signals to generate a Ready signal.

Parameter No. 19-05

Gear ratio No.: Record the number of the gear ratio that is to be displayed in Parameters 1906 to

1910. First set the number of the gear ratio, then in Parameters 1906 to 1910 the necessary values for this gear ratio. The next gear ratio is then selected in Parameter 1905 and the same procedure is repeated.

Parameter No. 19-06

Gear ratio numerator: Record the numerator value for the gear ratio. That is the encoder pulses of the slave drive. To make fine adjustment possible by means of inputs 32 and 33 a ratio of for example 7:16 must be programmed as 7000:16000.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

4. Synchronisation

Parameter No. 19-07

Gear ratio denominator: Record the denominator value of the gear ratio. This value corresponds to the master pulses.

Parameter No. 19-08

Slave markers: Record the number of slave markers for the marker ratio. Ensure that the gear ratio and the marker ratio match each other.

Parameter No. 19-09

Master markers: Record the number of master markers for the marker ratio. Ensure that the gear ratio and the marker ratio match each other.

Parameter No. 19-10

Fixed Offset: Record a fixed position offset for the selected gear ratio (quad counts). This value specifies the position deviation between the slave marker and the master marker. During operation the offset can be changed by means of inputs 32 and 33. Note: Offset is related to the master position. Offset related to the slave position can be calculated as follows:

Syncronising Controller MCO 350 Operating

Instructions

Offset_slave

Parameter No. 19-11

Parameter No. 19-12

Step width: In marker synchronisation mode, Offset Parameter 1908 is changed by this value when Terminal 32 or Terminal 33 is activated.

Parameter No. 19-13

Slave speed factor: Record the factor by which the slave speed must be multiplied, so that the desired value is displayed. To calculate the value use the following formula:

Factor

Example:

resolution 1024 increments, desired display 100 at 15001/min

Factor

Parameter No. 19-14

Master speed factor: Record the factor by which the master speed must be multiplied, so that the desired value is displayed. To calculate the value use the following formula:

Set

1500

Offset x Par

Par

400

x Slaveencoder_resolution

min

60x100

.19− 06

.19− 07

xDisplay_value

400x1024

Umdr

Inkr

= 102400

400

Factor

Parameter No. 19-15

Synchronising error display factor: Record the factor by which the error must be multiplied, so that the desired value is displayed. To calculate the value, use the following formula:

MG.33.Q1.02 - VLT

Set

x Slaveencoder_resolution

xDisplay_value

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

400

Factor

The settings are automatically saved.

Set

xSlaveencoder_resolution

xDisplay_value

4.9.7. Operation and Operating Functions

After all the values have been set as described, the drive can now be operated normally.

Starting synchronisation

Synchronisation of the slave is started by means of SyncStart (I1), then the master is started. This ensures optimum synchronisation. The slave drive travels in position synchronisation to the master until both slave and master marker has been detected. The slave accelerates or slows down, according to the setting of Parameter 3323, in order to attain the marker position plus the set offset. It may happen that the slave drive travels faster than the master does, if the slave drive needs to catch up with the position.

Stopping synchronisation

On opening contact I1 (SyncStart), the slave is stopped at the permitted acceleration.

4. Synchronisation

Fine setting of the position

As soon as the slave drive is in position synchronisation to the master, an adjustment of this position can be made by means of Inputs 32 + 33. Note: Offset is related to the master position. Offset related to the slave position can be calculated as follows:

O ffset_slave

Switching to another gear ratio

During synchronisation, a new gear ratio can be selected at Inputs 9 and 10. The gear ratio is then activated by means of the Switching Input (I2). The slave will then proceed at the permitted acceleration to this new gear ratio. The offset is related to the first gear ratio after SyncStart. Therefore a stop and then start must be performed if the offset must relate to the latest gear ratio it the gear ratio has been changed.

Error procedure

Errors of tracking, over current etc. make the drive stop and the Ready output (O8) is set low. Reset is done with Input 27 or fieldbus bit 1.9. Reset is also possible with of the [Reset] button on the local control panel of the drive.

O ffset x Par

In case the drive has stopped because of earth fault or short-circuit, disconnect the drive from the mains before resetting!

Par

.19− 06

.19− 07

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

5. Appendix

Syncronising Controller MCO 350 Operating

Instructions

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

5. Appendix

5.1. Messages and Error Reference

5.1.1. Warnings and Error Messages

All messages are shown in the LCP display of the FC 300 in short and in the APOSS software in plain text. You can find brief information on the error messages in the table or detailed information in the following section. The tables contain the messages in numerical order. Letters following a % sign represent variables which can be used in plain text at the corresponding locations.

Error No. Error text Description

103 Illegal axis num. Axes not in system. 105 Error not reset Error not cleared. 106 Home not done Failed to move to HOME position. 107 Home vel. zero Home was executed with Home Velocity set to zero. 108 Position error Position error. 109 Index not found Index pulse (encoder) not found. 110 Unknown cmd. Unknown command. 111 SW end limit Software end limit activated. 112 Unknown param. Illegal parameter number. 113 FC not enabled FC 300 is not ready but the PID controller is active. 114 Too many loops Too many nested loops. 115 Par. save failed Parameters save failed. 116 Param. memory Parameters in memory are corrupted.

5. Appendix

117 Progr. Memory Programs in memory are corrupted. 118 Reset by CPU Reset by CPU. 119 User abort User abort. 125 HW end limit HW end limit activated. 149 Too many inter. Too many interrupt functions. 150 No ext. 24V External supply is missing. 151 Too many gosub Too many nested GOSUB commands 152 Too many return Too many RETURN commands. 154 D. out overload Digital Output overloaded. 155 LINK failed LINKGPAR command failed. 162 Memory error Error in verifying; EEPROM: address % defect. 170 Array sise (DIM) Error in DIM command. 171 Array too small Attempt was made to cross array bounds 179 Waitndx timeout Timeout while waiting for index. 184 Too many ontime Too many time interrupts. 187 Out of memory No more room for variables. 190 Memory locked The program memory is write-protected. 191 Illegal cam array Curve array wrong. 192 Encoder error Encoder error 199 Internal MCO fault Encoder error

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

5. Appendix

5.1.2. Errors

Syncronising Controller MCO 350 Operating

Instructions

Error 103 Illegal axis num.

An attempt has been made to find an axis which does not exist in the controller. Check to see if the program axis command has an invalid number or a general axis command (...X(*)).

Error 105 Error not reset

An attempt has been made to execute a motion command, although a momentary error message has not been cleared.

Error 106 Home not done

Failed to move to HOME position. According to the axis par. 33-00 Force HOME, a forced move to the machine zero-point is demanded, before other motion commands can be executed. This move to the machine zero-point has not been executed.

Error 107 Home vel. zero

An attempt was made to execute the HOME command but the motor is set to 0 in par.

Velocity of Home Motion.

33-03

Error 108 Position error

The distance between the set and the real position was greater than the Maximum Tolerated Position Error defined in par. 32-67. Causes:

- Mechanically blocked or overloaded

drive

- Par. 32-67

Error

- Commanded speed greater than FC

300 parameters 4-13

High Limit

Max. Tolerated Position

too small

and 3-03

Motor Speed

Maximum Ref-

erence

- Commanded acceleration too great

- Par. 32-60

small, or

- FC 300 not enabled.

Error 109 Index not found

Proportional Factor

too

At reference or index search, the encoder index pulse could not be found within a motor rotation. Causes:

- An encoder without an index pulse

has been used

- Index pulse not connected

- Index pulse incorrect (all three chan-

nels must have a simultaneous low), or

- The par. 32-01

(ENCODER) is set too low.

tion

Error 110 Unknown comm

Cause: A communication or program error. The program must be re-compiled and re-loaded.

Error 111 SW end limit

A motion command will cause or has caused the software end limit to be activated. Identification of attainment of software limit at a motion in the speed mode will only be made after the current position is identical to the software limit switch. The control unit will be switched off and the drive must be manually moved back to within the admissible area, or the monitoring of the software limit switch must be temporarily deactivated via the Negative and Positive Software End Limit in parameters 33-43 and 33-44. Only then is it possible to clear the error. In positioning mode, it will be known before motion start that the target position lies outside the path. In this case, the movement will not be executed and the error message can be cleared.

Error 112 Unknown param.

An attempt has been made to change a parameter (SET or SETVLT command), which does not exist.

Error 113 FC not enabled

FC 300 is not ready but the PID controller is active. The FC status word (Bit 09 and Bit 11) is monitored every 20 ms when the PID con-

Incremental Resolu-

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

5. Appendix

troller is active. The FC 300 is in the “Not ready” state when:

- It has an alarm

- It is in local mode

- Local LCP stop is activated

Error 114 Too many loops

Too many nested loops exist in the executed program.

Error 115 Par. Save failed

Saving of the option parameter failed.

Error 116 Param. memory

The parameters in EEPROM are no longer correct because of

- EEPROM defective or

- Power outage while saving

NB!

You have to re-initialise the parameter with a 14-22 Reset and then overwrite these parameters again with your own application parameters.

The processor has been stopped and a re-set has automatically been executed (watchdog). Causes could be:

- Short term voltage drop

- Voltage peak, or

- Short circuit

Error 119 User abort

Autostart

The the user. Or the [CANCEL] key was pressed during switching on and a Master Reset triggered.

Error 125 HW end limit

A motion command has caused an axis limit switch to be activated. Through activation of an end limit switch, the controller (depending on the par. 33-40

haviour at End Limit Switch

switched off and the drive must be manually moved out of this position, before the error message can be cleared.

Error 149 Too many inter.

More interrupt functions than the maximum possible number were used. Permitted are:

program has been aborted by

be-

) is automatically

Otherwise motion programs which require application parameters will no longer function correctly.

Error 117 Progr. Memory

The program data stored in EEPROM cannot be found or are no longer correct because of

- EEPROM defective or

- Power outage while saving

You have to do a 3-finger reset to reset all parameters to their defaults (ex factory) and to delete all user programs, arrays, and application parameters. Afterwards re-load the programs and parameters. This corresponds to the →

or a →

PROM

menu.

Error 118 Reset by CPU

Reset complete

Erase Option EE-

in the APOSS

32 ON INT 32 ON STATBIT 32 ON COMBIT 10 ON PARAM 20 ON APOS, ON MAPOS, ON MCPOS

Error 150 No ext. 24V

External supply is missing.

Error 151 Too many gosub

In the program exists too many calls from one subroutine to another subroutine. The error usually occurs when there is a recurrent reference to one of the subprograms in a subprogram. Avoid too many (10 is maximum) opposing subroutine calls, and avoid subroutines which call themselves (re-cursive subroutine procedures).

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

5. Appendix

Syncronising Controller MCO 350 Operating

Instructions

Error 152 Too many return

There are either more RETURN than corresponding GOSUB commands in the program, or there is a direct jump from a subroutine with a GOTO command. Only one RETURN is allowed per subprogram. It is always better to jump to the beginning of a subprogram and then to jump with IF… to a previously defined label.

Error 154 D. out overload

Digital output overloaded.

Error 155 LINK failed

LINKGPAR command failed.

Error 162 Memory error

After saving something in the EEPROM (a program or parameters) an error was detected during verification. Delete the EEPROM with a 3-finger reset and try to save the program or parameters again. If this is not successful please call the technical service department.

Error 170 Array sise (DIM)

The definition of an array in a DIM command does not correspond to an already existing array in the MCO 350. Cause might be that the fields are from older SYNCPOS/APOSS programs. The current program has other definitions. Either adapt the APOSS program to the correct array sise or delete the old arrays.

NB!

Remember to follow the recommendations concerning saving programs and parameters before deleting the EEPROM.

Error 171 Array too small

An attempt was made to describe an array element that is located outside of the defined array limits. Cause might be an error in the APOSS program. Array sising does not agree with the space required (e.g. due to an incorrectly programmed loop).

Or the array is too small for the number of test drives triggered by TESTSTART. Check loop variables.

Error 179 Waitndx timeout

The command WAITNDX was executed and the timeout listed was exceeded. The timeout is probably too short or the index impulse could not found (see also Error 109).

Error 184 Too many ontime

Too many interrupts (ON TIME or ON PERIOD commands) were used within the program. A maximum of 12 of these ON TIME and/or ON PERIOD commands are allowed within one program.

Error 187 Out of memory

No more space for variables. When the APOSS program is started the space for the necessary variables is reserved dynamically. This space is now no longer available. You may have selected a maximum number of variables which is too high. Reduce the maximum number in ard = 92). Or the memory available is occupied with programs or arrays. Delete the programs or delete both the programs and arrays, i.e. by deleting the entire memory.

Error 190 Memory locked

The program memory is write-protected and cannot be altered. This means that auto recognition can neither be set nor deleted and programs can neither be saved nor deleted. Equally, →

EEPROM delete

and →

Error 191 Illegal cam array

An incorrect or old array is defined in the DIM instruction for SETCURVE.

Settings Compiler→

NB!

Remember to follow the recommendations concerning saving programs and parameters before deleting the EEPROM.

will not be executed.

(Stand-

RAM

save

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

An old array may exist if the CNF file with all parameters and arrays has not been loaded into the An incorrect array could be caused by the following:

Error 192 Encoder error

Error from encoder monitoring: open or short circuit in accordance with the displayed LED.

CAM-Editor.

- It was not created by the curve edi-

tor

- Previous version of a curve editor.

Such an array must first be converted by the current CAM-Editor (→

load

and

save

)

- Or the order of the arrays in the DIM

instruction does not match the order in the cnf file. Refer to the number of the array in the title bar of the

in this respect.

Editor

5. Appendix

CAM-

NB!

An error will be indicated even if no encoder is connected.

Error 199 Internal MCO fault

If such an error should occur, please contact your dealer and report the error number displayed to the technical service department.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

5. Appendix

5.2. Parameter Overview

5.2.1. Parameter Overview: 1900

Parameter Number Description 1900 Store Data

Factory setting: 0 Setting range from 0 - 1

User setting:

1901

1902

User setting (%):

1903

User setting:

User setting (%):

Test run: Program 1:

Test Run Speed

Factory setting: 10% Setting range from 1 - 100%

User setting (%):

Synchronous Operation: Program 2:

Type of Operation

Factory setting: 0 Setting range from 0 - 7

User setting:

Test run: Program 1:

Test Run Acceleration

Factory setting: 10% Setting range from 1 - 200%

Synchronous Operation: Program 2:

Hold Function

Factory setting: 0 Setting range from 0 - 1

User setting:

Test run: Program 1:

Test Run Distance

Factory setting: 4096 quad counts Setting range from 1 - 2147483647 quad counts

Synchronous Operation: Program 2:

Hold Speed

Factory setting: 10% Setting range from 0 - 100 %

Syncronising Controller MCO 350 Operating

Instructions

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

Parameter Number Description 1904

User setting:

1905

User setting:

Gear Ratio No.

5. Appendix

Test run: Program 1:

Synchronising Type (Sync Type)

Factory setting: 0 Setting range from 0 - 1

Synchronous Operation: Program 2:

Delta Hold Speed

Factory setting: 5% Setting range from 1 - 100 %

User setting (%):

Test run: Program 1:

Activate Feed Forward and PID Calculation (FFVEL calc.)

Factory setting: 0 Setting range from 0 - 2

Factory setting: 0 Setting range from 0 - 3

1906 Gear Ratio Numerator

Factory setting: 1000 Setting range from - MLONG - MLONG

1907 Gear Ratio Denominator

Factory setting: 1000 Setting range from - MLONG - MLONG

1908 Slave Marker Quantity

Factory setting: 1 Setting range from 1 - 2147483647

1909 Master Marker Quantity

Factory setting: 1 Setting range from 1 - 2147483647

1910 Fixed Offset

Factory setting: 1 Setting range from -2147483647 - 2147483647

1905 Gear Ratio No. 1 2 3 4 1906 Numerator 1907 Denominator 1908 Slave Markers 1909 Master Markers 1910 Fixed Offset

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

5. Appendix

Syncronising Controller MCO 350 Operating

Parameter Number Description 1911 Step Time

Factory setting: 100 ms Setting range from 10 - 2147483647 ms

1912 Step Width

1913 Slave Speed Factor

1914 Master Speed Factor

1915 Synchronising Error Display Factor

1916 Virtual Master Reference Value

1917 Virtual Master Acceleration

1918 Virtual Master Maximum Speed

User setting (ms):

Factory setting: 1 Setting range from -2147483647 - 2147483647

User setting:

Factory setting: 400 Setting range from 1 - 2147483647

User setting:

Factory setting: 400 Setting range from 1 - 2147483647

User setting:

Factory setting: 400 Setting range from 1 - 2147483647

User setting:

Factory setting: 0 Setting range from 0 - 3

User setting:

Factory setting: 25600

Setting range from 1 - 2147483647Hz/

User setting (Hz/s):

Factory setting: 25600 Setting range from 1 - 21474836471/

User setting (Hz/s):

Instructions

1919 Control Source Test Run (Contr. testrun)

Factory setting: 0 Setting range from 0 - 1

User setting:

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

Parameter Number Description 1920 Control Source Synchronising (Contr. synchron)

1921 Brake on Delay (Brake on delay)

1922 Brake Off Delay (Brake off delay)

1923 Marker Monitor (Marker monitor)

5. Appendix

Factory setting: 0 Setting range from 0 - 1

User setting:

Factory setting: 0 Setting range from 0 - 5000 msec.

User setting (msec.):

Factory setting: 0 Setting range from 0 - 5000 msec.

User setting (msec.):

Factory setting: 0 Setting range from 0 - 2

User setting (msec.):

1924 Resync. (Resync.)

Factory setting: 0 Setting range from 0 - 1

User setting:

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

5. Appendix

5.2.2. Parameter Overview: 3200

Parameter Number Description 3200 Slave Incremental Encoder Type

Factory setting: 1 Setting range from 0 - 2

3201 Slave Incremental Encoder Resoulution

3202 Slave Encoder Absolute Protocol

3203 Slave Encoder Absolute Resolution

3205 Slave Encoder Absolute Data Length

3206 Slave Encoder Absolute Clock Frequency

3207 Slave Encoder Absolute Clock Generation

3208 Slave Encoder Absolute Cable Length

3209 Slave Encoder Hardware Monitor

User setting:

Factory setting: 1024 Setting range from 1 - MLONG

User setting:

Factory setting: 0 Setting range from 0 - 5

User setting:

Factory setting: 8192 Setting range from 1 - MLONG

User setting:

Factory setting: 25 Setting range from 8 - 37

User setting:

Factory setting: 262000 Setting range from 78125 - 2000000

User setting:

Factory setting: On Setting range from Off - On

User setting:

Factory setting: 0 Setting range from 0 - 300

User setting:

Factory setting: Off Setting range from Off - On

Syncronising Controller MCO 350 Operating

Instructions

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

Parameter Number Description 3210 Direction of Rotation

3230 Master Incremental Encoder Type

3231 Master Incremental Encoder Resolution

3232 Master Encoder Absolute Protocol

3233 Master Encoder Absolute Resolution

3235 Master Encoder Absolute Data Length

3236 Master Encoder Absolute Clock Frequency

3237 Master Encoder Absolute Clock Generation

3238 Master Encoder Absolute Cable Length

User setting:

Factory setting: 1 Setting range from -2 - 2

User setting:

Factory setting: 1 Setting range from 0 - 1

User setting:

Factory setting: 1024 Setting range from 1 - MLONG

User setting:

Factory setting: 0 Setting range from 0 - 5

User setting:

Factory setting: 8192 Setting range from 1 - MLONG

User setting:

Factory setting: 25 Setting range from 8 - 37

User setting:

Factory setting: 262000 Setting range from 78125 - 2000000

User setting:

Factory setting: On Setting range from Off - On

User setting:

Factory setting: 0 Setting range from 0 - 300

5. Appendix

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

5. Appendix

Syncronising Controller MCO 350 Operating

Parameter Number Description 3239 Master Encoder Hardware Monitor

Factory setting: Off Setting range from Off - On

3240 Master Encoder Hardware Termination

3260 P-Portion

3261 D-Portion

3262 I-Portion

3263 Limitation for I-Portion

3264 Band Width PID Controller

3265 Velocity Feed Forward

3266 Acceleration Feed Forward

User setting:

Factory setting: On Setting range from Off - On

User setting:

Factory setting: 10 Setting range from 0 - 65000

User setting:

Factory setting: 0 Setting range from 0 - 65000

User setting:

Factory setting: 0 Setting range from 0 - 65000

User setting:

Factory setting: 1000 Setting range from 0 - 65000

User setting:

Factory setting: 1000 Setting range from 0 - 65000

User setting:

Factory setting: 0 Setting range from 0 - 65000

User setting:

Factory setting: 0 Setting range from 0 - 65000

Instructions

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

Parameter Number Description 3267 Maximum Track Error

3268 Reversing Behaviour

3269 PID-Sample Time

3280 Maximum Speed

3281 Minimum Ramp

3282 Ramp Type

User setting:

Factory setting: 10000 quad counts Setting range from 1 - 2147483647

User setting (quad counts):

Factory setting: 0 Setting range from 0 - 2

User setting:

Factory setting: 1 ms Setting range from 1 - 1000 ms

User setting (ms):

min

Factory setting: 1500 Setting range from 1 - 65535 1/

User setting (1/

Factory setting: 100 ms Setting range from 50 - 2147483647 ms

User setting (ms):

Factory setting: 0 Setting range from 0 - 1

5. Appendix

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

5. Appendix

5.2.3. Parameter Overview: 3300

Parameter Number Description 3300 Home Force

Factory setting: 0 Setting range from 0 - 1

3302 Home Acceleration

3303 Home Velocity

3304 Home Force Function

3313 Accuracy

3314 M-S Tolerance Speed

3317 Marker Inter val at t he M as t er

3319 Master Marker Type

User setting:

Factory setting: 10 % Setting range from 1 - 200 %

User setting (%):

Factory setting: 10 % Setting range from 0 - 100

User setting:

Factory setting: 0 Setting range from 0 - 4

User setting:

Factory setting: 1000 quad counts Setting range from -2147483647 - 2147483647 quad counts

User setting (quad counts):

Factory setting: 0 % Setting range from 0 - 100 %

User setting (%):

Factory setting: 4096 quad counts Setting range from 0 - 2147483647 quad counts

User setting (quad counts):

Factory setting: 0 Setting range from 0 - 3

User setting:

Syncronising Controller MCO 350 Operating

Instructions

3320 Slave Marker Type

Factory setting: 0 Setting range from 0 - 3

User setting:

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

Parameter Number Description 3321 Marker Window Master

3322 Marker Window Slave

3323 Master Synchronising Mode

3324 Marker Quantity FAULT

5. Appendix

Factory setting: 0 Setting range from 1 - 2147483647

User setting:

Factory setting: 0 Setting range from 1 - 2147483647

User setting:

Factory setting: 0 Setting range from 0 - 1005

User setting:

Factory setting: 5 markers Setting range from 1 - 10000 markers

User setting (markers):

3325 Marker Quantity READY

Factory setting: 10 markers Setting range from 1 - 10000 markers

3326 Velocity Filter

User setting:

User setting (markers):

Factory setting: 0 Setting range from 0 - 65000

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

5. Appendix

5.3. Glossary of Key Terms

Master-Slave

It means that a signal is taken from a master drive. The signal is then used to control a second “slave“ drive that follows the master. The master drive does not have to be a drive; it can be any given part of a power transmission system.

Incremental Encoder

This is an encoder system that picks up the speed and the direction of rotation and transmits on the appropriate configuration. The number of tracks, and thus the number of signals, indicate the properties of the encoder system. There are single-track systems that deliver a pulse signal dependent on the speed as well as a fixed direction signal. Dual-track systems deliver two pulse signals that are offset 90 degrees. By evaluating the two tracks, the direction signal is also obtained. Three-track encoders deliver, as well as the two tracks of the dual-track encoder, an additional “zero-track“. This emits a signal when the zero transit is passed through.

Incremental Encoder Signals

Syncronising Controller MCO 350 Operating

Instructions

Quad Counts

Through edge detection, a quadrupling of the increments is produced by both tracks (A/B) of the incremental encoder. This improves the resolution.

Absolute Encoder

This is a special form of encoder, as it indicates the absolute physical position. This is communicated via transfer of the position in parallel form or in the form of a telegram in serial form. Absolute encoders also come in two versions: Single-Turn encoders supply an absolute position on a shaft rotation; Multi-Turn encoders can report the absolute position via a specific quantity, or via a freely definable number of rotations.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

Track Error

The synchronising controller of the slave drive uses the master drive signal and the gear ratio to calculate a reference position value for the slave drive. The deviation of the feedback position from the calculated position is known as the track error. This is specified in quad counts. The maximum track error is also a threshold value that defines the permitted operating area of the synchronising controller.

Accuracy

This value specifies the permitted deviation between the master and slave at which synchronisation is still present.

PPR

Pulses per revolution.

Virtual master

If several axes are to travel in synchrony, or if the synchronisation error is so to be kept as small as possible, it is often more advantageous not to take the reference position from a drive, but to have a master that simulates the reference position. This has the advantage that the cycle times of the individual drives are not added. These differences are illustrated below for the synchronous control of three conveyor belts. First, we show the classic synchronisation procedure where the reference value signal is taken from the preceding drive in each case.

5. Appendix

Illustration 5.1: Synchronisation without Virtual Master

As can be seen from the diagram below, at Start, as well as with every change in speed of the master drive, the cycle times are added. They are then compensated for again based on the control characteristics of the controller in question.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

5. Appendix

Syncronising Controller MCO 350 Operating

Instructions

Illustration 5.2: Addition of the Cycle Times

In this case, the same application is realised by means of incorporating a virtual master. Although the way that the reference value is introduced at the first belt is analogous, the value is used to set the virtual master signals.

Illustration 5.3: Synchronisation with Virtual Master

It can be seen from the diagram below that the cycle time error is not added; instead, one cycle time applies for all the drives. The advantage of this is that the control has fewer errors to correct.

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Syncronising Controller MCO 350 Operating Instructions

Illustration 5.4: No Addition of the Cycle Times

5. Appendix

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Index

Syncronising Controller MCO 350 Operating

Instructions

Index

Absolute Encoder 96

Acceleration Feed Forward 38

Accuracy 40

Activate Feed Forward 28

Admixture 51

Angle Synchronisation 58

Application Example 62

Approvals 5

Band Width Pid Controller 92

Brake Off Delay 12

Brake On Delay 33

Calculation 13

Changing The Gear Ratio With An Analogue Value 51

Control Source Synchronising 89

Control Source Test Run 32

Corrected Numerical Values 13

Data Layout 23

Delta Hold Speed 28

Denominator 29

Description Of Fieldbus Interface 23

Description Of Parameters 27

Description Of Terminals 51

Digital Inputs: 17

Digital Outputs 17

Direction Of Rotation 36

Disposal Instruction 5

D-portion 37

Earth Leakage Current 6

Embossing Patterns On Mould 62

Encoder Monitor 16

Encoder Resolution 53

Encoder Velocity 29

Error Messages 81

Error Procedure 58

Error Reference 81

Example Of Encoder Interface Connections 19

Ffvel Calc 28

Fieldbus Control Signals 24

Fieldbus Status Signals 25

Fine Setting Of The Gear Ratio 58

Fine Setting Of The Position 68

Fixed Offset 30

Function Description 11

Function Diagrams For Marker Synchronisation 69

Function Diagrams For Position Synchronisation 60

Function Diagrams For Speed Synchronisation 47

Gear Changing 50

100

MG.33.Q1.02 - VLT

is a registered Danfoss trademark

Danfoss VLT 6000 HVAC Operating guide

Specifications and Main Features

Frequently Asked Questions

User Manual