Danfoss VLT 6000 HVAC Operating guide

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

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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

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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

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1. Safety Regulation

Syncronising Controller MCO 350 Operating

Instructions

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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:

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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

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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

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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

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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

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2. Introduction

Syncronising Controller MCO 350 Operating

Instructions

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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.

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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

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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

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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

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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)

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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:

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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.

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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

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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)

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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.

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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.

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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

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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:

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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.

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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)

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3. Programming

Syncronising Controller MCO 350 Operating

Instructions

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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”).

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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

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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).

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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

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