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Operating Instructions

1. 8 MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller EXTERNAL SUPPLY DIGITAL IN OUTPUT MK3A ON qu MK3C 01 02 03 04 05 06 07 NNNNNNNA 08 SW 1 1 OFF 24V V CONTROL CARD COM SW 1 2 OFF 24V COM EXTERNAL SUPPLY 24Vd c 175ZA259 13 MG 50 P3 02 VLT is a registered Danfoss trademark E NCE Wl 1757A068 10 DANFOSS ufi Positioning Controller Technical Data 10 Terminals I EE EE EE OE N EE DE Plugs with screw connections Maximum cable size sees se ee Re ee ee a ee ee ee ee ee ee ee Ee ee enn nent nenne 1 3 mm AWG 16 Digital inputs MK3A Terminal designationS il pe e e b te d 11 18 Voltage leva laicos cete tene bee cott te ide 0 24 V DC PNP positive logic Voltage threshold logical Os bsr enerne anani T AA ee nn enne nnne nnn tenter nennen nns 5V DC Voltage threshold logical 15 2 rei rt e E Rp e ee EUR EE Ee 10 V DC Maximum voltage s nto ave oleae ORE i te ENG 28 V DC Input impedance ii eet tete tree tet e lt OE IE ire 4kQ Min pulse duration ON INT ccceccceeeeeceeeeeceseeceeeeeeeaeeesaaeeeeaeeseaeeecaaeeesaaeedeaeeseeeeesaeeseaeseeeeesneeeeaas 1 msec Galvanic isolation All digital inputs are galvanically isolated by means of optocouplers but with the same common
2. 0 but without the search for the index position Instead the HOME position is defined as the position at which the reference switch goes low After defining the HOME position the drive is then ramped down with the home ramp P729 and stopped MG 50 P3 02 VLT is a registered Danfoss trademark 27 ad Positioning Controller No Parameter Default Range Description value 2 Like 0 but without reversing before leaving the reference switch Rather the movement is slowly continued in the same direction out of the switch 32 Like 1 but without reversing before leaving the reference switch Rather the movement is slowly continued in the same direction out of the switch 732 User unit numerator 1 000 1 100 000 P732 and P733 together define the ratio between User Units UU and quad counts QC Let s illustrate this parameter with the follo wing example By measurement it has been determined that 1000 mm of travel correspond to 16345 QC quad counts USER UNIT NOM Now instead of defining the target positions in QC but rather in mm the setting of P732 must be 16345 and the setting of P733 must be 1000 NB The target positions stored in memory is defined according to the settings of P732 P733 so changing the P732 P733 ratio might require that up to 32 positions must be reprogrammed to achieve the same result as before the change 733 User unit 1 000 1 100 000 P732 and P
3. Operating Instructions Positioning Controller VLT 5000 VLT 5000 FLUX Positioning Controller Danfoss Table of contents Safety regulations Introduction H rd ri Emm VET control card tet amp mimals mee RO Uere ed Techmcal data uc ds Option card terminals eee PR PD erp POR REED t rire EP e piena e ri E e oe GEGEE rE ge is lb Ep Encoder monitor i ete eie it bec ee ice Ii bete e DIR br EE EE sedans Option card layout SEE RE eG tte ek ep Reed Se ae BO ee i ee ee Technical Data cion ii 10 Description of the electrical and field bus interface 12 Electrical interface VET rette rr or EE pe EE EE EE EE e 12 Option card MK3A n eoe DE een ueni ic 14 Optoncard MKSE i e Ee SE Es ESE tii 15 Option card MK3B secondary position feedback for absolute encoders when using VLT 5000 Flux 15 Option card MK3D primary position feedback sesse se see ee ee se eene nono nooo nc en eene be ee ee ee 16 Field Dus niue RR 17 Data Layout rx NN 17 Description of the available parameters 20 Special LCP ie RE OE ose dece ee e ive tote E A EE EE OR OS 20 D seription of parametets eee teet rident ere dine ree eese ep Se VER Ge GR ee pere Ee ed Sek e ok Ken Gede gee ee 21 An application example 35 Wiring diagram eso ea NERO AIRE 36 Basic Ein EE D E ER EE er HER 36 Parameter SEEN PS ie ot Rc Reuse A 38 Troubleshooting 41 Frequently asked Questio
4. 1 enabled When the power recovery function is dis abled 0 it is not possible to drive the application by any means neither jogging nor positioning as long as the application is outside the HW or SW limits The only way to recover from this situation is to move the application by hand When the power recovery function is activated 1 however it is possible to make a partial reset of the limit error P798 2 3 4 5 whereby it will be possible to use the jogging function to drive the application out of the HW or SW limit area It is not possible to drive the application otherwise by means of homing positioning or jogging in the wrong direction as long as the application is still within the HW or SW limit area The error occurred output MK3C 2 will remain high to indicate that these restrictions are in effect As soon as the application is moved outside the HW or SW limit area the error is automatically cleared and the error occurred signal goes low to indicate that normal operation is now restored 737 Link LCP input to index LINK INDEX INPUT 0 disabled 1 enabled When activating this function 1 P738 will be automatically updated with the last posi tion reference number that has been loa ded into memory This enables to operator to see what position reference is currently given by the PLC system The function is deactivated when set to 0 This is necessary when pr
5. Positioning Controller Field bus Field bus mode Corresponding input word bit 1 11 Quick Bus Type Absolute T N A 1 12 Quick Bus Type Relative 7 N A 1 13 Quick Bus Type Touch Probe positive T N A 1 14 Quick Bus Type Touch Probe negative T N A 1 15 Teach in via LCP or fieldbus T KEYPAD JOG amp FW D REW 1 16 Change sign on Quick Bus Target Position 7 N A 2 Quick Bus Target Position MSB N A 3 Quick Bus Target Position LSB N A 4 Quick Bus Target Velocity N A 5 Quick Bus Target Acceleration N A 6 Quick Bus Target Deceleration N A 7 1 Reference index bit 0 LSB T 16 7 2 Reference index bit 1 T 17 7 3 Reference index bit 2 T 18 7 4 Reference index bit 3 T 19 7 5 Reference index bit 4 Digital MSB T 29 7 6 Reference index bit 5 Fieldbus MSB T N A MG 50 P3 02 VLT is a registered Danfoss trademark Field bus status signals Positioning Controller Danfoss Field bus Field bus mode Corresponding word bit output parameter 1 1 Homing done T 1 1 2 Referenced position reached T 2 1 3 Error occurred T 3 1 4 Electro mechanical brake output T 04 1 5 Touch probe position locked T 42 26 Flux 1 6 Watchdog output toggling 45 46 Flux 1 7 Positive hardware limit T N A 1 8 Negative hardware limit T N A 2 1 Current index bit 0 LSB T 4 2 2 Current index bit 1
6. REV buttons to store that position in memory 20 MG 50 P3 02 VLT is a registered Danfoss trademark Description of parameters Positioning Controller Past No Parameter Default value Range Description 701 Operating mode POSITIONING MODE 1 1 POSITIONING This parameter never needs changing 702 703 Proportional gain PROP GAIN Derivative gain DER GAIN 30 1 65 000 0 65 000 The proportional gain is the factor that is multiplied with the PID tracking error to produce the proportional part of the output frequency The higher the setting of this parameter the harder is the resulting control NB Too high a setting of this parameter will cause the controller to become unstable The derivative gain is the factor that is multiplied with the change in the PID tracking error to produce the derivative part of the output frequency The higher the setting of this parameter the harder is the resulting control The derivative gain has best effect if the encoder is mounted directly on the motor and an encoder with good resolution 4096 pulses rev is used NB Too high a setting of this parameter will cause the controller to become unstable 704 Integral gain INT GAIN 0 65 000 The integral gain is the factor that is multi plied with the integrated PID tracking error to produce the integral part of the output frequency The ma
7. T 5 2 3 Current index bit 2 T 6 24 Current index bit 3 T 7 2 5 Current index bit 4 Digital MSB T 8 2 6 Current index bit 5 Fieldbus MSB T NA 3 Actual Position MSB 795 MSB 4 Actual Position LSB 795 LSB 5 Error Status 798 MG 50 P3 02 VLT is a registered Danfoss trademark ad Positioning Controller Description of the available parameters Special LCP functions Multiple parameters display To have multiple read only parameters displayed at once on the LCP simply press the DISPLAY STATUS button after start up This will prompt the top line of the LCP to display up to three read only parameters that can be specified in PO10 PO11 and PO12 The default settings will bring up the following display 175ZA571 11 OPT 98 OPT 97 PT 95 QF DISPLAY QUICK MENU STATUS MENU CHANGE Ml CANCEL DATA A the error status In the middle P797 the PID tracking error To the right P795 the actual D position O ALARM WARNING QOON A STOP FWD RESET JoG REV START Figure text To the left P798 Holding down the DISPLAY STATUS button will display which parameters are shown in the top line of the display The TEACH IN function Pressing the JOG and FWD REV buttons at the same time will cause the target position P739 to be updated with the actual position This provides an easy way of programming several positions Simply jog to the desired position then press the JOG and FWD
8. 100 P724 Default 1500 P728 Default 0 P734 Default 0 P747 Default 0 P777 Default 0 P778 0 no password protection required Timing of the electromechanical brake P715 P718 If the application is not equipped with an electromechanical brake P716 P718 are not very important Then however it is very important to set P715 to 0 to enable the drive also at standstill This application is equipped with mechanical brakes to allow it to stop rapidly even if the drive is some how prevented from stopping the motor damaged motor cables damaged or short circuited motor inverter overload and so on P716 P718 is provided to time the interaction between the mechanical brake and the drive A description of these parameters can be found in the parameter list above In this application the default values of P716 and P717 is used 200 ms but the P718 setting is changed to 30 seconds to minimize wear of the brake Setting P732 and P733 38 Distances are measured in quad counts QC but defined in millimetres Therefore it is necessary to measure how many QC correspond to how many millimetres To do this the cart is first moved as far to the left as possible by activating the Manual jog negative input terminal 54 The position is then marked on the application and the corresponding value of P795 is noted Then the cart is moved as far to the right as possible by activating the
9. By setting this parameter to 1 it is pos sible to clear the error flag provided that 1 reset error the reason for the error is not still present RESET ERROR The parameter automatically resets to 0 when the error is successfully cleared 728 Home offset 0 UU 33 554 432 This parameter defines an offset to the 33 554 431 UU zero HOME position Any change in this setting will immediately affect the actual HOME OFFSET position displayed in P795 UU 729 Home ramp time 5 000 ms 50 100 000 ms The home ramp time is defined as the time in milliseconds it would take to ramp from standstill to the maximum allowed velocity HOME RAMP TIME P799 730 Home velocity 100 ERPM 20 000 20 000 The home velocity is entered here Notice ERPM that the sign of the velocity determines the direction in which the homing sequence HOME VELOCITY will be performed 731 Home type 0 2 3 There are six types of homing sequences 2 No homing is needed the actual posi HOME TYPE tion when using an incremental enco der after power up is set in parameter 750 1 No homing is needed the actual position when using an incremental encoder after power up is zero 0 2 The drive moves to the reference switch MK3A 4 with home velocity P730 then reverses and slowly at 3096 of home velocity leaves the switch subsequently moves to the next index pulse The HOME position is defined as that index position 12 Like
10. Flux in closed loop mode In that case input MK3D has an incremen tal encoder fitted feedback for Flux and MK3B has an absolute encoder fitted for positioning feedback The text in parame ter 713 and 714 changes accordingly 749 Control source 0 0 1 Choose control source for pos controller Enter 0 for digital inputs or 1 for fieldbus FIELDBUS MODE control 750 User APOS setting 0 1 073 741 824 At power up if homing type is 2 see 1 073 741 824 parameter 731 the actual position is equal SET APOS the value set here 751 Positive SW limit 1 0 1 Enter 0 to disable positive software limit active switch This should be done only when not positioning within two fixed limits POS SW LIM ACT 752 Negative SW limit 1 0 1 Enter 0 to disable negative software limit active switch This should be done only when not NEG SW LIM ACT positioning within two fixed limits 32 MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller Danfoss No Parameter Default Range Description value 753 Endless positioning 0 0 1 Set this parameter to 1 if drive must per form positioning continuously in one direc tion Remember to also set parameter 751 ENDLESS POS 752 and 736 to 0 776 Factory reset 0 0 disabled By setting this parameter to 1 it is 1censbl d possible to reset all pa
11. as input for the absolute encoder and enter 1 in parameter 748 Then enter the absolute encoder type and resolution in parameter 713 and 714 9 Repeat step 8 to 10 to test the encoder direction 10 Press the DISPLAY STATUS button on the VLT 5000 control panel Now the following values appear in the upper line of the display Error status PID tracking error actual position 11 Rotate the slave drive motor shaft manually in the positive direction you can repeat step 7 Now the display should show an ascending count of the actual position 12 If the count is descending with an incremental encoder exchange the feedback encoder track A by B and A by B If there is no counting in the display then check the wiring of the encoder When you have tested the encoders and the wiring of motor and encoders continue as follows 13 Change parameter 002 back to Remote and start the VLT 5000 by pressing the START button on the local control panel LCP 14 Select Enable syncpos in P700 15 Reset any error by toggling input 27 Now you come to the test run 16 Drive the application back and forth by closing the contacts on terminal 53 positive direction or terminal 54 negative direction Watch the PID track error via the LCP display during these tests Now you can optimise the controller 17 Optimise the Feed forward velocity P707 by following the procedure described in the parameter list for P710 parameter the FFVEL aut
12. ms 0 1 000 ms Used in conjunction with the automatic brake control function The brake delay is the delay after activating the control and BRAKE DELAY magnetizing the motor before the brake is deactivated Useful in applications with typically large motors that take a longer time to be fully magnetized than the time it takes for the electro mechanical brake to deactivate 718 Hold delay 0s 0 10 000 s Used in conjunction with the automatic brake control function The hold delay is a waiting period in which the brake is not HOLD DELAY activated even though the application is at standstill Useful in applications where a sequence of fast positioning commands is followed by longer standstill periods 719 Quick ramp time 5 000 ms 50 65 535 ms The quick ramp time is defined as the time to ramp down from the maximum velocity to standstill QUICK RAMP NIE TIME The quick ramp time is used when the quick stop function is activated or an error has occurred 720 Ramp type 0 0 trapezoidal Select trapeze shaped ramps to get the l optimal acceleration 1 sinusoidal RAMP TYPE 721 Motor encoder gear 1 1 1 000 If the encoder is mounted on a gear where nominator 5 revolutions of the motor correspond to 2 revolutions of the encoder P721 should be set to 5 the number of motor revolutions MOT ENC GEAR and P722 should be set to 2 the number Non of encoder revoluti
13. transporting a loaded pallet and travelling at its top speed it is not allowed to simply activate the electromechanical brake all the products on the pallet would be scattered across to floor because of the deceleration So if a safety cage or other safety device is opened and the quick stop input is activated the drive should ramp down with the appropriate ramp and then activate the safety brake This functionality is achieved by setting P725 to 0 and tuning P719 to the lowest allowable setting Other settings P726 P735 P736 P746 The maximum PID track error was brought down to approximately 100 QC during the optimising sequence described above steps 17 20 Therefore it is an indication of an error if the PID track error should suddenly grow larger than approximately 200 QC Thus P726 Maximum tolerated PID error is set at 200 The maximum tolerated travel of the brake before replacement is estimated at 4 mm so P735 Brake wear limit is set to 4 If the application for some reason should ever go into the not allowed area beyond the SW limits it should be possible to bring the application back into the allowed area by resetting the limit error and using the jog inputs This is achieved by setting P736 Power recovery to 1 The allowed position tolerance is defined to be 10 mm in this application so P746 Target position window is set to 10 40 MG 50 P3 02 VLT is a registered Danfoss trademark Posi
14. 4 8 175ZA818 10 First check the motor connection Please be ware the mechanical brake control cannot be trusted during this basic setup therefore control brake externally from the option until setup is finished Also ensure that the motor can rotate freely without causing damage or injury to personal Remove all signals to inputs 16 33 and 11 18 Only Input 27 coast 18 q stop l HW limit and 12 HW limit must be connected and high Select Disable syncpos in P700 Select Local function in Parameter 002 VLT 5000 stops display flashing Input the motor name plate data in P102 P106 and activate the Automatic Motor Adaptation function in P107 1 2 3 MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller Data 5 Press the START button on the VLT 5000 control panel and wait for the AMA to be completed 6 Setthe frequency for a low positive value for example 3 Hz in Parameter 003 please note that motor should now rotate 7 Press the START button on the VLT 5000 control panel and then the STOP Reset button watching the direction of rotation on the motor If the motor rotates in the wrong negative direction then exchange the motor phases When you have tested the motor speed direction you test encoder connection as follows if an incremental encoder is used go to step 10 if an absolute encoder is used go to step 8 8 If you are using a VLT 5000 Flux remember to use MK3B
15. 733 together define the ratio denominator between User Units UU and quad counts QC The setting of this parameter is illustrated in the description of P732 USER UNIT DEN NB The target positions stored in memory is defined according to the settings of P732 P733 so changing the P732 P733 ratio might require that up to 32 positions must be reprogrammed to achieve the same result as before the change 734 Block reversal 0 0 no blocking By selecting 1 it is defined as an error situation Reverse operation prohibited P798 12 if the drive is moving in reverse BLOCK 2 block forward direction DIRECTION 1 block reverse By selecting 2 it is defined as an error situation Forward operation prohibited P798 13 if the drive is moving in forward direction Selecting 0 disables the function 28 MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller Past No Parameter Default value Range Description 735 Brake wear limit BRAKE WEAR LIMIT 0 0 disabled 1 073 741 824 UU Setting a value higher than 0 disabled the drive defines an error situation Brake wear limit exceeded P798 7 if the drive moves more than the number of UU specified in this parameter while the elec tronic brake is activated 736 Power recovery POWER RECOVERY 0 disabled
16. IES Reference index Bit 4 Reference position index number bit 4 most significant bit Not used in field bus mode EEN Go to HOME position While this input is high the drive executes the homing sequence While this input is high no position or jog operations are carried out Any homing sequence is interrupted by a low state on this input Not used in field bus mode MEE LATCH new reference Active on the rising edge must be 0 min 1 ms to guarantee position index number edge detection Latches reference position index number specified on terminal 16 17 18 19 29 into memory Digital output MK3C 4 8 is changed to mirror the new reference index specified when using digital input control Not used in field bus mode MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller Pase Terminal Designation Description COM 240V AC 2A Common terminal for Relay 01 03 EE Connect to electro Normal Open mechanical brake Relay 01 03 is open brake activated during power off and NO start up of the VLT 5000 It is always open after a Quick Stop procedure or in connection with an error situation Relay 01 03 only closes in connection with motion procedures or if specified in P715 04 COM 50V AC 1A 75V Common terminal for Relay 04 05 DC 1A TEE Brake activated Normal Closed Relay 04 05 is closed to indicate an activated electromechanical brake It is open t
17. Manual jog positive input terminal 53 The travelled distance in mm is now measured from the position of the mark to the position of the cart Likewise the distance in QC is calculated by subtracting the current value of P795 from the noted value of P795 In this example it is measured that 871380 QC correspond to 4000 mm To prevent eventually overflow the parameters values are a factor 10 smaller than the measured QC and mm so P732 is set to 87138 and P733 is set to 400 Positions will now be displayed and entered in millimetres Settings like P732 set to 43569 and P733 set to 200 will also give the positions in millimetres MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller Data Settings for the homing procedure P728 P731 The HOME ramp setting P729 is reduced to the lowest allowable setting to get the fastest HOMING procedure possible The HOME velocity setting however should never be very high to enable a precise result of the homing procedure and because the exact position is not known during homing it is not advisable to go with a very high velocity for safety reasons The default setting of P730 at 100 encoder revolutions per minute approx 1 1 5 of the max velocity is therefore maintained in this application The default homing type defined in P731 is also maintained The resulting homing sequence is illustrated below Leave HOME switch Start in revers direction HOME switc
18. P799 NB This parameter is automatically up dated depending on P738 741 Index ramp down time RAMP DOWN TIME 5 000 50 100 000 ms This setting is relevant during positioning with the current trajectory index The index ramp down time is defined as the time in milliseconds it would take to ramp from the maximum allowed velocity P799 to standstill NB This parameter is automatically up dated depending on P738 742 Index maximum velocity MAX VELOCITY 100 ERPM 1 999 999 ERPM This setting is relevant during positioning with the current trajectory index NB This parameter is automatically updated depending on P738 The setting should never exceed a value that is approx 5 lower than the value calculated in P799 743 Index trajectory type RAJECTORY 0 absolute 1 relative 2 touch probe positive 3 touch probe negative The function of this parameter setting is described under P739 NB This parameter is automatically updated depending on P738 744 Positive software limit POS SW LIMIT 1 073 000 000 1 073 000 000 1 073 000 000 UU If the actual position P795 exceeds the value specified in this parameter an error situation is defined P798 4 and handled according to the setting of the Error behaviour parameter P725 MG 50 P3 02 VLT is a registered Danfoss trademark 31 Dar
19. Re AA ee ee Ee ee ee ee nana cnn ee ee ee ie 4096 MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller Pase Encoder input 2 MK3D primary Terminaldesignaliong srta citar ERE ATA A2 A2 B2 B2 Z2 Z2 Incremental SIVE 5 V differential REUS Icd PELLUS Linedriver RS422 INPUT impedariGe siii ld 1200 Maximum ST 220 kHz at 50 duty cycle Phase displacement between A and B sse nennen nnne 90 30 Absolute SIEUT E 5 V differential Sigiiali type dice tatc MC ED rmt SEE Ee KL mL e SSI Protocol eT Gray code Data tongi eee eanan eiie echo EE id Lis MIRI eS AE io theca Ei OE EE OE M CE 25 bit up none Glock frequeticy tert tat tee tette tiat TT 105 or 260 kHz Maximum positions per revolution tsere ee AR ee AR ee AR ee AA SA AR nennen nennen nnne nennen 8192 Maximum number of revolutions ecnin ee ke ee ee Re ee ee aE ee ke ee ee ke ee ee ee ee ke ee ee nn ee ee Re ee 4096 Encoder cable Cable type Twisted pair and screened Note Please observe the prescriptions of the encoder supplier Cable length Observe the prescriptions of the encoder supplier Absolute encoder is tested ok up to 150 meter cable at 105 kHz clock and 100 m at 260 kHz clock Tested with TR electronic encoder type CE 65 M 8192 4096 and appropriate cable prescribed by TR electronic Maximum allowed time delay betw
20. a tionship between the nominal motor speed in RPM and the nominal encoder speed in ERPM must be specified Track error The PID track error is defined as the difference between the internal control ler set point and the actual position The track error is specified in UU and is displayed in P797 NOTE The maximum tolerated PID error is entered in P726 in QC Touch probe trajectory type 2 175ZA819 10 Touchprobe End position 7A P739 705 amp 3 133 PCD 1 4 I1 Velocity Pa N 17 PCD 1 7 O 42 26FLUXy Cd PCD 1 5 Input 33 is the latch reference index input in digital control mode PCD 1 4 is the latch reference index input in fieldbus control mode Input 1 is the touchprobe input Input 7 is the reset touchprobe input in digital control mode PCD 1 7 is the reset touchprobe input in fieldbus control mode Output 42 26 for Flux is the touchprobe locked indicator output in digital control mode PCD 1 5 is the touchprobe locked indicator output in fieldbus control mode NOTE A delay in the touchprobe sensor will make the target position drift This means the target position will become larger than stated in parameter 739 To compensate for this please specify a delay value in parameter 747 Only a constant delay can be compensated not a variable delay MG 50 P3 02 VLT is a registered Danfoss trademark 47 Dare Index A Absolute value encoder seeren 46 Actual in
21. a registered Danfoss trademark Positioning Controller Hardware VLT control card terminals Dare The terminals on the control card are allocated for positioning controller functions the following parameter settings should therefore not be changed in positioning mode set up 1 Digital inputs 16 17 18 19 27 29 32 and 33 Parameters 300 303 and 305 307 are set to No operation default setting then the inputs are ignored by the control card but used as inputs to the positioning controller Analogue inputs 53 54 and 60 Parameters 308 311 and 314 are set to No operation then the inputs are ignored by the control card but used as inputs to the positioning controller Digital analogue outputs 42 and 45 VLT 5000 Parameters 319 and 321 are set to OPTION 0 20 mA 91 analogue output default setting Digital outputs 26 and 46 Analogue outputs 42 and 45 VLT 5000 Flux Parameters 319 and 321 are set to OPTION 0 20 mA 90 analogue output default setting Parameters 341 and 355 are set to OPTION digital 90 digital output default setting Technical data Technical data on the control card terminals can be found in the VLT 5000 design guide Option card terminals There are two encoder interfaces which are covering the following functions e Primary Feedback encoder input e Secondary encoder input Terminal A1 Al B1 Bl zi Z1 Incremental inpu
22. able effect on most of these parameters but P707 should always be recalculated using the auto calculation function P710 Q3 The inverter frequently trips on ALARM 7 DC LINK OVERVOLTAGE while ramping down A5 Harder settings of the PID controller may be requi red re optimise the PID controller parameters P702 P709 Q6 The option sometimes seems to forget changes to parameter values A3 8 Use a higher ramp time setting P719 for quick stop P724 for jogging and P738 P741 for posi tioning b If a lower ramp time is required a brake resistor should be installed MG 50 P3 02 VLT is a registered Danfoss trademark A6 Changes to parameter values are not stored after power down unless P777 STORE DATA is acti vated before power down Changes to trajectory data P705 P709 in POSITIONING MODE is ignored unless the correct password is entered in P778 41 Dare Error messages All messages are shown in P798 in the VLT 5000 LCP display You can find detailed information additional notes on possible causes of errors as well as tips for clearing errors in the following section P798 0 Status OK No errors detected Meaning No errors detected P798 1 Homing needed Meaning The user has issued a positioning command to a certain position while the home position is not defined Note The error must be cleared and a homing sequence successfully completed before the next p
23. ammed using P738 P743 as interface First the application must be homed to get at fixed reference for measuring and entering the positions When this is done the first position is programmed a P738 is set to 1 either directly or by using the digital inputs and the link functionality of P737 b The position is programmed in P739 either directly on the LCP or by using the TEACH IN functionality simply use the jog inputs 54 53 to drive the application to the desired position then press the JOG and FWD REV buttons to store that position in memory c The individual ramp and velocity settings for this position is specified in P740 P742 d For trajectory type absolute is selected in P743 set to 0 Positioning Controller The following table shows the complete list of settings for each of the 6 target positions P738 P739 P740 P741 P742 P743 1 40000 900 900 500 0 2 80000 2000 2000 500 0 3 150000 900 900 500 0 4 220000 900 900 500 0 5 260000 2000 2000 500 0 6 330000 900 900 500 0 Software limits P744 P745 The software limits are placed just in front of the hardware limit switches with a distance to the hardware limit switches that allows for the cart to be stopped with the shortest allowable ramp P719 before the HW limit switch is activated The settings are P744 370000 and P745 10000 Setting P719 and P725 If the pallet cart is
24. apping two motor phases if direction of motor rotation is wrong MG 50 P3 02 VLT is a registered Danfoss trademark 23 Dare Positioning Controller No Parameter Default Range Description value 713 Encoder type 0 0 incremental It is possible to use two types of encoder If 1 you select any absolute encoder the home absolute im l PRSE 260kHz clock flag is instantly set high thus no homing is ENCODER TYPE required preceding a positioning 2 absolute command OS Type 3 and 4 are to be used for linear 3 absolute absolute encoder A possible leap in the 260kHz clock position data can be detected if it is larger amp error than the encoder resolution 2 The correc correction tion is made by means of an artificial Asael position value which is calculated from the 105kHz clock last velocity If the error continues for more orror than 100 read outs gt 100 ms there will be no further correction which will then correction EM lead to a tolerated position error exceeded 5 ee Type 3 and 4 are only available if encoder encoder feedback is via MK 3 D see description of monitor parameter 748 type 100 104 like 0 4 however hard ware monitoring of the encoder will be activated Error 92 will be issued in case of open or short circuit NB When switching from a setting of ab solute encoder to a setting of incremental encoder th
25. as the digital outputs Digital outputs MK3C Terminal designaltioris cee A i ae ee ee iy O1 O8 Voltage level d de jh ce e ecrit eset teer epi ee ios Re AN 0 24 V DC Maximum load GE ee td 0 7A with external power supply Boelie MA Rn a o 1 msec Galvanic isolation All digital outputs are galvanically isolated by means of optocouplers but with the same common as the digital inputs External 24 V DC supply see VLT 5000 manual Encoder input 1 MK3B secondary Terminal designations iese ese ee ee RA RA EA ER EA AA Ee ee anar Re Re de ee ee ee ee n nnns A1 Al B1 B1 Z1 Z1 Incremental Signal level RE et ce tete EE Luce e I EE os 5 V differential Signalitype ie cene medo too eb entered ced t ht cien Linedriver RS 422 Inp t irmpedaricg RE EE Rx AT ELE HE COE Su N 120 Q Dip switch 1 3 ON EA EE aee etd tts gt 24 kQ Dip switch 1 3 OFF Maximum fredueNCY ese ee se ee Re AA Re AA nennen ennemi nnne AE nennen Re ee nn 220 kHz at 50 duty cycle Phase displacement between A and B sse eene eren nnne 90 1309 Absolute SEE i ll 5 V differential ER Ad SSI Data COM c Gray code A O OO 25 bit Pa le oie abia none Glock UE O T 105 or 260 kHz Protocol eI Gray Maximum positions per revolution seriinin ee ee ee AR ee AR ee nono ee narrar rr 8192 Maximum number of revolutions urere se ee EE Ee ee EE Re EAEE ed AE
26. connocccnonocccocononcnnnanoncnnonnnnononnnnos 6 SyncPos option error occured ssssse 43 T Target position P739 eneren 30 Target position window P746 essssss 32 Technical Data ccccccccooonnnnncnnccononononnnnnnninonanononnns 5 10 Terminal description 6 Terminals ete tet 10 Touch probe delay P747 sees 32 Touch probe trajectory type OT esse ee ee 47 Trackettor eeepc etes 47 Trajectory type P743 sss 31 Troubleshooting ee ee ee Re ee 41 U User APOS setting P750 sess 32 User unit denominator P7383 cecce 28 User unit numerator P732 ereere 28 V VLT control card terminals ese ee ee ee 5 VLT Exception error detected 43 VLT local jog P711 et 23 VET Not FUNNING see ee ee a pinaiiral 42 W Warning against unintended start 3 49 www danfoss com drives Danfoss can accept no responsibility for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All right
27. d Danfoss trademark Positioning Controller Data No Parameter Default Range Description value P722 motor encoder gear ratio denominator For VLT 5000 Flux the following parameters influence the result and must be set correctly beforehand P205 maximum reference rpm P713 encoder type P714 encoder resolution P721 motor encoder gear ratio numerator P722 motor encoder gear ratio denominator NB If you change any one of these para meters you should prompt a recalculation since the optimum value of 702 703 704 and 707 will have changed 711 VLT local mode 0 0 Pos control By setting this parameter to 1 the VLT 1 VLT control changes to setup 2 Manual running of the VLT is now possible VLT MANUAL 712 Positive direction 2 right rotation Here you specify which encoder direction is considered positive If you change this setting the current actual position P795 POS DIRECTION 1 right rotation will also change sign 1 left rotation 2 left rotation 12 standard position is counting positive when the drive is running forward 1 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 2 as 1 but with opposite sign of the reference to the drive This can be used as alternative to sw
28. e ON Moving to pallet outlet no 2 A MG 50 P3 02 VLT is a registered Danfoss trademark PALLET INLET 43 PALLET OUTLET 2 PALLET INLET 4 DELIVERY TRUCK Moving the empty pallet conveyor cart to pallet inlet no 1 to pick up a loaded pallet Waiting until the pallet is successfully transferred to the cart Waiting until the pallet is successfully transferred to the outlet conveyor and so on 35 Wiring diagram Reference Reference Reference Reference COM Coast error reset Reference index Bit 4 index index index index Start Homing Latch reference index DIP Switch Brake aktivated indication Touchprobe position locked in Watchdog output 10V for terminal 53 54 Manual JOG positive Manual JOG negative Positioning Controller From mains supply Bit O Bit 1 Bit 2 Bit 3 Digital inputs 1 2 and 3 ON 4 OFF To mechanical brake Analog in outputs Touchprobe input Positioning Controller Limitswitch positive Limitswitch negative Home swi Enable positioning itch Reset home Reset touchprobe Quickstop 24V Supply from PLC Homing completed Ref position reacded Error occurred Reference Reference Reference Reference Reference COM from index index index index index PLC Basic set up 36 DIP Switch 1 and 2 3 and 4 1 2 3 Bit O 4 Bit 1 5 Bit 2 6 Feedback encoder Bit 3 7 Bit
29. e Positioning Controller No Parameter Default Range Description value 745 Negative software 1 073 000 000 1 073 000 000 If the actual position P795 goes below limit 1 073 000 000 UU the value specified in this parameter an error situation is defined P798 5 and handled according to the setting of the NEG SW LIMIT Error behaviour parameter P725 746 Target position 0 0 UU P726 During a positioning sequence the Refe window 1 073 741 824 UU renced position reached output MK3C 2 is set according to this parameter TARGET WINDOW If the setting of this parameter is 0 then the Referenced position reached output goes high immediately when the internal PID target position is equal to the reques ted target position If the setting of this parameter is larger than 0 i e 200 then the Referenced position reached output goes high when the actual position P795 is within 200 UU of the requested target position 747 Touch probe delay 0 O 100 000 ms This parameter enables for compensation in any fixed delay there may be in the PROBE DELAY touch probe 748 Feedback input 0 0 1 Choose feedback input for positioning con troller Enter 0 to use MK3D enter 1 to use MK3B This is used to enable the use SWAP ENCODER of absolute encoders for feedback together with VLT 5000
30. e home flag is automatically cleared A homing procedure afterwards is necessary before any positioning com mands can be executed 714 Encoder resolution 4 096 ps 1 1 000 000 The encoder resolution must be entered in pulses pulses per revolution not quad counts per revolution ENCODER RES 715 Automatic brake 1 0 disabled When the automatic brake control function control is enabled the electromechanical brake is 1 enabled automatically activated every time the application has been at standstill for a time AUTO BRAKE period specified in parameter 718 This is CTRL especially useful in hoist applications where the motor could overheat if it has to deliver full torque at standstill for a pro longed period of time When the automatic brake control function is disabled the drive controls the applica tion also at standstill 24 MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller Data No Parameter Default Range Description value 716 Coast delay 200 ms 0 1 000 ms Used in conjunction with the automatic brake control function The coast delay is the delay after activating the electromecha COAST DELAY nical brake before disabling the controller and coasting the drive Useful in hoisting applications where the load would otherwise have a tendency to drop a little after each stop because the activation of the brake is slower than the deactivation of the drive 717 Brake delay 200
31. een clock and data signal measured at the controller terminals EE EE ER N EE ee ge yd ne eee Dee ai 105 kHz clock 9usec H EE 260 kHz clock 3 5 usec INCREMENTAL ENCODER ABSOLUT ENCODER 5V A CLOCK B DATA z ov ov DANFOSS 175ZA256 10 DANFOSS 175ZA258 10 MG 50 P3 02 VLT is a registered Danfoss trademark 11 afd Positioning Controller Description of the electrical and field bus interface Electrical interface VLT 12 Terminal Designation Description MP 24v Dc 24V power supply for switches etc maximum load 200 mA MEJO 24v Dc 24V power supply for switches etc maximum load 200 mA MG Reference index Bit 0 Reference position index number bit 0 least significant bit Not used in field bus mode Reference index Bit 1 Reference position index number bit 1 Not used in field bus mode ETE Reference index Bit 2 Reference position index number bit 2 Not used in field bus mode MIKE Reference index Bit 3 Reference position index number bit 3 Not used in field bus mode Ground for 24V is normally bridged with Terminal 39 but can be set to OFF by means of Switch SW 4 on the control card Errors are cleared on the rising edge must be 0 min 1 ms to guarantee edge detection Not used in field bus mode To enable operation this input must be maintained at 1 in either digital control mode or field bus control mode M
32. el input must be connected to 5V common as shown below An encoder fault will only result in an Option error 92 if encoder monitoring is activated via parameter 713 Note Monitoring of the secondary feedback encoder is disabled when switch 1 3 is OFF 5V DC gt wy O O q lt lt m m m IN oO00009Oo00 1752A782 10 MG 50 P3 02 VLT is a registered Danfoss trademark 7 ab Positioning Controller Option card layout Option card layout showing the position of connectors and dip switch Encoder monitor secondary Encoder monitor primary input input channel A B and Z gt channel A B and Z LED off Short or open circuit z LED off Short or open circuit LED green Ok LED green Ok 5V monitor LED off no 5V LED Green 5V ok CPU monitor LED must flash at 1 Hz to indicate a running CPU system l NEK TERE ie Hd 2 liti y e SW 1 1 Connect ON disconnect OFF 24 V from control card see description of supply voltages SW 1 2 Connect ON disconnect OFF 24 V common from control card SW 1 3 Connect ON disconnect OFF termination resistor for secondary encoder Note When OFF the secondary encoder monitor is disabled SW 1 4 Switch Z channel encoder monitor ON OFF for both encoder inputs Default setting of switch 1 1 1 4 is ON
33. emental encoder signals see ee 46 Index number P738 esee 30 Integral gain P704 21 luii m 12 IMNTODUCHION cote e n c EE ta 4 J Jog ramp time P724 26 L LOP eie ER ura 20 Limit integral part P705 i e ees sees ee ee 21 Limit PID output P706 eese 22 Link LCP input to index P737 sssss 29 M Maximum allowed velocity P799 34 Maximum jog velocity P723 ssss 26 Maximum tolerated PID error P726 26 Maximum velocity P742 eene 31 Motor encoder gear denominator P722 eese 26 gear nominator P721 25 Motor encoder gear ratio 47 N Negative hardware limit exceeded 42 Negative software limit exceeded 42 Negative software limit P745 ssss 32 Negative SW limit active P752 ss 32 O Operating mode P701 c oooonncccinccccoccccnoncnanccnoncncancnnnnos 21 Option card layout 8 Option card MKIA 2 enndem 14 Option card MK3B secondary position feedback 15 Option card MKAO ee ee ke Re RA ee ee 15 MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller Option card MK3D primary position feedback 16 Option card terminalS oooooccccnnocccinocccnnononcnnnnnannnnnnnnos 5 OVER CURRENT ci
34. erence index bit 2 Not used in field bus mode Reference index bit 3 Active high Mirror of the currently locked in reference index bit 3 Not used in field bus mode Active high Mirror of the currently locked in reference index bit 4 EEG Reference index bit 4 Not used in field bus mode NEE 2v 0c Option card MK3B secondary position feedback for absolute encoders when using VLT 5000 Flux EAN 5V DC Encoder supply ETA Encoder supply ES Zero track inverted Not used MG 50 P3 02 VLT is a registered Danfoss trademark 15 aft Positioning Controller Option card MK3D primary position feedback Encoder supply Zero track inverted Not used DANFOSS 175HA465 10 Ey MKS D Encoder Fig Encoder connection for positioning applications 16 MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller Data NOTE This section is only relevant if the VLT is eguipped with a Field bus interface option as well as the Positioning controller Field bus interface The Positioning controller can be controlled via the digital analogue inputs or via field bus The control source can be selected in parameter 749 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 exceptions are listed in the digital i
35. f the dual track encoder an additional zero track This emits a signal when the zero transit is passed through Ix He x e A track A track B track B track Time Time B track before A track anticlockwise A track before B track clockwise Fig Incremental encoder signals Quadcounts Through edge detection a quadrupling of the increments is produced by both tracks A B of the incremental encoder This improves the resolution tx A track B track Quadcounts Time Fig Derivation of quad counts Absolute value encoder This is a special form of incremental encoder as it indicates not only the speed and direction of rotation but also 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 value 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 ERPM The speed is defined in relation to the RPM of the encoder To underline this the term encoder revolutions per minute is chosen as unit 46 MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller Danfoss AMA Automatic Motor Adaptation function in P107 Motor encoder gear ratio Since the encoder is not necessarily mounted on the motor itself the rel
36. h left search for index pulse i v i HOME position defined i Positioning at home Ramp setting position i P729 1 OME position chieved P730 30 4 I l l l l l l high Low Terminal 32 HOME switch Index pulse Terminal 32 high high found low HOME switch MK3C1 low high 175ZA567 10 Programming positions P737 P743 The program positions the conveyor cart in front of the various inlets and outlets Different acceleration and deceleration is allowed between the different positions An empty pallet cart can be accelerated as fast as possible while this is not allowed when transporting a fully loaded pallet Different settings for each position are available because every position is programmed with its own setting for ramp and velocity The different positions are defined below Position 1 palletizer inlet 1 lt Negative HW limit switch 4 Negative SW limit position 4 Home reference switch lt Position 2 palletizer outlet 1 4 Position 3 palletizer inlet 2 4 Position 4 palletizer inlet 3 4 Position 5 palletizer outlet 2 4 Position 6 palletizer inlet 4 4 Positive SW limit position 4 Positive HW limit switch PALLET CART 0 mm 2000 mm 4000 mm 0 QC 435690 QC 871380 QC MG 50 P3 02 VLT is a registered Danfoss trademark 39 Dare The different positions are progr
37. in function of the inte gral part is to provide zero steady state tracking error The higher the setting the faster the application will reach a zero steady state tracking error The dynamic tracking error however increases with increasing setting of this parameter NB Too high a setting of this parameter will cause the controller to become unstable 705 Limit integral part INT LIMIT 1 000 0 65 000 Here it is possible to clamp the integral part of the PID output A setting of 1000 corresponds to 10096 of the maximum allowed reference specified in parameter 205 MG 50 P3 02 VLT is a registered Danfoss trademark 21 Dare Positioning Controller No Parameter Default value Range Description 706 Limit PID output PID LIMIT 1 000 0 1 000 Here it is possible to clamp the total output of the PID controller A setting of 1000 corresponds to 100 96 of the maximum allowed reference specified in parameter 205 707 Feed forward velocity gain F FWD VEL GAIN 0 65 000 The velocity feed forward gain is the factor that is multiplied with the set point desired trajectory velocity to produce the feed forward part of the output frequency The function of the feed forward part is to pro vide a fast and fairly accurate starting point for the calculation of the output fre quency NB To get the fastest and most stable controlle
38. ion position o P739 After a jog or homing command Last Target HOME position position Eris 0 1752A569 10 m If P743 2 the application will move in the positive direction until a touch probe posi tion is defined If a touch probe position is already defined the application will move directly to that position A touch probe position is defined as the po sition at which the touch probe switch input MK3A 1 goes high plus the value of P739 A touch probe position is cleared by a high signal on the reset touch probe position input MK3A 7 input The output Touch probe position locked VLT5000 Terminal 42 is high if a touch probe position is defined If P743 3 the application will move in the negative direction until a touch probe posi 30 MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller Danfoss No Parameter Default value Range Description tion is defined If a touch probe position is already defined the application will move directly to that position NB This parameter is automatically up dated depending on P738 740 Index ramp up time RAMP UP TIME 5 000 50 100 000 ms This setting is relevant during positioning with the current trajectory index The index ramp up time is defined as the time in milliseconds it would take to ramp from standstill to the maximum allowed velocity
39. is is done by opening switch 1 1 and 1 2 Each digital input on the option card takes 8 mA Each digital output on the option card can supply up to 0 7 A external 24V supply depending on the load The load from the 24 V supply internal or external can be calculated as follows 8 mA number of digital inputs 5V MK3B MK3D Common MK3B MK3D Load on digital outputs mk3 C O1 O8 24V MK3A MK3C Common MK3A MK3C load on 5 V supply mk3 B D 5 V com vidi SW 1 2 Load on control card 24V from control carc 24 V supply terminal 12 13 and Common control card outputs terminal 42 45 26 46 DANFOSS 175HA461 11 6 MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller Danfoss Encoder monitor Both encoder interfaces are equipped with a monitoring circuit that can detect open circuit as well as short circuit of each encoder channel Each encoder channel has a LED showing the status Green light means ok no light means fault Zero channel monitoring can be switched off by means of switch 1 4 this is necessary when using incremental encoders without Zero channel or absolute encoders Switch 1 4 disables monitoring of both Zero channels If disabling of only one of the two Zero channels is required e g when using incremental Flux feedback encoder and absolute option feedback encoder the unused Zero chann
40. itov ccseccccceseceeeseseeeseseeceeneseeeeeesseeenes 7 Encoder resolution P714 eese 24 Encoder type P713 niine 24 Endless positioning P753 33 ERP Moscas ita 46 Error behaviour P725 sss 26 Error from encoder monitoring 43 Error messages esse dee de ee ee ke ee ee ke ee ed ee 42 Errorreset P727 sae ese tac 27 Erroristatus AK EE OE iaaii 34 Example Pallet conveyor system 35 External 24 V DC supply sss 10 F Factory reset P776 33 Feedback input P748 seen 32 Feed forward acceleration gain P708 sees 22 velocity gain P707 sesse ee esse ee ee ee ee ee ee 22 48 Positioning Controller FFVEL auto calculation P710 ssss 22 Field bus control signals senn 17 Data layout nee hne ties 17 dead ae Decree dedos odora 12 17 status signals ees ee Re Re ee ee 19 Forward operation prohibited 43 Frequently asked questions sssusss 41 G Glossary of key terms 46 H Hardware nitet diene ico 5 Hold delay 718 ane 25 Home offset P728 sss 27 Home ramp time P729 eeir 27 Home type P731 eene 27 Home velocity P730 ss 27 Homing needed AA 42 l Incremental encoder ee ee Re ee 46 Incr
41. l be displayed even if no encoder is connected and the monitor is active P713 gt 100 43 Dare Appendix Positioning Controller Binary selection of reference positions using digital control 44 Pos Number target Pos Number chosen 18 S E A 7 8 0 1 2 3 4 5 6 7 8 9 20 21 22 23 24 25 26 27 28 29 30 31 Pos Number target Pos Number chosen IN 29 MSB PCD 7 6 1813 PCD 2 6 IN 19 PCD 7 5 PCD 2 5 IN 18 IN 17 IN 16 LSB PCD 7 4 PCD 7 3 PCD 7 2 PCD 7 1 PCD 2 4 PCD 7 3 PCD 2 2 15753 MG 50 P3 02 VLT is a registered Danfoss trademark Pos Number target Pos Number chosen PCD 7 6 1813 Positioning Controller PCD 7 5 PCD 7 4 PCD 7 3 PCD 2 5 PCD 2 4 PCD 7 3 MG 50 P3 02 VLT is a registered Danfoss trademark PCD 7 2 PCD 2 2 PCD 7 1 LSB 45 aft Positioning Controller Glossary of key terms Incremental encoder This is an encoder system that picks up the speed and the direction of rota tion and transmits on the appropriate configuration The number of tracks and thus the number of signals indicates 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 o
42. m a second homing sequence Not used in field bus mode Active high This input clears the touch probe position flag The reset is necessary to carry out a touch probe positioning command to a new target position Reset touch probe position Not used in field bus mode Active low This input activates the Quick Stop function The drive is stopped according to the setting of P725 After that the electromechanical brake is always activated when the Quick stop input is activated regardless of the P715 setting 14 MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller Pase Option card MK3C MK Homing completed Active high This output is always high if an absolute encoder is specified in P713 EE Reterenced position Active high This output is set when the target position is reached reached according to the setting of P746 ME Error occurred Active high This output is set every time an error occurs It is cleared every time a successful error clear is carried out This output will remain high as long as the Power recovery function is selected P736 and active MZ Reference index bit 0 Active high Mirror of the currently locked in reference index bit 0 Not used in field bus mode ME Reference index bit 1 Active high Mirror of the currently locked in reference index bit 1 Not used in field bus mode ENG Reference index bit 2 Active high Mirror of the currently locked in ref
43. nal safety considerations make it necessary to ensure that no unintended start occurs these stop functions are not sufficient 2 While parameters are being changed the motor may start Consequently the stop key STOP RESET must always be activated following which data can be modified 3 A motor that has been stopped may start if faults occur in the electronics of the VLT frequency converter or if a temporary overload or a fault in the supply mains or the motor connection ceases Warning Touching the electrical parts may be fatal even after the equipment has been disconnected from mains Also make sure that other voltage inputs have been disconnected such as external 24 V DC load sharing linkage of DC intermediate circuit as well as the motor connection for kinetic back up Using VLT 5001 5006 220 and 500 V units wait at least 4 minutes Using VLT 5008 5500 220 and 500 V units wait at least 15 minutes Using VLT 5001 5005 550 600 V units wait at least 4 minutes Using VLT 5006 5022 550 600 V units wait at least 15 minutes Using VLT 5027 5250 550 600 V units wait at least 30 minutes MG 50 P3 02 VLT is a registered Danfoss trademark 3 als Positioning Controller Introduction The Positioning Controller is an application option for the VLT 5000 and VLT 5000 Flux Series It is based on the SyncPos option card The positioning controller can be used in a wide range of applications where a frequency converter is used f
44. nco nein td e eee 41 P Pallet conveyor system eene 35 Basic setup ior tier etie dese 36 Parameter settings ees ee ee ee Re ee 38 Wiring diagram ees ees ee ee ee Re ee ee 36 Parameter save P777 essen 33 Parameters Description sese 21 Password P 78 cirio a 33 PID sample interval P709 eeen 22 PID TRACK ERROR TOO BIG sss 41 PID tracking error P797 ees ee ee Re ee 33 Positive direction P712 ee ee ee Re ee ee 23 Positive hardware limit exceeded 42 Positive software limit exceeded 42 Positive software limit P744 cecce 31 Positive SW limit active P751 ssssss 32 Power recovery P7368 eese 29 Proportional gain P702 ee ee Re Re ee 21 Q QuadooUnts ie een e nd Ne 46 Quick ramp time P719 ee ee ee ee ee Re Re Re ee 25 Quick stop input activated 43 R Ramp down time P741 31 RampiypeP lO t eee ts 25 Ramp up time P740 ese ee ee ee Re ee 31 Reverse operation prohibited 43 MG 50 P3 02 VLT is a registered Danfoss trademark S Safety regulations ssseeee 3 SAMPLE INTERVAL eene 22 Software version P779 sse 33 Status OK No errors detected ssssse 42 STORE DATA nece oerte Ve ed ee 41 Supply VO Ages ooooco
45. netized in a situation where it should have been The electromechanical brake is immediately activated in this case regardless of the settings in P718 and P725 Causes While the motor was holding driving the load the drive has tripped connection to terminal 27 was lost or the STOP button was pressed on the LCP P798 7 Brake wear limit exceeded Meaning This error message is given if the drive has moved more than the allowed number of user units specified in P735 while the electronic brake was activated Causes The mechanical brake is worn and should be replaced in the near future or the limit specified in P735 is too low MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller P798 8 Quick stop input activated Meaning The quick stop input has been activated As a safety precaution the electromechanical brake is activated according to the setting of P725 and the drive is coasted regardless of the setting of P715 Normal operation is resumed if the error is cleared P798 9 Controller PID tracking error too big Meaning The difference between the desired set point posi tion and the actual position read via the encoder feedback has exceeded the limit specified in P726 Causes Several reasons may exist 1 The encoder is not properly connected Check the encoder connection 2 The encoder is counting positive in the wrong direction Switch A and B chan nels if necessa
46. ns eel deer pee ele Gee ge rb p reper reed a tede e rere pete ie deve dee tee 41 Appendix 44 Binary selection of reference positions using digital control iese sesse ee ee ee GR Re ee GR Re nennen enne nene Re de ee en 44 Binary selection of reference positions using fieldbus control essen nennen enne 44 Glossary Of key MS iet eeu tiep dte deep respete 46 Index tee Deer ore poteit did 48 MG 50 P3 02 VLT is a registered Danfoss trademark ad Positioning Controller Positioning Controller for VLT 5000 and VLT 5000Flux Software Version 2 1X Software Version number See Parameter 779 2 MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller ate The voltage of the freguency converter is dangerous whenever the equipment is connected to mains Incorrect installation of the motor or the frequency converter ma cause damage to the equipment serious personal injury or death Consequently the instructions in this manual as well as national and local rules and safety regulations must be complied with Safety regulations The VLT frequency converter must be disconnected from mains if repair work is to be carried out Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs The STOP RESET key on the control panel of the frequency converter does not disconnect the equipment from mains and is th
47. nterface section In field bus mode it is possible to specify only the target position and velocity If the acceleration and deceleration PCDs are left blank then the last used acceleration and deceleration chosen via an index is used This enables the use of PPO type 4 Data layout Control and status signals are transferred via the so called process data channel PCD of the various field bus interfaces The telegram structure and the available number of data words depends on the Field bus used please refer to the manual of the Field bus 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 Parameter channel Process data channel PCD 1 PCD 3 pco 4 PCD 5 eco 6 PCD 7 Pcp 8 PCD pco 10 6 15 e 13 re s e Bit 1 1 Quick bus go to target 175ZA820 10 Field bus control signals Field bus Field bus mode Corresponding input word bit 11 Quick bus go to target T N A 12 Reset error T 27 13 Go to home Stop positioning T Go to position 1 32 14 Read new trajectory index T 33 1 5 Automatic T manual 1 mode 5 1 6 Reset home status T 6 1 7 Reset touch probe position T 7 1 8 Quick stop J 8 1 9 Positive jog T 53 1 10 Negative jog T 54 MG 50 P3 02 VLT is a registered Danfoss trademark 17 Dare 18
48. o calculation function 18 If the track error after entering 2 in parameter 710 is within specification when jogging there is no reason to optimise any further move to step 21 19 Increase the P portion par 702 After each change you should make a test run to find the right setting If the drive becomes unstable or if a message is given about over voltage or over current then reduce the value in parameter 702 to about 70 8096 of the set value 20 Increase the other PID parameters P703 if needed by following the same approach Read the description concerning these parameters in the parameter list To store the optimised values 21 Change the value of parameter 777 to 1 When the value returns to 0 the parameters have been successfully saved see the parameter list for a description of how the P777 parameter works MG 50 P3 02 VLT is a registered Danfoss trademark 37 al Positioning Controller Parameter settings Now determine the parameter settings fitting this application The following list of parameters can be determined right away P701 Default Positioning mode P702 P711 Determined during optimising of the PID controller P712 Default 1 P713 Incremental encoder used 0 P714 Encoder resolution 4096 P720 Trapeze ramps is used for fastest response 0 P721 Default encoder mounted directly on motor 1 P722 Default encoder mounted directly on motor 1 P723 Default
49. o indicate a deactivated electromechanical brake Not used in field bus control mode MES Touch probe position A high 1 signal is present when a rising edge has been locked in VLT 5000 detected on digital input 1 terminal MK3A and a target position Flux only is fixed in memory A low signal is present when no target position has yet been determined Not used in field bus mode 39 Ground for analogue inputs outputs is normally bridged with Terminal 20 but can be set to OFF by means of Switch SW 4 on the control card TEEN Touch probe position A high 1 signal is present when a rising edge has been locked in VLT 5000 detected on digital input 1 terminal MK3A and a target position Process only is fixed in memory A low signal is present when no target position has yet been determined Not used in field bus mode MZ Watchdog output in VLT 5000 Process This output toggles continually as long as the program is active only MC Watchdog outputin This output toggles continually as long as the program is active VLT 5000 Flux only MEA 10v DC 17mA Power supply for manual JOG inputs terminal 53 and 54 When high above 5V the drive will travel with jogging speed P723 and ramp P724 in the positive direction Manual jog positive When low below 5V the drive will ramp down and stop if no other motion procedure is activated Jog positive has higher priority than Jog negative N
50. ogramming a position number different from the one loaded into the PLC memory MG 50 P3 02 VLT is a registered Danfoss trademark 29 Dare Positioning Controller No Parameter Default Range Description value 738 Index number INDEX NUMBER 0 O 31 Here it is possible to specify which position 0 63 in field bus data that should be displayed in P739 743 mode Whenever this number is changed the current values of P739 P743 are stored in memory under the previously specified index number After that the value of P739 743 is updated with the data stored in memory relevant to the newly specified index number 739 Index target position TARGET POSITION 0 1 073 741 824 The meaning of this parameter depends 1 073 741 824 UU on the position type specified in P743 If P743 0 the value of this parameter refers to an absolute position relative to the fixed HOME position If P743 1 and the last position was obtai ned through jogging the value of this para meter is a position relative to that position If the last position was reached as a result of a positioning command then the value of this parameter specifies a position relati ve to the last target position whether it was reached or not Different positioning type Absolute positioning Target HOME position o P739 After a relativ or absolute positioning command Last target Target HOME posit
51. ons If the encoder is mounted directly on the motor shaft this parameter setting should remain at 1 MG 50 P3 02 VLT is a registered Danfoss trademark 25 Dare Positioning Controller No Parameter Default value Range Description 722 Motor encoder gear denominator MOT DEN AR ENC GE 0 1 000 See the description of P721 If the encoder is mounted directly on the motor shaft this parameter setting should remain at 1 723 Maximum jog velocity MAX JOG VELOCITY 100 ERPM d ess 999 999 ERPM The maximum speed allowed while jogging the application is specified in terms of Encoder Revolutions Per Minute ERPM NB This setting must never exceed a value that is approx 5 lower than the value calculated in P799 724 Jog ramp time JOG RAMP TIME 5 000 ms 50 100 000 ms This parameter specifies both the ramp up time as well as the ramp down time used during jogging The ramp time is defined as the time in milliseconds it would take to ramp from standstill to the maximum allowed velocity P799 725 Error behaviour RROR EHAVIOUR E t9 electronic brake mechanical brake This parameter determines the behaviour of the drive after an error is detected If O is selected the drive will ramp down to standstill with the shortest possible ramp P719 After achieving
52. or positioning The controller holds information of up to 32 64 in field bus mode fixed positions Relative positions can be added to each other by triggering a new relative positioning command when the controller is already executing a relative positioning command Full field bus support is now included meaning starting and stopping etc can be done via bus In field bus mode a quickbus mode is introduced to enable writing a target position directly Hence an unlimited number of positions can be reached Positions are defined either relative to a fixed home position absolute positions or relative to other positions or relative to a movable touch probe sensor An advanced mechanical brake controller is included It is strongly advised to use this brake function as suppose to the VLT mechanical brake handler If absolute encoders must be used for positioning feedback in conjunction with VLT 5000 Flux this is now possible Encoder input MK 3B can be programmed as option feedback input allowing the feedback encoder input MK 3D to be used for VLT 5000 Flux The encoder s connected can now hardware wise be monitored for open or short circuits Last but not least VLT manual run mode is introduced It is selected via parameter 711 This manual consists of the following parts Hardware Description of the electrical interface Description of the available parameters An application example Troubleshooting Appendix 4 MG 50 P3 02 VLT is
53. osition command is issued to the application P798 2 Positive hardware limit exceeded Meaning The positive hardware switch input has been activated Causes The application has hit the positive limit marker switch Alternatively the connection to the limit switch has been lost or the limit switch is defect P798 3 Negative hardware limit exceeded Meaning The negative hardware switch input is activated Causes The application has hit the negative limit marker switch Alternatively the connection to the limit switch has been lost or the limit switch is defect 42 Positioning Controller P798 4 Positive software limit exceeded Meaning A motor command will cause has caused the software limit switch to be activated The maximum limit specified in P744 Note Before the error can be cleared the application must be moved back from the limit If power recovery is enabled in P736 this can be done through an error reset and a negative jog input 54 P798 5 Negative software limit exceeded Meaning A motor command will cause has caused the software limit switch to be activated The minimum limit specified in P745 Note Before the error can be cleared the application must be moved back from the limit If power reco very is enabled in P736 this can be done through an error reset and a positive jog input 53 P798 6 VLT not running Meaning The motor was not mag
54. ot used in field bus mode MG 50 P3 02 VLT is a registered Danfoss trademark 13 afd Positioning Controller Terminal Designation Description When high above 5V the drive will travel with jogging speed P723 and ramp P724 in the negative direction When low Manual jog negative below 5V the drive will ramp down and stop if no other motion procedure is activated Not used in field bus mode Not used Option card MK3A Terminal Description MA Touch probe switch Interrupt triggered on the rising edge If this signal goes high when no touch probe target position is currently locked VLT 5000 Process terminal 42 low VLT 5000 Flux terminal 26 low a new touch probe target position is calculated and locked in memory MIE Positive HW limit switch input Interrupt triggered on the falling edge Triggers a HW limit error and the drive is stopped according to P725 EMEN Negative HW limit Interrupt triggered on the falling edge Triggers a HW limit error switch input and the drive is stopped according to P725 MIE HOME reference Active high Marks the HOME position in the application switch input EE Go to the referenced Active high Upon activation the drive goes to the specified target target position position A low signal interrupts any positioning sequence Not used in field bus mode MIG Reset home flag Active high This input clears the home flag This allows the user to perfor
55. puts P796 ee ese ee Re ee ee ee 33 Actual position P795 ees ee ee ee ee Re ee 33 adjust the maximum allowed velocity 41 ACARM dict se it eed eia 41 ALARM 7 noce tcs rene e eer a du 41 joo dM rm 44 Application example een 35 AUTOCALC FFVEL eene 22 Automatic brake control P715 sssss 24 B Binary selection of reference positions using digital control Re nano nos 44 using fieldbus control ees ee ee 44 Block reversal P734 sees 28 Brake delay P717 eese 25 Brake wear limit exceeded ee 42 Brake wear limit P735 29 C Coast delay P710 isanos 25 Control source P749 ee ee Re ee RA Re ee 32 Controller PID tracking error too big 43 D Data layout iii tarada 17 DC LINK OVERVOLTAGE ccccooccccocccnonccnonccnancnnancnannnos 41 Derivation of quad Counts eeen 46 Derivative gain P703 sse 21 Description of the available parameters sssse 20 Digital inputs MK3A sess 10 Digital outputs MK3C ee ee Re Ge Re 10 E Electrical interface 12 Encoder cable sss 11 Encoder connection ccooocccccnoncccnnnncnnnononcncnnnancnnnnnn nono 16 Encoder input 1 MK3B secondary 10 Encoder input 2 MK3D primary 11 Encoder MOm
56. r response this parameter should be set optimally For this purpose parameter 710 gives access to a function that automatically calculates the optimal setting of this parameter 708 Feed forward acceleration gain F FWD GAIN ACC 0 65 000 The acceleration feed forward gain is the factor that is multiplied with the set point acceleration to produce the feed forward part of the output frequency 709 PID sample interval SAMPLE INTERVAL ims 1 100 ms The sampling frequency of the controller can be adjusted in this parameter Normal ly the fastest possible setting 1 ms is preferable but in cases with low resolution of the feedback signal it is a good idea to set this parameter at a slightly higher value 710 FFVEL auto calculation AUTOCALC FFVEL 0 disabled 1 FFVEL enabled 2 FFVEL PID enabled Setting this parameter to 1 will prompt the program to calculate the optimal setting of parameter 707 Setting this parameter to 2 will prompt the program to calculate the optimal setting of parameter 702 703 704 and 707 For VLT 5000 Process the following parameters influence the result and must be set correctly beforehand P104 nominal motor frequency P106 nominal motor speed P205 maximum reference frequency P713 encoder type P714 encoder resolution P721 motor encoder gear ratio numerator 22 MG 50 P3 02 VLT is a registere
57. rademark 33 ad Positioning Controller No Parameter Default Range Description value 798 Error status 0 0 OK READ ONLY PARAMETER 1 Homing The current error code is displayed in this ERROR STATUS needed parameter 2 Pos HW limit 3 Neg HW limit 4 Pos SW limit 5 Neg SW limit 6 VLT not running 7 Brake wear limit 8 Quick stop 9 PID error too big 10 Option error 11 VLT Exception 12 Rev operation 13 Fwd operation 92 Encoder hardware error 799 Maximum allowed 1 500 1 999 999 READ ONLY PARAMETER velocity ERPM ERPM The maximum velocity allowed is calcula ted on the basis of P104 P106 P205 P721 P722 and the result is presented in this parameter To increase this value one or more of the above mentioned parame ters must be changed usually just P205 MAX VELOCITY 34 MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller An application example Danfoss The drawing below shows a layout of a pallet conveyor system Loaded pallets are coming from four different product lines via the pallet inlet conveyors Each pallet must be transported from one of the four inlet conveyors to the one of the two outlet conveyors To do this a movable pallet conveyor cart is used PALLET PALLET INLET 1 INLET 2 PALLET CART PALLET OUTLET 1 DELIVERY TRUCK z ui A typical work process could b
58. rameter values to E default This also resets all trajectory data FACTORY RESET P739 P743 The parameter automatically resets to 0 when the reset is successfully carried out 777 Parameter save 0 0 no action Parameter and trajectory data is not auto matically stored in EEPROM and will thus 12 SAVE EEPROM not automatically be available after power STORE DATA down and power up To permanently store changes made to parameter values and or trajectory data parameter P777 must be set to 1 This parameter automatically resets to O when the data is successfully stored 778 Password 1 234 O 999 999 999 Not used PASSWORD 779 Software version 210 210 The text in this parameter shows the VERSION 2 10 current version number of the Positioning Controller program 795 Actual position 0 2 000 000 000 READ ONLY PARAMETER ACTUAL 2 000 000 000 UU This parameter displays the latest position POSITION obtained from the feedback encoder 796 Actual inputs 00000000 00 00 00 00 READ ONLY PARAMETER 11 11 11 11 This parameter displays the last read ACTUAL INPUTS status of the digital input on the option card MK3A The status of the digital inputs on the VLT5000 control card is accessible via P528 797 PID tracking error 0 2 000 000 000 READ ONLY PARAMETER PID TRACK 2 000 000 000 UU The current PID tracking error is displayed ERROR in this parameter in user units MG 50 P3 02 VLT is a registered Danfoss t
59. ry 3 The PID controller settings are not pro perly optimised Follow the instructions for optimising 4 The limit specified in P726 may be too low P798 10 SyncPos option error occurred Meaning An internal error on the option card has occurred Please note the corresponding error number and contact Danfoss with a description of the conditions before and after the error occurred P798 11 VLT Exception error detected Meaning An internal VLT 5000 error was detected during start up of the option card program Please note the corresponding error number and contact Danfoss Causes EMC in the environment surrounding the VLT5000 might cause exception errors to arise If the excep tion error occurs at different code addresses it is a good indication that EMC is causing the trouble If the exception error occurs repeatedly at the same code address it is an indication that the EPROM s might be damaged MG 50 P3 02 VLT is a registered Danfoss trademark Past P798 12 Reverse operation prohibited Meaning The drives has been operated in reverse direction while this was not allowed according to the setting of P734 P798 13 Forward operation prohibited Meaning The drives has been operated in forward direction while this was not allowed according to the setting of P734 P798 92 Error from encoder monitoring Meaning Open or short circuit in accordance with the dis played LED An error wil
60. s reserved M G 5 8 P 3 Q 2
61. standstill it will activate the electronic brake according to the setting of P716 If the drive is coasted at any point during ramp down e g due to an OVER CURRENT trip ALARM 13 the drive will immediately activate the brake and coast the drive If 1 is selected the drive will immediately activate the brake and coast the drive NB The brake is always activated after an error situation or quick stop regardless of the P715 setting 726 Maximum tolerated PID error AX ERROR TRACK 20 000 qc 0 1 000 000 000 qc The PID track error is defined as the diffe rence between the internal controller set point and the actual position The better tuning of the PID controller P702 709 the lesser the PID track error At every sample time the current track error is compared with the setting of P726 It is defined as an error situation PID track error too big P798 9 if the track error is bigger than the setting of P726 26 MG 50 P3 02 VLT is a registered Danfoss trademark Positioning Controller Danfoss No Parameter Default Range Description value After tuning the PID controller optimally this parameter should be set to a value approx 50 larger than the maximum observed value of P797 NB The unit is quad counts QC not user units UU 727 Error reset 0 0 no reset
62. t Ain Ain Bin Bin Zin Zin Absolute input Clk out Clk out Data in Data in Not used Not used Fig 1 Terminal A2 A2 B2 B1 Z2 22 Incremental input A in A in Bin B in Zin Zin Absolute input CIk out Clk out Data in Data in Not used Not used Fig 2 MG 50 P3 02 VLT is a registered Danfoss trademark al Positioning Controller Terminal description There are 4 terminal blocks 2 with 10 poles and 2 with 8 poles See figure below MK3A Digital Inputs MK3B Secondary feedback H 2 13 4 is ie 17 I8 24V com sv Jeou at ar er si zi a MK3C Digital Outputs MK3D Primary feedback Oi os os O4 os os O7 OB 24V COM sv com a2 a2 e2 2 zz z Supply voltages The option card is supplied by the internal 24 V DC supply of VLT 5000 but as the available power is limited it can be necessary to use an external 24 V DC supply The 24 V DC supply of VLT 5000 can supply a total of 420 mA including the load on the control card terminal 12 13 and output 42 and 45 26 and 46 for VLT 5000 Flux The 5 V output on the option card is generated from the 24 V supply The maximum power on the 5 V side is 5 V 280 mA 1 4 W this corresponds to app 60 mA on the 24 V side When an external 24 V DC voltage source is used the internal 24 V supply from the control card must be disconnected th
63. tioning Controller Troubleshooting Frequently asked questions Q1 When I have a PID TRACK ERROR TOO BIG error P798 9 the inverter also trips on ALARM 13 OVER CURRENT Past Q4 The inverter frequently trips on ALARM 13 OVER CURRENT while ramping up A1 a Check that the velocity setting P723 for jogging and P738 P742 for positioning is at least 5 lower than the maximum allowed velocity calculated in P799 Either lower the velocity P723 or P742 setting or raise the maximum allowed velocity P799 by setting a higher value of P205 please see Q2 b The quick stop ramp time P719 could be too short Try to increase the setting Q2 How do adjust the maximum allowed velocity in P799 A4 a The ramp settings may require too much torque Try to determine which operation quick stop manual move or positioning caused the trip and then set the corresponding ramp time P719 for quick stop P724 for jogging and P738 P741 for positioning with a higher ramp time setting b The PID controller settings may be unstable re optimise the PID controller parameters P702 P709 Q5 The correct target position is reached but the PID tracking error P797 is too big while the drive moves A2 You need to raise the setting of P205 Doing this will also affect the performance of the parameters P702 P703 P704 P707 and P708 Smaller changes to P205 may not have any notice
64. us not to be used as a safety switch 3 Correct protective earthing of the equipment must be established the user must be protected against supply voltage and the motor must be protected against overload in accordance with applicable national and local regulations The earth leakage currents are higher than 3 5 mA Protection against motor overload is not included in the factory setting If this function is desired set parameter 128 to data value ETR trip or data value ETR warning Note The function is initialized at 1 16 x rated motor current and rated motor frequency For the North American market The ETR functions provide class 20 motor overload protection in accordance with NEC 6 Do not remove the plugs for the motor and mains supply while the frequency converter is connected to mains Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs 7 Please note that the frequency converter has more voltage inputs than L1 L2 and L3 when load sharing linking of DC intermediate circuit and external 24 V DC have been installed Check that all voltage inputs have been disconnected and that the necessary time has passed before repair work is commenced N qna Warning against unintended start The motor can be brought to a stop by means of digital commands bus commands references or a local stop while the frequency converter is connected to mains If perso

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