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Operating Instructions

1. 58 packaging ee eene 69 Option card layout sssseeeeeeenne 10 Option card MK3A sse 17 Option card MK3B master encoder 18 Option card MKIC ies eiecit 18 Option card MK3D slave encoder 19 Option card terminals eeeeee 7 P Packaging iE Re eei pe eren 61 Parameter overview sssssssssseeee 72 Paramelers ccelestis iius 22 PID calculation nete vee 75 Position displacement with a running master 51 Position synchronization ssssssss 4 49 P2DOMION etur ue E 72 R Ramp type x eponuceenEHeui pedis 738 Reversing behaviour eseeen 738 S Setting the parameters admixture ani bete inte deat aaa 43 embossing patterns on mould 538 PACKAGING Eq 63 NAV ies cick oes rah ke Ses a okt AA c EMIL Ee 80 Slave encoder resolution sessssss 73 Slave encoder type sssseeeeeeeeeee 73 Slave marker quantity sees 76 Slave marker type sse 74 Slave markers sss 77 Slave POSION oin an i shanna ci eee 79 86 Synchronizing controller Slave speed nie i ettet ee 79 Slave speed factor sssseeees 77 Software version number cccsccceeeeceeeesteeeeeeees 79 Speed synchronization
2. ccccesscceeesseeeeeseeeees 4 37 Standard RS485 Interface susssse 17 Starting synchronization admixt te EE eet Hes o bete bags 48 embossing patterns on mould 58 packaging irens reie iero a e a pene 69 Status of Synchronization 79 Step Ime 4 eon iiie ia 77 Step width Lees ede ie 77 Stopping synchronization agrmixIure 2i der DERE eis 48 embossing patterns on mould 58 DACKAGING 3 d dee tete ertt e tte hte 69 Store data e nece eme 72 Supply voltages petere 8 Switching to another gear ratio admixt re iced tte de eevee 48 embossing patterns on mould 58 packaglfig 5 irte Ren 69 iae In o m ERR 79 Synchronizing error display factor 77 Synchronizing type Sync type 75 Seca 38 to a running master sssssssseeseses 50 to a running master after Power ON 60 to a stationary master ssssssssssssss 50 T Technical Data nau retire de 7 12 Terminal configuration adimixt re 2 3 1 X mee dbi 42 embossing patterns on mould 52 packaging i 2 e tete tad teretes 62 Terminal description 8 Terminals sse 12 15 Test run acceleration ssssssssssssss 74 Test run distance reete he eaten 74 Tes
3. Slave marker signal 175ZA834 10 ur Figure 22 Conveyor belt with marker synchronization MG 10 N4 02 VLT is a registered Danfoss trademark 59 Paanfots Synchronizing controller Function diagrams for marker synchronization SyncStart to a running master after Power ON If the slave is synchronized to a running master drive the slave automatically synchronizes its position to the master After at least one slave marker and one master marker have been detected the marker compensation comes into effect V m s m s Pa 175ZA810 10 OF Pd ZZA Master p a Marker Bees correction Catching up with Master Slave l l i T l SyncStart t gt Master marker l Slave r marker t s Figure 23 Initial start up with marker synchronization Marker correction during operation During operation marker correction is always carried out when the markers is detected This ensures optimum synchronization no matter whether the gear ratios are not accurate or there is a slip 60 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panfots V m s eee 1752A812 10 at m a ZZA Master di Pe m Marker Marker LH NET correction correction Catching up with Master zz Slave l l l l i SyncStart t gt l Master I l marker
4. 52 packaging epi dipende t debi eect 62 Direction of rotation 73 Display parameters se 79 D pOrtlOn axes oe le eat ela eee ties 72 E Encoder Input 1 master 12 input 2 MK3D Slave sess 13 Output Virtual master 13 Encoder cable ness 13 Encoder monitor 1 erret cru detecte 9 Encoder veloGClty ene riv oirein 75 Error MOSSAQES ceeeeceeeeseeceteeseeeeeesneeeeeseesenesseeeee 70 Error procedure agdmiXxtUEe iet Ur DM RR 48 embossing patterns on mould 58 PACKAGING eile ee eee ee ea 69 Error reference cccceceeeeeeeeeneeeeeeeeeeenneeeeeeeeeeeeees 70 Examples of encoder interface connections 14 External 24 V DC supply sss 12 F FEVEL cale i de nr ete erts 75 Field bus control signals 20 IDt rfaCe aene mie m mote fo ae 20 MG 10 N4 02 VLT is a registered Danfoss trademark Status SIGMAIS isc norme nes 21 Fine setting of the gear ratio admixture 48 Fine setting of the position embossing patterns on mould 58 PACKAGING vie re anavan Saanson daai 69 Fixed offset eene pure 77 Function description seeeeeeee 4 Function diagrams for marker synchronization seeren 60 position synchronization eeren 50 speed synchronization 38 G Gear changing nn 40 Gea
5. First step is to optimize velocity feed forward this can be done via the automatic calculation function Velocity feed forward calculation is activated by setting parameter 729 to 1 remember to make the required parameter settings according to the description of par 729 before starting the calculation The calculation is done when the value of par 729 returns to 0 Velocity feed forward can also be optimized manually by the following procedure 9 Set parameter 706 PID bandwidth to 0 10 Set parameter 719 maximum track error to a high value e g 1 000 000 11 Set parameter 707 velocity feed forward to 100 12 Start test run with virtual master with a known velocity via input 3 1 13 Increase parameter 707 while watching master and slave velocity press DISPLAY STATUS to get the velocity readouts You have found the optimal velocity feed forward when slave velocity is approximately equal to the master velocity 14 Stop test run by input 3 0 15 Reset parameter 719 to the original value 16 Reset parameter 706 to 1000 Second step is to optimise the PID controller a good starting point can be found be means of the automatic calculation function By setting parameter 729 to 2 velocity feed forward calculation is activated as well as calculation of PID sample time and P D factors remember to make the required parameter settings according to the description of par 729 before starting the calculation T
6. Operating Instructions Synchronizing Controller VLT 5000 VLT 5000 FLUX Synchronizing controller Paanfets Table of contents Safety regulations Introduction Function description erre reet rer iret rte ear pese eoe Ree e eoe Nate oh aoaeiao hisser Pues pe ere ren eM ea so Eve Ea teed 4 Speed synchro Zaton ien O D OODRI DUO hubs stds avs oben Sense Dite pre bite 4 Position synchronization angle SyncChromization ccssccesscecsseceeececsseceeeeecsaeceeeeecsaeceeeecsecesaeecsaeessaeeecaeceeneeesaeeenees 4 Marker synchroniz tion o ote ttr RU e cave UAE INE PEE a E FERE ebd e bue eere evertere eee umm a 4 Mechanical B OCI CXVIII EE 5 Tips and tricks for synchronization tasks ecce esee e eese eerte ee enne seen eae to tosta asse tas tete etae sena e e eaae s 5 jUr 7 VE T control card terminals ero eroe eR EU cov ERES PEORES PEU e SE EREN EU eee Ee ee U EE Ne SR RENE RE SEV EO 7 Techical data iretur oe eer eere IP ee tee EI eere RERO XE EUR ERREUR RE HER EIS derer es 7 Option card terminals eret pe Po eere eo ree oar E E EEEE EES EERE r T EErEE EEEE r E arei reh 7 Suppli voltages see e C Ota p ERG paul dives ie on atit ir a pic ish 8 Encoder qonttor i eco eto Estee e eT re ER a tebe cold te cob qoos cete se dubs cbe ee tes ee tube NEP tubs e exe UR 9 Option card layout eere epe eO Sepa ped C Sede HE RG oe ene
7. 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 VLT frequency converter does not disconnect the equipment from mains and is thus not to be used as a safety switch 3 Correct protective earthing of the equipment must be established the user must be protected against supply voltage and the motor must be protected against overload in accordance with applicable national and local regulations 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 initialised 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 VLT 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
8. 72 Parameter number 702 703 704 705 706 707 708 709 710 Description P portion Factory setting 10 Setting range from 0 to 65000 User setting D portion Factory setting 0 Setting range from 0 to 65000 User setting l portion Factory setting 0 Setting range from 0 to 65000 User setting Limitation for I portion Factory setting 1000 Setting range from 0 to 65000 User setting Band width PID controller Factory setting 1000 Setting range from 0 to 65000 User setting Velocity feed forward Factory setting 0 Setting range from 0 to 65000 User setting Acceleration feed forward Factory setting 0 Setting range from 0 to 65000 User setting Velocity filter Factory setting 0 Setting range from 0 to 65000 User setting Store data Factory setting 0 Setting range from 0 to 1 User setting MG 10 N4 02 VLT is a registered Danfoss trademark 711 712 713 714 715 716 717 718 ak 720 Synchronizing controller Slave encoder type Factory setting 0 Setting range from 0 to 102 User setting Slave encoder resolution Factory setting 1024 increments Setting range from 1 to 2147483647 increments User setting increments Master encoder type Factory setting 0 Setting range from 0 to 102 User setting Master encoder resolution Factory setting 1024 increments Setting range from 1 to 2147483647 incr
9. 3 for a negative edge Parameter 724 Master marker interval Record the interval between two marker signals of the master Input of the interval is in quad counts If the interval is not known it can also be determined during the test run Parameter 725 Test run speed Record the speed at which you want to carry out the optimization run Record the speed as a percentage of the speed in Parameter 716 Parameter 726 Test run acceleration Record the acceleration for the test run in percent of the minimum acceleration time 10096 represents the minimum acceleration 5096 is half as fast as minimum acceleration the ramp time is thus twice as long Parameter 727 Test run distance Record the distance quad counts for the drive to travel during optimization How to check the motor connection When you have programmed the above parameters you check the motor connection as follows 1 Remove all signals to terminals 16 33 and 11 18 Only input 27 must be connected and closed 2 Select Local function in parameter 002 VLT 5000 stops display flashing 3 Setthe frequency for a low value for example 3 Hz in parameter 003 4 Press the START button on the VLT 5000 control panel and then the STOP Reset button watching the direction of the motor If the motor rotates in the wrong direction then exchange the motor phases How to test the incremental encoders When you have tested the motor speed direction you test the incremental
10. 3 Now set the D portion parameter 703 to 5 times the value of parameter 702 4 If a lower synchronizing error is required the I portion parameter 704 can be set to a low value e g 10 but be careful a too high value will course overshoot and instability To store the optimized values Activate Input I4 Store or change first the value of parameter 710 to 1 How to program synchronization 56 Change the value of parameter 701 to 2 This will start the synchronization program of VLT 5000 To do the synchronization programming you use the following parameters Parameter 725 Type of operation Record 1 or 4 for position synchronization Parameter 729 Home function Specify the start function of the drive 0 no defined position 1 Home run must be carried out before the first start of synchronization 2 Home run must be carried out before each start of synchronization Parameter 730 Home speed Set the speed 96 of maximum speed at which Homing is to be made Positive values for clockwise rotation negative values for counter clockwise rotation Parameter 731 Home acceleration Set the acceleration 96 of minimum acceleration for homing Parameter 733 Accuracy Record a value quad counts for a tolerance within which the slave position may deviate from the position of the master With a negative value the synchronizing error parameter 797 show the error with a sign Parameter 734 Marker quantity
11. Offset is related to the master position Offset related to the slave position can be calculated as follows Offset Parameter 738 Offset_slave Parameter739 743 Synchronous operation Program 2 Step time Enter the time after which e with the Hold function activated and the presence of one of the signals at Terminal 32 or 33 a change in speed takes place e in the engaged state without Hold the next change of the slave position takes place Input is in milliseconds 744 Synchronous operation Program 2 Step Length Enter the step value for changing the position offset in quad counts Parameter 742 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 MG 10 N4 02 VLT is a registered Danfoss trademark 29 Panfisi Synchronizing controller Synchronous operation Program 2 Slave speed factor Enter here the factor by which the slave speed must be scaled so that the desired value is displayed The following formula applies for calculation of the factor N sa 400 Slaveencoder _ resolution Factor 398 60 Display _ value Example Resolution 1024 PPR desired display 100 at 1500 Vmin 1500 400 1024 4i Factor 102400 60 100 746 Synch
12. Test run acceleration Factory setting 10 96 Setting range from 1 to 200 96 User setting 96 Synchronous operation Program 2 Hold function Factory setting 0 Setting range from 0 to 1 User setting 727 Test run Program 1 Test run distance Factory setting 4096 quad counts Setting range from 1 to 2147483647 quad counts 74 MG 10 N4 02 VLT is a registered Danfoss trademark 728 729 730 731 Synchronizing controller PDanfets User setting quad counts Synchronous operation Program 2 Hold speed Factory setting 10 Setting range from 0 to 100 User setting 96 Test run program 1 Synchronizing type Sync type Factory setting 0 Setting range from 0 to 1 User setting Synchronous operation Program 2 Delta hold speed Factory setting 5 Setting range from 1 to 100 User setting 96 Test run program 1 Activate feed forward and PID calculation FFVEL calc Factory setting 0 Setting range from 0 to 2 User setting Synchronous operation Program 2 Home function Factory setting 0 Setting range from 0 to 2 User setting Test run program 1 Encoder velocity Encoder RPM Factory setting 1500 Setting range from 1 to 65000 RPM User setting RPM Synchronous operation Program 2 Home speed Factory setting 10 96 Setting range from 1 to 100 96 User setting 96 Home acceleration Factory setting 10 96 Setting range from 1 to 2
13. setting If the drive becomes unsteady or if a message is given about over voltage or over current then reduce the value in parameter 702 to about 70 80 of the set value 7 Now set the D portion parameter 703 to 5 times the value of parameter 702 8 If a lower synchronizing error is required the l portion parameter 704 can be set to a low value e g 10 but be careful a too high value will course overshoot and instability For test run with virtual master the following parameters must be set Parameter 748 Virtual master reference Select the reference source for setting the velocity of the virtual master 0 is analogue input 53 1 is analogue input 60 2 is parameter 216 and 3 is Field bus PCD 2 Parameter 749 Virtual master acceleration Set the acceleration of the virtual master in encoder pulses per second Parameter 750 Virtual master maximum speed Set the maximum velocity of the virtual master in encoder pulses per second Then use the following procedure 1 Start test run with virtual master by activating input 3 During test run you can read the track error in the last value of the first display line At stop the maximum track error during the test run is read out Because velocity synchronization is selected parameter 728 0 the track error is velocity deviance between master and slave 2 If more accurate and dynamic control is required the P portion parameter 702 must be increased If the slave becomes u
14. 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 synchronization 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 P 755 brake on delay and P 756 brake off delay Please note that the brake output is kept low in VLT mode input 8 high That means the brake must be opened for example by means of the VLT mechanical brake function in set up 2 Tips and tricks for synchronization tasks When configuring the drives to be synchronized 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 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 co
15. 10 AKTIT N PALA ec E 12 Examples of encoder interface connections scccsscssssscssssscsssscssssccsssscsssccssssessssesssssascesssssessssssassssses 14 Description of terminals ee 15 Description of Field bus interface cccccccisssssscsasssoosssssnssssnsossecdsssenssonssssenisoovessseteseeed ssdnesesssseveessdescesenesvectes 20 Data layouten oe fone or DID o t e rei e ei HR Reden 20 Description of parameters reete secus en epo at enero se Sa poke en Fe eb etos eese eas o rues ris bore cantore rl sees eo eu vosi sisas ini rae 22 Initializing the parameters eese eo reote eoe et ouo uo panier eee epe eon Pea voee ee Ee eo a EVER sa Paene Se oe e VR eS os Vas ess esos Ssi 36 Speed synchronization 37 Function diagrams for speed synchronization Lecce ee esee esee esee eese en neta setae sten setas etas etna e toss sea 38 SYNC SALES 5 secs T M 38 Up down factor te Rer ee ettet le ce Me ea tiie d eode stetisse e Pete net Ried ete ope 38 Hold function t eerte ete EP Ete ineo e rie pee tores e ee teer tnst 40 Gear CHAN BING Seasons ease Bet tene Denm p ae oat e tute DIRE Eo ESSEE Eaa IESP 40 Changing the gear ratio with an analogue value eseeeeeeeeeeeeeeeeneene nennen nennen nein rene eene nennen nre 41 Application example Admixture 5 lt c0 lt secisoecsosssoosseceinnnssocsisocsecssenssettovesteedtenssussesosssosevsastoesesensteeesonssoees 42 De
16. 13 Measuring master marker Not used 7 distance 1 14 Measuring slave marker Not used 8 distance 1 15 Test run left Not used 32 1 16 Test run right Not used 33 2 Virtual master reference Virtual master reference 53 60 Only when Parameter 748 3 Field bus status signals Field bus Test run Synchronizing Corresponding word bit output parameter 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 P775 797 3 Not used Synchronizing error P797 4 Not used Status of Synchronization P778 5 Slave speed Slave speed P798 6 Master speed Master speed P799 MG 10 N4 02 VLT is a registered Danfoss trademark 21 uuf tt Synchronizing controller Description of parameters 22 Parameter Description number Selection of the operation mode 1 test run 2 synchronization P portion of the Synchronizing controller Setting see Examples D portion of the Synchronizing controller Setting see Examples I portion of the Synchronizing controller Setting see Examples Limitation for l portion Setting see Examples Band width for PID controller Velocity feed forward Setting see Examples Acceleration feed forward Setting see Examples Velocity filter Store data Here you can save the selected dat
17. First step is to optimise velocity feed forward this can be done via the automatic calculation function Velocity feed forward calculation is activated by setting parameter 729 to 1 remember to make the required parameter settings according to the description of par 729 before starting the calculation The calculation is done when the value of par 729 returns to 0 54 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Pranfets Velocity feed forward can also be optimized manually by the following procedure 1 Set parameter 706 PID bandwidth to 0 Set parameter 719 maximum track error to a high value e g 1 000 000 Set parameter 707 velocity feed forward to 100 Start test run with virtual master with a known velocity via input 3 1 Increase parameter 707 while watching master and slave velocity press DISPLAY STATUS to get the velocity readouts You have found the optimal velocity feed forward when slave velocity is approximately equal to the master velocity 6 Stop test run by input 3 0 7 Reset parameter 719 to the original value 8 Reset parameter 706 to 1000 c OI Second step is to optimise the PID controller a good starting point can be found be means of the automatic calculation function By setting parameter 729 to 2 velocity feed forward calculation is activated as well as calculation of PID sample time and P D factors remember to make the required parameter settings acco
18. Master gi mi 2 l a Step time Ps Up Factor po qos Down t s Figure 11 Up down factor with speed synchronization MG 10 N4 02 VLT is a registered Danfoss trademark 39 Panfisi Synchronizing controller Hold function The Hold function operates the slave drive in closed loop speed control at a speed independent of the master With Parameter 726 Hold function you can choose whether the slave is to run at a fixed speed set in Parameter 727 or whether it is to maintain current speed For the duration of the Hold signal the speed of the master is no longer taken into account the master can even stop without this having any effect on the slave drive While the Hold function is activated you can change the speed with inputs 32 and 33 The speed is changing according to the settings in parameter 728 Delta hold speed and parameter 744 Step width 175ZA805 10 V m s Slave Master 5tep time Up Factor Down Hold t s Figure 12 Hold speed Gear changing During synchronous operation it is possible to switch between 4 fixed gear ratios set in parameters 737 739 The fixed gear ratios are selected at terminals 16 and 17 Input 16 input 17 To activate the new ratio you must activate input I2 The newly set gear ratio is attained with the minimum possible ramp 40 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panfets
19. OFF Maximum frequengcy rriki ae e EEA ennemi nnne ERTA 220 kHz at 50 duty cycle Phase displacement between A and B sse eene eren nnne 90 30 Absolute Signal leveli E 5 V differential SIgiali type ness Moe cr asc e a MER a aS c e a eerer SSI Data COGO c Gray code BEWEIS 25 bit up none Glock frequeticy d ote dtes ciet T 105 or 260 kHz ai eisreo eI Gray Maximum positions per revolution seriinin smaa ai eana S E e nennen enne AEE nn nnne nennen 8192 Maximum number of revolutions ess urere naa EAn ANE EAEE ATAARE EAE nne sn EE nannten nene 4096 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panfets Encoder input 2 MK3D slave Terminal designaltioris rtt e ER EM EQ EE PAARE ER Feu EYE A2 A2 B2 B2 Z2 Z2 Incremental SIVE 5 V differential Signalty e Icd PELLUS Linedriver RS422 INPUT impedariGe ct ce ptit et EAT ee itte d ntt Peli eet aval tt dad Gd 120 Q Maximum frequengcy rsio aaa AEAEE A nnne nter nn nennen entren nn 220 kHz at 50 96 duty cycle Phase displacement between A and B sse nennen nnne 90 30 Absolute SIEUT E 5 V differential Sigiiali type dice tatc MC CLA CIL rmt SEE Ee KL mL e SSI Protocol eT Gray code Data tongi eee eanan eiie echo hl ecelesie Lis MIRI eS AE tae theca Ei elit hot t
20. be em i te e i esit atenta 28 V DC Input impedance ii eet tete tree tet e e tee et 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 as the digital outputs Digital outputs MK3C Terminal designatis ci irna ria ei eite good ete ee da ce nee e ep eet ee ce eite e eed O1 O8 volage level 5 d de jh ce e ecrit eset teer epi ed ios Re AN 0 24 V DC Maximum load ee a aaa eee creep Y eue n perii 0 7A with external power supply Update ate oic Rn isin tin cien ei e T ee Ra eh e itii Rr 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 master Terminal designations ssssssssssssssssssssesee eene nnne nnne A1 Al B1 B1 Z1 Z1 Incremental SIG Mall level xe ee ce tese e xata id te cnr s et rra xe cane 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 cinta ek i Rx Ate ua ESPERTO ERRARE SEODLURR HE COE Su S Se DERE 120 Q Dip switch 1 3 ON sihpebot tee sb Entente bb ett Pv tb seta o ced rtf ab eo aee etd tts gt 24 kQ Dip switch 1 3
21. encoder connection as follows 1 Remove all signals to terminals 16 33 and 11 18 Only input 27 must be connected and closed 2 Press the DISPLAY STATUS button on the VLT 5000 control panel Now the following values appear in the upper line of the display slave position master position and track error 3 Rotate the slave drive motor shaft manually in the allowed direction Now the display shows an ascending count of the slave position If the count is descending exchange the slave encoder track A by B and A by B If there is no counting in the display then check the wiring of the encoder Follow the same procedure when you test the master encoder Note To be right the count must be ascending here 64 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller ufi Remember to change parameter 002 back to Remote and start VLT 5000 by pressing the START button on the control panel How to optimize the controller Synchronization is obtained via two main elements of the controller Velocity feed forward and the PID controller NOTE Before starting the optimizing procedures it is important to select the right type of synchronization in parameter 728 in this example it must be 1 for position synchronization Please always have the necessary degree of accuracy in mind you could go on optimizing for a long time but it might not be necessary to have a 10096 accuracy in the application you are dealing with
22. functions Ho After all values have been set as described and the controller has been optimized for the application Parameter 729 Home function is set to the value of 2 The drive can now be operated normally me run As parameter 729 is set to 2 homing must be carried out before each start To start homing the contact at Terminal 19 is closed The slave drive then travels to the home switch and stops there If the reversing procedure is set to 0 the slave travels back to the start of the home switch otherwise the offset arising from disabling reversing is added to the fixed offset Starting synchronization Preferably the master is first similarly brought into its start position and the slave activated by means of l1 SyncStart then the master is started This produces optimum synchronization The slave can of course also be started by e g a start signal from the master although in that case it should be noted that the delay of the start signal can be prolonged by the scan time of e g the PLC Attention should be paid to the accuracy of the start signal Hence it is better to start the slave drive when the master is in position The position of the master plus the value of the fixed offset is the synchronization position to which the slave drive will travel at the maximum permitted acceleration when started It may happen here that the slave drive travels faster than the master as the slave drive needs to catch u
23. o Master markers Fixedoffset 1 Step time Factory setting 100 ms Setting range from 10 to 2147483647 ms User setting ms Step width Factory setting 1 Setting range from 2147483647 to 2147483647 User setting Slave speed factor Factory setting 400 Setting range from 1 to 2147483647 User setting Master speed factor Factory setting 400 Setting range from 1 to 2147483647 User setting Synchronizing error display factor Factory setting 400 Setting range from to 2147483647 User setting Virtual master reference value Factory setting 0 Setting range from 0 to 3 User setting Virtual master acceleration Factory setting 25600 Setting range from 1 to 2147483647 He n User setting 3 MG 10 N4 02 VLT is a registered Danfoss trademark Zane 77 Panfiii Synchronizing controller 750 Virtual master maximum speed Factory setting 25600 Setting range from 1 to 2147483647 t User setting p 751 Marker window slave Factory setting 0 Setting range from 1 to 2147483647 User setting 752 Marker window master Factory setting 0 Setting range from 1 to 2147483647 User setting 753 Control source test run Contr testrun Factory setting 0 Setting range from 0 to 1 User setting 754 Control source synchronizing Contr synchron Factory setting 0 Setting range from 0 to 1 User setting 755 Brake on delay B
24. seen 72 M Marker correction during operation 60 Marker interval at the master ssssuuuss 74 Marker interval at the slave ssssssuuusse 74 Marker quantity FAULT eseese 76 Marker quantity READY seeeeeeeee 76 Marker synchronization eesessssssssss 4 59 Marker synchronizing mode ssssss 76 Marker window master sssssssessssessess 78 85 Zane Marker window slave eessssseeeee 78 Masltet ico nine reise Pe 80 Master encoder resolution eeren 73 Master encoder type eeeeeeeeesneeeeeeneeeeeenneeereeaes 73 Master marker quantity sees 76 Master marker type sse 74 Master markers sssssssssseseeesneeeenent 77 Master position eeeeeeeeeeeeeeeeeeeeneneeeene 79 Master speed eese 79 Master speed factor sseeeee 77 Maximum speed eene 73 Maximum track error cccccceeeeeeeeeceeeeeeeseeeesneeeeeeees 73 Mechanical brake control 5 MeSSa0Qg65 uc ee ate e ED E err eiie 70 Minimum ramp eeeeeennnm eer 73 M S tolerance speed sssseeesee 76 N N rmerator 5 nne er Ee eub 77 O Operation and operating functions admyixt le a cente E E 48 embossing patterns on mould
25. slave Record 1 if the slave is to run in the opposite direction Record maximum RPM measured at the slave encoder Minimum ramp Set the time in ms for the slave drive to accelerate from standstill to maximum speed par 716 The value is important as this setting highly affects the control accuracy MG 10 N4 02 VLT is a registered Danfoss trademark 53 Auuf tt Synchronizing controller Parameter 718 Ramp type Record 0 for linear ramp and 1 for s ramp Note S ramp requires higher acceleration torque Parameter 719 Maximum track error Record the value that is to generate Track error indication in the display if exceeded Input is in quad counts Parameter 720 Reversing behaviour Record 0 if reversing is allowed 1 if the slave must always follow the direction of the master or 2 if reversing is not allowed How to check the motor connection When you have programmed the above parameters you check the motor connection as follows 1 Remove all signals to terminals 16 33 and 11 18 Only input 27 must be connected and closed 2 Select Local function in Parameter 002 VLT 5000 stops display flashing Set the frequency for a low value for example 3 Hz in parameter 003 4 Press the START button on the VLT 5000 control panel and then the STOP RESET button watching the speed direction of the motor If the motor rotates in the wrong direction then exchange the motor phases e Testing th
26. that the VLT 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 gy 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 personal safety considerations make it necessary to ensure that no unintended start occurs these stop functions are not sufficient 2 While parameters are being changed the motor may start Consequently the stop key STOP RESET must always be activated following which data can be modified 3 A motor that has been stopped may start if faults occur in the electronics of the VLT frequency converter or if a temporary overload or a fault in the supply mains or the motor connection ceases Warning Touching the electrical parts may be fatal even after the equipment has been disconnected from mains Also make sure that other voltage inputs have been disconnected such as external 24 V DC load sharing linkage of DC intermediate circuit as well as the motor connection for kinetic back up Using VLT 5001 5006 220 and 500 V units wait at least 4 minutes Using VLT 5008 5500 220 and 500 V units wait at least 15 minutes Using VLT 5001 500
27. to 31000 is accepted NOTE This parameter is only used in marker synchronizing mode parameter 725 2 or 5 MG 10 N4 02 VLT is a registered Danfoss trademark 31 Panfisi Synchronizing controller Control source test run Contr testrun This parameter is used to select the control source in test run mode par 701 1 There can only be one control source at a time Digital inputs or field bus control word Only exception is input 27 which is always stop also with field bus control When digital control is selected status signals are updated on the digital outputs when field bus control is selected status signals are updated on digital outputs as well as field bus Setting range 0 4 Digital inputs Field bus 0 means that all control commands are activated via the digital inputs according to the description of the terminals 1 means that all control commands are activated via the field bus control word according to the description of field bus control NOTE The new control source selected in par 753 is not active before next power up power cycle remember to save par 710 or input 4 the settings before power down 754 Control source synchronizing Contr synchron This parameter is used to select the control source in synchronizing mode par 701 2 There can only be one control source at a time Digital inputs or field bus control word Only exception is input 27 which is always stop al
28. to the calculated master speed taking the gear ratio into account There is no position control v 1 s 175ZA835 10 Master speed Slave speed Deviation gt t s Figure 8 Control behaviour with speed synchronization In the above diagram it can be seen that the slave drive is following the speed of the master drive Note Position deviations arising in connection with speed changes are not adjusted This type of control could for example be used for dosing pumps mixing two liquids See example The example shows a batching unit where an admixture to a basic substance is carried out The mixing proportion is freely selectable by means of the gear ratio The advantage of pure speed synchronizing control can also be seen as it makes little sense to compensate for position deviations that arise i e too large an amount of Product B being added for example by means of reducing the speed of the slave drive as that would only lead to an insufficient amount of Product B being added subsequently Ji 17524832 10 Master encoder Product A c l Product B Ez Slave encoder nT VLT5000 OO synchroni sin controller Feedback Reference Figure 9 Mixing Speed synchronizing control MG 10 N4 02 VLT is a registered Danfoss trademark 37 Paanfots Synchronizing controller Function diagrams for speed s
29. 00 96 User setting 96 MG 10 N4 02 VLT is a registered Danfoss trademark 75 Zane 732 733 734 735 736 LEX 738 739 740 741 76 Synchronizing controller Marker synchronizing mode Factory setting 0 Setting range from 0 to 1005 User setting Accuracy Factory setting 1000 quad counts Setting range from 2147483647 to 2147483647 quad counts User setting quad counts Marker quantity FAULT Factory setting 5 markers Setting range from 1 to 10000 markers User setting markers Marker quantity READY Factory setting 10 markers Setting range from 1 to 10000 markers User setting markers M S tolerance speed Factory setting 0 96 Setting range from 0 to 100 96 User setting 96 Gear ratio no Factory setting 0 Setting range from 0 to 3 Gear ratio numerator Factory setting 1000 Setting range from 1 to 2147483647 Gear ratio denominator Factory setting 1000 Setting range from 1 to 2147483647 Slave marker quantity Factory setting 1 Setting range from 1 to 2147483647 Master marker quantity Factory setting 1 Setting range from 1 to 2147483647 MG 10 N4 02 VLT is a registered Danfoss trademark 744 745 746 147 748 749 Synchronizing controller Fixed offset Factory setting 0 Setting range from 2147483647 to 2147483647 Gearrationo 0 a p a Numerator Z O Denominator T Slave markers
30. 00 msec The value must be set according to the reaction time of the mechanical brake 757 Marker monitor This parameter specifies the behavior when markers are missing in Marker Synchronizing mode par 725 2 or 5 Setting range 0 Output 2 fault is set when not accuracy for x number of markers x par 734 1 Output 2 fault is set when not accuracy for x number of markers x par 734 OR when x number of markers are missing 2 Output 2 fault is set when not accuracy for x number of markers x par 734 and Output 2 fault is set and the error handler is called when x number of markers are missing NOTE This function can only be used if marker windows are used par 751 and 752 758 Resync With resync active synchronisation will remain active while the slave is stopped Input 1 and or Input 27 0 The actual synchronizing error will be corrected with the set velocity and acceleration when restarting synchronisation Setting range 0 inactive 1 active 775 Synchronous operation program 2 Track error read only This parameter indicates the actual PID error during synchronization same as par 797 in test run mode MG 10 N4 02 VLT is a registered Danfoss trademark 33 Panfisi Synchronizing controller Input status read only Digital control par 753 and par 754 This parameter is showing the actual status of the 8 digital inputs 11 18 on MK3A as a binary code Ex
31. 175ZA806 10 v m s Slave ZA Master aS Factor x lt Factor 2 X Factor 1 X Factor 3 l l l E i i HN Figure 13 Changing the gear ratio in speed synchronization ts Changing the gear ratio with an analogue value As an alternative the gear ratio can be set via analogue input 54 with a 10V signal this function is active when synchronizing type 6 or 7 is selected in parameter 725 The gear ratio denominator is fixed to 500 The gear ratio numerator is set by input 54 5V corresponds to 500 which then gives a gear ratio of 1 1 MG 10 N4 02 VLT is a registered Danfoss trademark 41 Panfisi Synchronizing controller Application example Admixture A feed screw conveyor pump leads substance 1 to a nozzle adding substance 2 For different end products it must be possible to select different mixing ratios ratio 1 1 1 ratio 2 1 1 12 ratio 3 1 1 2 ratio 4 1 1 21 During operation it must be possible manually to make slight adjustments of the selected mixing ratio Description of terminals and terminal configuration From mains supply wwe VLT 5000 Choice of gear ratio To motor Reset Gear ratio Gear ratio Sync Start Change of setup Save MK 3B A1 BL Bl Z1 Zi Master encoder Accuracy Saving 40 MK3D D Running 9 0 B2 Unit ready Z2 Z Slave encoder Figure 14 Wiring diagram Batch control 42 MG 10 N4 02 VLT is a registered Da
32. 2 Synchronous operation Program 2 Marker synchronous operation For marker synchronization select how the slave is to synchronize to the master O0 last marker pulse i e the slave synchronizes to the last detected marker pulse This is achieved by accelerating to this position 1 next marker pulse The slave waits for the next marker pulse and synchronizes to it 2 once the master speed is reached marker correction to next following markers take place may catch up slow down 3 same as 0 but after master speed is reached 4 same as 1 but after master speed is reached 5 once the master speed is reached marker correction to closest marker take place If 1000 is added to the previous choices the fixed offset is not executed before the marker correction has taken place NOTE This parameter is only used in marker synchronizing mode parameter 725 2 or 5 MG 10 N4 02 VLT is a registered Danfoss trademark 27 Panfisi Synchronizing controller Synchronous operation Program 2 Accuracy This parameter specifies that maximum master slave deviance this is used to control the accuracy output O 3 The accuracy output will only be high 24V if the actual master slave deviance is within this value In velocity synchronization parameter 725 0 3 6 or 7 the value must be set in RPM Rounds Per Minute in all other modes it must be set in quad counts With a negative value in this parameter the synchr
33. 38 Gear ratio numerator Record the numerator value for the gear ratio That is the encoder pulses of the slave drive To make fine adjustment possible by means of inputs 32 and 33 a ratio of for example 7 16 must be programmed as 7000 16000 Parameter 739 Gear ratio denominator Record the denominator value of the gear ratio This value corresponds to the master pulses Parameter 740 Slave markers Record the number of slave markers for the marker ratio Ensure that the gear ratio and the marker ratio match each other Parameter 741 Master markers Record the number of master markers for the marker ratio Ensure that the gear ratio and the marker ratio match each other Parameter 742 Fixed Offset Record a fixed position offset for the selected gear ratio quad counts This value specifies the position deviation between the slave marker and the master marker During operation the offset can be changed by means of inputs 32 and 33 Note Offset is related to the master position Offset related to the slave position can be calculated as follows Offset Parameter 738 Parameter739 Offset_slave Parameter 743 Step time Record the delay in ms from one frequency change to another hold mode and from one gear ratio numerator factor change to another synchronization mode when there is a signal on terminal 32 or 33 MG 10 N4 02 VLT is a registered Danfoss trademark 67 uuf tt Synchronizing controller Parameter 744 Step width I
34. 5 550 600 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 10 N4 02 VLT is a registered Danfoss trademark 3 Panfisi Synchronizing controller Introduction The Synchronizing Controller is an application option for VLT5000 and VLT5000Flux The application option consists of two parts e Synchronizing controller part e Test Run part Function description The Synchronizing controller can be used in any application where a drive is to operate synchronously with a master drive The synchronizing 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 e Speed synchronization e Position synchronization or e Marker synchronization Speed synchronization This is the simplest type of synchronization It can be used to compensate for speed differences where it is not necessary to compensate for position errors The speed synchronization 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 Position synchronization angle synchr
35. Data in Data in Not used Not used Fig 2 e Master encoder input virtual master output There are 8 digital inputs 8 digital output and terminals for 5 V and 24 V supply The functions and technical data of the terminals are described in the following MG 10 N4 02 VLT is a registered Danfoss trademark 7 uuf tt Synchronizing controller Terminal description There are 4 terminal blocks 2 with 10 poles and 2 with 8 poles See figure below MK3A Digital Inputs MKS3B Master Virtual Master 1 2 13 IM 15 l6 I7 18 24V COM sv com ai ar ei a1 zi a MKSC Digital Outputs MKS3D Feedback o1 o2 03 O4 O5 O6 O7 OB 24V COM sv com a2 e e2 2 z z2 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 The 5 V output on the option card is generated from the 24 V supply The maximum power on the 5 V side is 5 V 280 mA 1 4 W this corresponds to app 60 mA on the 24 V side When an external 24 V DC voltage source is used the internal 24 V supply from the control card must be disconnected this is done
36. Fault Inaccuracy Record the number of marker signals to generate a Fault signal Parameter 735 Marker quantity Ready Accuracy Record the number of marker signals to generate a Ready signal Parameter 737 Gear ratio No Record the number of the gear ratio that is to be displayed in Parameters 738 to 739 First set the number of the gear ratio then the necessary values for this gear ratio can be set in Parameters 738 and 739 The next gear ratio is then selected in Parameter 737 and the same procedure is repeated Parameter 738 Gear ratio numerator Enter here the numerator value of the gear ratio The value corresponds to the encoder pulses of the slave drive To make fine adjustment possible by means of inputs 32 and 33 a ratio of for example 7 16 must be programmed as 7000 16000 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Pranfets Parameter 739 Gear ratio denominator Record the denominator value of the gear ratio This value corresponds to the master pulses Parameter 742 Fixed Offset Record a fixed position offset for the selected gear ratio quad counts You use this value to specify the position deviation between slave and master During operation you can change the value by means of inputs 32 and 33 Note Offset is related to the master position Offset related to the slave position can be calculated as follows Offset Parameter738 Offset_slave Parameter739 Parameter 743 Step tim
37. a permanently in the EEPROM 0 no function 1 data are being saved While saving continues the value remains 1 when saving is finished the value automatically reverts to 0 Similarly during saving Output O5 Saving is set to 1 Saving is not possible during operation but only in the disengaged stopped state Slave encoder type Setting range 0 Incremental encoder 1 Absolute encoder with 262kHz clock frequency 2 Absolute encoder with 105kHz clock frequency 100 as 0 but with hardware monitor active 101 2 as 1 but with hardware monitor active 102 as 2 but with hardware monitor active Slave encoder resolution in increments per rotation Master encoder type Setting range 0 Incremental encoder 1 Absolute encoder with 262kHz clock frequency 2 Absolute encoder with 105kHz clock frequency 100 as 0 but with hardware monitor active 101 2 as 1 but with hardware monitor active 102 as 2 but with hardware monitor active Master encoder resolution in increments per rotation MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panfots 715 Direction of rotation standard position is counting positive when the drive is running forward position is counting negative when the drive is running forward as 1 but with opposite sign of the reference to the drive This can be used as alternative to swapping two motor p
38. agram below at Start as well as with every change in speed of the master drive the cycle times are added they are then compensated for again based on the control characteristics of the controller in question 175ZA828 10 Start Position Conv 1 Position Conv 2 Position Conv 3 E Cycle time Time delay Figure 30 Addition of the cycle times In this case the same application is realised by means incorporating a virtual master Although the way that the reference value is introduced at the first belt is analogous the value is used to set the virtual master signals C Conveyor 1 CX Conveyor 2 OC Conveyor 3 Slave Slave Slave feedback feedback feedback Syne Sync Sync control control control 175ZA829 10 Virtual Master Signal Virtual Master Reference Figure 31 Synchronization with virtual master 82 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panfets It can be seen from the diagram below that the cycle time error is not added instead one cycle time applies for all the drives The advantage of this is that the control has fewer errors to correct 175ZA827 10 Virtual Master start signal Position Conv 1 Position Conv 2 Position Conv 3 Cycle time Time delay Figure 32 No addition of the cycle times MG 10 N4 02 VLT is a registered Danfoss trademark 83 Pranfots Synch
39. ample Input 3 7 and 8 high 776 11000100 Input 1 and 3 high 776 101 Field bus control par 753 and par 754 This parameter is showing the status of the field bus control word PCD 1 as a decimal value Example Bit 3 7 and 8 high 776 196 Bit 1 and 3 high 776 5 777 PID sample time The parameter is setting the sample time of the control algorithm The value should be increased if e The pulse frequency is very low e g 1 to 2 quad counts per sample time you need at least 10 to 20 quad counts per sample time e The system is very slow and heavy high inertia Controlling systems with 1 ms can make big motors vibrate The correct value can be calculated automatically see test run parameter 729 NOTE The parameter setting has direct influence on the PID loop if you for example double the Sample time the P portion parameter 702 also has the double effect 34 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panfiii Et The following are display parameters only read only Status of Synchronization The following status flags are defined for position and marker synchronization The flags are not updated when using speed synchronization Flag Decimal value X Bit SYNCREADY 1 0 SYNCFAULT 2 1 SYNCACCURACY 4 2 Only marker Synchronization Master marker HIT 8 3 Slave marker HIT 16 4 Master marker Error 32 5 Slave marker Error 64 6 The flags are reset when restarting synchr
40. ans of SyncStart I1 then the master is started This ensures optimum synchronization The slave drive travels in position synchronization to the master until both slave and master marker has been detected The slave accelerates or slows down according to the setting of Parameter 732 in order to attain the marker position plus the set offset It may happen that the slave drive travels faster than the master does if the slave drive needs to catch up with the position Stopping synchronization On opening contact I1 SyncStart the slave is stopped at the permitted acceleration Fine setting of the position As soon as the slave drive is in position synchronization to the master an adjustment of this position can be made by means of Inputs 32 33 This setting is only temporary i e the fine setting data are lost as soon as the converter is disconnected from the mains If the adjustment data are to be retained storage must be carried out by activating the Save Input I4 or by means of Parameter 710 before switching off the drive Note Offset is related to the master position Offset related to the slave position can be calculated as follows Offset Parameter 738 Offset slave Parameter739 Switching to another gear ratio During synchronization a new gear ratio can be selected at Inputs 16 and 17 The gear ratio is then activated by means of the Switching Input I2 The slave will then proceed at the permitted acceleration to this
41. as d Lees E iSi M CE 25 bit up none Glock frequeticy tert tat tee tette tiat TT 105 or 260 kHz Maximum positions per revolution tsere a aa a ara aAA AA SA n nennen nennen nnne nennen 8192 Maximum number of revolutions ecnin aai aE e TE AA 4096 Encoder cable Cable type Twisted pair and screened Note Please observe the prescriptions of the encoder supplier Cable length Observe the prescriptions of the encoder supplier Absolute encoder is tested ok up to 150 meter cable at 105 kHz clock and 100 m at 260 kHz clock Tested with TR electronic encoder type CE 65 M 8192 4096 and appropriate cable prescribed by TR electronic Maximum allowed time delay between clock and data signal measured at the controller terminals A sea doa uv dedi aldo eaa quies tie Teas ede a eu Ne e vu Vi e EE dala aA dads Perdre ga e a unu 105 kHz clock 9usec ms idadunuat cai devadedussnusdcusertdetuasuctccncertpatuaaateccnsaatdadunanstechsahadcaubontedcnesitaatuscuctacnscragadvsaten 260 kHz clock 3 5 usec Encoder output MK3B Terminal designations c ccccceceeeeeeeeeeeceeeeeeeeeeeaaaeceeeeeeesecaaaeeeeeeeseseaeeeeeeeeeeees A1 Al B1 B1 Z1 Z1 Signalltype maed ebd end gere NIS eat Ln Linedriver RS485 Maximum freQUuency RE 150 kHz Minimum TreQuency c 150 Hz Maximum number of slaves 00 0 eee eeceeeeeeneeeeeeeaeeeeeeaeeeeeeaaeeeeeaeeeeeenaes 31 more when using rep
42. 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 lead 5V Common MK3A MK3C oad on supply mk3 B D 5 V com TN NI SW 1 2 Load on control card 24V from control card 24 V supply terminal 12 13 and Common control card outputs terminal 42 45 DANFOSS 175HA461 11 8 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Pranfets 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 master and slave Zero channel If disabling of only one of the two Zero channels is required e g when using incremental master encoder and absolute slave encoder the unused Zero channel input must be connected t
43. can be selected via parameter 725 BEJ Take over gear ratio Synchronous operation Program 2 Activates the gear ratio selected at Terminals 16 and 17 Test run Program 1 ME 5 Start Stop virtual master Start test run with virtual master Synchronous operation Program 2 The virtual master is accele rated up to the set pulse frequency or stopped with the set ramp time EEE 4 Saving the settings 1 All 7xx parameters are saved Input 4 must be reset to 0 to end the save procedure Parameter 710 will be 1 and output 5 will be high while saving Note saving is only possible if all inputs except input 27 are low Input 27 must be high EN 05 Master marker When using external marker signal for the master drive it must be input connected to this input EJ 6 Slave marker input When using external marker signal for the slave drive it must be connected to this input I7 Measuring of the Test run Program 1 master marker interval Measuring of the master marker interval is started Home switch Synchronous operation Program 2 If a home position is to be attained the home switch must be connected here The signal must show a rising edge MG 10 N4 02 VLT is a registered Danfoss trademark 17 uuf tt Synchronizing controller 8 I8 measuring of the slave marker interval Test run Program 1 Measurement of the slave marker interval is started 18 VLT mode sel
44. e Record the delay in ms from one frequency change to another hold mode and from one gear ratio numerator factor change to another synchronization mode when there is a signal on terminal 32 or 33 Parameter 744 Step width Record a value to specify the position displacement between slave and master Parameter 745 Slave speed factor Record the factor by which the slave speed must be multiplied so that the desired value is displayed To calculate the value use the following formula N 400 Slaveencoder _ resolution Factor 4 60 Display value Example Resolution 1024 increments desired display 100 at 1500 s 1500 1 400 1024 me 10240 60 100 Factor Parameter 746 Master speed factor Record the factor by which the master speed must be multiplied so that the desired value is displayed To calculate the value use the following formula N 400 Masterencoder _ resolution Factor 4 60 Display value Parameter 747 Synchronization error display factor Record the factor by which the error must be multiplied so that the desired value is displayed To calculate the value use the following formula N sa 400 Slaveencoder _ resolution Factor 60 Display value Store your data settings by means of Store Input I4 or by changing Parameter 710 to 1 MG 10 N4 02 VLT is a registered Danfoss trademark 57 Panfisi Synchronizing controller Operation and operating
45. e gear the first stage is formed from two pinions 126 to 27 and the second stage from two pinions 117 to 18 126 117 Ek 0 The ratio is calculated as 18 301 3 The specified value of 30 33 thus deviates by 0 1 o9 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 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 1024Incr 126 117 20 27 18 40 102 7 Master side 1024Incr 97 43 27 10 11 22 510 7z Slave side To remove Pi from the equations substitute both equations into the combined formula Masterside Slaveside 1024Incr 126 117 20 1024Incr 97 43 27 27 18 40 102 z 10 11 22 510 7z 1024Incr 126 117 20 510 77 10 11 22 27 18 40 1024Incr 97 43 27 102 m Reduce by Pi and 1024 incr 126 117 20 510 10 11 22 T 5 5 11 22 117 SS Reduce further 27 18 40 97 43 27 102 27 97 43 27 6 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller oft 4954950 3040659 This is an absolute value as i
46. e incremental encoders When you have tested the motor speed direction you test the incremental encoder connection as follows 1 Remove all signals to terminals 16 33 and 11 18 Only Input 27 must be connected and closed 2 Press the DISPLAY STATUS button on the VLT 5000 control panel Now the following values appear in the upper line of the display slave position master position and track error 3 Rotate the slave drive motor shaft manually in the allowed direction Now the display shows an ascending count of the slave position If the count is descending exchange the slave encoder track A by B and A by B If there is no counting in the display then check the wiring of the encoder Follow the same procedure when you test the master encoder Note To be right the count must be ascending here Remember to change parameter 002 back to Remote and start VLT 5000 by pressing the START button on the control panel How to optimise the controller Synchronization is obtained via two main elements of the controller Velocity feed forward and the PID controller NOTE Before starting the optimizing procedures it is important to select the right type of synchronization in parameter 728 in this example it must be 1 for position synchronization Please always have the necessary degree of accuracy in mind you could go on optimizing for a long time but it might not be necessary to have a 10096 accuracy in the application you are dealing with
47. e outputs but they are only available via Field bus when Field bus is selected as control source 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 2 pco 3 Poo 4 Pco s pco s pco 7 Po s pco pco 10 Bit 16 15 elele ele fa v e s s Bit 1 1 Start of synchronisation 175ZA813 11 Field bus control signals Field bus Test run Synchronizing Corresponding input word bit 1 1 Not used Start of synchronization 1 1 2 Not used Take over gear ratio 2 1 3 Start stop virtual master Start stop virtual master 3 1 4 Save settings Save settings 4 1 5 Not used VLT mode 8 1 6 Not used Gear ratio select MSB 16 1 7 Not used Gear ratio select LSB 17 1 8 Not used Start homing 19 20 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller 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
48. e version number This is the software version number of your synchronizing controller 795 Slave position The slave position is displayed in quad counts 796 Master position The master position is displayed in quad counts 797 Test run Program 1 Track error The track error is displayed in quad counts Synchronous operation Program 2 Sync error The synchronization error is displayed with the value calculated in Parameter 747 798 Slave speed The slave speed is displayed with the value calculated in Parameter 745 799 Master speed The master speed is displayed with the value calculated in Parameter 746 MG 10 N4 02 VLT is a registered Danfoss trademark 79 Panfiii Synchronizing controller Glossary of key terms Master Slave It means that a signal is taken from a master drive The signal is then used to control a second slave drive that follows the master The master drive does not have to be a drive it can be any given part of a power transmission system Incremental encoder This is an encoder system that picks up the speed and the direction of rotation and transmits on the appropriate configuration The number of tracks and thus the number of signals 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 off
49. eaters Maximum cable length essiri rarr i E EEEE nennen nnn nnne rnnt nnn OA 400 m INCREMENTAL ENCODER ABSOLUTE ENCODER MK3D 5V ov DANFOSS DANFOSS 175ZA258 10 175ZA256 11 MG 10 N4 02 VLT is a registered Danfoss trademark 13 Panfiii Synchronizing controller Examples of encoder interface connections DANFOSS 175HA466 10 CDC e MK3B Master Encoder Slave Encoder Figure 6 Master Slave connection DANFOSS 175HA467 11 I l Virtual master MK3B connection MK3B L 31 1 wkap 3 31 4 MK3D Slave 1 Slave 2 Encoder Encoder Figure 7 Virtual Master Slave connection 14 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panfets Description of terminals 12 24V DC 24V power supply for switches etc maximum load see page 8 13 24V DC 24V power supply for switches etc maximum load see page 8 EET Gear ratio 2 Synchronous operation Program 2 Gear ratio most significant bit Gear ratio 2 Synchronous operation Program 2 Gear ratio least significant bit 19 Synchronous operation Program 2 Starts the homing 20 Ground for 24V normally brid
50. ection Synchronous operation Program 2 Switches the VLT to normal frequency converter operation The settings for this operating mode are to be made in Parameter set 2 Refer to the VLT 5000 Product Manual Option card MK3B master encoder BEH 5V Dc Encoder supply 8 Z1 Zero track inverted Not used Option card MK3C 01 READY Synchronous operation Program 2 Ready i e for the number of marker signals that were specified in Parameter 735 the slave drive has run within the tolerance Accuracy O2 FAULT Synchronous operation Program 2 Fault i e for the number of marker signals that were specified in Parameter 734 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 757 ME 03 AccuRACY Synchronous operation Program 2 The drive runs within the tolerance specified in Parameter 733 18 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panfots BEEN 04 Brake contro This output can be used to control a mechanical brake 0 means that the brake must be closed braking 1 means that the brake must be open not braking EE 05 Saving This output stays high while saving is in progress The saving is initiated by Parameter 710 Input 4 or fieldbus bit 4 EJ 06 Drive running Signal 1 when the drive is running O7 Home reached Synch
51. ements User setting increments Direction of rotation Factory setting 1 Setting range from 2 to 2 User setting Maximum speed Factory setting 1500 min Setting range from 1 to 65535 min User setting fii Minimum ramp Factory setting 100 ms Setting range from 50 to 2147483647 ms User setting ms Ramp type Factory setting 0 Setting range from 0 to 1 User setting Maximum track error Factory setting 10000 quad counts Setting range from 1 to 2147483647 quad counts User setting quad counts Reversing behavior Factory setting 0 Setting range from 0 to 2 MG 10 N4 02 VLT is a registered Danfoss trademark 73 uuf tt Synchronizing controller User setting 721 Slave marker type Factory setting 0 Setting range from 0 to 3 User setting 722 Marker interval at the slave Factory setting 4096 quad counts Setting range from 0 to 2147483647 quad counts User setting quad counts 723 Master marker type Factory setting 0 Setting range from 0 to 3 User setting 724 Marker interval at the master Factory setting 4096 quad counts Setting range from 0 to 2147483647 quad counts User setting quad counts 725 Test run Program 1 Test run speed Factory setting 10 96 Setting range from 1 to 100 96 User setting 96 Synchronous operation Program 2 Type of operation Factory setting 0 Setting range from 0 to 7 User setting 726 Test run Program 1
52. error 13 may show on the display To avoid this you can set parameter 014 to disable but that will disable the stop function of the local control panel O ERR 16 Programs in EEPROM are corrupted Meaning The program data recorded in the memory are no longer available or no longer correct Causes Defective EEPROM Note Replace the option card O ERR 18 Parameters in EEPROM are corrupted Meaning The parameter set recorded in the memory is no longer correctly available Causes Defective EEPROM or power failure during the parameter save procedure Note You must re initialise the parameters by following the initialising procedure on page 36 If this does not cure the problem the option card must be replaced MG 10 N4 02 VLT is a registered Danfoss trademark Reset by CPU Meaning The processor was stopped This in turn was detected by an internal monitoring circuit Watch dog and automatically triggered a reset Causes Temporary voltage drop voltage peak or short circuit O ERR 92 Encoder error Meaning There is a short or open circuit on one of the encoder inputs Causes A defective encoder or a problem with the encoder cable O ERR xx Internal error Meaning If an error like this appears please perform a power cycle if the problem persists the option card must be replaced 71 Zane Synchronizing controller Parameter overview
53. ery important that the VLT is optimized for the motor before optimizing the Synchronizing controller First you record the motor data and perform an AMA Automatic Motor Adaptation if possible and then you can start programming your synchronization functions Parameter 205 Maximum reference Set the frequency for a value that is about 10 higher than the maximum value of parameter 716 Example Motor 7 5kW 1460 min at 50Hz speed of the application approx 1800 min F Nom PON Loplicdidh 1 50Hz 2 1800 N 14605 Nom min 1 1 62Hz maximum ref value Parameter 701 Record 1 to start the test program Parameter 709 When performing position synchronization this parameter is used to insert a filter to compensate for an oscillating master signal If for example the master is experiencing shock loads the pid loop of the synchronizing controller will have a tendency to oscillate as well A negative value must be entered Example If a filter factor of 100000 100 ms is used the correction is balanced within 1000 filter factor 10 1 second Parameter 711 Record the slave encoder type 0 represents an incremental encoder Parameter 712 Record the resolution of the slave encoder Parameter 713 Record the master encoder type 0 represents an incremental encoder Parameter 714 Record the resolution of the master encoder Parameter 715 Direction of rotation Record 1 for clockwise rotation of the
54. eseeeeeeeeen eene nennen ren rennen nete tene tern tree tren trennen 50 Figure 19 Position displacement a nne trennen rene a tenete ne E ea tren trennen rennes 51 Figure 20 Wiring diagram application example sess enne netene trennen tren neen eene 52 Figure 21 Control behaviour with marker synchronization en eene nene nennen nenne 59 Figure 22 Conveyor belt with marker synchronization sesessssseseseeeeeeneenrene enne terere nrne trennen nennen 59 Figure 23 Initial start up with marker synchronization eese ener enne trennen nenne ene 60 Figure 24 Marker correction during operation sessessesssesesseeeeeee eene enne entente trennen trennen reete etre 61 Figure 26 Wiring diagram conveyor belt regulation sess enne en een nenne tene trennen trenes 62 Figure 27 Incremental encoder signals sssesesseeeeeseeeeeeeenee vosie oeron nennen rene eenne enne trente ee trennen nennen 80 Figure 28 Derivation of quad counts esseseeseeseeeeeseeeeeee enne neen rennen enne enne enne enne tene tren tren tren reete nein 80 Figure 29 Synchronization without virtual master essere eene enne neen trennen reet nest 81 Figuie 30 Addition of the cycle times ies ere ee tegeret ie dedic eee eb ge eode 82 Figure 31 Synchronization with virtual master eseesessseeeseeeeeeeeeeee nennen nennen eren rennen trennen
55. ext change of the counter factor of the gear ratio is carried out after this time on the presence of one of the signals at terminal 32 or 33 The time input is in milliseconds Parameter 744 Step width In speed synchronization the gear ratio numerator is changed by this amount if one of the terminals 32 or 33 is closed Parameter 745 Slave speed factor Record the factor by which the slave speed must be multiplied so that it can be displayed Use the following formula N a 400 Slaveencoder _ resolution Factor 1 60 Display _ value Example Resolution 1024 increments desired display 100 at 1500 s 1500 400 10242 60 100 Factor 102400 MG 10 N4 02 VLT is a registered Danfoss trademark 47 Panfiii Synchronizing controller Parameter 746 Master speed factor Record the factor by which the master speed must be multiplied so that it can be displayed Use the following formula Fadiora Se 490 Ma renconer roa 60 Display _ value Parameter 747 Synchronizing error display factor This factor must be 100 the synchronizing error is then displayed in RPM related to the slave Store your data settings by means of Store Input 14 or by changing Parameter 710 to 1 Operation and operating functions After all the values have been set as described and the controller optimized for the application normal operation can begin Starting synchronization Synchronization with the ma
56. f the zero track 1 falling edge of the zero track 2 rising edge at l6 3 falling edge at l6 NOTE This parameter is only used in marker synchronizing mode parameter 725 2 or 5 Marker interval at the slave Enter here the interval between two markers at the slave drive in quad counts If this value is not known it can be determined during the test run For procedure see description in the section Testing the incremental encoders in the packaging application example NOTE This parameter is only used in marker synchronizing mode parameter 725 2 or 5 MG 10 N4 02 VLT is a registered Danfoss trademark 23 Panfisi Synchronizing controller Master marker type Select here the type of marker signal for the master drive O rising edge of the zero track 1 falling edge of the zero track 2 rising edge at 5 3 falling edge at l5 NOTE This parameter is only used in marker synchronizing mode parameter 725 2 or 5 724 Marker interval at the master Enter here the interval between two markers at the master drive in quad counts If this value is not known it can be determined during the test run For procedure see as described in the section Testing the incremental encoders in the Loading belt Marker synchronization application example NOTE This parameter is only used in marker synchronizing mode parameter 725 2 or 5 725 Test run Program 1 Test run speed Specify here the speed at wh
57. follow the direction of the master or 2 if reversion is not allowed How to check the motor connection When you have programmed the above parameters you check the motor connection as follows 1 Remove all signals to terminals 16 33 and 11 18 2 Select LCP control open loop 1 in parameter 013 Select Local function in Parameter 002 VLT 5000 stops display flashing 3 Setthe frequency for a low value for example 3 Hz in Parameter 003 4 Press the START button on the VLT 5000 control panel and then the STOP Reset button watching the speed direction of the motor If the motor rotates in the wrong direction then exchange the motor phases How to test the incremental encoders When you have tested the motor speed direction you test the incremental encoder connection as follows 1 Remove all signals to terminals 16 33 and 11 18 2 Press the DISPLAY STATUS button on the VLT 5000 control panel Now the following values appear in the upper line of the display slave position master position and track error 3 Rotate the slave drive motor shaft manually in the forward direction Now the display shows an ascending count of the slave position If the count is descending exchange the slave encoder track A by B and A by B If there is no counting in the display then check the wiring of the encoder Follow the same procedure when you test the master encoder Remember to change parameter 002 back to Remote and sta
58. for clearing errors O ERR 5 Error not cleared Cause An attempt was made to execute a command to move although an existing error message had not been erased O ERR 8 Position error Meaning The interval between the reference position and the feedback position was greater than defined in Tolerated Position Error Parameter Causes Mechanically blocked or overloaded drive tolerated position error too small reference speed greater than VLT Parameters 202 and 205 reference acceleration too great Proportional factor too low or VLT not released O ERR 9 Index pulse encoder not found Meaning During a reference or index search the encoder index pulse could not be found within one encoder rotation Causes A encoder without an index pulse is being used the index pulse is not correctly connected incorrect index pulse or the encoder resolution has been set too low MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller O ERR 13 Zane O ERR 17 VLT NOT READY Cause VLT is not ready but the PID controller is active The VLT status word Bit 09 and bit 11 is monitored every 20msec when the PID controller is active The VLT is in the Not ready state when e ithas an alarm e itis in local mode parameter 002 local e local LCP stop is activated O ERR 13 can be reset by toggling input 27 Note When pressing local stop on the LCP
59. ged with Terminal 39 but this can be set to OFF by means of Switch SW4 on the control card Reset Enable Error reset on rising edge To enable operation this input must be switched to 1 0 motor coast 29 Synchronous operation Program 2 The drive is held at a programmable or the present speed Synchronous control is not activated 32 Test run reverse Test run Program 1 Test run reverse at the speed defined in Parameter 725 Speed Pos Synchronous operation Program 2 In velocity synchronous mode P 725 0 1 6 or 7 the gear ratio and thus the velocity of the slave can be changed by the value specified in parameter 744 In position synchronous and marker synchronous operation P 725 2 1 2 4 or 5 the position offset of the slave can be changed by the value specified in Parameter 744 The sign of the value in parameter 744 selects the offset type to be absolute or relative Absolute offset means that the fixed offset of parameter 742 is changed and this offset is executed when restarting synchronization Relative offset means that the actual slave position is displaced but the fixed offset of parameter 742 is unchanged This again means that the actual slave position is maintained when restarting synchronization 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 the
60. hases if direction of motor rotation is wrong 2 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 Maximum speed Enter here the maximum speed of the slave drive measured at the slave encoder in revolutions per minute Minimum ramp Enter here the minimum possible ramp in which the slave drive can accelerate from 0 to the speed specified in Parameter 716 This is input in milliseconds Ramp type Specify here the ramp type to be used 0 linear ramp 1 sinusoidal ramp Please note that a sinusoidal ramp requires a greater acceleration torque than a linear ramp On the other hand a sinusoidal ramp produces less stress to the mechanics 719 Maximum track error Enter here the maximum track error This is the permitted error between the calculated position and the feedback position If the value is exceeded the drive stops and displays the error message O ERR 8 Position error The value should be set higher than the permitted tolerance range ACCURACY in Parameter 733 Input in quad counts 720 oo behaviour means that the slave drive may always reverse e g after overshooting the target position 1 the slave drive may only reverse when the master is reversing 2 the slave drive may never reverse Slave marker type Select here the type of marker signal for the slave drive O0 rising edge o
61. he calculation is done when the value of par 729 returns to 0 Using the test run functions can optimise the PID factors further There is two types of test run available Positioning where the slave drive moves a specific distance and Synchronizing with virtual master where the slave follows the virtual master in position or speed Generally it is better to use test run with virtual master as that comes closer to the operating conditions in synchronizing mode program 2 For test run with positioning the following parameters must be set Parameter 725 Test run speed Record the speed as a percentage of the maximum speed of parameter 716 Parameter 726 Test run acceleration record the acceleration time in per cent 10096 is minimum acceleration 5096 is half as fast as minimum acceleration the ramp time will thus be twice as long Parameter 727 Test run distance Record the distance quad counts for the drive to run during optimization MG 10 N4 02 VLT is a registered Danfoss trademark 65 uuf tt Synchronizing controller Then use the following procedure 5 Close the contacts at terminal 32 clockwise direction or terminal 33 counter clockwise During the test the last value of the first display line will indicate the track error PID error After the test run is completed you can see the maximum track error PID error 6 Increase the P portion par 702 After each change you should make a test run to find the right
62. i tee etre te ere PU ne rne e avs eere eee YE even De Yee eere eese ERO 54 Testing the incremental encoders e eeen ea enne nnne tene trennen tren ne E enne Er SE ISren p nennen 54 MG 10 N4 02 VLT is a registered Danfoss trademark 1 Panfisi Synchronizing controller How to optimise the controller nis iesi nte etc e IRURE Eo DRE T IRR INSEE E E SEA SEES ri tte SSE 54 How to program synchronization ect Hed ee te pedet epe t be aeree p pepe tpe iun 56 Operation and operating functions esses enne enne SEEE ESEE EE E EEEE trente senem enne nennt tenerent 58 Marker synchronizing 59 Function diagrams for marker synchronization eee eee eere e eee ee eee ee seen nest easet tense etas ee ease eaae 60 SyncStart to a running master after Power ON sssssesssesseeeeeeenreneeene ener tren TOES EE ARSE ISE enne enne 60 Marker correction during operation enne ener nennen trennen rete ennen nne enne tenete retener entren 60 Application example Packaging 4 ecce esee ee eese esse seen seta eo st ease aa eee en P sean esso Eee e ea eee en s saspe sepa esas 61 Terminals and terminal configuration sees nennen eren rennen ne enne entere tenerent entren 62 Setting the parameters epe pe eee n neenon iter 63 How to check the motor connectton ie rent her niter RELIER ETE RR EU EE HE PR EEO HERE ee a RER E ESETE 64 How to testthe 1ncremental e
63. ich the test runs are to be carried out The speed is specified as a percentage of the maximum speed defined in Parameter 716 Synchronous operation Program 2 Type of operation Select here the type of operation of the Synchronizing Controller Setting range 0 Speed synchronizing Position synchronizing Marker synchronizing Speed synchronizing with motor coast after stop Position synchronizing with motor coast after stop Marker synchronizing with motor coast after stop Speed synchronizing with motor coast after stop and setting of gear ratio via analogue input 54 7 Speed synchronizing with setting of gear ratio via analogue input 54 OORUN ll With the selections 0 2 and 7 the motor is always controlled keeping the actual position when stopping synchronization input 1 O 726 Test run Program 1 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 Parameter 717 50 means that the drive only proceeds with half the acceleration i e the acceleration takes twice as long as with the minimum ramp specified in Parameter 717 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 If O is set the slave drive is brought to the
64. imum acceleration the ramp time will thus be twice as long Parameter 727 Test run distance Record the distance quad counts for the drive to run during optimization MG 10 N4 02 VLT is a registered Danfoss trademark 45 46 uuf tt Synchronizing controller Then use the following procedure 1 Close the contacts at terminal 32 clockwise forward direction or terminal 33 counter clockwise reverse During the test the last value of the first display line will indicate the track error PID error After the test run is completed you can see the maximum track error PID error in the display 2 Increase the P portion par 702 After each change you should make a test run to find the right setting If the drive becomes unsteady or if a message is given about over voltage or over current then reduce the value in parameter 702 to about 70 80 of the set value 3 Now set the D portion parameter 703 to 5 times the value of parameter 702 4 f a lower synchronizing error is required the I portion parameter 704 can be set to a low value e g 10 but be careful a too high value will course overshoot and instability For test run with virtual master the following parameters must be set Parameter 748 Virtual master reference Select the reference source for setting the velocity of the virtual master 0 is analogue input 53 1 is analogue input 60 2 is parameter 216 and 3 is Field bus PCD 2 Parameter 749 Virtua
65. imum reference Set the frequency for a value that is about 1096 higher than the maximum value of parameter 716 Example Motor 7 5kW 1460 min at 50Hz speed of the application approx 1800 min 50Hz 1800 sin min 1460 Nom min Jun i N option 1 1 1 62Hz Maximum ref value Torque limit for motor mode Set for maximum Choose a lower value if special safety precautions are necessary Torque limit for regenerative operation Set for maximum Choose a lower value if special safety precautions are necessary Set the minimum current that is to activate the brake Choose a value that is below the motor magnetisation current Record 1 to start the test program When performing position synchronization this parameter is used to insert a filter to compensate for an oscillating master signal If for example the master is experiencing shock loads the pid loop of the synchronizing controller will have a tendency to oscillate as well A negative value must be entered Example If a filter factor of 100000 100 ms is used the correction is balanced within 1000 filter factor 10 1 second Record the slave encoder type 0 represents the incremental encoder Record the resolution of the slave encoder Record the master encoder type 0 represents the incremental encoder Record the resolution of the master encoder Record 1 for clockwise rotation of both master and
66. ive uses the master drive signal and the gear ratio to calculate a reference position value for the slave drive The deviation of the feedback position from the calculated position is known as the track error This is specified in quad counts The maximum track error is also a threshold value that defines the permitted operating area of the synchronizing controller Accuracy This value specifies the permitted deviation between the master and slave at which synchronization is still present PPR Pulses per revolution Virtual master If several axes are to travel in synchrony or if the synchronization error is so to be kept as small as possible it is often more advantageous not to take the reference position from a drive but to have a master that simulates the reference position This has the advantage that the cycle times of the individual drives are not added These differences are illustrated below for the synchronous control of three conveyor belts First we show the classic synchronization procedure where the reference value signal is taken from the preceding drive in each case C Conveyor 1 CX Conveyor 2 CC Conveyor 3 e Slave feedback feedback Sync control 175ZA830 10 Reference Slave 1 Reference Slave 2 Reference Figure 29 Synchronization without virtual master MG 10 N4 02 VLT is a registered Danfoss trademark 81 uuf tt Synchronizing controller As can be seen from the di
67. l master acceleration Set the acceleration of the virtual master in encoder pulses per second Parameter 750 Virtual master maximum speed Set the maximum velocity of the virtual master in encoder pulses per second Then use the following procedure 1 Disconnect the master encoder from the synchronizing controller MK3B Start test run with virtual master by activating input 3 During test run you can read the track error in the last value of the first display line At stop the maximum track error during the test run is read out Because velocity synchronization is selected parameter 728 0 the track error is velocity deviance between master and slave 2 If more accurate and dynamic control is required the P portion parameter 702 must be increased If the slave becomes unstable the value must be reduced to by approximately 25 3 Now set the D portion parameter 703 to 5 times the value of parameter 702 4 If a lower synchronizing error is required the I portion parameter 704 can be set to a low value e g 10 but be careful a too high value will course overshoot and instability To store the optimized values Activate Input I4 Store or change the value of parameter 710 to 1 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Pranfets How to program synchronization Change the value of parameter 701 to 2 This will start the synchronization program of VLT 5000 VLT 5000 Flux To do the sy
68. le The virtual master must correspond to an encoder with 1024 inc rotation The maximum speed of 25 encoder rotations per second must be attained in 1 second Virtual master acceleration 251 1994 Ter Virtual master acceleration E 1 ev 25600 Hz s S 750 Virtual master maximum speed Enter here the maximum speed of the virtual master in Hz Increments Rev Virtual master maximum speed Rev S Example The maximum virtual master signal must correspond to an incremental encoder with 1024 inc rotation at a rotational speed of 50 rotations s 1024 50 Virtual master maximum speed 51200 1 s S 751 Marker window slave Here you can enter how large the permitted tolerance for the occurrence of the marker is The factory setting 0 means all markers are used At every other setting only those markers are accepted which are within the window Example Marker interval 30000 and marker window 1000 Only markers with an interval of 29000 to 31000 is accepted NOTE This parameter is only used in marker synchronizing mode parameter 725 2 or 5 752 Marker window master Here you can enter how large the permitted tolerance for the occurrence of the marker is The factory setting 0 means all markers are used At every other setting only those markers are accepted which are within the window Example Marker interval 30000 and marker window 1000 Only markers with an interval of 29000
69. lerance speed 100 If the M S tolerance speed value is set to 50 the slave will not travel more slowly than half the master speed 737 Synchronous operation Program 2 Gear ratio no Select the number of the gear ratio that you want to edit in Parameters 738 742 738 Synchronous operation Program 2 Gear ratio numerator Enter the numerator for the gear ratio selected in Parameter 737 Ensure that the gear ratio matches the marker ratio 739 Synchronous operation Program 2 Gear ratio denominator Enter the denominator for the gear ratio selected in Parameter 737 Ensure that the gear ratio matches the marker ratio 28 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panfets Synchronous operation Program 2 Slave marker quantity Enter the number of slave markers for the marker ratio Ensure that the gear ratio matches the marker ratio NOTE This parameter is only used in marker synchronizing mode parameter 725 2 or 5 741 Synchronous operation Program 2 Master marker quantity Enter the number of master markers for the marker ratio Ensure that the marker ratio matches the gear ratio NOTE This parameter is only used in marker synchronizing mode parameter 725 2 or 5 742 Synchronous operation Program 2 Fixed offset 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 Note
70. lue of parameter 701 to 2 This will start the synchronization program of VLT 5000 To do the synchronization programming you use the following parameters Parameter 725 Type of operation Record 2 or 5 for marker synchronization Parameter 732 Marker synchronization behaviour Specify here how the slave drive is to react while synchronizing to the master marker 0 means the last marker pulse of the master the slave synchronizes to the last master marker pulse already registered it catches up 1 means the next master marker pulse the slave waits for the next master marker and synchronizes to it the slave slows down 2 means that the slave uses the nearest master marker it decides for itself whether to catch up or slow down Parameter 733 Accuracy Record a value quadcounts for a tolerance within which the slave position may deviate from the position of the master Parameter 734 Marker quantity Fault Inaccuracy Record the number of market signals to generate a Fault signal Parameter 735 Marker quantity Ready Accuracy Record the number of marker signals to generate a Ready signal Parameter 737 Gear ratio No Record the number of the gear ratio that is to be displayed in Parameters 738 to 742 First set the number of the gear ratio then in Parameters 738 to 742 the necessary values for this gear ratio The next gear ratio is then selected in Parameter 737 and the same procedure is repeated Parameter 7
71. mes unsteady or if a message is given about over voltage or over current then reduce the value in parameter 702 to about 70 80 of the set value 3 Now set the D portion parameter 703 to 5 times the value of parameter 702 4 If a lower synchronizing error is required the l portion parameter 704 can be set to a low value e g 10 but be careful a too high value will course overshoot and instability For test run with virtual master the following parameters must be set Parameter 748 Virtual master reference Select the reference source for setting the velocity of the virtual master 0 is analogue input 53 1 is analogue input 60 2 is parameter 216 and 3 is Field bus PCD 2 Parameter 749 Virtual master acceleration Set the acceleration of the virtual master in encoder pulses per second Parameter 750 Virtual master maximum speed Set the maximum velocity of the virtual master in encoder pulses per second MG 10 N4 02 VLT is a registered Danfoss trademark 55 Panfisi Synchronizing controller Then use the following procedure 1 Start test run with virtual master by activating input 3 During test run you can read the track error in the last value of the first display line At stop the maximum track error during the test run is read out 2 If more accurate and dynamic control is required the P portion parameter 702 must be increased If the slave becomes unstable the value must be reduced to by approximately 25
72. n be executed when restarting synchronization and the min or max limit of parameter 742 would eventually be reached MG 10 N4 02 VLT is a registered Danfoss trademark 15 uuf tt Synchronizing controller 33 Test run forward Test run Program 1 Test run forward at the speed defined in Parameter 725 Speed Pos Synchronous operation Program 2 In velocity synchronous mode P 725 0 1 6 or 7 the gear ratio and thus the velocity of the slave can be changed by the value specified in parameter 744 In position synchronous and marker synchronous operation P 725 2 1 2 4 or 5 the position offset of the slave can be changed by the value specified in Parameter 744 The sign of the value in parameter 744 selects the offset type to be absolute or relative Absolute offset means that the fixed offset of parameter 742 is changed and this offset is executed when restarting synchronization Relative offset means that the actual slave position is displaced but the fixed offset of parameter 742 is unchanged This again means that the actual slave position is maintained when restarting synchronization 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 synchronization and the min or max limit of parameter 742 would eventually be reached EIN Com 240v AC 2A Relay o
73. n marker synchronization mode Offset Parameter 740 is changed by this value when Terminal 32 or Terminal 33 is activated Parameter 745 Slave speed factor Record the factor by which the slave speed must be multiplied so that the desired value is displayed To calculate the value use the following formula N a 400 Slaveencoder _ resolution Factor 60 Display value Example resolution 1024 increments desired display 100 at 1500 Vmin 1500 3 400 1024 5 min 10240 60 100 Factor Parameter 746 Master speed factor Record the factor by which the master speed must be multiplied so that the desired value is displayed To calculate the value use the following formula N 400 Masterencoder _ resolution Factor 4 60 Display _ value Parameter 747 Synchronizing error display factor Record the factor by which the error must be multiplied so that the desired value is displayed To calculate the value use the following formula N sa 400 Slaveencoder _ resolution Factor 60 Display value Store your data settings by means of Store Input I4 or by changing Parameter 710 to 1 68 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Pranfets Operation and operating functions After all the values have been set as described the drive can now be operated normally Starting synchronization Synchronization of the slave is started by me
74. nchronization programming you use the following parameters Parameter 725 Type of operation Record 0 or 3 for speed synchronization Parameter 726 Hold function Specify how the drive is to react when Input 29 is activated Hold switches the drive from master synchronization to a fixed frequency Choose 0 to use the frequency set in par 727 and 1 to use the current frequency Parameter 727 Hold speed Set here as a percentage of the maximum speed the speed at which the drive should move when you activate Hold and the value O was selected in Parameter 726 Parameter 728 Delta hold speed Set here the step width by which the hold speed is to be changed upwards or downwards by activating Terminals 32 33 Parameter 737 Gear ratio No Record the number of the gear ratio that is to be displayed in Parameters 738 to 739 Then you set the values required in Parameters 738 to 740 Follow the same procedure for the next gear ratio s Parameter 738 Gear ratio numerator Record the numerator value of the gear ratio That is the encoder pulses of the slave drive To make fine adjustment possible by means of inputs 32 and 33 a ratio of for example 7 16 must be programmed as 7000 16000 Parameter 739 Gear ratio denominator Enter here the denominator value of the gear ratio This value corresponds to the master pulses Parameter 743 Step time In Hold mode the next frequency change and in synchronization mode the n
75. ncoders rese ett erect a Fer need epe eur Probes eee Pu ends 64 How to optimise the controller m aenneren teet eerte t the cbevench edbvscnovtes reel erint eE SEEE a iE 65 How to program synchronization esses eene nennen ener S tene teen y e trente e enne TUAE E trennen 67 Operation and operating functions nip pie ate sire Eten eee Tre ete EE E e aeree E ESEE r 69 Appendix 70 Messages and error reference iicvsscccsecsccescassensscesacsescdessennsovenssescecessesesdendceussosseasdenscecncscssnaseconsssesesressosonees 70 Tabl of error messages dt SiS eet steels Bal ep Ie eae ls Rel ee SR a Re A Ril 70 Parameter OVEEVICW ico re ctuseisnseicessuseesshovssssectactesosousuienstndansustens sesusssiesesssustssescenutestuanedsisaasnvesssens 72 Glossary of key ters wissccccccccsccccssscccscessonncdsevessoonssssnnssssuees sbaseestasssuncssnecestesesuecs NETO Stu Saee e e MEN Seo Rie Pene e opas 80 List Ilii CE 84 lino T 85 Synchronizing Controller for VLT 5000 and VLT 5000Flux Software Version 2 1X Software Version number See Parameter 779 2 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Pranfets The voltage of the frequency 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
76. new gear ratio The offset is related to the first gear ratio after SyncStart Therefore a stop and then start must be performed if the offset must relate to the latest gear ratio it the gear ratio has been changed Error procedure Errors of tracking over current etc make the drive stop and the Ready output O8 is set low Reset is done with Input 27 or fieldbus bit 1 9 Reset is also possible with the STOP RESET key of the local control panel of the drive This is only possible if the local stop function is disabled in parameter 014 Note You cannot stop the drive via the local control panel if local stop is disabled In case the drive has stopped because of earth fault or short circuit disconnect the drive from the mains before you reset MG 10 N4 02 VLT is a registered Danfoss trademark 69 Zane Appendix Messages and error reference All messages are shown in abbreviated form in the VLT LCP display You can find brief information on the error messages in the table or detailed information in the section following the table Table of error messages The table contains the messages in numerical order O ERR LCPDISPLAY error VLT NOT READY PROGR ERROR EEPROM RESET BY CPU ENCODER ERROR 8 i9 70 Synchronizing controller Error messages in detail As in the table above the messages are in numerical order here you will find additional notes on possible causes of errors as well as tips
77. nfoss trademark Synchronizing controller Pranfets Setting the parameters For this work we recommend you to have the description of parameters at hand See the VLT 5000 VLT5000Flux Operating Instructions NOTE It is very important that the VLT is optimized for the motor before optimizing the Synchronizing controller First you record the motor data and perform an AMA Automatic Motor Adaptation if possible and then you can start programming your synchronization functions Parameter 205 Maximum reference Set the frequency for a value that is about 10 higher than the maximum value of parameter 716 Example Motor 7 5 kW 1460 mi at 50 Hz speed of the application approx 1800 min eNO 50Hz 1800 4 Prion N sonication 1 1 1 1 62Hz maximum ref value N Nom 146055 Parameter 221 Torque limit for motor mode Set for maximum Choose a lower value if special safety precautions are necessary Parameter 222 Torque limit for regenerative operation Set for maximum Choose a lower value if special safety precautions are necessary Parameter 701 Record 1 to start the test program Parameter 709 This parameter configures the velocity filter for speed synchronization Since speed synchronization is based on speed a small fluctuation in master speed when running at low speed can have an effect on the pid loop control Hence this filter will even out the effect Cmdvel Old Cmdvel Actvel Old Cmd
78. nnected to an 8 toothed chain conveyor with a tooth pitch of 200mm Encoder 1752A833 10 Master drive Gearbox 1 Gearbox 2 Chain ves Enco der Slave drive Figure 1 Calculation example MG 10 N4 02 VLT is a registered Danfoss trademark 5 Panfiii Synchronizing controller Calculation with insufficient numerical values The master slave gear ratio numerator to denominator is now calculated as follows Master side increments i1 i2 power take off 1024incr 3033 20 l1 __ 48 460995 40 102mm z Slave side increments i1 power take off 1024incr 46 54 29 7856 8 200mm pard 48 460995 This gives a ratio of 29 7856 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 stag
79. ns on mould Moulds of two different kinds and lengths are embossed with a pattern The conveyor belt operator changes the position of the pattern by means of two buttons Each of the two incremental encoders has a zero track for marker synchronization Description of terminals and terminal configuration From mains supply Choice of gear ratio Home 2 Digital inputs Reset Offset Offset 3 Analog In outputs Sync Start Synchronizing controller Change of setup Save 5V com A1 Home switch Ai MK 3B B1 Master encoder Bi Z1 Sync Ready Sync Fault Sync Accuracy Saving Slave encoder Running Home Unit ready 175ZA815 10 Figure 20 Wiring diagram application example 52 MG 10 N4 02 VLT is a registered Danfoss trademark Dane Synchronizing controller Setting the parameters For this we recommend you to have the description of parameters at hand See the VLT 5000 VLT5000Flux Operating Instructions NOTE It is very important that the VLT is optimized for the motor before optimizing the Synchronizing controller First you record the motor data and perform an AMA Automatic Motor Adaptation if possible and then you can start programming your synchronization functions Parameter 205 Parameter 221 Parameter 222 Parameter 223 Parameter 701 Parameter 709 Parameter 711 Parameter 712 Parameter 713 Parameter 714 Parameter 715 Parameter 716 Parameter 717 Max
80. nstable the value must be reduced to by approximately 25 3 Now set the D portion parameter 703 to 5 times the value of parameter 702 4 If a lower synchronizing error is required the I portion parameter 704 can be set to a low value e g 10 but be careful a too high value will course overshoot and instability If the interval between two marker signals at the slave is not known this interval can now be measured To do this the contact at the Slave marker search input I8 is closed The slave drive now rotates at the set test run speed With each master signal the interval can be read off in Parameter 722 If the marker search is stopped by opening the Slave marker search contact 18 an average of all the marker intervals is taken and this is entered as the value in Parameter 722 Similarly the intervals between the marker signals of the master drive are measured by means of the Master marker search input I7 To do this it is necessary to start the master The intervals are continuously displayed in Parameter 724 After opening the Master marker search contact I7 the calculated average of all the measurements is again entered as the final result in Parameter 724 After the drive has been optimized the data found are stored by activating Input I4 Store or by changing Parameter 710 to 1 66 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller ufi How to program synchronization Change the va
81. ntroller in use appears here 795 Slave position The slave position is displayed in quad counts 796 Master position The master position is displayed in quad counts MG 10 N4 02 VLT is a registered Danfoss trademark 35 Panfisi Synchronizing controller Test run Program 1 Track error The track error is displayed in quad counts Synchronous operation Program 2 Sync error The synchronization error is displayed with the value calculated in Parameter 747 798 Slave speed The slave speed is displayed with the value calculated in Parameter 745 799 Master speed The master speed is displayed with the value calculated in Parameter 746 Initializing the parameters It is possible to restore parameter default values by means of the initialise function in parameter 620 All parameter except parameter 500 501 600 605 615 617 will be reset to factory default setting NOTE The VLT must be in stop mode before initialising can be carried out Procedure for initialising 1 Select initialise in parameter 620 2 Press the OK key 3 Set parameter 710 to 1 Wait until it changes to O app 0 5 sec 4 Switch off mains supply and wait until the display is dark 5 Switch on the mains supply 36 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panfiii Speed synchronization The speed synchronization controller raise or lower the speed of the slave drive matching it
82. o 5V common as shown below An encoder fault will only result in an Option error 92 if encoder monitoring is activated via parameter 713 master and 711 slave Note Monitoring of the master encoder is disabled when switch 1 3 is OFF m m N N eo O 0 0 O0 OQ COM 5V Oo e gt o 2 1752A782 10 MG 10 N4 02 VLT is a registered Danfoss trademark Pranfots Synchronizing controller Option card layout Option card layout showing the position of connectors and dip switch Encoder monitor slave channel A B and Z Encoder monitor master LED off Short or open circuit channel A B and Z i 5 LED green Ok LED off Short or open s circuit 5V monitor LED off no 5V D Green 5V ok CPU monitor LED must flash at 1 Hz to indicate a running CPU system M Se d PI E Er m CL mM m C E C E DANFOSS 175ZA068 10 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 master encoder see description of virtual master function Note When OFF the master encoder monitor is disabled SW 1 4 Switch Z channel encoder monitor ON OFF for both master and slave Default setting of switch 1 1 1 4 is ON 10 MG 10 N4 02 VLT is a regi
83. on 175ZA807 10 V m s Master Slave SyncStart Figure 17 Synchronizing to a stationary master ts SyncStart to a running master If synchronization is effected to a running master the slave drive first makes up the deviation of distance then it proceeds synchronously with the master Any Offset setting is taken into account 175ZAB08 10 V m s p lt ZZA Master Pd Faf a with master Slave SyncStart t s Figure 18 Synchronizing to a running master 50 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panfets Position displacement with a running master If one of the Inputs 32 or 33 is activated during synchronous travel the actual position in relation to the master is displaced by the value set in Parameter 742 If the displacement is positive the slave accelerates in order to travel the necessary distance in order then again to travel synchronously to the master at the speed determined via the gear ratio If the displacement is negative the slave decelerates in order to attain the necessary distance to then again travel synchronously with the master at the speed determined via the gear ratio 175ZA809 10 V m s z LAU Master Slave Pos t s Figure 19 Position displacement MG 10 N4 02 VLT is a registered Danfoss trademark 51 Panfisi Synchronizing controller Application example Embossing patter
84. onization 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 suffi cient for regaining its position to the master drive l control like Marker synchronization Marker synchronization is an extended position control Apart from ensuring a constant angle position between master and slave drives marker synchronization provides the option of using either an addi tional 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 synchronization the slave is position synchronized 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 distur bance like belt elongation etc that are not directly measurable Similarly with marker synchronization 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 4 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Pranfets Mechanical brake control The Synchronizing controller has a 24V dc digital output Output 4
85. onization SyncStart SYNCACCURACY Each millisecond it is checked if the actual position deviance between master and slave is smaller than parameter 733 accuracy if this is true the SYNCACCURACY flag is set 1 otherwise the flag is reset 0 SYNCFAULT SYNCREADY For every marker pulse it is checked whether the SYNCACCURACY flag is present or not If itis not present the fault counter is increased and the ready counter set to O if it is present the ready counter is increased and the fault counter set to 0 If the ready counter is higher than the value set in parameter 735 marker quantity ready then the flag SYNCREADY is set if not the flag is reset If the fault counter is higher than the value in parameter 734 marker quantity fault the flag SYNCFAULT is set 1 if not the flag is reset 0 Marker HIT flags The marker HIT flags are set 1 after detecting n marker pulses n parameter 740 and 741 Marker error flags It is checked at each n marker pulse n parameter 740 or 741 whether the distance between the actual marker position and the last registered marker position is lower than 1 8 times the value of parameter 722 or 724 If this is not true then the associated flag is set 1 When using marker windows par 751 and 752 it is checked whether a marker is detected within the window If no marker is detected the error flag is set 1 Software version number The software version of the synchronizing co
86. onizing error parameter 797 is shown with a sign otherwise the synchronizing error is unsigned 734 Synchronous operation Program 2 Marker quantity FAULT Enter when a FAULT signal O2 must be set Input the number of marker pulses i e a setting of 10 means that ACCURACY must be low for 10 marker pulses before the FAULT signal is set In position synchronization parameter 725 1 or 4 only the slave marker is used in marker synchronization parameter 725 2 or 5 both slave and master marker must be detected before counting 735 Synchronous operation Program 2 Marker quantity READY Enter when a READY signal O1 must be set Enter the number of marker pulses i e a setting of 10 means that ACCURACY must be present for 10 marker pulses before the READY signal is set In position synchronization parameter 725 1 or 4 only the slave marker is used in marker synchronization parameter 725 2 or 5 both slave and master marker must be detected before counting 736 Synchronous operation Program 2 M S tolerance speed Specify here the tolerated speed deviation between master and slave while the slave during synchronizing The following apply here Slave must catch up The slave can travel at the maximum permitted speed or at the speed master speed master speed M S tolerance speed 100 whichever of the two is lowest Slave must slow down The slave travels at the minimum speed master speed master speed M S to
87. onnect the drive from the mains before you reset 48 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Position synchronization angle synchronization The position controller adjusts the slave drive position or angle to the master Zane V 1 s 175ZA836 10 Deviation Master speed Speed synchronized slave speed Figure 15 Control behaviour with position synchronization is It appears from the diagram that the control accuracy depends on the master acceleration and on the speed deviation between slave and master A typical application for this type of synchronizing could be the replacement of a mechanical shaft Or mixing controls where a mixing rate is required The following example shows how embossing patterns on moulds is controlled This application requires accurate position control VLT5000 Master signal with Slave feedback Embossing tool Conveyor 1 175ZA831 10 ur Figure 16 Embossing with position synchronization MG 10 N4 02 VLT is a registered Danfoss trademark 49 Paanfots Synchronizing controller Function diagrams for position synchronization SyncStart to a stationary master If the slave is synchronized to a stationary master drive the slave will remain stationary However if a fixed offset is defined for the activated gear ratio the slave travels to the extent of this offset during synchronizati
88. p with the master position Stopping synchronization On opening the SyncStart contact I1 the slave is stopped at the permitted acceleration Because Home function is set at 2 a new start is only possible after a renewed Home run Fine setting of the position As soon as the slave drive is in position synchronization to the master a displacement of this position can be effected by means of Inputs 32 33 These settings are only temporary i e the fine setting data are lost as soon as the converter is disconnected from the mains If the displacement data are to be retained they must be stored by activating save Input 14 or by means of Parameter 710 before switching off Offset is related to the master position Offset related to the slave position can be calculated as follows Offset Parameter 738 Parameter 139 Offset slave Switching to another gear ratio Er 58 During synchronization a new gear ratio can be selected at Inputs 16 and 17 The gear ratio is then activated by means of the Switching Input 12 The slave will then proceed at the permitted acceleration to this new gear ratio The offset is related to the first gear ratio after SyncStart Therefore a stop and then start must be performed if the offset must relate to the latest gear ratio it the gear ratio has been changed ror procedure Errors of tracking over current etc make the drive stop The Ready output O8 is set low Reset is done with Inp
89. ple time par 777 proportional factor par 702 and derivative factor par 703 Setting range 0 No action 1 Activate calculation of velocity feed forward par 707 The calculation is based on the following parameters that must be set before the calculation is started VLT5000 Par 104 Nominal motor frequency Par 205 Maximum reference Par 711 Slave encoder type Par 712 Slave encoder resolution Par 730 encoder velocity Par 777 PID sample time VLT5000Flux Par 711 Slave encoder type Par 712 Slave encoder resolution Par 730 encoder velocity Par 777 PID sample time 2 Activate calculation of velocity feed forward par 707 PID sample time par 777 Proportional factor par 702 and derivative factor par 703 The calculations are based on the following parameters that must be set before the calculation is started VLT5000 Par 104 Nominal motor frequency Par 205 Maximum reference Par 711 Slave encoder type Par 712 Slave encoder resolution Par 716 Maximum velocity Par 730 encoder velocity VLT5000Flux Par 711 Slave encoder type Par 712 Slave encoder resolution Par 716 Maximum velocity Par 730 encoder velocity The parameter value is automatically reset to 0 when the calculation is done NOTE If any of the above mentioned parameters are changed the calculation must be repeated Synchronous operation Program 2 Home function Selec
90. r ratio denominator sesseeess 76 Gear ratio NO eeeeeeeeeeeeeennnnnnnnnnnnn 76 77 Gear ratio numerator sssseeeeeeee 76 C o I MEL 80 H Hardware eoe um 7 Hold f nctiOn eui eie 40 74 Hold speed 2 5 mei me ber RS 74 Home acceleration esssssssssssse 75 Home function e eee oaeee ae ranae eaaa eder aa 75 Home run embossing patterns on mould 58 Home speed eese ener 75 How to check the motor connection admixtUte x 5 tenet ER iib ea 44 embossing patterns on mould 54 packaging ioyos dece totes 64 How to optimize the controller admlixtU te eirca teo ett der deo US 45 embossing patterns on mould 54 packaging 2 3 ein cu en e reete venies 65 How to program synchronization admlixture EE EE DR RI 47 embossing patterns on mould 56 pacKagllig ien siete ote aiat er Peer Eaa 67 How to test the incremental encoders admixt re one cire net cte RP ide cete FORMES 44 embossing patterns on mould 54 packaging tenu pe 64 l Incremental encoder seessessssssssss 80 Initializing the parameters neee 36 Inp ut status 5 onte tee 79 INtFODUCLION 3 21 92 erii tte ic Deed dera 4 DOMMION cc E 72 L Limitation for l portion
91. rake on delay Factory setting 0 Setting range from 0 to 5000msec User setting msec 756 Brake off delay Brake off delay Factory setting 0 Setting range from 0 to 5000msec User setting msec 157 Marker monitor Marker monitor Factory setting 0 Setting range from 0 to 2 User setting 758 Resync Resync Factory setting 0 Setting range from 0 to 1 User setting 78 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panfots 775 Synchronous operation program 2 Track error read only 776 Input status read only Digital control par 753 and par 754 This parameter is showing the actual status of the 8 digital inputs 11 18 on MK3A as a binary code Field bus control par 753 and par 754 This parameter is showing the status of the field bus control word PCD 1 as a decimal value 777 PID sample time Factory setting 1 ms Setting range 1 1000 ms User setting ms The following are display parameters only read only 778 Status of Synchronization The following status flags are defined for position and marker synchronization The flags are not updated when using speed synchronization Flag Decimal value Bit SYNCREADY 1 SYNCFAULT 2 1 SYNCACCURACY 4 2 Only marker Synchronization Master marker HIT 8 3 Slave marker HIT 16 4 Master marker Error 32 5 Slave marker Error 64 6 The flags are reset when restarting synchronization SyncStart 779 Softwar
92. rding to the description of par 729 before starting the calculation The calculation is done when the value of par 729 returns to 0 Using the test run functions can optimise the PID factors further There is two types of test run available Positioning where the slave drive moves a specific distance and Synchronizing with virtual master where the slave follows the virtual master in position or speed Generally it is better to use test run with virtual master as that comes closer to the operating conditions in synchronizing mode program 2 For test run with positioning the following parameters must be set Parameter 725 Test run speed Record the speed as a percentage of the maximum speed of parameter 716 Parameter 726 Test run acceleration record the acceleration time in per cent 10096 is minimum acceleration 5096 is half as fast as minimum acceleration the ramp time will thus be twice as long Parameter 727 Test run distance Record the distance quad counts for the drive to run during optimization Then use the following procedure 1 Close the contacts at terminal 32 clockwise direction or terminal 33 counter clockwise During the test the last value of the first display line will indicate the track error PID error After the test run is completed you can see the maximum track error PID error 2 Increase the P portion par 702 After each change you should make a test run to find the right setting If the drive beco
93. ronizing controller List of illustrations Figuie 1 Calculation example epe e tien a Re ien e i tt e b bereits 5 Figure 6 Master Slave connections ie inienn riere eE EEEE E ERE OEE EES AE ETEA EEK EEEE ASEE EE e 14 Figure 7 Virtual Master Slave connection seeeeeeseeeeeeeeeeeee eene nennen ener enne enne tre entre trennen tren trennen rennes 14 Figure 8 Control behaviour with speed synchronization sessi nren nenne enne 37 Figure 9 Mixing Speed synchronizing control eese enne tene E trennen trente 37 Figure 10 SyncStart with speed synchronization eese eene nene enne netter tree tren trennen nennen 38 Figure 11 Up down factor with speed synchronization ener nnne trennen nennen 39 Figure 12 Hold speed esee e peo nme e pt Dr PH eres DB eret tees 40 Figure 13 Changing the gear ratio in speed synchronization seseseeeeeeeeneneeeeee nennen trennen rennes 41 Figure 14 Wiring diagram Batch control esses enne enne enn en nentes en tenter entente nenne 42 Figure 15 Control behaviour with position synchronization eere nren eene 49 Figure 16 Embossing with position synchronization sese enne erret nren trennen nennen 49 Figure 17 Synchronizing to a stationary Master oe elec cee eene nennen nre nennen eren eene etene tenerse trennen nennen 50 Figure 18 Synchronizing to a running master eeeeseeeeeee
94. ronous operation Program 2 If the data value 1 or 2 was chosen in Parameter 729 this output shows 1 homing is completed EN os Ready no error The Synchronizing controller is ready for operation E BETHE con Option card MK3D slave encoder BEH Dc Encoder supply 8 Z1 Zero track inverted Not used MG 10 N4 02 VLT is a registered Danfoss trademark 19 uuf tt Synchronizing controller Description of Field bus interface NOTE This section is only relevant if the VLT is equipped with a Field bus interface option as well as the Synchronizing controller The Synchronizing controller can be controlled via the digital analogue inputs or via field bus The control source can be selected individually for test run and synchronizing in the parameters 753 test run and 754 synchronizing 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 synchronizing 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 synchronization 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 analogu
95. ronous operation Program 2 Master speed factor Enter here the factor by which the master speed must be scaled so that desired value is displayed The formula for calculation of the factor is N sa 400 Masterencoder _ resolution Factor B292 60 Display _ value 747 Synchronous operation Program 2 Synchronizing error display factor Enter the factor by which the error must be scaled so that the desired value is displayed The formula for calculation of the factor is Speed synchronization The factor should be 100 the synchronizing error is then displayed in RPM related to the slave Position synchronization 400 Slaveencoder _ resolution Factor Userunit Example Resolution 1024 PPR user unit is 100 mm revolution 400 1024 Factor 4096 100 748 Virtual master reference value Select here the type of reference value for the virtual master O reference value signal 0 10V via Terminal 53 1 reference value signal 0 20mA via Terminal 60 2 reference value can be set via Parameter 216 3 reference value is set via Field bus PCD 2 1000 corresponds to maximum virtual master velocity parameter 750 30 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller ufi Virtual master acceleration Enter here the acceleration for the virtual master in Hz s Pulsfrequency Hz tis Examp
96. rt VLT 5000 by pressing the START button on the control panel 44 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Paanfots How to optimize the controller Synchronization is obtained via two main elements of the controller Velocity feed forward and the PID controller NOTE Before starting the optimizing procedures it is important to select the right type of synchronization in parameter 728 in this example it must be 0 for velocity synchronization Please always have the necessary degree of accuracy in mind you could go on optimizing for a long time but it might not be necessary to have a 10096 accuracy in the application you are dealing with First step is to optimize velocity feed forward this can be done via the automatic calculation function Velocity feed forward calculation is activated by setting parameter 729 to 1 remember to make the required parameter settings according to the description of par 729 before starting the calculation The calculation is done when the value of par 729 returns to 0 Velocity feed forward can also be optimized manually by the following procedure 1 Set parameter 706 PID bandwidth to 0 Set parameter 719 maximum track error to a high value e g 1 000 000 Set parameter 707 velocity feed forward to 100 Start test run with virtual master with a known velocity via input 3 1 Increase parameter 707 while watching master and slave velocity pres
97. s DISPLAY STATUS to get the velocity readouts You have found the optimal velocity feed forward when slave velocity is approximately equal to the master velocity 6 Stop test run by input 3 0 7 Reset parameter 719 to the original value 8 Reset parameter 706 to 1000 Oreo Second step is to optimize the PID controller a good starting point can be found be means of the automatic calculation function By setting parameter 729 to 2 velocity feed forward calculation is activated as well as calculation of PID sample time and P D factors remember to make the required parameter settings according to the description of par 729 before starting the calculation The calculation is done when the value of par 729 returns to 0 Using the test run functions can optimize the PID factors further There is two types of test run available Positioning where the slave drive moves a specific distance and Synchronizing with virtual master where the slave follows the virtual master in position or speed Generally it is better to use test run with virtual master as that comes closer to the operating conditions in synchronizing mode program 2 For test run with positioning the following parameters must be set Parameter 725 Test run speed Record the speed as a percentage of the maximum speed of parameter 716 Parameter 726 Test run acceleration record the acceleration time in per cent 100 is minimum acceleration 50 is half as fast as min
98. scription of terminals and terminal configuration esses eene eere enne nennen rennen nete 42 Setting the parameters ectetuer RU UE e EE EO RO E SE e dune niet eee SEU ge etit eR 43 How to check the motor connection eessen Ea e E E EEE ER EE A E e a e a S oh 44 How to test th incremental encoders 5 rrr rrr ere e ETER EEE EE 44 How to optimize the controller eie RU eU UR ERU io Reb iius 45 How ard ue eter EE 47 Operation and operating functions eese ener ee trennen reet entren ne en nre enne tenete e tenerent entren 48 Position synchronization angle synchronization 49 Function diagrams for position synchronizatiOn eeee eee e ee eene eee eee ee eee tn aset en setate seta aset eaae eaa ae 50 SyncStart to a stationary master dee reri ebbe ire e ra Ene ie bI traer Sins eph iS ETE eura ages eR S 50 Syn St rt to running in stet esce eee Det a aE I IR ere ale tere ge Ree RE e Te eae Feriae e eei eI Enel 50 Position displacement with a running master sseeeeseeeseeeeeeenee eene nennen eene etre enne err tret trennen 51 Application example Embossing patterns on mould eee ee eee eee crees eene eee etas ena sense sete nue 52 Description of terminals and terminal configuration eene nennen nennen enne enne trennen 52 Setting the paramieters s ies eee pet intu aede dist DEI ten teer icri on dert 53 How to check the motor connectlon nascian
99. set 90 degrees By evaluating the two tracks the direction signal is also obtained Three track encoders deliver as well as the two tracks of the dual track encoder an additional zero track This emits a signal when the zero transit is passed through ix 175ZA823 10 iu 195 3A8OSTD A track A track a B track B track Time Time B track before A track anticlockwise A track before B track clockwise Figure 27 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 175ZA826 10 tx A track B track Quadcounts Time Figure 28 Derivation of quad counts 80 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Pranfets 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 Track error The synchronizing controller of the slave dr
100. slave Record 1 if the slave is to run in the opposite direction Parameter 716 Record maximum RPM measured at the slave encoder Parameter 717 Minimum ramp Set the time in ms for the slave drive to accelerate from standstill to maximum speed par 716 Consider the value carefully as this setting will highly affect the control accuracy Parameter 718 Ramp type Record 0 for linear ramp and 1 for s ramp NOTE S ramp requires higher acceleration torque Parameter 719 Maximum track error Record the value that is to generate Track error indication in the display if exceeded Parameter 720 Reversing procedure Record 0 if reversing is allowed 1 if the slave must always follow the direction of the master or 2 if reversing is not allowed MG 10 N4 02 VLT is a registered Danfoss trademark 63 Panfiii Synchronizing controller Parameter 721 Slave marker type As external marker signals are used you can set the type of edge triggering of the external marker signal 2 for a positive edge 3 for a negative edge Parameter 722 Slave marker interval Record the interval between two marker signals of the slave Input of the interval is in quad counts If the interval is not known it can also be determined during the test run Parameter 723 Master marker type As external marker signals are used you can set the type of edge triggering of the external marker signal here 2 for a positive edge
101. so with field bus control When digital control is selected status signals are updated on the digital outputs when field bus control is selected status signals are updated on digital outputs as well as field bus Setting range O Digital inputs 1 Field bus 0 means that all control commands are activated via the digital inputs according to the description of the terminals 1 means that all control commands are activated via the field bus control word according to the description of field bus control NOTE The new control source selected in par 754 is not active before next power up power cycle remember to save par 710 or input 4 the settings before power down 755 Brake on delay Brake on delay This parameter is used to specify the delay time between closing the mechanical brake output 4 and disabling motor control motor coast This is necessary to avoid loosing the load because of the reaction time of the mechanical brake Setting range 0 5000 msec The value must be set according to the reaction time of the mechanical brake 32 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panfets Brake off delay Brake off delay This parameter is used to specify the delay time between activating motor control and opening the mechanical brake output 4 This is necessary to avoid loosing the load because of the reaction time of the mechanical brake Setting range 0 50
102. speed set in Parameter 727 If 1 is set the actual speed is maintained While these signals are present the current Hold speed can be changed by means of Inputs 32 and 33 24 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panfets Test run Program 1 Test run distance Specify here the distance for the test run in quad counts Synchronous operation Program 2 Hold speed If Hold function O was selected enter here the speed as a percentage of the maximum speed Parameter 716 728 Test run program 1 Synchronizing type Sync type This parameter is used to specify the type of synchroni zation used when optimizing the PID controller for synchronization by means of the virtual master Setting range 0 Speed synchronizing 1 Position synchronizing Select 0 if you are going to use speed synchronizing in synchronous mode or select 1 if you are going to use position or marker synchronizing 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 MG 10 N4 02 VLT is a registered Danfoss trademark 25 Panfisi Synchronizing controller Test run program 1 Activate feed forward and PID calculation FFVEL calc This parameter is used to trigger automatic calculation of the optimal value for velocity feed forward par 707 as well as PID sam
103. ster is achieved by closing the SyncStart contact 11 the drive accelerates the maximum permitted acceleration to the speed of the master calculated by means of the gear ratio Stopping synchronization When the SyncStart contact 11 is opened the slave is stopped at the permitted acceleration Fine setting of the gear ratio Fine setting of the gear ratio can now be undertaken by means of Inputs 32 33 This setting is only temporary i e the fine setting data will be lost as soon as VLT 5000 is disconnected from the mains If the setting is to be saved a Store operation must be carried out by closing the Store contact 14 or by means of Parameters 710 before the VLT 5000 is switched off Switching to another gear ratio During synchronization a new gear ratio can be selected at Inputs 16 and 17 The gear ratio is then activated by means of the Switching Input I2 The slave will then proceed at the permitted acceleration to this new gear ratio Error procedure Errors of tracking over current etc make the drive stop and the Ready output O8 is reset Reset is done with Input 27 or fieldbus bit 1 9 Reset is also possible with the SSTOP RESET key of the local control panel of the drive This is only possible if the local stop function is disabled in parameter 014 Note You cannot stop the drive via the local control panel if local stop is disabled In case the drive has stopped because of earth fault or short circuit do disc
104. stered Danfoss trademark Synchronizing controller EXTERNAL SUPPLY DIGITAL IN OUTPUT MK3A qu MK3C 01 02 03 04 05 06 07 NNNNNNNSN 08 SW 1 1 OFF 24V COM SW 1 2 OFF 24V COM EXTERNAL SUPPLY 24Vd c 175ZA259 13 V CONTROL CARD VIRTUAL MASTER MK3B COM gt g gt za Al B1 E 3 21 iz MK3B SV COM The terminating resistors on both end of the bus have to be switch on with dip switch SW 1 3 MG 10 N4 02 VLT is a registered Danfoss trademark MASTER SW 1 3 ON SLAVE 1 SW 1 3 OFF SLAVE n SW 1 3 ON 11 ufi Synchronizing controller Technical Data 12 Terminals I Plugs with screw connections Maximum cable SZO ea a a a e a enin trn enn nent nenne 1 3 mm AWG 16 Digital inputs MK3A Terminal desighaltloris e pee eoe pe e e b te d I1 18 Voltage level 5 in decode cete tene bee cott te hs 0 24 V DC PNP positive logic Voltage threshold logical Os bsr enerne anani T AA TEE A ETA A S 5VDC Voltage threshold bocal 15 2 rei rt e E Rp e ee EUR TE 10 V DC Maximum voltage s nto ave oleae a
105. t contains no infinite number sequences and no rounded values This gives a ratio of Hardware VLT control card terminals The terminals on the control card are allocated for synchronizing controller functions the following parameter settings should therefore not be changed in synchronizing 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 they can still be used as inputs to the synchronizing 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 they can still be used as inputs to the synchronizing controller Digital analogue outputs 42 and 45 Parameters 319 and 321 are set to OPTION 0 20mA 91 analogue 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 Feedback encoder input Terminal A1 Al B1 Bl zi z Incremental input A in Ain Bin Bin Zin Zin Absolute input Clk out Clk out Data in Data in Not used Not used Virtual master A out A out B out B out Z out Z out 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
106. t how the drive is to behave on starting O the drive can synchronize from its current position 1 after switching on and after an error the drive must first be homed from where it can synchronize 2 the drive must be homed before each synchronization 26 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Pranfets Test run program 1 Encoder velocity Encoder RPM This parameter is used to specify the encoder velocity this is required for the velocity feed forward and PID calculation in parameter 729 Setting range 0 65000 RPM Rotations Per Minute VLT5000 The setting must be the encoder velocity in RPM corresponding to the nominal motor frequency in par 104 VLT5000Flux The setting must be the encoder velocity in RPM corresponding to the maximum reference in parameter 205 Synchronous operation Program 2 Home speed Set here as a percentage of the maximum speed Parameter 716 the speed for seeking the home position Too high a home speed will impair the accuracy and repeatability 731 Synchronous operation Program 2 Home acceleration Specify here the acceleration for the homing as a percentage of the maximum acceleration 100 means that the drive accelerates with the minimum ramp specified in Parameter 717 50 means that the drive only proceeds with half the acceleration i e the acceleration takes twice as long as with the minimum ramp specified in Parameter 717 73
107. tr n Speed oni eei itr eicere 74 TIps and tricks lire rrt e Hen ev de re etes 5 Track erro it s cette oer ertet 79 81 Type of operation ccescceecesseeeesceceeseseeeeseseneeneees 74 U Up down factor 2 2 edere cde 38 V Velocity feed forward 72 Melocity filter pesenane nem ert esee 72 Virtual Taster ooi pr e else 81 Virtual master acceleration sssse 77 Virtual master maximum speed 78 Virtual master reference value 77 VLT control card terminals cccceesseeeeeeeeeeeees 7 MG 10 N4 02 VLT is a registered Danfoss trademark 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 rights reserved M G 1 8 N 4 8 2
108. trennen eene 82 Figure 32 No addition of the cycle times eee eene nenne ener enne eeeee trennen tren trennen enne 83 84 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Index A Absolute value encoder seeren 81 Acceleration feed forward eeren 72 ACCUIQCV2 diii eiie Lt 76 81 Activate feed forward calculation 75 Adtmixt te eei etd rre cse edite ts 42 Angle synchronization 4 49 Application example agdmixt le aas utet to td eed 42 embossing patterns on mould 52 packaglng 2 eie ere decade eee 61 B Band width PID controller sssssss 72 Brake off delay nine 78 Brake on delay tete ee 78 C Calculation sample with corrected numerical values 6 with insufficient numerical values 6 Changing the gear ratio with an analogue value 41 Control source synchronizing ueesss 78 Control source test run seseeeeeene 78 D Data layouts onn ee e Rete qoe 20 Delta hold speed esee 75 Denominaltor 2 p Le I Idein Css 77 Description of Field bus interface 20 Description of parameters 22 Description of terminals eerren 15 admixtute sena aet nerit aes 42 embossing patterns on mould
109. ut 27 or fieldbus bit 1 9 Reset is also possible with of the local control panel of the drive This is only possible if the local stop function is the STOP RESET key disabled in parameter 014 Note You cannot stop the drive via the local control panel if local stop is disabled In case the drive has stopped because of earth fault or short circuit disconnect the drive from the mains before you reset MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller ufi Marker synchronizing Using Marker synchronizing you do not predefine the start position The Marker will alter the position during operation as required Marker synchronizing is for example used to compensate for any undesired slip 175ZA837 10 V 1 s Marker corrections Deviation Marker signals t s Figure 21 Control behavior with marker synchronization It appears from the diagram that the control accuracy depends on the master acceleration and on the speed deviation between slave and master The following example shows the use of marker synchronization to compensate for friction slip that can arise from dropping a box onto Conveyor belt 1 By means of marker correction in the form of object recognition the slave belt is controlled so that the product will always be placed right in the middle of the box even if the box itself is not centrally positioned in its conveyor compartment VLTS5000 Master marker signal Master signal
110. utput EM NO Function can be configured by means of Parameter 323 n c 75V DCAA Function can be configured by means of Parameter 326 39 Ground for analogue inputs outputs normally bridged with Terminal 20 but this can be set to OFF by means of Switch SW 4 on the control card EE Slave velocity The output value is scaled to maximum slave velocity parameter 716 the signal type can be selected in parameter 319 The output value is scaled to maximum slave velocity parameter 716 multiplied by the gear ratio the signal type can be selected in parameter 321 45 Master velocity Power supply for reference value potentiometer 50 10V DC 17mA BED iov Serves as reference input for the virtual master if 0 is selected in Parameter 748 E iov Synchronous operation Program 2 Serves as numerator for the gear ratio if 6 or 7 is selected in parameter 725 16 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panett W 20ma in Serves as reference input for the virtual master if 1 is selected in Parameter 748 Standard RS485 Interface 61 Ground RS485 Not used 68 RS485 P Not used 69 RS485 N Not used Option card MK3A BE 1 Sync Start Synchronous operation Program 2 Start and stop of synchronization Input 1 must be toggled if synchronization was interrupted by an error or by input 27 motor coast Behaviour at stop
111. vel ms tau filt Cmdvel set velocity Old Cmdvel last set velocity Actvel actual velocity of master ms sample time parameter 777 tau filt filter time constant For standard encoders the following table can be used Encoder resolution Tau filt ms 250 39500 256 38600 500 19500 512 19000 1000 9500 1024 9300 2000 4500 2048 4400 2500 3500 4096 1900 5000 1400 MG 10 N4 02 VLT is a registered Danfoss trademark 43 Auuf tt Synchronizing controller Parameter 711 Record the type of slave encoder 0 represents the incremental encoder Parameter 712 Record the resolution of the slave encoder Parameter 713 Record the type of master encoder 0 represents the incremental encoder Parameter 714 Record the resolution of the master encoder Parameter 715 Record 1 for clockwise rotation of both master and slave Record 1 if the slave is to run in the opposite direction Parameter 716 Record maximum RPM measured at the slave encoder Parameter 717 Minimum ramp Set the time in Ms for the slave drive to accelerate from standstill to maximum speed par 716 This value is important as this setting highly affects the control accuracy Parameter 718 Ramp type Record 0 for linear ramp and 1 for s ramp NOTE S ramp requires higher acceleration torque Parameter 720 Reversing behavior Record 0 if reversing is allowed 1 if the slave must always
112. x Slave marker S t s Figure 24 Marker correction during operation Application example Packaging This example is a conveyor belt with cardboard boxes of low weight and different lengths To ensure that the components to be packed are placed right in the middle of the boxes you must use synchronization with marker correction The grab belt is controlled by position synchronization and as soon as one of the two markers is recognized the grab belt is either moved forward to the conveyor belt position or slowed down It is also possible for the operator to change the position by means of two pushbuttons MG 10 N4 02 VLT is a registered Danfoss trademark 61 Synchronizing controller Terminals and terminal configuration VLT 15000 From mains supply l Digital inputs l l l l l l l l l Reset l Offset Offset 1 l l l i l Analog in outputs l l l l l l es z Sync Start Synchronizing controller Change of setup Save Mastermarker Slavemarker Master encoder Sync Ready Sync Fault Sync Accuracy Saving Running Slave encoder Home Unit ready 175ZA821 10 Figure 26 Wiring diagram conveyor belt regulation 62 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller ufi Setting the parameters For this we recommend to have the description of parameters at hand See the VLT 5000 VLT5000Flux Operating Instructions NOTE It is v
113. ynchronization SyncStart When closing the SyncStart contact Terminal I1 the slave drive accelerates with minimum ramp time to the speed of the master drive taking the gear ratio into account When I1 is opened the slave drive ramp or coast to stop Stop behaviour is selected in parameter 725 V m s 1752A803 10 LO Master T SyncStart ts Figure 10 SyncStart with speed synchronization Up down factor After the slave has been synchronized to the speed of the master by means of SyncStart Terminal I1 the gear ratio can be changed during operation By means of Inputs 33 Speed Up factor or 32 Speed Down factor the gear ratio can be changed by the value set in Parameter 744 step width This change affects only the slave factor For more sensitive adjustment of the gear ratio the gear ratio digits should be extended and a small step width should be selected If one of the two inputs is on longer than the time defined in Parameter 743 step time a further step will be executed Example Gear ratio i 22 43 If the step width is equal to 1 the first upward step will result in i 22 44 which represents almost 3 It would be better to set the ratio as i 2200 4300 Then the upward step will result in i 2200 4301 which represents a change of approx 0 03 38 MG 10 N4 02 VLT is a registered Danfoss trademark Synchronizing controller Panfiii 175ZA804 10 V m s Slave

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