Danfoss MCO 305 Operating Instructions Manual
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Danfoss MCO 305 Operating Instructions Manual

Programmable motion controller
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MAKING MODERN LIVING POSSIBLE
Operating Instructions
Programmable Motion Controller - MCO 305

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Summary of Contents for Danfoss MCO 305

  • Page 1 MAKING MODERN LIVING POSSIBLE Operating Instructions Programmable Motion Controller - MCO 305...

  • Page 2: Table Of Contents

    Contents MCO 305 Operating Instructions Contents 1 Introduction 1.1 Available Literature for VLT AutomationDrive, MCO 305 and MCT 10 Motion Control Tool 1.2 Symbols and Conventions 1.3 Abbreviations 2.1 High Voltage Warning 2.2 Safety Instructions 2.3 Before Commencing Repair Work 2.4 Avoid Unintended Start...
  • Page 3 Contents MCO 305 Operating Instructions 4.2 Significance and Influence of the Controller Parameters 4.3 PID Factors 4.3.1 Derivative Value for PID Control 4.3.2 Integral Factor: KINT 4.3.3 Limit Value for Integral Sum: KILIM 4.3.4 Velocity Feed-forward: FFVEL 4.3.5 Acceleration Feed-forward: FFACC 4.3.6 Sampling Time for PID Control: TIMER...

  • Page 4: Introduction

    AutomationDrive, MCO 305 and MCT 10 property-damage-only accidents. Motion Control Tool NOTE The MCO 305 Design Guide entails all technical Indicates highlighted information that should be regarded information about the option board and with attention to avoid mistakes or operate equipment at customer design and applications.

  • Page 5: Abbreviations

    Introduction MCO 305 Operating Instructions 1.3 Abbreviations Automatic Motor Adaptation Direct Current Frequency Converter Local Control Panel Master Unit Millisecond Minute Motion Control Option Motion Control Tool Parameter par. Protective Extra Low Voltage PELV Position Control Loop Pulses per Revolution...

  • Page 6: High Voltage Warning

    Operating Instructions Software version: 5.xx These Operating Instructions can be used for the MCO 305 option board with all FC 300 frequency converters with software version later than 5.xx. The software version number can be seen from 15-43 Software Version for the frequency converter and in 15-61 Option SW Version for the MCO 305 2.1.1 High Voltage Warning...

  • Page 7: Safe Stop Of Fc 302

    Safety Instructions and Gen... MCO 305 Operating Instructions 2.5 Safe Stop of FC 302 The FC 302 can perform the Designated Safety Function Uncontrolled Stopping by removal of power (as defined by IEC 61800-5-2) or Stop Category 0 (as defined in EN 60204-1).

  • Page 8: How To Install

    NOTE ways: When carrying out manual initialization, serial communi- Recommended initialisation (via 14-22 Operation Mode) cation and fault log settings are reset. All MCO 305 Select 14-22 Operation Mode programs and arrays are deleted! Press [OK] This method initializes all except: Select “Initialization”...

  • Page 9: System Overview

    How to Install MCO 305 Operating Instructions 3.2 System Overview This is only relevant if the MCO 305 is delivered as an Mounting kit depending on frame Order no. option for upgrading an existing VLT AutomationDrive. Bookstyle When ordered with the frequency converter, MCO 305 is...
  • Page 10 How to Install MCO 305 Operating Instructions Illustration 3.2 Compact - A5, B (except B3), C, D, E, F ® MG.33.K3.02 - VLT is a registered Danfoss trademark...

  • Page 11: Electrical Installation

    See also VLT AutomationDrive Design of the same MCO 305 in all frame sizes. See Illustration 3.5 Guide (MG.33.AX.YY) for more information regarding EMC to locate the terminal blocks: correct cable installation.

  • Page 12: Terminal Overview

    How to Install MCO 305 Operating Instructions 3.2.3 Terminal overview MCO control terminals are plug connectors with screw terminals. Terminals X55, X56, X57, X58 and X59 are duplicated to be used for both bookstyle and compact Terminal Terminal number Descriptive Name Encoder 2 frame size.

  • Page 13: Encoder Connections Examples

    Terminal Terminal number MCO CAN Bus block CAN - L DRAIN Illustration 3.8 24V Absolute Encoder (SSI) Supplied by MCO 305 CAN - H 3.2.4 Encoder Connections Examples 5V GND Illustration 3.9 24V Absolute Encoder (SSI) Supplied by an External Power Source 5V incremental encoder Illustration 3.6 5V Incremental Encoder (RS-422) Supplied by...

  • Page 14: Virtual Master Connection

    How to Install MCO 305 Operating Instructions 3.2.5 Virtual Master Connection When more than 2 MCO 305 master encoder interfaces are interconnected termination must be on (32-40 Encoder Termination = ON) at both ends of the bus. Termination must be off (32-40 Encoder Termination = OFF) in all other MCOs.

  • Page 15: Commissioning Guide

    32-06 Absolute Encoder Clock Frequency 262000 DPV1. 32-07 Absolute Encoder Clock Generation [1] On Then follow these steps to set-up and optimize MCO 305. 32-08 Absolute Encoder Cable Length 32-09 Encoder Monitoring [0] Off Setting of basic MCO 305 parameters (groups 32- For CAN Encoders ** and 33-**).

  • Page 16: Setting Of Parameters For Canopen Master Encoder

    How to Install MCO 305 Operating Instructions 3.4.5 Setting of Home Parameters 32-3* Encoder 1 - Master 32-30 Incremental Signal Type [1] RS422 Homing is not necessary in standard synchronization 32-31 Incremental Resolution 1024 applications and applications using an absolute encoder.

  • Page 17: Connecting And Testing The Encoder(S)

    How to Install MCO 305 Operating Instructions Check the encoder connections by means of the test 33-1* Synchronization Default program: Select the file “Enc-S.m” via the MCT 10. APOSS 33-10 Sync Factor Master and with that the file is opened automatically .

  • Page 18: Sample Program: Feed-Forward Calculation

    How to Install MCO 305 Operating Instructions 3.6.1 Sample Program: Feed-forward The following basic settings can be used in most Calculation applications with a 1024 PPR encoder connected directly to the motor shaft and maximum reference (3-03 Maximum Reference) is 1500 RPM:...

  • Page 19: Executing A Test Program

    How to Install MCO 305 Operating Instructions If the motor doesn’t move at all, then the Proportional Examples 32-60 32-61 32-62 32-65 Factor of the PID filter is probably too low or the VLT 1024 PPR encoder 1000 10200 AutomationDrive has not been enabled.

  • Page 20: Optimizing The Pid Controller

    To do that you only need to know a millisecond (interval is programmable by the TIMER few things about the control scheme of MCO 305: parameter). The MCO 305 is by default set with soft “fit for all” controller parameters. The APOSS position controller has two parts:...

  • Page 21: Pid Factors

    (the internal speed-reference to the VLT AutomationDrive). The controller in the MCO 305 utilizes two control Since the calculated control signal is proportional to the strategies at the same time: position deviance (or error) this kind of control is called proportional control.

  • Page 22: Derivative Value For Pid Control

    Optimizing the PID controll... MCO 305 Operating Instructions overall control signal (the internal speed-reference) is Influence of the Proportional Factor: maxed out for long periods of time. KPROP too small large position deviation due to non- This feature is also very helpful in applications where the...

  • Page 23: Optimizing Your Controller Settings Step-By-Step

    Optimizing the PID controll... MCO 305 Operating Instructions which could be jeopardized by vibrations, for example, a 32-81 Shortest Ramp. If these settings change crane with a heavy load then you can limit the bandwidth again at a later point, the controller may need in which the PID controller should function.32-64 PID...
  • Page 24 Optimizing the PID controll... MCO 305 Operating Instructions View the velocity profiles: If during acceleration used. Setting this parameter though is a trade-off the actual velocity is constantly lower than the between achieving zero steady-state error fast reference velocity profile, then set a higher value (which is good) and increasing overshoot and of Acceleration Feed-forward and →...

  • Page 25: How To Install The Application

    5.1 Download Application Program and Save the project. Configuration Now parameters and MCO 305 data is stored in the project Follow these steps to create and download MCO 305 file, restore by the following steps: program and configuration using MCT 10 and APOSS Open the project file with MCT 10 Set-up Open MCT 10.

  • Page 26: How To Connect And Run Multiple Frequency Converters

    How to Install the Applicat... MCO 305 Operating Instructions 5.3 How to Connect and Run Multiple Frequency Converters Use MCT 10 Networking or start APOSS directly by clicking on the application's icon. This stand-alone operation mode allows APOSS to switch frequency converters or connect to multiple frequency converters.

  • Page 27: General Specifications

    Table 6.3 Digital Outputs AutomationDrive LCP. 1) Terminals X59-1 and X59-2 can be programmed as MCO 305 can be combined with other VLT input, 33-60 Terminal X59/1 and X59/2 Mode. AutomationDrive options e.g. PROFIBUS and 2) Selected in 5-00 Digital I/O Mode.

  • Page 28: Supply Voltage Overview

    General Specifications MCO 305 Operating Instructions 2) 8V is only available at terminal block X55. General specifications: Number of encoder inputs Terminal block X55 and X56 Sample time of position PID loop 1ms Terminal number 5, 6, 7, 8, 9, 10, 11, 12 Positioning accuracy ±...

  • Page 29: Troubleshooting

    Troubleshooting MCO 305 Operating Instructions 7 Troubleshooting You can find brief information on the error messages in the table or detailed information in the following section. 7.1 Warnings and Error Messages The tables contain the messages in numerical order. Letters following a % sign represent variables which can All messages are shown in the LCP display of the VLT be used in plain text at the corresponding locations.
  • Page 30 Troubleshooting MCO 305 Operating Instructions Error no. LCP display Error text Too many testindices Too many test indices in data logging command. Code too old Code is too old for the current firmware. Limit sw. violation rong direction after limit switch tripped and error reset.
  • Page 31 Troubleshooting MCO 305 Operating Instructions NOTE Error 109 Index not found Using virtual inputs as limit switches is dangerous because At reference or index search, the encoder index pulse it eliminates the direct connection between the limit could not be found within a motor rotation.
  • Page 32 Troubleshooting MCO 305 Operating Instructions Error 117 Limit switches and reference switches allow the usage of Programs in memory are corrupted any input. That means not only 1..8 are supported but also The program data stored in EPROM cannot be found or are larger numbers as well as virtual inputs or outputs.
  • Page 33 The definition of an array in a DIM command does not Not enough memory for variables: When the APOSS correspond to an already existing array in the MCO 305. program is started the space for the necessary variables is Cause might be that the fields are from older SYNCPOS/ reserved dynamically.
  • Page 34 Troubleshooting MCO 305 Operating Instructions Memory locked Error 191 The program memory is write-protected and cannot be Illegal cam array altered. An incorrect or old array is defined in the DIM instruction This means that auto recognition can neither be set nor for SETCURVE.

  • Page 35: Aposs Software Messages

    Troubleshooting MCO 305 Operating Instructions Error in axis parameter part of file 7.2 APOSS Software Messages When re-saving a configuration (e.g. Controller → Parameters → Restore from file) the computer recognizes The APOSS software messages are arranged in alphabetical that the data in the area of the axis parameters is order.

  • Page 36: Appendix

    Appendix MCO 305 Operating Instructions 8 Appendix Conversion index 8.1 Parameter Lists This number refers to a conversion figure used when writing or reading by means of a frequency converter. The parameters are determined by parameter numbers. We Please see for all conversion indices the VLT recommend using the alphabetical overview as a guide;...

  • Page 37: Mco Basics Settings, Parameter Group

    Appendix MCO 305 Operating Instructions 8.1.2 MCO Basics Settings, Parameter Group 32-** Par. No. # Parameter name Parameter Default setting Changes 4-set-up Conver- Type description during sion index operation 32-0* Encoder 2 - Slave 32-00 ENCODERTYPE Incremental Signal [1] RS422...
  • Page 38 Appendix MCO 305 Operating Instructions Par. No. # Parameter name Parameter Default setting Changes 4-set-up Conver- Type description during sion index operation 32-40 MENCODER TERM Encoder [1] On TRUE 1 set-up Uint8 Termination 32-43 MENCCONTROL Enc.1 Control TRUE 2 set-ups...

  • Page 39: Mco Advanced Settings, Parameter Group

    Appendix MCO 305 Operating Instructions Par. No. # Parameter name Parameter Default setting Changes 4-set-up Conver- Type description during sion index operation 32-88 JERKMIN3 Dec. up for limited 0 ms TRUE 2 set-ups Uint32 jerk 32-89 JERKMIN4 Dec. down for...
  • Page 40 Appendix MCO 305 Operating Instructions Par. No. # Parameter Parameter Default setting Changes 4-set-up Conver- Type name description during sion index operation 33-26 SYNCVFTIME Velocity Filter 0 ms TRUE 1 set-up Int32 33-27 SYNCOFFTIME Offset Filter Time 0 ms TRUE...
  • Page 41 Appendix MCO 305 Operating Instructions Par. No. # Parameter Parameter Default setting Changes 4-set-up Conver- Type name description during sion index operation 33-59 I_FUNCTION_10 Terminal X57/10 [0] no function TRUE 1 set-up Uint8 Digital Input 33-60 IOMODE Terminal X59/1 and...

  • Page 42: Mco Data Readouts, Parameter Group

    Appendix MCO 305 Operating Instructions 8.1.4 MCO Data Readouts, Parameter Group 34-** Par. No. # Parameter Parameter Default Changes 4-Setup Conver- Type Name description setting during sion Index operation 34-0* PCD Write Parameters 34-01 PCD 1 Write to MCO 1 set-up...

  • Page 43: Index

    To Connect And Run Multiple Frequency Converters..25 Approvals....................3 To Control Process Works............. 19 To Get Started..................7 Available Literature For VLT AutomationDrive, MCO 305 And To Install The Application............. 24 MCT 10 Motion Control Tool..3 Incremental Encoder Specifications..........27 Backup And Restore Via LCP.............
  • Page 44 Index MCO 305 Operating Instructions Restore...................... 24 Safe Stop Of FC 302................6 Safety Instructions.................. 5 Sample Program: Feed-forward Calculation......17 Sampling Time For PID Control:............21 Setting Of Encoder Parameters..............14 Of Home Parameters..............15 Of Synchronization Parameters..........15 Of Velocity Parameters..............
  • Page 45 130R0086 MG33K302 Rev. 2011-05-24 *MG33K302*...

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