Danfoss VLT 5000 Operating Instructions Manual
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Danfoss VLT 5000 Operating Instructions Manual

Positioning controller
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Operating Instructions
Positioning Controller
®
VLT
5000
®
VLT
5000 FLUX

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Summary of Contents for Danfoss VLT 5000

  • Page 1 Operating Instructions Positioning Controller ® 5000 ® 5000 FLUX...

  • Page 2: Table Of Contents

    Electrical interface VLT ............................... 12 Option card MK3A ..............................14 Option card MK3C ..............................15 Option card MK3B (secondary position feedback for absolute encoders when using VLT 5000 Flux)....15 Option card MK3D (primary position feedback)...................... 16 Field bus interface................................. 17 Data layout................................
  • Page 3 Positioning Controller Positioning Controller for VLT 5000 and VLT 5000Flux Software Version 2.1X Software Version number: See Parameter 779. MG.50.P3.02 - VLT is a registered Danfoss trademark...

  • Page 4: Safety Regulations

    Using VLT 5001-5005 550-600 V units: wait at least 4 minutes Using VLT 5006-5022 550-600 V units: wait at least 15 minutes Using VLT 5027-5250 550-600 V units: wait at least 30 minutes MG.50.P3.02 - VLT is a registered Danfoss trademark...

  • Page 5: Introduction

    Positioning Controller Introduction The Positioning Controller is an application option for the VLT 5000 and VLT 5000 Flux Series. It is based on the SyncPos option card. The positioning controller can be used in a wide range of applications where a frequency converter is used for positioning.

  • Page 6: Hardware

    (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: • Primary Feedback encoder input •...

  • Page 7: Supply Voltages

    24 V DC supply. The 24 V DC supply of VLT 5000 can supply a total of 420 mA including the load on the control card (terminal 12, 13 and output 42 and 45 + 26 and 46 for VLT 5000 Flux).

  • Page 8: Encoder Monitor

    An encoder fault will only result in an ”Option error” 92 if encoder monitoring is activated via parameter 713. Note: Monitoring of the secondary feedback encoder is disabled when switch 1.3 is ”OFF”. MG.50.P3.02 - VLT is a registered Danfoss trademark...

  • Page 9: Option Card Layout

    SW 1.3: Connect(ON)/disconnect(OFF) termination resistor for secondary encoder. Note: When OFF the secondary encoder monitor is disabled. SW 1.4: Switch Z-channel encoder monitor ON/OFF for both encoder inputs. Default setting of switch 1.1. - 1.4 is ON. MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 10 Positioning Controller MG.50.P3.02 - VLT is a registered Danfoss trademark...

  • Page 11: Technical Data

    Signal type ............................. SSI Data coding ..........................Gray code Data length ............................25 bit Parity..............................none Clock frequency........................105 or 260 kHz Protocol ............................... Gray Maximum positions per revolution .......................8192 Maximum number of revolutions ......................4096 MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 12 (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............................105 kHz clock = 9µsec ..........................260 kHz clock = 3.5 µsec MG.50.P3.02 - VLT is a registered Danfoss trademark...

  • Page 13: Description Of The Electrical And Field Bus Interface

    16, 17, 18, 19, 29 into memory. Digital output MK3C 4 – 8 is changed to mirror the new reference index specified when using digital input control. Not used in field bus mode. MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 14 Relay 01-03 is open (brake activated) during power off, and start-up of the VLT 5000. It is always open after a “Quick Stop” procedure or in connection with an error situation. Relay 01-03 only closes in connection with motion procedures or if specified in P715.

  • Page 15: Option Card Mk3A

    Interrupt triggered on the rising edge. If this signal goes high when no touch probe target position is currently locked (VLT 5000 input Process: terminal 42 low, VLT 5000 Flux: terminal 26 low), a new touch probe target position is calculated and locked in memory. Positive HW limit Interrupt triggered on the falling edge.

  • Page 16: Option Card Mk3C

    Active high. Mirror of the currently locked-in reference index bit 4. Reference index bit 4 Not used in field bus mode. 24V DC Option card MK3B (secondary position feedback for absolute encoders when using VLT 5000 Flux) 5V DC Encoder supply Encoder supply Incremental encoder...

  • Page 17: Option Card Mk3D (Primary Position Feedback)

    Incremental encoder Absolute encoder A-track Clock out A-track inverted Clock out inverted B-track Data in B-track inverted Data in inverted Zero-track Not used Zero-track inverted Not used Fig.: Encoder connection for positioning applications MG.50.P3.02 - VLT is a registered Danfoss trademark...

  • Page 18: Field Bus Interface

    Go to home / Stop positioning (↑) / Go to position (↓) Read new trajectory index (↑) Automatic (↑) / manual (↓) mode Reset home status (↑) Reset touch probe position (↑) Quick stop (↓) Positive jog (↑) 1.10 Negative jog (↑) MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 19 Reference index bit 0 (LSB) (↑) Reference index bit 1 (↑) Reference index bit 2 (↑) Reference index bit 3 (↑) Reference index bit 4 (Digital MSB) (↑) Reference index bit 5 (Fieldbus MSB) (↑) MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 20 Current index bit 2 (↑) Current index bit 3 (↑) Current index bit 4 (Digital MSB) (↑) Current index bit 5 (Fieldbus MSB) (↑) Actual Position (MSB) 795 (MSB) Actual Position (LSB) 795 (LSB) Error Status MG.50.P3.02 - VLT is a registered Danfoss trademark...

  • Page 21: Description Of The Available Parameters

    P739 to be updated with the actual position. This provides an easy way of programming several positions. Simply jog to the desired position, then press the [JOG] and [FWD./REV.] buttons to store that position in memory. MG.50.P3.02 - VLT is a registered Danfoss trademark...

  • Page 22: Description Of Parameters

    0 … 65,000 Here it is possible to clamp the integral part of the PID output. A setting of 1000 corresponds to 100% of the maximum INT. LIMIT allowed reference specified in parameter 205. MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 23 “2” will prompt the program to AUTOCALC. enabled calculate the optimal setting of parameter FFVEL 702, 703, 704 and 707. For VLT 5000 Process the following parameters influence the result and must be set correctly beforehand: P104 nominal motor frequency...
  • Page 24 -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. MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 25 When the automatic brake control function is disabled, the drive controls the applica- tion also at standstill. MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 26 “5” (the number of motor revolutions) MOT/ENC GEAR and P722 should be set to “2” (the number of encoder revolutions). If the encoder is mounted directly on the motor shaft this parameter setting should remain at “1”. MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 27 P726. It is defined as an error situation (“PID track error too big” - P798 = 9) if the track error is bigger than the setting of P726. MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 28 Instead the HOME position is defined as the position at which the reference switch goes low. After defining the HOME position the drive is then ramped down with the home ramp (P729) and stopped. MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 29 DIRECTION By selecting “2” it is defined as an error situation (“Forward operation prohibited” – P798 = 13) if the drive is moving in forward direction. Selecting “0” disables the function. MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 30 INPUT given by the PLC system. The function is deactivated when set to “0”. This is necessary when programming a position number different from the one loaded into the PLC memory. MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 31 The output “Touch probe position locked” (VLT5000 Terminal 42) is high if a touch probe position is defined. If P743 = 3 the application will move in the negative direction until a touch probe posi- MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 32 If the actual position (P795) exceeds the limit value specified in this parameter an error 1,073,000,000 UU situation is defined (P798 = 4) and handled according to the setting of the “Error POS. SW. LIMIT behaviour” parameter (P725). MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 33 MK3B. This is used to enable the use SWAP ENCODER of absolute encoders for feedback together with VLT 5000 Flux in closed loop mode. In that case input MK3D has an incremen- tal encoder fitted (feedback for Flux) and MK3B has an absolute encoder fitted for positioning feedback.
  • Page 34 VLT5000 control card is accessible via P528 PID tracking error –2,000,000,000 … READ-ONLY PARAMETER: PID TRACK 2,000,000,000 UU The current PID tracking error is displayed ERROR in this parameter in user units. MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 35 P104, P106, P205, P721, P722 and the result is presented in MAX. VELOCITY this parameter. To increase this value one or more of the above mentioned parame- ters must be changed (usually just P205). MG.50.P3.02 - VLT is a registered Danfoss trademark...

  • Page 36: An Application Example

    2) Waiting until the pallet is successfully transferred to the cart 3) Moving to pallet outlet no. 2. 4) Waiting until the pallet is successfully transferred to the outlet conveyor and so on… MG.50.P3.02 - VLT is a registered Danfoss trademark...

  • Page 37: Wiring Diagram

    I2 (HW limit) must be connected and high. 2. Select “Disable syncpos” in P700 3. Select “Local” function in Parameter 002. – VLT 5000 stops (display flashing) 4. Input the motor name plate data in P102-P106 and activate the “Automatic Motor Adaptation”...
  • Page 38 Positioning Controller 5. Press the [START] button on the VLT 5000 control panel and wait for the AMA to be completed. 6. Set the frequency for a low positive value, for example +3 Hz in Parameter 003 please note that motor should now rotate.

  • Page 39: Parameter Settings

    P732 is set to “87138” and P733 is set to “400”. Positions will now be displayed and entered in millimetres. Settings like P732 set to “43569” and P733 set to ”200” will also give the positions in millimetres. MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 40 Different settings for each position are available because every position is programmed with its own setting for ramp and velocity. The different positions are defined below. PALLET CART 0 mm 2000 mm 4000 mm 0 QC 435690 QC 871380 QC MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 41 This is achieved by setting P736 Power-recovery to “1”. The allowed position tolerance is defined to be +/- 10 mm in this application so P746 Target position window is set to “10”. MG.50.P3.02 - VLT is a registered Danfoss trademark...

  • Page 42: Troubleshooting

    Use a higher ramp time setting (P719 for “quick stop”, P724 for jogging and P738/P741 for posi- tioning). b) If a lower ramp time is required a brake resistor should be installed. MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 43 P798 – 4: Positive software limit exceeded Error messages Meaning All messages are shown in P798 in the VLT 5000 LCP display. You can find detailed information, A motor command will cause / has caused the additional notes on possible causes of errors as software limit switch to be activated.
  • Page 44 Danfoss with a description of the conditions before and after the error occurred. P798 – 11: VLT Exception error detected Meaning An internal VLT 5000 error was detected during start-up of the option card program. Please note the corresponding error number and contact Danfoss.

  • Page 45: Appendix

    Pos. Number target PCD 7,6 PCD 7,5 PCD 7,4 PCD 7,3 PCD 7,2 PCD 7,1 Pos. Number chosen (MSB) PCD 2,5 PCD 2,4 PCD 7,3 PCD 2,2 (LSB) PCD 2,6 PCD 2.1 MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 46 Pos. Number target PCD 7,6 PCD 7,5 PCD 7,4 PCD 7,3 PCD 7,2 PCD 7,1 Pos. Number chosen (MSB) PCD 2,5 PCD 2,4 PCD 7,3 PCD 2,2 (LSB) PCD 2,6 PCD 2.1 MG.50.P3.02 - VLT is a registered Danfoss trademark...

  • Page 47: Glossary Of Key Terms

    Turn encoders can report the absolute position via a specific quantity, or via a freely-definable number of rotations. ERPM The speed is defined in relation to the RPM of the encoder. To underline this the term “encoder revolutions per minute” is chosen as unit. MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 48 This means the target position will become larger than stated in parameter 739. To compensate for this please specify a delay value in parameter 747. Only a constant delay can be compensated not a variable delay. MG.50.P3.02 - VLT is a registered Danfoss trademark...

  • Page 49: Index

    Factory reset P776............33 Option card MK3A ............ 14 Feedback input P748 ..........32 Option card MK3B (secondary position feedback Feed-forward ................15 acceleration gain P708 .........22 Option card MK3C............ 15 velocity gain P707 ..........22 MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 50 Ramp down time P741..........31 VLT local jog P711 ........... 23 Ramp type P720 ............25 VLT not running............42 Ramp up time P740 ..........31 Reverse operation prohibited........43 Warning against unintended start ......3 MG.50.P3.02 - VLT is a registered Danfoss trademark...
  • Page 51 XREF__BC NOT LOADED ON RIP www.danfoss.com/drives 175R0305 MG50P302 *MG50P302* Rev. 2003-09-16...

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