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

Danfoss VLT 5000 Operating Instructions Manual

Synchronizing controller
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Operating Instructions
Synchronizing Controller
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  • Page 1 Operating Instructions Synchronizing Controller ® 5000 ® 5000 FLUX...

  • Page 2: Table Of Contents

    Position displacement with a running master......................51 Application example – Embossing patterns on mould ................52 Description of terminals and terminal configuration....................52 Setting the parameters............................... 53 How to check the motor connection.......................... 54 Testing the incremental encoders..........................54 MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 3 Table of error messages ............................70 Parameter overview............................72 Glossary of key terms ..........................80 List of illustrations............................84 Index................................85 Synchronizing Controller for VLT 5000 and VLT 5000Flux Software Version 2.1X Software Version number: See Parameter 779 MG.10.N4.02 - 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.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 5: Introduction

    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. MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 6: Mechanical Brake Control

    102mm. Via a 3-stage gear (i is specified to be 46,54) the slave drive is connected to an 8-toothed chain conveyor with a tooth pitch of 200mm. Figure 1: Calculation example MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 7 To remove Pi from the equations, substitute both equations into the combined formula: Masterside Slaveside 1024Incr 1024Incr ÷ π π π 1024 Incr Reduce by Pi and 1024 incr.: π 1024 Incr Reduce further: MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 8: 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: • Feedback encoder input...

  • Page 9: 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).

  • Page 10: Encoder Monitor

    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”. MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 11: Option Card Layout

    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. MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 12 Synchronizing controller 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...

  • Page 13: 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.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 14 Terminal designations ................... A1, A1 , B1, B1 , Z1, Z1 Signal type ........................Linedriver, RS485 Maximum frequency ........................150 kHz Minimum frequency ......................... 150 Hz Maximum number of slaves ..............31 (more when using repeaters) Maximum cable length........................400 m MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 15: Examples Of Encoder Interface Connections

    Synchronizing controller Examples of encoder interface connections Figure 6: Master-Slave connection Figure 7: Virtual Master-Slave connection MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 16: Description Of Terminals

    This high fixed offset would then 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...
  • Page 17 Serves as reference input for the virtual master if “0“ is selected in 10V-In Parameter 748. ± Synchronous operation; Program 2: 10V-In Serves as numerator for the gear ratio if “6” or “7” is selected in parameter 725. MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 18 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...
  • Page 19 Synchronous operation; Program 2: Switches the VLT to normal selection frequency converter operation. The settings for this operating mode are to be made in Parameter set 2. Refer to the VLT 5000 Product Manual. 24V DC Option card MK3B (master encoder)
  • Page 20 5V DC Encoder supply Encoder supply 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 MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 21: Description Of Field Bus Interface

    Not used Take over gear ratio Start/stop virtual master Start/stop virtual master Save settings Save settings Not used VLT-mode Not used Gear-ratio select MSB Not used Gear-ratio select LSB Not used Start homing MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 22 Ready, no error Ready, no error Track error Track error P775/797 Not used Synchronizing error P797 Not used Status of Synchronization P778 Slave speed Slave speed P798 Master speed Master speed P799 MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 23: Description Of Parameters

    100 = as “0” but with hardware monitor active. 101 = 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...
  • Page 24 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...
  • Page 25 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. MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 26 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...
  • Page 27 = the drive can synchronize from its current position; = after switching on, and after an error, the drive must first be homed, from where it can synchronize, = the drive must be homed before each synchronization. MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 28 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...
  • Page 29 Ensure that the gear ratio matches the marker ratio. 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. MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 30 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...
  • Page 31 = reference value signal 0.. ±20mA via Terminal 60, = reference value can be set via Parameter 216. = reference value is set via Field bus (PCD 2). +/- 1000 corresponds to maximum virtual master velocity (parameter 750). MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 32 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). MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 33 (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. MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 34 Setting range: 0 = inactive 1 = active 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...
  • Page 35 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. MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 36 Software version number: The software version of the synchronizing controller in use appears here. “Slave position”: The slave position is displayed in quad counts. “Master position”: The master position is displayed in quad counts. MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 37: Initializing The Parameters

    3. Set parameter 710 to “1”. Wait until it changes to “0”(app. 0.5 sec) 4. Switch off mains supply and wait until the display is dark 5. Switch on the mains supply MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 38: Speed Synchronization

    (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. Figure 9: Mixing. Speed synchronizing control MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 39: Function Diagrams For Speed Synchronization

    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 %. MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 40: Figure 11: Up/Down Factor With Speed Synchronization

    Synchronizing controller Figure 11: Up/down factor with speed synchronization MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 41: Hold Function

    737 - 739. The fixed gear ratios are selected at terminals 16 and 17: Input 16 Input 17 Gear ratio # To activate the new ratio you must activate input I2. The newly set gear ratio is attained with the minimum possible ramp. MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 42: Changing The Gear Ratio With An Analogue Value

    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...

  • Page 43: Application Example - Admixture

    U n i t r e a d y S l a v e e n c o d e r 2 4 v c o m Figure 14: Wiring diagram – Batch control MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 44: Setting The Parameters

    = filter time constant For standard encoders the following table can be used: Encoder resolution Tau_filt (ms) 39500 38600 19500 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...

  • Page 45: How To Check The Motor Connection

    3. 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.

  • Page 46: How To Optimize The Controller

    50% 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...
  • Page 47 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...

  • Page 48: How To Program Synchronization

    Use the following formula: Slaveencod resolution Factor = Display value Example: Resolution 1024 increments, desired display 100 at 1500 Incr 1500 1024 Factor = 102400 MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 49: Operation And Operating Functions

    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 (I4) or by means of Parameters 710 before the VLT 5000 is switched off.

  • Page 50: Position Synchronization (Angle Synchronization)

    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. Figure 16: Embossing with position synchronization MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 51: Function Diagrams For Position Synchronization

    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. Figure 18: Synchronizing to a running master MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 52: Position Displacement With A Running Master

    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. Figure 19: Position displacement MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 53: Application Example - Embossing Patterns On Mould

    Each of the two incremental encoders has a zero track for marker synchronization. Description of terminals and terminal configuration Figure 20: Wiring diagram – application example MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 54: Setting The Parameters

    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...

  • Page 55: How To Check The Motor Connection

    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.
  • Page 56 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...

  • Page 57: How To Program Synchronization

    Activate Input I4 (Store) or change first the value of parameter 710 to “1” . How to program synchronization 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”...
  • Page 58 To calculate the value use the following formula: Slaveencod resolution Factor = 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...

  • Page 59: Operation And Operating Functions

    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...

  • Page 60: Marker Synchronizing

    Figure 22: Conveyor belt with marker synchronization MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 61: Function Diagrams For 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. MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 62: Application Example - Packaging

    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...

  • Page 63: Terminals And Terminal Configuration

    Synchronizing controller Terminals and terminal configuration Figure 26: Wiring diagram - conveyor belt regulation MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 64: Setting The Parameters

    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...

  • Page 65: How To Check The Motor Connection

    3. 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 direction of the motor. If the motor rotates in the wrong direction then exchange the motor phases.

  • Page 66: How To Optimise The Controller

    Synchronizing controller 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.
  • Page 67 (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”. MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 68: How To Program Synchronization

    Synchronizing controller How to program synchronization 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 “2” or “5” for marker synchronization.
  • Page 69 To calculate the value, use the following formula: Slaveencod resolution Factor = 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...

  • Page 70: Operation And Operating Functions

    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...

  • Page 71: Appendix

    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...
  • Page 72 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. MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 73: Parameter Overview

    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...
  • Page 74 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...
  • Page 75 Factory setting: 0 Setting range from: 0 to: 1 User setting: __________ Test run; Program 1: Test run distance Factory setting: 4096 quad counts Setting range from: 1 to: 2147483647 quad counts MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 76 Factory setting: 10 % Setting range from: 1 to: 100 % User setting: __________ % Home acceleration Factory setting: 10 % Setting range from: 1 to: 200 % User setting: __________ % MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 77 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...
  • Page 78 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 User setting: __________ MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 79 User setting: __________ msec Marker monitor (Marker monitor) Factory setting: 0 Setting range from 0 to 2 User setting: __________ Resync. (Resync) Factory setting: 0 Setting range from 0 to 1 User setting: __________ MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 80 The synchronization error is displayed with the value calculated in Parameter 747. „Slave speed“. The slave speed is displayed with the value calculated in Parameter 745. „Master speed“, The master speed is displayed with the value calculated in Parameter 746. MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 81: Glossary Of Key Terms

    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. Figure 28: Derivation of quad counts MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 82: Figure 29: Synchronization Without Virtual Master

    First, we show the classic synchronization procedure, where the reference value signal is taken from the preceding drive in each case. Figure 29: Synchronization without virtual master MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 83: Figure 30: Addition Of The Cycle Times

    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. Figure 31: Synchronization with virtual master MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 84: Figure 32: No Addition Of The Cycle Times

    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. Figure 32: No addition of the cycle times MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 85: List Of Illustrations

    Figure 29: Synchronization without virtual master ......................81 Figure 30: Addition of the cycle times..........................82 Figure 31: Synchronization with virtual master ......................82 Figure 32: No addition of the cycle times........................83 MG.10.N4.02 - VLT is a registered Danfoss trademark...

  • Page 86: Index

    Marker quantity FAULT ..........76 Marker quantity READY ........... 76 FFVEL calc ...............75 Marker synchronization ........4, 59 Field bus Marker synchronizing mode ........76 control signals ............20 Marker window master ..........78 interface ..............20 MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 87 Slave encoder type ...........73 Virtual master maximum speed........ 78 Slave marker quantity ..........76 Virtual master reference value ......... 77 Slave marker type .............74 VLT control card terminals ......... 7 Slave markers ............77 Slave position............79 MG.10.N4.02 - VLT is a registered Danfoss trademark...
  • Page 88 XREF__BC NOT LOADED ON RIP www.danfoss.com/drives 175R0237 MG10N402 *MG10N402* Rev. 2003-09-16...

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