manual control posicionamie

8/13/2019 Manual Control Posicionamie

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VLT Series 5000 Positioning Controller

MG.50.P1.02 - VLT is a registered Danfoss trademark 1

Table of contents

Safety Note _____________________________________________________________________ 3These provisions are for your safety................................................................................................................................3Warning: unintentional start-up.......................................................................................................................................3

Introduction ________________________________________________________________ 4

Part one: Description of the electrical interface___________________________ 5Standard RS485-Interface .......................................................... ........................................................ .............................6Option card MK3A..........................................................................................................................................................7Option card MK3C..........................................................................................................................................................8Option card MK3D (position feedback)..........................................................................................................................8

Hardware ______________________________________________________________________ 9Input and output terminals...............................................................................................................................................9VLT control card terminals ............................................................. ............................................................. ...................9Technical data ............................................................ ............................................................... ......................................9

Option card terminals ........................................................ .................................................................. ............................9Power supply voltages ___________________________________________________________ 11

Layout of the option card ________________________________________________________ 12

Technical Data_________________________________________________________________ 13

Part two: Description of the available parameters_____________________ 14Special LCP functions............................................................... ................................................................ ....................14Description of parameters ............................................................ .............................................................. ...................14

Part three: An application example!______________________________________ 26Basic set-up ......................................................... ............................................................ .............................................. 26Parameter settings..........................................................................................................................................................27

Part four: Troubleshooting _______________________________________________ 31Frequently asked questions............................................................................................................................................31Error messages ...................................................... ........................................................ ................................................ 31

Part five: Glossary of key terms___________________________________________ 34


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VLTSeries 5000 Positioning Controller

2 MG.50.P1.02 - VLT is a registered Danfoss trademark

VLT 5000 Series Positioning Controller

Manual

Software Version 1.0X

Software Version number: See Parameter 779.


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Safety Note

When connected to the mains, the

frequency converter is at a voltage dangerous tolife. Incorrect installation of the motor or of the

VLT frequency converter may result in

equipment failure, serious personal injury or

even fatal injuries.

Therefore, always follow the instructions in this

manual as well as the national and international

regulations and safety provisions currently in

force.

These provisions are for your safety

1. During repairs, the power supply to the VLT

frequency converter must be switched off.Ensure that the mains supply has been cut off

and that the necessary time has elapsed

before removing the motor plug and the mains

plug.

2. The [STOP/RESET] button on the control

panel of the VLT frequency converter does not

cut off the electricity mains. Therefore, it must

not be used as an emergency switch or a

repairs switch.

3. Care must be taken to ensure that the

equipment is properly earthed according to

local and national regulations, that the user isprotected against conducted voltage and that

the motor is fused against overload.

4. The current leakage to earth is higher than

3.5 mA.

5. The factory setting does not include overload

protection for the motor. If this function is

desired, set Parameter 128 to data value ETR

shut-down or data value ETR warning.

Note: This function is initialised at 1.16 x

nominal motor current and nominal motor

frequency (Page 101 in operating instructions).

6. The motor and mains supply plugs

must not be removed when the VLT frequency

converter is connected to the mains supply.

Ensure that the mains supply has been cut off andthat the necessary time has elapsed before

removing the motor plug and the mains plug.

7. There is no galvanic safety isolation (PELV)

when the Suppress radio noise switch is set to

OFF. As a result, all control inputs and outputs

can no longer be regarded as low voltage

terminals .

8. Please note that the VLT frequency converter

has more voltage inputs than L1, L2 and L3 if

intermediate circuit coupling (interconnection of

the DC intermediate circuit) and external 24 V DC

are installed. Check that all voltage inputs havebeen switched off and that the necessary time has

elapsed before beginning repair work.

Warning: unintentional start-up

9. The motor can be stopped by a digital

command, a bus command, a reference value or

"Local Stop" while the VLT frequency converter is

still under mains voltage. If, however, according to

the provisions for personal safety, unintentional

start-up of the motor is not permitted, the Stop

functions described above are not sufficient.10. While the VLT frequency converter is being

programmed, the motor may start without prior

warning. Therefore, always press the [STOP/

RESET] button before changing data values.

11. If the motor is switched off, it can automatically

start up again if the electronics of the VLT

frequency converter is defective or if a short-term

overload or an error in the supply voltage and/or at

the motor connection is removed.

175ZA439.10

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: wait at least 4 minutes

Using VLT 5008-5250: wait at least 15 minutes


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Introduction

The Positioning Controller is a special application option for the VLT 5000 Series. It is based onthe SyncPos option card.

The application option consists of two parts

Positioning Controller part

Test Run part

The positioning controller can be used in any application where a drive is used for positioning.The controller holds information of up to 32 fixed positions and an endless number of relativepositions can be achieved.Positions are defined either relative to a fixed home position (absolute positions) or relative to

other positions, or relative to a movable touch probe sensor.

This manual consists of the following parts:

Part one: Description of the electrical interfacePart two: Description of the available parametersPart three: An application example!Part four: TroubleshootingPart five: Glossary of key terms.


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Part one: Description of the electrical interface

Termi- Designation Descriptionnal

12 24V DC 24V power supply for switches etc. maximum load 200mA

13 24V DC

16 Reference index Bit 0(LSB)

Reference position index number bit 0 (least significant bit).

17 Reference index Bit 1 Reference position index number bit 1.



20 GND Ground for 24V is normally bridged with Terminal 39, butcan be set to OFFby means of Switch SW 4 on thecontrol card.

27 Reset / ENABLE(error clear)

Errors are cleared on the rising edge (must be 0min. 300ms. to guarantee edge detection).

To enable operation, this input must be maintained at 1.

29 Reference index Bit 4(MSB)

Reference position index number bit 4 (most significant bit).

32 Go to HOME position While this input is high the drive executes the homingsequence. While this input is high no position or jogoperations are carried out. Any homing sequence isinterrupted by a low state on this input.

33 LATCH newreference positionindex number

Active on the rising edge (must be 0min. 300 ms. toguarantee edge detection):

Latches reference position index number specified onterminal 16, 17, 18, 19, 29 into memory. Digital outputMK3C 48 is changed to mirror the new reference indexspecified.

01 COM; 240V AC/2A Common terminal for Relay 01-03.

02 NO

03 Connect to electromechanical brake

Relay 01-03 is open (deactivated) during power off, andstart-up of the VLT 5000. It is always open after a QuickStopprocedure or in connection with an error situation.Relay 01-03 only closes in connection with motionprocedures or if specified in P715.


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04 COM; 50V AC/1A; 75VDC/1A

Common terminal for Relay 04-05.

05 Brake activated Relay 04-05 is closed to indicate a closed (activated)electro mechanical brake. It is open to indicate an open(deactivated) electromechanical brake.

39 GND Ground for analogue inputs/outputs is normally bridgedwith Terminal 20, but can be set to OFFby means ofSwitch SW 4 on the control card.

42 Touch probe positionlocked in

A high (1) signal is present when a rising edge has beendetected on digital input 1 (terminal MK3A) and a target inposition is fixed in memory.

A low signal is present when no target position has yetbeen determined.

45 Watchdog output This output toggles continually as long as the program is

active.

50 10V DC 17mA Power supply for manual JOG inputs (terminal 53 and 54)

53 10V-In

Manual jog positive

When high (above 5V), the drive will travel with joggingspeed (P723) and ramp (P724) in the positive direction.When low (below 5V), the drive will ramp down and stop ifno other motion procedure is activated.

54 10V-In

Manual jog negative

When high (above 5V), the drive will travel with joggingspeed (P723) and ramp (P724) in the negative direction.When low (below 5V), the drive will ramp down and stop ifno other motion procedure is activated.

60 20mA-In Not used

Standard RS485-Interface

61 Ground RS485 Not used

68 RS485-P Not used

69 RS485-N Not used


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Option card MK3A

1 Touch probe switch input Interrupt triggered on the rising edge. If this signal goeshigh when no touch probe target position is currentlylocked (terminal 42 low), a new touch probe target

position is calculated and locked in memory.

2 Positive HW limit switchinput

Interrupt triggered on the falling edge. Activation triggersa HW limit error and the drives are stopped according toP725.

3 Negative HW limit switchinput

Interrupt triggered on the falling edge. Activation triggersa HW limit error and the drives are stopped according toP725.

4 HOME reference switchinput

Active high. Marks the HOME position in the application.

5 Go to the referencedtarget position

Active high. Upon activation the drive goes to thespecified target positioning. A low signal interrupts anypositioning sequence.

6 Reset home flag Active high. This input clears the home flag. This allowsthe user to perform a second homing sequence.

7 Reset touch probeposition

Active high. This input clears the touch probe positionflag. The reset is necessary to carry out a touch probepositioning command to a new target position.

8 Quick stop Active low. This input activates the Quick Stop function.

The drive is stopped according to the setting of P725.After that the electromechanical brake is alwaysactivated when the Quick stopinput is activatedregardless of the P715 setting.

9 24V DC

10 COM


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Option card MK3C

1 Homing completed Active high. This output is always high if an absoluteencoder is specified in P713

2 Referenced positionreached

Active high. This output is set when the target position isreached according to the setting of P746.

3 Error occurred Active high. This output is set every time an error occurs. Itis cleared every time a successful error clear is carried out.This output will remain high as long as the Power recoveryfunction is selected (P736) and active.

4 Reference index bit 0 Active high. Mirror of the currently locked-in referenceindex bit 0.





9 24V DC

10 COM

Option card MK3D (position feedback)

1 5V DC Encoder supply

2 COM Encoder supply

3 A1 A-track

4 /A1 A-track inverted

5 B1 B-track

6 /B1 B-track inverted

7 Z1 Zero-track

8 /Z1 Zero-track inverted


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Hardware

Input and output terminals

There are two interfaces for the SyncPos option

36 Terminals on the option card

24 Terminals on the VLT control card

VLT control card terminals

The control card terminals can be used forsynchronisation functions, as long as thefollowing parameter settings are used:

Digital Inputs 16, 17, 18, 19. 27, 29, 32 and 33If Parameters 300-303 and 305-307 are set to

"no function" (factory setting), the VLT-controlcard inputs can be ignored and can be used asinputs for the option card.Parameter 304 cannot be set to "no function".Hence, Input 27 always has a stop function.

Analogue Inputs 53, 54 and 60If you set Parameters 308, 311 and 314 to "nofunction", the VLT control card inputs are ignoredand they can then be used as option card inputs.

Digital/analogue Outputs 42 and 45Outputs 42 and 45 can be controlled by the

application program if Parameters 319 and 321are set to the following Settings:OPTION DIGITAL Digital output

OPTION D - 20 mA Analogue output (factory setting)OPTION 4 - 20 mA analogue outputOPTION 0 - 32000P pulse output

Relay Outputs 01 and 04:The relay outputs can be controlled by theapplication program if Parameters 323 and 326 areset to the following factory setting:

Control word bit 11/12

Technical data

You will find the technical data relating to the control

card terminals in the VLT 5000 Product Manual.

Option card terminals

One encoder interface for position feedback.

There are 8 digital inputs, 8 digital outputs andterminals for 5V and 24V power supply. Thefunctions and technical data of the terminals aredescribed below.

Description of terminalsThere are 4 terminal blocks, 2 ten-pole and 2

eight-pole.(See diagram below)

MK3A Digital Inputs MK3B Not used

I1 I2 I3 I4 I5 I6 I7 I8 24V COM 5V COM A1 /A1 B1 /B1 Z1 /Z1

MK3C Digital Outputs MK3D Feedback

O1 O2 O3 O4 O5 O6 O7 O8 24V COM 5V COM A1 /A1 B1 /B1 Z1 /Z1


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Digital inputs

MK3A is a ten-pole terminal block with

8 digital inputs (I1 - I8) and 2 terminals for 24V

power supply (see Page , Power supply

voltages).

The digital inputs are used in the application

program. They are, therefore, described in detailin later chapters.

Digital outputs

MK3C is a ten-pole terminal block with 8 digital

outputs and 2 terminals for 24V power supply

(see Page 9, Power supply voltages). The digital

outputs are controlled by means of the application

program. They are, therefore, described in detail

in later chapters.

Encoder interface

MK3D is an eight-pole terminal block with 6

terminals for the encoder signals and 2 terminals

with 5V power supply (see Page 9, Power supply

voltages).

The encoder interface is used for feedback for the

positioning controller.

Figure 1 shows the function of each terminal in the

three possible operating modes.

NOTE!

The following overview shows the function of each

terminal in the two possible operating modes.

Terminal A2 A2/ B2 B2/ Z2 Z2/

Incremental Input A in A in B in B in Z in Z in

Absolute Input Clk out Clk out Data in Data in Not used Not used

Figure 1: Encoder interface

Figure 2: Encoder connection for positioning applications


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MG.50.P1.02 - VLT is a registered Danfoss trademark

11

Power supply voltagesPower is supplied to the option card via the internal

24V DC power supply of the VLT 5000. However,

as the power is available limited, it may be

necessary to use an external 24V DC powersupply.

The 24V DC power supply of the VLT 5000 can

supply a total of 420 mA, including the load on the

control card (Terminal 12, 13 and Outputs 42 and

45).

The 5V output of the option card is produced by the

24V power supply. The highest output on the 5V

side is 5 V x 280 mA = 1.4 W. This corresponds to

approx. 80 mA on the 24V side.

When using an external 24V DC source, theinternal 24V power supply must be switched off by

the control card, by opening switches SW 1.1 and

1.5.

Each digital input on the option card takes 8 mA .

Depending on the load, each digital output on the

option card can supply up to 0.7 A (with external

24V power supply).

The load of the 24V power supply (internal or

external) can be calculated as follows:

8 mA x number of digital inputs

+

load of the digital outputs

(Mk3C, 01 - 08)

+

load of the 5V power supply

(Mk3BID, 5 V/com)

+

load of the control card

(24 V power supply voltage, Terminals 12/13

and outputs, Terminals 42/45)

Figure 3: Power supply to the inputs and outputs


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Layout of the option card

The illustration shows the position of the connections and the dip switches.

Figure 4: Layout of the option card

Dip switch SW 1

Labelled OFF ON

1.1 Option card must be powered by an

external 24V power supply voltage

Option card is powered by the control

card (24 V).

1.2 Not used Not used



1.5 Option card must be powered by an

external power supply voltage

(common).

Option card is powered by the control

card (common).


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Technical Data

Terminals:

Type ............................................................................................................ Plug with screw connectors

Max. cable size ........................................................................................................ 1.3 mm

2

(AWG 16)

Digital inputs

Number of inputs used by program ........................................................................................................ 8

Terminal designations .................................................................................................................... I1 - I8

Voltage level ........................................................................................ 0 - 24 V DC (PNP positive logic)

Voltage threshold logic "0" ................................................................................................................ 6 V

Voltage threshold logic "1" ............................................................................................................. 13.5V

Max. voltage ................................................................................................................................... 28 V

Input impedance .............................................................................................................................. 3 k

Min. signal length (for ON INT) ........................................................................................................ 1 ms

Galvanic isolation: All digital inputs are galvanically isolated by means of Opto couplers,

but have the same common lead as the digital outputs.

Digital outputs

Number of inputs used by the application program .............................................................................. 8

Terminal designations ................................................................................................................. O1 - O8

Voltage level ........................................................................................................................ 0 - 24 V DC

Max. load ............................................................................ 0.7 A (with external electricity power supply)

Updating interval ............................................................................................................................. 1 ms

Galvanic isolation: All digital outputs are galvanically isolated by means of Opto couplers,

but have the same common lead as the digital inputs.

External 24V DC power supply(see VLT 5000 Manual, Page 10)

Encoder input:

Terminal designations ..................................................................................... A2, A2/, B2, B2/, Z2, Z2/

lncremental:

Signal level ...................................................................................................................... 5 V differential

Signal type ............................................................................................................... Line driver, RS 422

Input impedance ........................................................................................................................... 670

Max. frequency ...................................................................................... 220 kHz (at 50% working cycle)

Phase displacement between A and B ..................................................................................... 9030

Absolute:

Signal level ....................................................................................................................... 5 V differential

Signal type ........................................................................................................................................ SSI

Protocol .................................................................................................................................. Gray code

Data length .................................................................................................................................... 25 bit

Parity ............................................................................................................................................. none

Switch frequency ....................................................................................................................... 250 kHz

Max. positions per revolution ........................................................................................................... 8192

Max. number of revolutions ............................................................................................................. 4096


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Part two: Description of the available parameters

Special LCP functions

Multiple parameters display: To have multiple read-only parameters displayed at once on the LCP

simply press the DISPLAY/STATUSbutton after start-up. This will prompt the top line of the LCPto display up to three read-only parameters that can be specified in P010, P011, and P012. The

default settings will bring up the following display:

Figure text: To the left: P798 the error status. In the middle: P799 - the maximum velocity. To

the right: P795the actual position.

Holding down the DISPLAY/STATUSbutton will display which parameters are shown in the top

line of the display.

The TEACH-IN function: Pressing the JOG and FWD./REV. buttons at the same time willcause the target position P739 to be updated with the actual position. This provides an easy way

of programming several positions. Simply use the jog inputs (54, 53) to drive the application to the

desired position, then press the JOGand FWD./REV.buttons to store that position in memory.

Description of parameters

Generally, the parameters apply in the same way in both the TEST-RUN MODE and the

POSITIONING MODE. However, a number of parameters are only accessible in the TEST-RUN

MODE. The reason for this is that these values need only to be set once. Furthermore, changing

these values on-linemight pose a safety risk and are therefore limited to the password protected

TEST-RUN MODE.


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The following list applies for TEST-RUN MODE

No. Parameter Defaultvalue

Range Description

701 Operating mode

TEST-RUN MODE

POSITIONING

MODE

1 1 (TEST-RUN) /2 (POSITIONING)

After the first start-up this parameter is set to 1 andthe parameter text should be TEST-RUN MODEto

reflect the current operating mode.When all parameters have been set up for thespecific application the user must change the settingto 2 and restart the VLT. The parameter text afterstart-up should now be POSITIONING MODE.

To protect the application from unauthorizedchanges to central parameters it is only possible tochange mode from POSITIONING MODEtoTEST-RUN MODEif the correct password isentered in parameter 778.

702 Proportional gain

PROP. GAIN

30 1 / 65.000 The proportional gain is the factor that is multipliedwith the PID tracking error to produce theproportional part of the output frequency.

The higher the setting of this parameter theharderis the resulting control.NB: Too high a setting of this parameter will

cause the controller to become unstable.703 Derivative gain

DER. GAIN

0 0 / 65.000 The derivative gain is the factor that is multiplied withthe change in the PID tracking error to produce thederivative part of the output frequency.

The higher the setting of this parameter theharderis the resulting control.

The derivative gain has best effect if the encoderis mounted directly on the motor and an encoder withgood resolution (4096 pulses/rev) is used.

NB: Too high a setting of this parameter will

cause the controller to become unstable.704 Integral gain

INT. GAIN

0 0 / 65.000 The integral gain is the factor that is multiplied withthe integrated PID tracking error to produce theintegral part of the output frequency. The mainfunction of the integral part is to provide zero steady-state tracking error.

The higher the setting, the faster the applicationwill reach a zero steady-state tracking error. Thedynamic tracking error however increases withincreasing setting of this parameter.

NB: Too high a setting of this parameter willcause the controller to become unstable.

705 Limit integral part

INT. LIMIT

1.000 0 / 65.000 Here it is possible to clamp the integral part of the

PID output. A setting of 1000 corresponds to 100%of the maximum allowed reference specified inparameter 205.

706 Limit PID output

PID LIMIT

1.000 0 / 1.000 Here it is possible to clamp the total output of the PIDcontroller. A setting of 1000 corresponds to 100% ofthe maximum allowed reference specified inparameter 205.

707 Feed-forwardvelocity gain

F-FWD. VEL.

GAIN

0 0 / 65.000 The velocity feed-forward gain is the factor that ismultiplied with the set-point (desired trajectory)velocity to produce the feed-forward part of theoutput frequency. The function of the feed-forwardpart is to provide a fast (and fairly accurate) startingpoint for the calculation of the output frequency.

NB: To get the fastest and most stable controllerresponse this parameter should be set optimally. For


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Range Description

this purpose parameter 710 gives access to afunction that automatically calculates the optimalsetting of this parameter.

708 Feed-forwardacceleration gain

F-FWD. ACC.

GAIN

0 0 / 65.000 The acceleration feed-forward gain is the factor thatis multiplied with the set-point acceleration toproduce the feed-forward part of the outputfrequency.

709 PID sampleinterval

SAMPLE

INTERVAL

1 ms. 1 / 100 ms. The sampling frequency of the controller can beadjusted in this parameter. Normally, the fastestpossible setting (1 ms) would be preferable, but incases with resolution of the feedback signal it is agood idea to set this parameter at a slightly highervalue.

710 FFVEL auto-calculation

AUTOCALC.

FFVEL

0 0 (disabled) /1 (enabled)

Setting this parameter to 1 will prompt the program tocalculate the optimal setting of parameter 707. Thefollowing parameters influence the result and mustbe set correctly beforehand:

- P104 nominal motor frequency- P106 nominal motor speed- P205 maximum reference frequency- P709 PID sample interval- P713 encoder type- P714 encoder resolution- P721 motor/encoder gear ratio numerator- P722 motor/encoder gear ratio denominator

NB: If you change any one of these parameters youshould prompt a recalculation, since the optimumvalue of P707 will have changed.

711 VLT local jogJOG LOCAL

0 0 (closed loop) /1 (open loop)

This function will be available in future softwareversions.

712 Positive direction

POS.

DIRECTION

1 -1 (left rotation) /1 (right rotation)

Here you specify which encoder direction isconsidered positive. If you change this setting thecurrent actual position (P795) will also change sign.Changing the positive direction is basically

equivalent to switching two motor phases andswitching A and B encoder signal lines at the sametime.

713 Encoder type

ENCODER TYPE

0 0 (incremental) /1 (absolute w/ shortcables) /2 (absolute w/ long

cables )

It is possible to use two types of encoder. If youselect 1or 2(absolute encoder) the home flag isinstantly set high, thus no homing is requiredpreceding a positioning command.

NB: When switching from a setting of 1or 2to asetting of 0 (relative encoder), the home flag isautomatically cleared. A homing procedureafterwards is necessary before any positioningcommands can be executed.

714 Encoderresolution

ENCODER RES.

4.096 ps. 1 / 100.000 pulses The encoder resolution must be entered in pulsesper revolution (not quad-counts per revolution).

715 Automatic brakecontrol

AUTO. BRAKE

CTRL


When the automatic brake control function isenabled, the electromechanical brake isautomatically activated every time the application has

been at standstill for a time period specified inparameter 718. This is especially useful in hoistapplications where the motor could overheat if it has


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Range Description

to deliver full torque at standstill for a prolongedperiod of time.

When the automatic brake control function isdisabled, the drive controls the application also atstandstill.

716 Coast delay

COAST DELAY

200 ms. 0 / 1.000 ms. Used in conjunction with the automatic brake controlfunction. The coast delay is the delay after activatingthe electromechanical brake before disabling thecontroller and coasting the drive.

Useful in hoisting applications where the loadwould otherwise have a tendency to drop a little aftereach stop because the activation of the brake isslower than the deactivation of the drive.

717 Brake delay

BRAKE DELAY

200 ms. 0 / 1.000 ms. Used in conjunction with the automatic brake controlfunction. The brake delay is the delay after activatingthe control and magnetizing the motor before thebrake is deactivated.

Useful in applications with (typically large) motorsthat take a longer time to be fully magnetized thanthe time it takes for the electro mechanical brake todeactivate.

718 Hold delay

HOLD DELAY

0 s. 0 / 10.000 s. Used in conjunction with the automatic brake controlfunction. The hold delay is a waiting period in whichthe brake is not activated even though the applicationis at standstill.

Useful in applications where a sequence of fastpositioning commands is followed by longer standstillperiods.

719 Quick ramp time

QUICK RAMP

TIME

5.000 ms. 50 / 65.535 ms. The quick ramp time is defined as the time to rampdown from the maximum velocity to standstill.

The quick ramp time is used when the quick stopfunction is activated or an error has occurred.720 Ramp type

RAMP TYPE

0 0 (trapezoidal) /1 (sinusoidal)

Select trapeze shaped ramps to get the optimalacceleration.

Select sinusoidal ramps to get a smoother rampat the beginning and end of the ramp.

721 Motor/encodergear nom.

MOT/ENC GEAR

NUM

1 1 / 1000 If the encoder is mounted on a gear where 5revolutions of the motor correspond to 2 revolutionsof the encoder, this P721 should be set to 5(thenumber of motor revolutions) and P722 should beset to 2(the number of encoder revolutions).

If the encoder is mounted directly on the motorshaft this parameter setting should remain at 1.

722 Motor/encodergear den.

MOT/ENC GEAR

DEN

1 1 / 1000 See the description of P721.

If the encoder is mounted directly on the motorshaft this parameter setting should remain at 1.

723 Maximum jogvelocity

MAX.JOG

VELOCITY

100ERPM

1 / 999.999 ERPM The maximum speed allowed while jogging theapplication is specified in terms of EncoderRevolutions Per Minute (ERPM).

NB: This setting must never exceed a value that isapprox. 5% lower than the value calculated in P799.

724 Jog ramp time

JOG RAMP TIME

5.000 ms. 50 / 100.000 ms. This parameter specifies both the ramp-up time aswell as the ramp-down time used during jogging.

The ramp time is defined as the time inmilliseconds it would take to ramp from standstill tothe maximum allowed velocity (P799).


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Range Description

3: Like 1but without reversing before leavingthe reference switch. Rather the movement is slowlycontinued in the same direction out of the switch.

732 User unitnominator

USER UNIT

NOM.

1.000 1 / 100.000 P732 and P733 together define the ratio betweenUser Units (UU) and quad-counts (QC).

Lets illustrate this parameter with the followingexample: By measurement it has been determinedthat 1000 mm. of travel correspond to 16345 QC(quad-counts).

Now instead of defining the target positions inQC but rather in mm, the setting of P732 must be16345, and the setting of P733 must be 1000.

NB: The target positions stored in memory is definedin UU, so changing the P732/P733 ratio mightrequire that up to 32 position must be reprogrammedto achieve the same result as before the change.

733 User unitdenominator

USER UNIT

DEN.

1.000 1 / 100.000 P732 and P733 together define the ratio betweenUser Units (UU) and quad-counts (QC).

The setting of this parameter is illustrated in thedescription of P732.

NB: The target positions stored in memory is definedin UU, so changing the P732/P733 ratio mightrequire that up to 32 position must be reprogrammedto achieve the same result as before the change.

734 Block reversal

BLOCK

DIRECTION

0 0 (no blocking) /1 (block reverse) /2 (block forward)

By selecting 1it is defined as an error situation(Reverse operation prohibited- P798=12) if thedrive is moving in reverse direction.

By selecting 2it is defined as an error situation(Forward operation prohibited- P798=13) if thedrive is moving in forward direction.

Selecting 0disables the function.735 Brake wear limit

BRAKE WEAR

LIMIT

0 0 (disabled) /2.000.000.000 UU.

Setting a value higher than 0(disabled) the drivedefines an error situation (Brake wear limitexceeded- P798=7) if the drive moves more thanthe number of UU specified in this parameter whilethe electronic brake is activated.

736 Power-recovery

POWER

RECOVERY


When the power recovery function is disabled (0), itis not possible to drive the application by any means(neither jogging nor positioning) as long as theapplication is outside the HW or SW limits. The onlyway to recover from this situation is to remove the

application by hand.When the power recovery function is activated(1) however it is possible to make a partial reset of the limit error (P798=2/3/4/5) whereby it willbe possible to use the jogging function to drive theapplication out of the HW or SW limit area. It is notpossible to drive the application otherwise by meansof homing, positioning or jogging (in the wrongdirection), as long as the application is still within theHW or SW limit area. The error occurredoutput(MK3C 2) will remain high to indicate that theserestrictions are in effect. As soon as the application ismoved outside the HW or SW limit area the error is

automatically cleared and the error occurredsignalgoes low to indicate that normal operation is nowrestored.


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Range Description

737 Link LCP input toindex

LINK INDEX-

INPUT


When activating this function (1) P738 will beautomatically updated with the last position referencenumber that has been loaded into memory. Thisenables to operator to see what position reference iscurrently given by the PLC system.

The function is deactivated when set to 0. Thisis necessary when programming a position numberdifferent from the one loaded into the PLC memory.

738 Index number

INDEX NUMBER

0 0 / 31 Here it is possible to specify which position data thatshould be displayed in P739-743.

Whenever this number is changed, the currentvalues of P739-P743 are stored in memory under thepreviously specified index number. After that, thevalue of P739-743 is updated with the data stored inmemory relevant to the newly specified indexnumber.

739 Index targetposition

TARGET

POSITION

0 -2.000.000.000 UU. /2.000.000.000 UU.

The meaning of this parameter depends on theposition type specified in P743.If P743=0, the value of this parameter refers to anabsolute position (relative to the fixed HOMEposition).If P743=1and the last position was obtainedthrough jogging, the value of this parameter is aposition relative to that position. If the last positionwas reached as a result of a positioning command,then the value of this parameter specifies a positionrelative to the last target position (whether it wasreached or not).

If P743=2the application will move in thepositive direction until a touch probe position isdefined. If a touch probe position is already defined

the application will move directly to that position.A touch probe position is defined as the position atwhich the touch probe switchinput (MK3A 1) goeshigh.A touch probe position is cleared by a high signal onthe reset touch probe positioninput (MK3A 7) input.The output Touch probe position locked(VLT5000Terminal 42) is high if a touch probe position isdefined.If P743=3the application will move in the negativedirection until a touch probe position is defined. If atouch probe position is already defined theapplication will move directly to that position.

NB: This parameter is automatically updateddepending on P738.


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Range Description

740 Index ramp uptime

RAMP UP TIME

5.000 50 / 100.000 ms. This setting is relevant during positioning with thecurrent trajectory index.The index ramp up time is defined as the time in

milliseconds it would take to ramp from standstill tothe maximum allowed velocity (P799).


741 Index ramp downtime

RAMP DOWN

TIME

5.000 50 / 100.000 ms. This setting is relevant during positioning with thecurrent trajectory index.The index ramp down time is defined as the time in

milliseconds it would take to ramp from themaximum allowed velocity (P799) to standstill.


742 Index maximumvelocity

MAX. VELOCITY

100ERPM

1 / 999.999 ERPM This setting is relevant during positioning with thecurrent trajectory index.

NB: This parameter is automatically updateddepending on P738.This setting should never exceed a value that isapprox. 5% lower than the value calculated in P799.

743 Index trajectorytype

TRAJECTORY

TYPE

0 0 (absolute) /1 (relative) /2 (touch probe pos) /3 (touch probe neg)

The function of this parameter setting is describedunder P739.


744 Positive softwarelimitPOS. SW.

LIMIT

100.000.000

-2.000.000.000 UU. /2.000.000.000 UU.

If the actual position (P795) exceeds the valuespecified in this parameter an error situation is

defined (P798 = 4) and handled according to thesetting of the Error behaviourparameter (P725).745 Negative

software limitNEG. SW.

LIMIT

-100.000.000

-2.000.000.000 UU. /2.000.000.000 UU.

If the actual position (P795) goes below the valuespecified in this parameter an error situation isdefined (P798 = 5) and handled according to thesetting of the Error behaviourparameter (P725).

746 Target positionwindow

TARGET WINDOW

0 0 UU (< P726) /2.000.000.000 UU.

During a positioning sequence the Referencedposition reachedoutput (MK3C 2) is set accordingto this parameter.If the setting of this parameter is 0then theReferenced position reachedoutput goes highimmediately when the internal PID target position isequal to the requested target position.

If the setting of this parameter is larger than 0i.e.200then the Referenced position reachedoutputgoes high when the actual position (P795) is within+/- 200 UU of the requested target position.

776 Factory reset

FACTORY RESET


By setting this parameter to 1it is possible to resetall parameter values to default. This also resets alltrajectory data (P739-P743).The parameter automatically resets to 0when thereset is successfully carried out.

NB: The internal procedure of writing data to theEEPROM takes 2-3 seconds in which time no errormonitoring is possible. Therefore, this function is only

carried out when the application is in a safe state(the electromechanical brake is activated). Theelectromechanical brake is always activated when


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Range Description

the Quick stopinput (MK3A 8) is activated.777 Parameter save

STORE DATA

0 0 (no action) /1 (SAVE EEPROM)

Parameter and trajectory data is not automaticallystored in EEPROM and will thus not automatically beavailable after power-down and power-up.

To permanently store changes made toparameter values and/or trajectory data parameterP777 must be set to 1. This parameterautomatically resets to 0when the data issuccessfully stored.

NB: The internal procedure of writing data to theEEPROM takes 2-3 seconds in which time no errormonitoring is possible. Therefore, this function is onlycarried out when the application is in a safe state(the electromechanical brake is activated). Theelectromechanical brake is always activated whenthe Quick stopinput (MK3A 8) is activated.

778 Password

PASSWORD

1.234 0 / 999.999.999 To protect the application from unauthorizedchanges to central parameters during normaloperation (P701=POSITIONING MODE) the correctpassword must be specified in P778.In test-run mode (P701=TEST-RUN MODE) it ispossible to specify what value is considered correctin P778.

779 Software versionVERSION 1.03

0 0 / 0 The text in this parameter shows the current versionnumber of the Standard Positioning Controllerprogram.

795 Actual positionACTUAL

POSITION

0 -2.000.000.000 UU /2.000.000.000 UU

READ-ONLY PARAMETER:This parameter displays the latest position obtainedfrom the feedback encoder.

796 Actual inputs

ACTUAL INPUTS

00000000 00.00.00.00 /11.11.11.11 READ-ONLY PARAMETER:This parameter displays the last read status of thedigital input on the option card (MK3A). The status ofthe digital parameters on the VLT5000 control card isaccessible via P528

797 PID trackingerrorPID TRACK

ERROR

0 -2.000.000.000 UU /2.000.000.000 UU

READ-ONLY PARAMETER:The current PID tracking error is displayed in thisparameter in user units.

798 Error status

ERROR STATUS

0 0 (OK) /1 (Homing needed) /2 (Pos. HW limit) /3 (Neg. HW limit ) /4 (Pos. SW limit) /5 (Neg. SW limit) /6 (VLT not running) /7 (Brake wear limit) /8 (Quick stop) /9 (PID error too big) /10 (Option error) /11 (VLT Exception) /12 (Rev. operation) /13 (Fwd. operation)

READ-ONLY PARAMETER:The current error code is displayed in this parameter.

799 Maximumallowed velocity

MAX. VELOCITY

1.500ERPM

1 / 999.999 ERPM READ-ONLY PARAMETER:The maximum velocity allowed is calculated on thebasis of P104, P106, P205, P721, P722 and theresult is presented in this parameter. To increase thisvalue one or more of the above mentionedparameters must be changed (usually just P205).


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Note:Last-minute parameter changes is not carried from TEST-RUN MODEto POSITIONING

MODEunless the STORE DATAfunction in P777 is activated.

The following list applies for POSITIONING MODE


Range Description

701 Operating mode

TEST-RUN MODE

POSITIONING

MODE

2 1 (TEST-RUN) /2 (POSITIONING)

After the first start-up this parameter is set to 1 andthe parameter text should be TEST-RUN MODEtoreflect the current operating mode.

When all parameters have been set up for thespecific application the user must change the settingto 2 and restart the VLT. The parameter text afterstart-up should now be POSITIONING MODE.

To protect the application from unauthorizedchanges to central parameters, it is only possible tochange mode from POSITIONING MODEtoTEST-RUN MODEif the correct password is

entered in parameter 778.702 Error reset

RESET ERROR

0 0 (no reset) /1 (reset error)

By setting this parameter to 1it is possible to clearthe error flag (provided that the reason for the error isnot still present).

The parameter automatically resets to 0whenthe error is successfully cleared.

703 Hold delay

HOLD DELAY

0 s. 0 / 10.000 s. Used in conjunction with the automatic brake controlfunction. The hold delay is a waiting period in whichthe brake is not activated even though the applicationis at standstill.

Useful in applications where a sequence of fastpositioning commands is followed by longer standstillperiods.

704 Index number

INDEX NUMBER

0 0 / 31 Here it is possible to specify the position data to bedisplayed in P705-709.

Whenever this number is changed, the currentvalues of P705-709 is stored in memory under thepreviously specified index number. After that, thevalue of P705-709 is updated with the data stored inmemory relevant to the newly specified indexnumber.

705 Index targetposition

TARGET

POSITION

0 -2.000.000.000 UU. /2.000.000.000 UU.

The meaning of this parameter depends on whatposition type is specified in P704.

If P709=0, the value of this parameter refers toan absolute position (relative to the fixed HOMEposition).

If P709=1and the last position was obtainedthrough jogging, the value of this parameter is aposition relative to that position. If the last positionwas reached as a result of a positioning command,then the value of this parameter specifies a positionrelative to the last target position (whether it wasreached or not).

If P709=2, the application will move in thepositive direction until a touch probe position isdefined. If a touch probe position is already definedthe application will move directly to that position.

A touch probe position is defined as the positionat which the touch probe switchinput (MK3A 1)

goes high.A touch probe position is cleared by a high signal

on the reset touch probe positioninput (MK3A 7)


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Range Description

input.The output Touch probe position locked

(VLT5000 Terminal 42) is high if a touch probeposition is defined.

If P709=3the application will move in thenegative direction until a touch probe position isdefined. If a touch probe position is already definedthe application will move directly to that position.

NB: This parameter is automatically updateddepending on P704, but changes are not used orstored unless the correct password is entered inP778.

706 Index ramp uptime

RAMP UP TIME

5.000 50 / 100.000 ms. This setting is relevant during positioning with thecurrent trajectory index.The index ramp up time is defined as the time in

milliseconds it would take to ramp from standstill tothe maximum allowed velocity (P799).

NB: This parameter is automatically updateddepending on P704, but changes is not used orstored unless the correct password is entered inP778.

707 Index ramp downtime

RAMP DOWN

TIME

5.000 50 / 100.000 ms. This setting is relevant during positioning with thecurrent trajectory index.The index ramp down time is defined as the time in

milliseconds it would take to ramp from themaximum allowed velocity (P799) to standstill.


708 Index maximumvelocity

MAX. VELOCITY

100ERPM

1 / 999.999 ERPM This setting is relevant during positioning with thecurrent trajectory index.


This setting should never exceed a value that isapprox. 5% lower than the value calculated in P799.

709 Index trajectory

typeTRAJECTORY

TYPE

0 0 (absolute) /

1 (relative) /2 (touch probe pos) /3 (touch probe neg)

The function of this parameter setting is described

under P705.


710 Link LCP input toindex

LINK INDEX-

INPUT


When activating this function (1), P704 will beautomatically updated with the last position referencenumber that has been loaded into memory. Thisenables to operator to see what position reference iscurrently given by the PLC system.

The function is deactivated when set to 0. Thisis necessary when you want to program a position

number that is different from the one that the PLChas loaded into memory.777 Parameter save 0 0 (no action) / Parameter and trajectory data are not automatically


25/35




Range Description

STORE DATA1 (SAVE EEPROM) stored in EEPROM and will thus not automatically be

available after power-down and power-up.To permanently store changes made to

parameter values and/or trajectory data parameterP777 must be set to 1. This parameterautomatically resets to 0when the data issuccessfully stored.

NB: The Watchdog output is not toggled while theThe internal procedure of writing data to theEEPROM has a duration of 2-3 seconds in whichtime no error monitoring is possible. Therefore thisfunction is only carried out when the application is ina safe state (the electro-mechanical brake isactivated). The electromechanical brake is alwaysactivated when the Quick stopinput (MK3A 8) isactivated.

778 Password

PASSWORD

1.234 0 / 999.999.999 To protect the application from unauthorizedchanges to central parameters during normaloperation (P701=POSITIONING MODE) the correctpassword must be specified in P778.

In test-run mode (P701=TEST-RUN MODE) it ispossible to specify what value is considered correctin P778.

779 Software versionVERSION 1.03

0 0 / 0 The text in this parameter shows the current versionnumber of the Standard Positioning Controllerprogram.

795 Actual positionACTUAL

POSITION

0 -2.000.000.000 UU /2.000.000.000 UU

READ-ONLY PARAMETER:This parameter displays the latest position obtainedfrom the feedback encoder.

796 Actual inputs

ACTUAL INPUTS

00000000 00.00.00.00 /11.11.11.11 READ-ONLY PARAMETER:This parameter displays the last read status of thedigital input on the option card (MK3A). The status ofthe digital parameters on the VLT 5000 control cardis accessible via P528

797 PID trackingerrorPID TRACK

ERROR

0 -2.000.000.000 UU /2.000.000.000 UU

READ-ONLY PARAMETER:The current PID tracking error is displayed in thisparameter in user units.

798 Error status

ERROR STATUS

0 0 (OK) /1 (Homing needed) /2 (Pos. HW limit) /3 (Neg. HW limit ) /4 (Pos. SW limit) /5 (Neg. SW limit) /6 (VLT not running) /7 (Brake wear limit) /8 (Quick stop) /9 (PID error too big) /10 (Option error) /11 (VLT Exception) /12 (Rev. operation) /13 (Fwd. operation)

READ-ONLY PARAMETER:The current error code is displayed in this parameter.

799 Maximumallowed velocity

MAX. VELOCITY

1.500ERPM

1 / 999.999 ERPM READ-ONLY PARAMETER:The maximum allowed velocity is calculated on thebasis of P104, P106, P205, P721, P722 and theresult is presented in this parameter. To increase thisvalue, one or more of the above mentionedparameters must be changed (usually just P205).


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Part three: An application example!

The drawing below shows a layout of a pallet conveyor system. Loaded pallets are coming from

four different product lines via the pallet inlet conveyors. Each pallet must be transported from one

of the four inlet conveyors to the one of the two outlet conveyors. To do this a movable pallet

conveyor cart is used.

PALLET

INLET #1

PALLET

INLET #2

PALLET

INLET #3

PALLET

INLET #4

PALLET

OUTLET

#1

PALLET

OUTLET

#2

DELIVERY

T R U C K

DELIVERY

T R U C K

PALLET

CART

A typical work process could be; 1) moving the (empty) pallet conveyor cart to pallet inlet no. 1 to

pick up a loaded pallet 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

Basic set-up

First, check the motor connection:

1. Remove all signals to terminals 16-33 and I1-18. Only Input 27, 8, 3 and 2 must be

connected and closed.

2. Select Disable syncposin P700

3. Input the motor name plate data in P102-P106, and activate the Automatic Motor

Adaptationfunction in P107. Wait for the AMA to be completed.

4. Select Localfunction in Parameter 002.VLT 5000 stops (display flashing)

5. Set the frequency for a low positive value, for example +3 Hz in Parameter 003

6. Press the [START] button on the VLT 5000 control panel and then [the [STOP/Reset]

button watching the speed and direction of the motor. If the motor rotates in the wrong

(negative) direction then exchange the motor phases.


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When you have tested the motor speed direction you test the incremental encoder connection as

follows:

7. Remove all signals to terminals 16-33 and I1-18. Only Input 27, 8, 3 and 2 must be

connected and closed

8. Press the [DISPLAY/MENU] button on the VLT 5000 control panel. Now the following

values appear in the upper line of the display: Error status, maximum velocity, actual

position.9. Rotate the slave drive motor shaft manually in the positive direction. Now the display

shows an ascending count of the actual position. If the count is descending, exchange the

feedback encoder track A by B and A/ by B/. If there is no counting in the display then

check the wiring of the encoder.

When you have tested the encoders and the wiring of motor and encoders, continue as follows:

10. Change parameter 002 back to Remote and start the VLT 5000 by pressing the

[START] button on the local control panel (LCP).

11. Select Enable syncposin P700

12. Reset any error by toggling input 27.

Now you come to the test run:13. Make the PID track error visible in the top line of the LCP display by selecting user parm.

97in P010.

14. Drive the application back and forth by closing the contacts on terminal 53 (positive

direction) or terminal 54 (negative direction). Watch the PID track error via the LCP

display during these tests.

Now you can optimise the controller:

15. Optimise the Feed forward velocity P707 by following the procedure described in the

parameter list for P710 parameter (the FFVEL auto-calculation function).

16. 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.

17. Increase the other PID parameters P703 (if needed) by following the same approach.

Read the description concerning these parameters in the parameter list above.

To store the optimised values

18. Change the value of parameter 777 to 1. When the value returns to 0the parameters

have been successfully saved (see the parameter list for a description of how the P777

parameter works).

Parameter settings

Now determine the parameter settings fitting this application. The following list of parameters can

be determined right away:

P701 Default (TEST-RUN mode)

P702 - P711 Determined during optimising of the PID controller

P712 Default

P713 Incremental encoder used (0)

P714 Encoder resolution (4096)

P720 Trapeze ramps is used for fastest response

P721 Default (encoder mounted directly on motor)

P722 Default (encoder mounted directly on motor)

P723 DefaultP724 Default


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P728 Default

P734 Default

P747 Default

P777 Default

P778 0no password protection required

Timing of electromechanical brake (P715-P718)If the application is not equipped with an electromechanical brake, P716-P718 are not very

important. However, it is very important to set P715 to 0to enable the drive also at standstill.

This application is equipped with mechanical brakes to allow it to stop rapidly even if the drive is

somehow prevented from stopping the motor (damaged motor cables, damaged or short circuited

motor, inverter overload and so on).

P716-P718 is provided to time the interaction between the mechanical brake and the drive. A

description of these parameters can be found in the parameter list above. In this application the

default values of P716 and P717 is used (200 ms) but the P718 setting is changed to 30 seconds

to minimize wear of the brake.

Setting P732 and P733

Distances are measured in quad-counts (QC) but defined in millimetres. Therefore, it is necessaryto measure how many QC correspond to how many millimetres. To do this the cart is first moved

as far to the left as possible by activating the Manual jog negative input (terminal 54). The

position is then marked on the application and the corresponding value of P795 is noted. Then the

cart is moved as far to the right as possible by activating the Manual jog positiveinput (terminal

53). The travelled distance in mm is now measured from the position of the mark to the position of

the cart. Likewise the distance in QC is calculated by subtracting the current value of P795 from

the noted value of P795.

In this example it is measured that 871380 QC correspond to 4000 mm so P732 is set to 87138

and P733 is set to 400. Positions will now be displayed and entered in millimetres.

Settings for the homing procedure (P728-P731)

The HOME ramp setting (P729) is reduced to the lowest allowable setting to get the fastest

HOMING procedure possible. The HOME velocity setting, however, should never be very high to

enable a precise result of the homing procedure, and because the exact position is not known

during homing, it is not advisable to go with a very high velocity for safety reasons. The default

setting of P730 at 100 encoder revolutions per minute (approx 1/15thof max velocity) is therefore

maintained in this application. The default homing type defined in P731 is also maintained.

The resulting homing sequence is illustrated below.

>

Programming positions (P737-P743)

The program positions the conveyor cart in front of the various inlets and outlets. Differentacceleration and deceleration is allowed between the different positions. An empty pallet cart can

be accelerated as fast as possible while this is not allowed when transporting a fully loaded pallet.

Different settings for each position are available because every position is programmed with its

own setting for ramp and velocity. The different positions are defined below.


29/35



PALLET

CART

NegativeHWl

imitswitch

PositiveHWli

mitswitch

Position1(palletizerinlet#1)




Position2(palletizeroutlet#1)

Position5(palletizeroutlet#2)

Homereferenc

eswitch

0 mm

0 QC

2000 mm

435690 QC

4000 mm

871380 QC

NegativeSWl

imitposition

PositiveSWlim

itposition

The different positions are programmed using P738-P743 as interface. First, the application must

be homed to get at fixed reference for measuring (and entering) the positions. When this is done

the first position is programmed;

a) P738 is set to 1either directly or by using the digital input and the linkfunctionality of P737.

b) The position is programmed in P739 either directly on the LCP or by using the TEACH-IN

functionality (simply use the jog inputs (54, 53) to drive the application to the desired position,

then press the JOGand FWD./REV.buttons to store that position in memory).

c) The individual ramp and velocity settings for this position is specified in P740-P742.

d) For trajectory type absoluteis selected in P743.

The following table shows the complete list of settings for each of the 6 target positions.

P738 P739 P740 P741 P742 P743

1 400 900 900 1200 0

2 800 2000 2000 1200 0

3 1500 900 900 1200 0

4 2200 900 900 1200 0

5 2600 2000 2000 1200 0

6 3300 900 900 1200 0

Software limits (P744-P745)

The software limits are placed just in front of the hardware limit switches with a distance to the

hardware limit switches that allows for the cart to be stopped with the shortest allowable ramp

(P719) before the HW limit switch is activated.

The settings are: P744 = 3700and P745 = -200.

Setting P719 and P725

If the pallet cart is transporting a loaded pallet and travelling at its top speed, it is not allowed to

simply activate the electromechanical brake (all the products on the pallet would be scattered

across to floor because of the deceleration). So if a safety cageor other safety device is opened

and the quick stopinput is activated, the drive should ramp down with the appropriate ramp and


30/35



then activate the safety brake. This functionality is achieved by setting P725 to 0 and tuning

P719 to the lowest allowable setting.

Other settings (P726, P735, P736, P746)

The maximum PID track error was brought down to approximately +/- 100 QC during the

optimising sequence described above (steps 15-17). Therefore, it is an indication of an error, if the

PID track error should suddenly grow larger than approximately +/- 200 QC. Thus P726 is set at200.

The maximum tolerated travel of the brake before replacement is estimated at 4 mm so P735 is

set to 4.

If the application for some reason should ever go into the not allowed area beyond the SW limits

it should be possible to bring the application back into the allowed area by resetting the limit error

and using the jog inputs. This is achieved by setting P736 to 1.

The allowed position tolerance is defined to be +/- 10 mm in this application so P746 is set to

10.


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Part four: Troubleshooting

Frequently asked questions

Q1: When I have a PID TRACK ERROR TOOBIGerror (P798=9), the inverter also trips onALARM 13 (OVER CURRENT).

A1.a: Check that the velocity setting (P723 forjogging and P738/P742 for positioning) is at least5% lower than the maximum allowed velocitycalculated in P799. Either lower the velocity (P723or P742) setting or raise the maximum allowedvelocity (P799) by setting a higher value of P205 -please see Q2.

A1.b: The quick stop ramp time (P719) could betoo short. Try to increase the setting.

Q2: How do I adjust the maximum allowed velocityin P799?

A2: You need to raise the setting of P205. Doingthis will also affect the performance of theparameters P702, P703, P704, P707 and P708.Smaller changes to P205 may not have anynoticeable effect on most of these parameters butP707 should always be recalculated using the auto-calculation function P710.

Q3: The inverter frequently trips on ALARM 7 (DCLINK OVERVOLTAGE) while ramping down.

A3.a: Use a higher ramp time setting (P719 forquick stop, P724 for jogging and P738/P741 forpositioning).A3.b: If a lower ramp time is required a brakeresistor should be installed.

Q4: The inverter frequently trips on ALARM 13(OVER CURRENT) while ramping

A4.a: The ramp settings may require too muchtorque. Try to determine which operation (quickstop, manual move or positioning) caused the trip,and then set the corresponding ramp time (P719for quick stop, P724 for jogging and P738/P741for positioning) with a higher ramp time setting.A4.b: The PID controller settings may be unstableplease re-optimise the PID controller parameters(P702-P709).

Q5: The correct target position is reached, but thePID tracking error (P797) is too big while the drivemoves

A5: Harder settings of the PID controller may berequiredplease re-optimise the PID controllerparameters (P702-P709).

Q6: The program sometimes seems to forgetchanges to parameter values.

A6: Changes to parameter values are not storedafter power-down unless P777 (STORE DATA) isactivated before power-down.

Changes to trajectory data P705-P709 inPOSITIONING MODE is ignored unless the correctpassword is entered in P778.

Error messages

All messages are shown in P798 in the

VLT5000 LCP display. You can find detailed

information in the following section.

Here you will find additional notes on

possible causes of errors as well as tips for

clearing errors.

P798 0: Status OK. No errors detected.

Meaning

No errors detected.

P798 1: Homing needed

Meaning

The user has issued a positioning command to acertain position while the home position is notdefined.

Note

The error must be cleared and a homingsequence successfully completed before the nextposition command is issued to the application.

P798 2: Positive hardware limit exceeded

Meaning

The positive hardware switch input has beenactivated.

Causes

The application has hit the positive limit markerswitch. Alternatively, the connection to the limitswitch has been lost or the limit switch is defect.


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P7983: Negative hardware limit exceeded

Meaning

The negative hardware switch input is activated.

Causes

The application has hit the negative limit markerswitch. Alternatively, the connection to the limitswitch has been lost or the limit switch is defect.

P7984: Positive software limit exceeded

Meaning

The actual position of the application hasexceeded the maximum limit specified in P744.

Note

Before the error can be cleared the applicationmust be moved back from the limit. If power

recoveryis enabled in P736, this can be donethrough an error reset and a negative manualmove command.

P7985: Negative software limit exceeded

Meaning

The actual position of the application hasexceeded the minimum limit specified in P745.

Note

Before the error can be cleared the applicationmust be moved back from the limit. If powerrecoveryis enabled in P736 this can be donethrough an error reset and a positive manualmove command.

P7986: VLT not running

Meaning

The motor was not magnetized in a situationwhere it should have been. The electromechanicalbrake is immediately activated in this case

regardless of the settings in P718 and P725.

Causes

While the motor was holding/driving the load, thedrive has tripped, connection to terminal 27 waslost or the STOPbutton was pressed on theLCP.

P7987: Brake wear limit exceeded

Meaning

The error message is provoked if the drive hasmoved more than the allowed number of user

units specified in P725 while the electronic brakewas activated.

Causes

The mechanical brake is worn and should bereplaced in the near future or the limit specified inP735 is too strict. Alternatively the coast delay(P716) could be too little.

P7988: Quick stop input activated

Meaning

The quick stop input has been activated. As asafety precaution the electromechanical brake isactivated according to the setting of P725 and thedrive is coasted regardless of the setting of P715.Normal operation is only resumed if the error iscleared.

P7989: Controller (PID) tracking error toobig

Meaning

The difference between the desired set-pointposition and the actual position read via theencoder feedback has exceeded the limitspecified in P726.

Causes

Several reasons may exist:

1) The encoder is not properly connected.Check the encoder connection.

2) The encoder is counting positive in thewrong direction. Switch A- and B-channels if necessary.

3) The PID controller settings are notproperly optimised. Follow the instructionsfor optimising.

4) The limit specified in P726 may be toostrict.

P79810: SyncPos option error occured

Meaning

An internal error on the option card has occurred.Please note the corresponding error number andcontact Danfoss with a description of theconditions before and after the error occurred.

P79811: VLT Exception error detected

Meaning

An internal VLT 5000 error was detected during

start-up of the option card program. Please notethe corresponding error number and contactDanfoss.


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Causes

EMC in the environment surrounding the VLT5000might cause exception errors to arise. If theexception error occurs at different code addressesit is a good indication that EMC is causing thetrouble. If the exception error occurs repeatedly atthe same code address it is an indication that theEPROMs might be damaged

P79812: Reverse operation prohibited

Meaning

The drives has been operated in reverse directionwhile this was not allowed according to the settingof P734.

P79813: Forward operation prohibited

Meaning

The drives has been operated in forward directionwhile this was not allowed according to the settingof P734.


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Part five: Glossary of key terms

Incremental encoder - This is an encoder system that picks up the speed and the directionof rotation and transmits on the appropriate configuration. The number oftracks, and thus the number of signals, indicates the properties of the

encoder system. There are single-track systems that deliver a pulse signaldependent on the speed as well as a fixed direction signal. Dual-tracksystems deliver two pulse signals that are offset 90 degrees. By evaluatingthe two tracks, the direction signal is also obtained. Three-track encodersdeliver, as well as the two tracks of the dual-track encoder, an additionalzero-track. This emits a signal when the zero transit is passed through.

Figure 5: Incremental encoder signals

Quadcounts - Through edge detection, a quadrupling of the increments is produced by bothtracks (A/B) of the incremental encoder. This improves the resolution.

Figure 6: Derivation of quad counts

Absolute value encoder - This is a special form of incremental encoder, as it indicates not onlythe 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 twoversions: Single-Turn encoders supply an absolute position on a shaft


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rotation; Multi-Turn encoders can report the absolute position via a specificquantity, or via a freely-definable number of rotations.

ERPM The speed is defined in relation to the RPM of the encoder. To underline thisthe term encoder revolutions per minuteis chosen as unit.

Motor/encoder

Gear ratio Since the encoder is not necessarily mounted on the motor itself, therelationship between the nominal motor speed in RPM and the nominalencoder speed in ERPM must be specified.

Track error The synchronizing controller of the slave drive uses the master drive signal and thegear ratio to calculate a reference position value for the slave drive. The deviationof 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

manual control posicionamie

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