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Illustration 4.12: Initial start-up with marker synchronisation

4.8.3. Marker Correction during Operation 

During operation, marker correction is always carried out when the markers is detected. This
ensures optimum synchronisation, no matter whether the gear ratios are not accurate or there is
a slip.

Illustration 4.13: Marker correction during operation

4.9. Application Example - Packaging 

This example is a conveyor belt with cardboard boxes of low weight and different lengths. To
ensure that the components to be packed are placed right in the middle of the boxes you must
use synchronisation with marker correction. The grab belt is controlled by position synchronisation

Syncronising Controller MCO 350 Operating

Instructions

4. Synchronisation

 MG.33.Q1.02 - VLT

 

®

 

 is a registered Danfoss trademark 

 

71

4

Summary of Contents for MCO 350

Page 1: ...Tasks 12 Introduction 12 Example 12 Calculation with Insufficient Numerical Values 13 Example with Corrected Numerical Values 13 Hardware 14 VLT Control Card Terminals 14 Technical Data 14 Introducti...

Page 2: ...Position Synchronisation angle synchronisation 58 Function Diagrams for Position Synchronisation 60 SyncStart to a Stationary Master 60 SyncStart to a Running Master 60 Position Displacement with a Ru...

Page 3: ...s 75 How to Optimise the Controller 75 How to Programme Synchronisation 77 Operation and Operating Functions 79 5 Appendix 81 Messages and Error Reference 81 Warnings and Error Messages 81 Errors 82 P...

Page 4: ...1 Safety Regulation Syncronising Controller MCO 350 Operating Instructions 4 MG 33 Q1 02 VLT is a registered Danfoss trademark 1...

Page 5: ...y collected with electrical and electronic waste according to local and currently valid legislation The FC 300 AutomationDrive DC link capacitors remain charged after power has been disconnected To av...

Page 6: ...plicable local and national rules and safety regulations Installation in high altitudes 380 500 V At altitudes above 3 km please contact Danfoss Drives regarding PELV 525 690 V At altitudes above 2 km...

Page 7: ...terminals 88 and 89 from load share applications 3 Wait for discharge of the DC link See period of time on the warning label 4 Remove motor cable 1 1 8 Avoid Unintended Start While FC 300 is connecte...

Page 8: ...ategory are appropriate and sufficient In order to install and use the Safe Stop function in accordance with the requirements of Safety Category 3 in EN 954 1 the related information and instructions...

Page 9: ...placed in an IP 54 enclosure Conse quently FC301 A1 must always be placed in an IP 54 enclosure Illustration 1 1 Bridge jumper between terminal 37 and 24 VDC The illustration below shows a Stopping C...

Page 10: ...2 Introduction Syncronising Controller MCO 350 Operating Instructions 10 MG 33 Q1 02 VLT is a registered Danfoss trademark 2...

Page 11: ...angle synchronisation This is the electronic shaft ensuring a constant angle position ratio between master and slave drives In case of a position deviation the slave drive is automatically accelerated...

Page 12: ...chronisation Tasks 2 3 1 Introduction When configuring the drives to be synchronised please keep in mind that the ratios should be of integer size When using gear it is also important to know the numb...

Page 13: ...tage is formed from two pinions 126 to 27 and the second stage from two pinions 117 to 18 The ratio is calculated as 126 x 117 27 x 18 30 33 The specified value of 30 33 thus deviates by 0 1 This may...

Page 14: ...s 510 515 are set to No operation default setting then the inputs are ignored by the control card but they are used as inputs for the synchronising controller Analogue inputs 53 54 Parameters 315 316...

Page 15: ...tive Name Digital Inputs 1 Digital Input 2 Digital Input 3 Digital Input 4 Digital Input 5 Digital Input 6 Digital Input 7 Digital Input 8 Digital Input 9 Digital Input 10 Digital Input Terminal X59 T...

Page 16: ...ault will result in an Option error 192 if encoder monitoring is activated via parameter 3239 master and 3209 slave 2 5 4 Option Card Layout MCO 350 control terminals are plug connectors with screw te...

Page 17: ...ross section wire with enclosed core 1 5 mm2 AWG 16 Minimum cross section 0 082 AWG 28 Digital inputs Number of programmable digital inputs 10 Terminal block X57 Terminal number 11 21 3 4 5 6 7 8 9 10...

Page 18: ...ance 120 Maximum voltage on inputs 5 V DC Cable type Screened cable with a twisted pair of wires for each encoder channel1 Incremental encoder type RS422 TTL Maximum frequency 410 kHz Phase displaceme...

Page 19: ...hen 2 or 3 supply voltages are used simultaneously the load must be reduced accordingly The following must be observed load24V load8V load5V 6W and load8V load5V 2W 2 8 V is only available at terminal...

Page 20: ...peration P 1901 1 2 4 or 5 the position offset of the slave can be changed by the value specified in Parameter 1912 The sign of the value in parameter 1912 selects the offset type to be absolute or re...

Page 21: ...the offset in the same direction as this would give a very high fixed offset when using absolute offset This high fixed offset would then be executed when restarting synchronisation and the min or ma...

Page 22: ...ker input When using external marker signal for the master drive it must be connected to this input 6 I6 Slave marker input When using external marker signal for the slave drive it must be connected t...

Page 23: ...ng controller can be controlled via the digital analogue inputs or via field bus The control source can be selected individually for test run and synchronising in the parameters 1919 test run and 1920...

Page 24: ...r ratio select MSB 10 1 8 Not used Start homing 19 1 9 Reset enable Reset enable 27 1 10 Not used Hold 29 1 11 Not used Speed position 32 1 12 Not used Speed position 33 1 13 Measuring master marker d...

Page 25: ...used Home reached 7 1 8 Ready no error Ready no error 8 2 Track error Track error Par 19 93 testrun Par 19 96 synchronising 3 Not used synchronising error Par 19 93 4 Not used Status of synchronisati...

Page 26: ...3 Programming Syncronising Controller MCO 350 Operating Instructions 26 MG 33 Q1 02 VLT is a registered Danfoss trademark 3...

Page 27: ...in par 32 80 19 01 Synchronous operation Program 2 Option Function Type of operation Select here the type of operation of the syn chronising Controller 0 Speed synchronising 1 Position synchronising 2...

Page 28: ...peed If Hold function 0 was selected enter here the speed as a percentage of the maximum speed par 32 80 19 04 Test run program 1 synchronising type Sync type Option Function This parameter is used to...

Page 29: ...lation is done NB If any of the above mentioned parameters are changed the calculation must be repeated Synchronous operation Program 2 Gear ratio no Select the number of the gear ratio that you want...

Page 30: ...07 19 11 Step time Option Function Enter the time after which with the Hold function activated and the presence of one of the signals at Terminal 32 or 33 a change in speed takes place in the engaged...

Page 31: ...on Function Enter the factor by which the error must be scaled so that the desired value is displayed The formula for calculation of the factor is Speed synchronisation The factor should be 100 the sy...

Page 32: ...est run Contr testrun Option Function This parameter is used to select the control source in test run mode par 33 80 1 There can only be one control source at a time Digital inputs or field bus contro...

Page 33: ...is used to specify the delay time between closing the mechanical brake output 4 and disabling motor control motor coast This is necessary to avoid loosing the load be cause of the reaction time of the...

Page 34: ...alogue output 42 Option Function 0 Slave speed 1 Master speed 19 92 Software version number Option Function The software version of the synchronising controller is displayed here 19 93 Test run Progra...

Page 35: ...coder is used 1 SSI 2 SSI with filter choose if the encoder signal is unstable 32 03 Absolute Resolution Slave Option Function Enter the positions per revolution 32 05 Absolute Encoder Data Length Sla...

Page 36: ...two motor phases if di rection of motor rotation is wrong 4 as 3 but with opposite sign of the reference to the drive This can be used as alternative to swapping two motor phases if di rection of mot...

Page 37: ...oder Cable Length Master Option Function Enter the cable length of the encoder please note that 300 me ters is the maximum 32 39 Encoder Monitoring Master Option Function Off No monitoring of encoder...

Page 38: ...message O ERR_108 Position error The value should be set higher than the permitted tolerance range ACCURACY in par 33 13 Input in quad counts 32 68 Reversing behaviour Option Function 0 means that th...

Page 39: ...par 3280 This is input in milliseconds 33 00 Home_Force Option Function If this param is set to 1 a home has to be carried out before sync can start 33 02 Home acceleration Option Function Specify he...

Page 40: ...M S tolerance speed 100 whichever of the two is lowest Slave must slow down The slave travels at the minimum speed master speed master speed M S tolerance speed 100 If the M S tolerance speed value is...

Page 41: ...ignal for the slave drive 1 falling edge of the zero track 2 rising edge at I6 1 falling edge of the zero track 3 falling edge at I6 NB This parameter is only used in marker synchronis ing mode par 19...

Page 42: ...arker pulse The slave waits for the next marker pulse and synchronises to it 2 once the master speed is reached marker correction to next fol lowing markers take place may catch up slow down 3 same as...

Page 43: ...is recommended to set a filter time based on resolution This is to avoid speed fluctuation at low speed or when using low resolution of encoders Please see fol lowing table Encoder Resolu tion Filter...

Page 44: ...speed synchronisation Flag Decimal value Bit SYNCREADY 1 0 SYNCFAULT 2 1 SYNCACCURACY 4 2 Only marker synchronisation Master marker HIT 8 3 Slave marker HIT 16 4 Master marker Error 32 5 Slave marker...

Page 45: ...flags are set 1 after detecting n marker pulses n par 19 08 and 19 09 Marker error flags It is checked at each n marker pulse n par 19 08 or 19 09 whether the distance between the actual marker positi...

Page 46: ...4 Synchronisation Syncronising Controller MCO 350 Operating Instructions 46 MG 33 Q1 02 VLT is a registered Danfoss trademark 4...

Page 47: ...1 Illustration 4 1 Figure 10 SyncStart with speed synchronisation 4 2 Function Diagrams for Speed Synchronisation 4 2 1 SyncStart When closing the SyncStart contact Terminal I1 the slave drive acceler...

Page 48: ...adjustment of the gear ratio the gear ratio digits should be extended and a small step width should be selected If one of the two inputs is on longer than the time defined in par 19 11step time a furt...

Page 49: ...s to maintain current speed For the duration of the Hold signal the speed of the master is no longer taken into account the master can even stop without this having any effect on the slave drive While...

Page 50: ...e fixed gear ratios are selected at terminals 9 and 10 Input 9 Input 10 Gear Ratio no 0 0 0 0 1 1 1 0 2 1 1 3 To activate the new ratio you must activate input I2 The newly set gear ratio is attained...

Page 51: ...you e g have set up 500 for masterfactor in gear 0 this would give a gear ratio of 1 1 4 3 Application Examples Admixture A feed screw conveyor pump leads substance 1 to a nozzle adding substance 2 F...

Page 52: ...ortant that the frequency converter is optimised for the motor before optimising the synchronising controller 1 Record the motor data and perform an AMA Automatic Motor Adaptation if possible 2 Start...

Page 53: ...s the velocity filter for speed synchronisation Since speed synchronisa tion is based on speed a small fluctuation in master speed when running at low speed can have an effect on the pid loop control...

Page 54: ...been programmed check the motor connection as follows 1 Remove all signals to terminals 18 33 and I1 I10 2 Press Hand On button on the LCP 3 Set the reference to a low value with the arrow keys 25 to...

Page 55: ...ity feed forward when slave velocity is approximately equal to the master velocity 6 Stop test run by input 3 0 7 Reset parameter 3267 to the original value 8 Reset parameter 3264 to 1000 Second step...

Page 56: ...the virtual master in encoder pulses per sec ond2 Parameter No 19 18 Virtual master maximum speed Set the maximum velocity of the virtual master in encoder pulses per second Then use the following pro...

Page 57: ...000 16000 Parameter No 19 07 Gear ratio denominator Enter here the denominator value of the gear ratio This value corre sponds to the master pulses Parameter No 19 11 Step time In Hold mode the next f...

Page 58: ...rried out by closing the Store contact I4 or by means of Parameters 1900 before the VLT is switched off 4 4 4 Switching to Another Gear Ratio During synchronisation a new gear ratio can be selected at...

Page 59: ...A typical application for this type of synchro nising could be the replacement of a mechanical shaft Or mixing controls where a mixing rate is required The following example shows how embossing patter...

Page 60: ...to the extent of this offset during synchronisation Illustration 4 7 synchronising to a stationary master 4 6 2 SyncStart to a Running Master If synchronisation is effected to a running master the sla...

Page 61: ...elerates in order to travel the necessary distance in order then again to travel synchro nously to the master at the speed determined via the gear ratio If the displacement is negative the slave decel...

Page 62: ...lt operator changes the position of the pattern by means of two buttons Each of the two incremental en coders has a zero track for marker synchronisation 4 7 2 Description of Terminals and Terminal Co...

Page 63: ...mit for regenerative operation Set for maximum Choose a lower value if special safety precautions are necessary Parameter No 33 80 Record 1 to start the test program Parameter No 33 26 When performing...

Page 64: ...heck the motor connection as follows Remove all signals to terminals 18 33 and I1 I10 Press Hand On button on the LCP Set the reference tor a low value with the arrow kkeys 25 to 50 rpm Please note th...

Page 65: ...approximately equal to the master velocity Stop test run by input 3 0 Reset parameter 3267 to the original value Reset parameter 3264 to 1000 Second step is to optimise the PID controller a good star...

Page 66: ...city of the virtual master in encoder pulses per second Then use the following procedure 1 Start test run with virtual master by activating input 3 During test run you can read the track error in the...

Page 67: ...ocedure is repeated Parameter No 19 06 Gear ratio numerator Enter here the numerator value of the gear ratio The value corresponds to the encoder pulses of the slave drive To make fine adjustment poss...

Page 68: ...at Terminal 19 is closed The slave drive then travels to the home switch and stops there If the reversing procedure is set to 0 the slave travels back to the start of the home switch otherwise the of...

Page 69: ...ng over current etc make the drive stop The Ready output O8 is set low Reset is done with Input 27 or fieldbus bit 1 9 Reset is also possible with of the Reset button on the local control panel of the...

Page 70: ...self is not centrally positioned in its conveyor compartment Illustration 4 11 Conveyor belt with marker synchronisation 4 8 2 SyncStart to a Running Master after Power ON If the slave is synchronised...

Page 71: ...llustration 4 13 Marker correction during operation 4 9 Application Example Packaging This example is a conveyor belt with cardboard boxes of low weight and different lengths To ensure that the compon...

Page 72: ...ans of two push buttons 4 9 1 Terminals and Terminal Configuration Wiring diagram conveyor belt regulation 4 9 2 Setting the Parameters For this purpose it is recommended to have the parameter descrip...

Page 73: ...be entered Example If a filter factor of 100000 100 ms is used the correction is balanced within 1000 filter factor 10 1 second Parameter No 32 00 32 02 Record the slave encoder type 0 represents an i...

Page 74: ...Parameter 3280 Parameter No 19 02 Test run acceleration Record the acceleration for the test run in percent of the minimum accel eration time 100 represents the minimum acceleration 50 is half as fast...

Page 75: ...First step is to optimise velocity feed forward this can be done via the automatic calculation function Velocity feed forward calculation is activated by setting parameter 1905 to 1 remember to make t...

Page 76: ...eter 3260 to about 70 80 of the set value 3 Now set the D portion parameter 3261 to 5 times the value of parameter 3260 4 If a lower synchronising error is required the I portion parameter 3262 can be...

Page 77: ...synchronising to the master marker 0 means the last marker pulse of the master the slave synchronises to the last master marker pulse already registered it catches up 1 means the next master marker p...

Page 78: ...ctor change to another synchronisation mode when there is a signal on terminal 32 or 33 Parameter No 19 12 Step width In marker synchronisation mode Offset Parameter 1908 is changed by this value when...

Page 79: ...r an adjustment of this position can be made by means of Inputs 32 33 Note Offset is related to the master position Offset related to the slave position can be calculated as follows O ffset_slave O ff...

Page 80: ...5 Appendix Syncronising Controller MCO 350 Operating Instructions 80 MG 33 Q1 02 VLT is a registered Danfoss trademark 5...

Page 81: ...r is active 114 Too many loops Too many nested loops 115 Par save failed Parameters save failed 116 Param memory Parameters in memory are corrupted 117 Progr Memory Programs in memory are corrupted 11...

Page 82: ...rotation Causes An encoder without an index pulse has been used Index pulse not connected Index pulse incorrect all three chan nels must have a simultaneous low or The par 32 01 Incremental Resolu tio...

Page 83: ...been stopped and a re set has automatically been executed watchdog Causes could be Short term voltage drop Voltage peak or Short circuit Error 119 User abort The Autostart program has been aborted by...

Page 84: ...g due to an incorrectly pro grammed loop Or the array is too small for the number of test drives triggered by TESTSTART Check loop variables Error 179 Waitndx timeout The command WAITNDX was executed...

Page 85: ...t match the order in the cnf file Refer to the number of the array in the title bar of the CAM Editor in this respect Error 192 Encoder error Error from encoder monitoring open or short circuit in acc...

Page 86: ...02 Test run Program 1 Test Run Acceleration Factory setting 10 Setting range from 1 200 User setting Synchronous Operation Program 2 Hold Function Factory setting 0 Setting range from 0 1 User setting...

Page 87: ...1906 Gear Ratio Numerator Factory setting 1000 Setting range from MLONG MLONG 1907 Gear Ratio Denominator Factory setting 1000 Setting range from MLONG MLONG 1908 Slave Marker Quantity Factory setting...

Page 88: ...splay Factor Factory setting 400 Setting range from 1 2147483647 User setting 1916 Virtual Master Reference Value Factory setting 0 Setting range from 0 3 User setting 1917 Virtual Master Acceleration...

Page 89: ...ec User setting msec 1922 Brake Off Delay Brake off delay Factory setting 0 Setting range from 0 5000 msec User setting msec 1923 Marker Monitor Marker monitor Factory setting 0 Setting range from 0 2...

Page 90: ...r setting 3205 Slave Encoder Absolute Data Length Factory setting 25 Setting range from 8 37 User setting 3206 Slave Encoder Absolute Clock Frequency Factory setting 262000 Setting range from 78125 20...

Page 91: ...Absolute Resolution Factory setting 8192 Setting range from 1 MLONG User setting 3235 Master Encoder Absolute Data Length Factory setting 25 Setting range from 8 37 User setting 3236 Master Encoder A...

Page 92: ...r setting 3262 I Portion Factory setting 0 Setting range from 0 65000 User setting 3263 Limitation for I Portion Factory setting 1000 Setting range from 0 65000 User setting 3264 Band Width PID Contro...

Page 93: ...actory setting 1 ms Setting range from 1 1000 ms User setting ms 3280 Maximum Speed Factory setting 1500 1 min Setting range from 1 65535 1 min User setting 1 min 3281 Minimum Ramp Factory setting 100...

Page 94: ...ng 1000 quad counts Setting range from 2147483647 2147483647 quad counts User setting quad counts 3314 M S Tolerance Speed Factory setting 0 Setting range from 0 100 User setting 3317 Marker Interval...

Page 95: ...etting range from 0 1005 User setting 3324 Marker Quantity FAULT Factory setting 5 markers Setting range from 1 10000 markers User setting markers 3325 Marker Quantity READY Factory setting 10 markers...

Page 96: ...ction signal is also ob tained Three track encoders deliver as well as the two tracks of the dual track encoder an additional zero track This emits a signal when the zero transit is passed through Inc...

Page 97: ...t as small as possible it is often more advantageous not to take the reference position from a drive but to have a master that simulates the reference position This has the advantage that the cycle ti...

Page 98: ...he value is used to set the virtual master signals Illustration 5 3 Synchronisation with Virtual Master It can be seen from the diagram below that the cycle time error is not added instead one cycle t...

Page 99: ...Illustration 5 4 No Addition of the Cycle Times Syncronising Controller MCO 350 Operating Instructions 5 Appendix MG 33 Q1 02 VLT is a registered Danfoss trademark 99 5...

Page 100: ...Digital Outputs 17 Direction Of Rotation 36 Disposal Instruction 5 D portion 37 E Earth Leakage Current 6 Embossing Patterns On Mould 62 Encoder Monitor 16 Encoder Resolution 53 Encoder Velocity 29 E...

Page 101: ...The Master 40 Marker Interval At The Slave 40 Marker Quantity Fault 42 Marker Quantity Ready 43 Marker Synchronising 69 Marker Synchronising Mode 41 Marker Window Master 41 Marker Window Slave 42 Mas...

Page 102: ...ng To Another Gear Ratio 58 Symbols 5 Synchronising Error Display 31 Synchronising Type 28 Syncstart To A Running Master 60 Syncstart To A Running Master After Power On 70 Syncstart To A Stationary Ma...

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