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Danfoss VLT 5000 Operating Instructions Manual Download Page 68

Synchronizing controller 

 
 

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

 67 

How to program synchronization 

Change the value of parameter 701 to “2”. This will start the synchronization program of VLT 5000

.

 

To do the synchronization programming you use the following parameters: 

 

Parameter 725 

Type of operation: Record “2” or “5” for marker synchronization. 

 
Parameter 732  Marker synchronization behaviour: Specify here how the slave drive is to react 

while synchronizing to the master marker. “0” means the last marker pulse of 
the master - the slave synchronizes to the last master marker pulse already 
registered - it catches up. “1” means the next master marker pulse - the slave 
waits for the next master marker and synchronizes to it - the slave slows down. 
“2” means that the slave uses the nearest master marker - it decides for itself 
whether to catch up or slow down. 

 
Parameter 733  Accuracy: Record a value (quadcounts) for a tolerance within which the slave 

position may deviate from the position of the master. 

 
Parameter 734  Marker quantity Fault: Inaccuracy: Record the number of market signals to 

generate a Fault signal. 

 
Parameter 735  Marker quantity Ready: Accuracy: Record the number of marker signals to 

generate a Ready signal. 

 
Parameter 737  Gear ratio No.: Record the number of the gear ratio that is to be displayed in 

Parameters 738 to 742. First set the number of the gear ratio, then in 
Parameters 738 to 742 the necessary values for this gear ratio. The next gear 
ratio is then selected in Parameter 737 and the same procedure is repeated.  

 
Parameter 738  Gear ratio numerator: Record the numerator value for the gear ratio. That is 

the encoder pulses of the slave drive. To make fine adjustment possible by 
means of inputs 32 and 33 a ratio of for example 7:16 must be programmed 
as 7000:16000. 

 
Parameter 739  Gear ratio denominator: Record the denominator value of the gear ratio. This 

value corresponds to the master pulses. 

 
Parameter 740  Slave markers: Record the number of slave markers for the marker ratio. 

Ensure that the gear ratio and the marker ratio match each other. 

 
Parameter 741  Master markers: Record the number of master markers for the marker ratio. 

Ensure that the gear ratio and the marker ratio match each other. 

 
Parameter 742  Fixed Offset: Record a fixed position offset for the selected gear ratio (quad 

counts). This value specifies the position deviation between the slave marker 
and the master marker. During operation the offset can be changed by means 
of inputs 32 and 33. 
Note: Offset is related to the master position. Offset related to the slave 
position can be calculated as follows:  

 

   Offset_slave 

= 

739

738

*

Parameter

Parameter

Offset

  

 
Parameter 743  Step time: Record the delay in ms from one frequency change to another (hold 

mode) and from one gear ratio numerator factor change to another 
(synchronization mode) when there is a signal on terminal 32 or 33. 

Summary of Contents for VLT 5000

Page 1: ...VLT 5000 Rev 2003 09 16 www danfoss com drives 175R0237 MG10N402 MG10N402 XREF__BC NOT LOADED ON RIP Operating Instructions Synchronizing Controller VLT 5000 FLUX ...

Page 2: ...Speed synchronization __________________________________________________________ 37 Function diagrams for speed synchronization 38 SyncStart 38 Up down factor 38 Hold function 40 Gear changing 40 Changing the gear ratio with an analogue value 41 Application example Admixture 42 Description of terminals and terminal configuration 42 Setting the parameters 43 How to check the motor connection 44 How...

Page 3: ...n example Packaging 61 Terminals and terminal configuration 62 Setting the parameters 63 How to check the motor connection 64 How to test the incremental encoders 64 How to optimise the controller 65 How to program synchronization 67 Operation and operating functions 69 Appendix _____________________________________________________________________ 70 Messages and error reference 70 Table of error ...

Page 4: ...frequency converter is connected to mains Check that the mains supply has been disconnected and that the necessary time has passed before removing motor and mains plugs 7 Please note that the VLT frequency converter has more voltage inputs than L1 L2 and L3 when load sharing linking of DC intermediate circuit and external 24 V DC have been installed Check that all voltage inputs have been disconne...

Page 5: ...cker acceleration speed than that of the master drive Position synchronization angle synchronization 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 to a speed level that is suffi cient for regaining its position to the master drive I control like Marker synchronizatio...

Page 6: ...r example by means of the VLT mechanical brake function in set up 2 Tips and tricks for synchronization tasks When configuring the drives to be synchronized please keep in mind that the ratios should be of integer size When using gear it is also important to know the number of teeth of the various gear stages ask the gear manufacturer as gears are normally set up with infinite gear ratios When cal...

Page 7: ...s a 2 stage gear the first stage is formed from two pinions 126 to 27 and the second stage from two pinions 117 to 18 The ratio is calculated as 1 3 30 18 27 117 126 The specified value of 30 33 thus deviates by 0 1 0 00 This may appear small if this error is related to the encoder resolution however it will be seen that even this error is serious From the example it can be seen that it is importa...

Page 8: ... control card but they can still be used as inputs to the synchronizing controller Digital analogue outputs 42 and 45 Parameters 319 and 321 are set to OPTION 0 20 mA 91 analogue output default setting Technical data Technical data on the control card terminals can be found in the VLT 5000 design guide Option card terminals There are two encoder interfaces which are covering the following function...

Page 9: ...A including the load on the control card terminal 12 13 and output 42 and 45 The 5 V output on the option card is generated from the 24 V supply The maximum power on the 5 V side is 5 V 280 mA 1 4 W this corresponds to app 60 mA on the 24 V side When an external 24 V DC voltage source is used the internal 24 V supply from the control card must be disconnected this is done by opening switch 1 1 and...

Page 10: ... switch 1 4 this is necessary when using incremental encoders without Zero channel or absolute encoders Switch 1 4 disables monitoring of both master and slave Zero channel If disabling of only one of the two Zero channels is required e g when using incremental master encoder and absolute slave encoder the unused Zero channel input must be connected to 5V common as shown below An encoder fault wil...

Page 11: ...ect ON disconnect OFF 24 V from control card see description of supply voltages SW 1 2 Connect ON disconnect OFF 24 V common from control card SW 1 3 Connect ON disconnect OFF termination resistor for master encoder see description of virtual master function Note When OFF the master encoder monitor is disabled SW 1 4 Switch Z channel encoder monitor ON OFF for both master and slave Default setting...

Page 12: ...Synchronizing controller MG 10 N4 02 VLT is a registered Danfoss trademark 11 The terminating resistors on both end of the bus have to be switch on with dip switch SW 1 3 ...

Page 13: ...s O1 O8 Voltage level 0 24 V DC Maximum load 0 7A with external power supply Update rate 1 msec Galvanic isolation All digital outputs are galvanically isolated by means of optocouplers but with the same common as the digital inputs External 24 V DC supply see VLT 5000 manual Encoder input 1 MK3B master Terminal designations A1 A1 B1 B1 Z1 Z1 Incremental Signal level 5 V differential Signal type L...

Page 14: ...coder cable Cable type Twisted pair and screened Note Please observe the prescriptions of the encoder supplier Cable length Observe the prescriptions of the encoder supplier Absolute encoder is tested ok up to 150 meter cable at 105 kHz clock and 100 m at 260 kHz clock Tested with TR electronic encoder type CE 65 M 8192 4096 and appropriate cable prescribed by TR electronic Maximum allowed time de...

Page 15: ...Synchronizing controller 14 MG 10 N4 02 VLT is a registered Danfoss trademark Examples of encoder interface connections Figure 6 Master Slave connection Figure 7 Virtual Master Slave connection ...

Page 16: ...st run reverse at the speed defined in Parameter 725 Synchronous operation Program 2 In velocity synchronous mode P 725 0 1 6 or 7 the gear ratio and thus the velocity of the slave can be changed by the value specified in parameter 744 In position synchronous and marker synchronous operation P 725 1 2 4 or 5 the position offset of the slave can be changed by the value specified in Parameter 744 Th...

Page 17: ...when always changing 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 synchronization and the min or max limit of parameter 742 would eventually be reached 01 COM 240V AC 2A 02 NO 03 NC Relay output Function can be configured by means of Parameter 323 04 COM 50V AC 1A 75V DC 1A 05 N...

Page 18: ...tual master Synchronous operation Program 2 The virtual master is accele rated up to the set pulse frequency or stopped with the set ramp time 4 I4 Saving the settings 1 All 7xx parameters are saved Input 4 must be reset to 0 to end the save procedure Parameter 710 will be 1 and output 5 will be high while saving Note saving is only possible if all inputs except input 27 are low Input 27 must be h...

Page 19: ...Clock out 4 A1 A track inverted Clock out inverted 5 B1 B track Data in 6 B1 B track inverted Data in inverted 7 Z1 Zero track Not used 8 Z1 Zero track inverted Not used Option card MK3C 1 O1 READY Synchronous operation Program 2 Ready i e for the number of marker signals that were specified in Parameter 735 the slave drive has run within the tolerance Accuracy 2 O2 FAULT Synchronous operation Pro...

Page 20: ... O6 Drive running Signal 1 when the drive is running 7 O7 Home reached Synchronous operation Program 2 If the data value 1 or 2 was chosen in Parameter 729 this output shows 1 homing is completed 8 O8 Ready no error The Synchronizing controller is ready for operation 9 24V DC 10 COM Option card MK3D slave encoder 1 5V DC Encoder supply 2 COM Encoder supply Incremental encoder Absolute encoder 3 A1...

Page 21: ...ignals for marker synchronization and the Home switch This is because these signals are too time critical for Field bus control Status signals are always available on the digital analogue outputs but they are only available via Field bus when Field bus is selected as control source Data layout Control and status signals are transferred via the so called process data channel PCD of the various fiel...

Page 22: ...t Not used 33 2 Virtual master reference Virtual master reference 53 60 Only when Parameter 748 3 Field bus status signals Field bus word bit Test run Synchronizing Corresponding output parameter 1 1 Not used Ready 1 1 2 Not used Fault 2 1 3 Not used Accuracy 3 1 5 Saving Saving 5 1 6 Running Running 6 1 7 Not used Home reached 7 1 8 Ready no error Ready no error 8 2 Track error Track error P775 7...

Page 23: ...ved While saving continues the value remains 1 when saving is finished the value automatically reverts to 0 Similarly during saving Output O5 Saving is set to 1 Saving is not possible during operation but only in the disengaged stopped state 711 Slave encoder type Setting range 0 Incremental encoder 1 Absolute encoder with 262kHz clock frequency 2 Absolute encoder with 105kHz clock frequency 100 a...

Page 24: ...soidal ramp produces less stress to the mechanics 719 Maximum track error Enter here the maximum track error This is the permitted error between the calculated position and the feedback position If the value is exceeded the drive stops and displays the error message O ERR_8 Position error The value should be set higher than the permitted tolerance range ACCURACY in Parameter 733 Input in quad coun...

Page 25: ...peed synchronizing 1 Position synchronizing 2 Marker synchronizing 3 Speed synchronizing with motor coast after stop 4 Position synchronizing with motor coast after stop 5 Marker synchronizing with motor coast after stop 6 Speed synchronizing with motor coast after stop and setting of gear ratio via analogue input 54 7 Speed synchronizing with setting of gear ratio via analogue input 54 With the s...

Page 26: ...izing type Sync type This parameter is used to specify the type of synchroni zation used when optimizing the PID controller for synchronization by means of the virtual master Setting range 0 Speed synchronizing 1 Position synchronizing Select 0 if you are going to use speed synchronizing in synchronous mode or select 1 if you are going to use position or marker synchronizing in synchronous mode Sy...

Page 27: ...PID sample time 2 Activate calculation of velocity feed forward par 707 PID sample time par 777 Proportional factor par 702 and derivative factor par 703 The calculations are based on the following parameters that must be set before the calculation is started VLT5000 Par 104 Nominal motor frequency Par 205 Maximum reference Par 711 Slave encoder type Par 712 Slave encoder resolution Par 716 Maximu...

Page 28: ...n 100 means that the drive accelerates with the minimum ramp specified in Parameter 717 50 means that the drive only proceeds with half the acceleration i e the acceleration takes twice as long as with the minimum ramp specified in Parameter 717 732 Synchronous operation Program 2 Marker synchronous operation For marker synchronization select how the slave is to synchronize to the master 0 last ma...

Page 29: ... marker pulses i e a setting of 10 means that ACCURACY must be present for 10 marker pulses before the READY signal is set In position synchronization parameter 725 1 or 4 only the slave marker is used in marker synchronization parameter 725 2 or 5 both slave and master marker must be detected before counting 736 Synchronous operation Program 2 M S tolerance speed Specify here the tolerated speed ...

Page 30: ...s in the placing of the encoder or markers Input is in quad counts Note Offset is related to the master position Offset related to the slave position can be calculated as follows Offset_slave 739 738 Parameter Parameter Offset 743 Synchronous operation Program 2 Step time Enter the time after which with the Hold function activated and the presence of one of the signals at Terminal 32 or 33 a chang...

Page 31: ...e Display resolution der Masterenco NSet _ 60 _ 400 747 Synchronous operation Program 2 Synchronizing error display factor 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 synchronization The factor should be 100 the synchronizing error is then displayed in RPM related to the slave Position synchronization ...

Page 32: ...s Virtual master maximum speed 1024 1 50 s 51200 1 s 751 Marker window slave Here you can enter how large the permitted tolerance for the occurrence of the marker is The factory setting 0 means all markers are used At every other setting only those markers are accepted which are within the window Example Marker interval 30000 and marker window 1000 Only markers with an interval of 29000 to 31000 i...

Page 33: ...is parameter is used to select the control source in synchronizing mode par 701 2 There can only be one control source at a time Digital inputs or field bus control word Only exception is input 27 which is always stop also with field bus control When digital control is selected status signals are updated on the digital outputs when field bus control is selected status signals are updated on digita...

Page 34: ... number of markers x par 734 1 Output 2 fault is set when not accuracy for x number of markers x par 734 OR when x number of markers are missing 2 Output 2 fault is set when not accuracy for x number of markers x par 734 and Output 2 fault is set and the error handler is called when x number of markers are missing NOTE This function can only be used if marker windows are used par 751 and 752 758 R...

Page 35: ...ample Bit 3 7 and 8 high 776 196 Bit 1 and 3 high 776 5 777 PID sample time The parameter is setting the sample time of the control algorithm The value should be increased if The pulse frequency is very low e g 1 to 2 quad counts per sample time you need at least 10 to 20 quad counts per sample time The system is very slow and heavy high inertia Controlling systems with 1 ms can make big motors vi...

Page 36: ...t to 0 if it is present the ready counter is increased and the fault counter set to 0 If the ready counter is higher than the value set in parameter 735 marker quantity ready then the flag SYNCREADY is set if not the flag is reset If the fault counter is higher than the value in parameter 734 marker quantity fault the flag SYNCFAULT is set 1 if not the flag is reset 0 Marker HIT flags The marker H...

Page 37: ...speed is displayed with the value calculated in Parameter 746 Initializing the parameters It is possible to restore parameter default values by means of the initialise function in parameter 620 All parameter except parameter 500 501 600 605 615 617 will be reset to factory default setting NOTE The VLT must be in stop mode before initialising can be carried out Procedure for initialising 1 Select i...

Page 38: ...nnection with speed changes are not adjusted This type of control could for example be used for dosing pumps mixing two liquids See example The example shows a batching unit where an admixture to a basic substance is carried out The mixing proportion is freely selectable by means of the gear ratio The advantage of pure speed synchronizing control can also be seen as it makes little sense to compen...

Page 39: ...inal I1 the gear ratio can be changed during operation By means of Inputs 33 Speed Up factor or 32 Speed Down factor the gear ratio can be changed by the value set in Parameter 744 step width This change affects only the slave factor For more sensitive 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 long...

Page 40: ...Synchronizing controller MG 10 N4 02 VLT is a registered Danfoss trademark 39 Figure 11 Up down factor with speed synchronization ...

Page 41: ...unt the master can even stop without this having any effect on the slave drive While the Hold function is activated you can change the speed with inputs 32 and 33 The speed is changing according to the settings in parameter 728 Delta hold speed and parameter 744 Step width Figure 12 Hold speed Gear changing During synchronous operation it is possible to switch between 4 fixed gear ratios set in pa...

Page 42: ...e gear ratio with an analogue value As an alternative the gear ratio can be set via analogue input 54 with a 10V signal this function is active when synchronizing type 6 or 7 is selected in parameter 725 The gear ratio denominator is fixed to 500 The gear ratio numerator is set by input 54 5V corresponds to 500 which then gives a gear ratio of 1 1 ...

Page 43: ...cted mixing ratio Description of terminals and terminal configuration 16 17 18 19 20 27 29 32 33 61 68 69 04 05 12 13 39 42 45 50 53 54 55 60 O1 O2 O3 O4 O5 O6 O7 O8 24v com I1 I2 I3 I4 I5 I6 I7 I8 24v com RS 485 VLT 5000 L1 91 L2 92 L3 93 PE U 96 V 97 W 98 PE 99 Digital inputs Analog in outputs Synchronising controller 5v com A1 A1 B1 B1 Z1 Z1 5v com A2 A2 B2 B2 Z2 Z2 MK 3A MK 3C MK 3B MK 3D Choi...

Page 44: ...um ref value Parameter 221 Torque limit for motor mode Set for maximum Choose a lower value if special safety precautions are necessary Parameter 222 Torque limit for regenerative operation Set for maximum Choose a lower value if special safety precautions are necessary Parameter 701 Record 1 to start the test program Parameter 709 This parameter configures the velocity filter for speed synchroniz...

Page 45: ... check the motor connection as follows 1 Remove all signals to terminals 16 33 and I1 I8 2 Select LCP control open loop 1 in parameter 013 Select Local function in Parameter 002 VLT 5000 stops display flashing 3 Set the frequency for a low value for example 3 Hz in Parameter 003 4 Press the START button on the VLT 5000 control panel and then the STOP Reset button watching the speed direction of th...

Page 46: ... to get the velocity readouts You have found the optimal velocity feed forward when slave velocity is approximately equal to the master velocity 6 Stop test run by input 3 0 7 Reset parameter 719 to the original value 8 Reset parameter 706 to 1000 Second step is to optimize the PID controller a good starting point can be found be means of the automatic calculation function By setting parameter 729...

Page 47: ...tual master 0 is analogue input 53 1 is analogue input 60 2 is parameter 216 and 3 is Field bus PCD 2 Parameter 749 Virtual master acceleration Set the acceleration of the virtual master in encoder pulses per second 2 Parameter 750 Virtual master maximum speed Set the maximum velocity of the virtual master in encoder pulses per second Then use the following procedure 1 Disconnect the master encode...

Page 48: ... 739 Then you set the values required in Parameters 738 to 740 Follow the same procedure for the next gear ratio s Parameter 738 Gear ratio numerator Record the numerator value of the gear ratio That is the encoder pulses of the slave drive To make fine adjustment possible by means of inputs 32 and 33 a ratio of for example 7 16 must be programmed as 7000 16000 Parameter 739 Gear ratio denominator...

Page 49: ...rmitted acceleration Fine setting of the gear ratio Fine setting of the gear ratio can now be undertaken by means of Inputs 32 33 This setting is only temporary i e the fine setting data will be lost as soon as VLT 5000 is disconnected from the mains If the setting is to be saved a Store operation must be carried out by closing the Store contact I4 or by means of Parameters 710 before the VLT 5000...

Page 50: ... appears from the diagram that the control accuracy depends on the master acceleration and on the speed deviation between slave and master A typical application for this type of synchronizing could be the replacement of a mechanical shaft Or mixing controls where a mixing rate is required The following example shows how embossing patterns on moulds is controlled This application requires accurate ...

Page 51: ...owever if a fixed offset is defined for the activated gear ratio the slave travels to the extent of this offset during synchronization Figure 17 Synchronizing to a stationary master SyncStart to a running master If synchronization is effected to a running master the slave drive first makes up the deviation of distance then it proceeds synchronously with the master Any Offset setting is taken into ...

Page 52: ...by the value set in Parameter 742 If the displacement is positive the slave accelerates in order to travel the necessary distance in order then again to travel synchronously to the master at the speed determined via the gear ratio If the displacement is negative the slave decelerates in order to attain the necessary distance to then again travel synchronously with the master at the speed determine...

Page 53: ...lds of two different kinds and lengths are embossed with a pattern The conveyor belt operator changes the position of the pattern by means of two buttons Each of the two incremental encoders has a zero track for marker synchronization Description of terminals and terminal configuration Figure 20 Wiring diagram application example ...

Page 54: ...t the minimum current that is to activate the brake Choose a value that is below the motor magnetisation current Parameter 701 Record 1 to start the test program Parameter 709 When performing position synchronization this parameter is used to insert a filter to compensate for an oscillating master signal If for example the master is experiencing shock loads the pid loop of the synchronizing contro...

Page 55: ...T 5000 control panel Now the following values appear in the upper line of the display slave position master position and track error 3 Rotate the slave drive motor shaft manually in the allowed direction Now the display shows an ascending count of the slave position If the count is descending exchange the slave encoder track A by B and A by B If there is no counting in the display then check the w...

Page 56: ...or test run with positioning the following parameters must be set Parameter 725 Test run speed Record the speed as a percentage of the maximum speed of parameter 716 Parameter 726 Test run acceleration record the acceleration time in per cent 100 is minimum acceleration 50 is half as fast as minimum acceleration the ramp time will thus be twice as long Parameter 727 Test run distance Record the di...

Page 57: ...ust be carried out before the first start of synchronization 2 Home run must be carried out before each start of synchronization Parameter 730 Home speed Set the speed of maximum speed at which Homing is to be made Positive values for clockwise rotation negative values for counter clockwise rotation Parameter 731 Home acceleration Set the acceleration of minimum acceleration for homing Parameter 7...

Page 58: ...4 Step width Record a value to specify the position displacement between slave and master Parameter 745 Slave speed factor Record the factor by which the slave speed must be multiplied so that the desired value is displayed To calculate the value use the following formula Factor value Display resolution er Slaveencod NSet _ 60 _ 400 Example Resolution 1024 increments desired display 100 at 1500 1 ...

Page 59: ...chronization On opening the SyncStart contact I1 the slave is stopped at the permitted acceleration Because Home function is set at 2 a new start is only possible after a renewed Home run Fine setting of the position As soon as the slave drive is in position synchronization to the master a displacement of this position can be effected by means of Inputs 32 33 These settings are only temporary i e ...

Page 60: ...from the diagram that the control accuracy depends on the master acceleration and on the speed deviation between slave and master The following example shows the use of marker synchronization to compensate for friction slip that can arise from dropping a box onto Conveyor belt 1 By means of marker correction in the form of object recognition the slave belt is controlled so that the product will al...

Page 61: ...cally synchronizes its position to the master After at least one slave marker and one master marker have been detected the marker compensation comes into effect Figure 23 Initial start up with marker synchronization Marker correction during operation During operation marker correction is always carried out when the markers is detected This ensures optimum synchronization no matter whether the gear...

Page 62: ...rent lengths To ensure that the components to be packed are placed right in the middle of the boxes you must use synchronization with marker correction The grab belt is controlled by position synchronization and as soon as one of the two markers is recognized the grab belt is either moved forward to the conveyor belt position or slowed down It is also possible for the operator to change the positi...

Page 63: ...Synchronizing controller 62 MG 10 N4 02 VLT is a registered Danfoss trademark Terminals and terminal configuration Figure 26 Wiring diagram conveyor belt regulation ...

Page 64: ...r will have a tendency to oscillate as well A negative value must 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 711 Record the slave encoder type 0 represents an incremental encoder Parameter 712 Record the resolution of the slave encoder Parameter 713 Record the master encoder type 0 represents an incremen...

Page 65: ...ong Parameter 727 Test run distance Record the distance quad counts for the drive to travel during optimization How to check the motor connection When you have programmed the above parameters you check the motor connection as follows 1 Remove all signals to terminals 16 33 and I1 I8 Only input 27 must be connected and closed 2 Select Local function in parameter 002 VLT 5000 stops display flashing ...

Page 66: ...ile watching master and slave velocity press DISPLAY STATUS to get the velocity readouts You have found the optimal velocity feed forward when slave velocity is approximately equal to the master velocity 14 Stop test run by input 3 0 15 Reset parameter 719 to the original value 16 Reset parameter 706 to 1000 Second step is to optimise the PID controller a good starting point can be found be means ...

Page 67: ...ut 3 During test run you can read the track error in the last value of the first display line At stop the maximum track error during the test run is read out Because velocity synchronization is selected parameter 728 0 the track error is velocity deviance between master and slave 2 If more accurate and dynamic control is required the P portion parameter 702 must be increased If the slave becomes u...

Page 68: ...2 First set the number of the gear ratio then in Parameters 738 to 742 the necessary values for this gear ratio The next gear ratio is then selected in Parameter 737 and the same procedure is repeated Parameter 738 Gear ratio numerator Record the numerator value for the gear ratio That is the encoder pulses of the slave drive To make fine adjustment possible by means of inputs 32 and 33 a ratio of...

Page 69: ... 1024 increments desired display 100 at 1500 1 min Factor 1500 400 1024 60 100 1 min Inkr Umdr 102400 Parameter 746 Master speed factor Record the factor by which the master speed must be multiplied so that the desired value is displayed To calculate the value use the following formula Factor value Display resolution der Masterenco NSet _ 60 _ 400 Parameter 747 Synchronizing error display factor R...

Page 70: ... from the mains If the adjustment data are to be retained storage must be carried out by activating the Save Input I4 or by means of Parameter 710 before switching off the drive Note Offset is related to the master position Offset related to the slave position can be calculated as follows Offset_slave 739 738 Parameter Parameter Offset Switching to another gear ratio During synchronization a new g...

Page 71: ...ossible causes of errors as well as tips for clearing errors O ERR_5 Error not cleared Cause An attempt was made to execute a command to move although an existing error message had not been erased O ERR_8 Position error Meaning The interval between the reference position and the feedback position was greater than defined in Tolerated Position Error Parameter Causes Mechanically blocked or overload...

Page 72: ...s Defective EEPROM or power failure during the parameter save procedure Note You must re initialise the parameters by following the initialising procedure on page 36 If this does not cure the problem the option card must be replaced O ERR_17 Programs in EEPROM are corrupted Meaning The program data recorded in the memory are no longer available or no longer correct Causes Defective EEPROM Note Rep...

Page 73: ..._ 705 Limitation for I portion Factory setting 1000 Setting range from 0 to 65000 User setting __________ 706 Band width PID controller Factory setting 1000 Setting range from 0 to 65000 User setting __________ 707 Velocity feed forward Factory setting 0 Setting range from 0 to 65000 User setting __________ 708 Acceleration feed forward Factory setting 0 Setting range from 0 to 65000 User setting ...

Page 74: ...ng range from 1 to 2147483647 increments User setting __________ increments 715 Direction of rotation Factory setting 1 Setting range from 2 to 2 User setting __________ 716 Maximum speed Factory setting 1500 1 min Setting range from 1 to 65535 1 min User setting __________ 1 min 717 Minimum ramp Factory setting 100 ms Setting range from 50 to 2147483647 ms User setting __________ ms 718 Ramp type...

Page 75: ...ng 4096 quad counts Setting range from 0 to 2147483647 quad counts User setting __________ quad counts 725 Test run Program 1 Test run speed Factory setting 10 Setting range from 1 to 100 User setting __________ Synchronous operation Program 2 Type of operation Factory setting 0 Setting range from 0 to 7 User setting __________ 726 Test run Program 1 Test run acceleration Factory setting 10 Settin...

Page 76: ...m 1 to 100 User setting __________ 729 Test run program 1 Activate feed forward and PID calculation FFVEL calc Factory setting 0 Setting range from 0 to 2 User setting __________ Synchronous operation Program 2 Home function Factory setting 0 Setting range from 0 to 2 User setting __________ 730 Test run program 1 Encoder velocity Encoder RPM Factory setting 1500 Setting range from 1 to 65000 RPM ...

Page 77: ... __________ markers 735 Marker quantity READY Factory setting 10 markers Setting range from 1 to 10000 markers User setting __________ markers 736 M S tolerance speed Factory setting 0 Setting range from 0 to 100 User setting __________ 737 Gear ratio no Factory setting 0 Setting range from 0 to 3 738 Gear ratio numerator Factory setting 1000 Setting range from 1 to 2147483647 739 Gear ratio denom...

Page 78: ... range from 2147483647 to 2147483647 User setting __________ 745 Slave speed factor Factory setting 400 Setting range from 1 to 2147483647 User setting __________ 746 Master speed factor Factory setting 400 Setting range from 1 to 2147483647 User setting __________ 747 Synchronizing error display factor Factory setting 400 Setting range from to 2147483647 User setting __________ 748 Virtual master...

Page 79: ...e test run Contr testrun Factory setting 0 Setting range from 0 to 1 User setting __________ 754 Control source synchronizing Contr synchron Factory setting 0 Setting range from 0 to 1 User setting __________ 755 Brake on delay Brake on delay Factory setting 0 Setting range from 0 to 5000msec User setting __________ msec 756 Brake off delay Brake off delay Factory setting 0 Setting range from 0 to...

Page 80: ...dated when using speed synchronization Flag Decimal value Bit SYNCREADY 1 0 SYNCFAULT 2 1 SYNCACCURACY 4 2 Only marker Synchronization Master marker HIT 8 3 Slave marker HIT 16 4 Master marker Error 32 5 Slave marker Error 64 6 The flags are reset when restarting synchronization SyncStart 779 Software version number This is the software version number of your synchronizing controller 795 Slave pos...

Page 81: ...us the number of signals indicates the properties of the encoder system There are single track systems that deliver a pulse signal dependent on the speed as well as a fixed direction signal Dual track systems deliver two pulse signals that are offset 90 degrees By evaluating the two tracks the direction signal is also obtained Three track encoders deliver as well as the two tracks of the dual trac...

Page 82: ...ck 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 that defines the permitted operating area of the synchronizing controller Accuracy This value specifies the permitted deviation between the master and slave at which synchronization is still present PPR Pulses per revolution Virtual master If sever...

Page 83: ...they are then compensated for again based on the control characteristics of the controller in question Figure 30 Addition of the cycle times In this case the same application is realised by means incorporating a virtual master Although the way that the reference value is introduced at the first belt is analogous the value is used to set the virtual master signals Figure 31 Synchronization with vir...

Page 84: ...Danfoss trademark 83 It can be seen from the diagram below that the cycle time error is not added instead one cycle time applies for all the drives The advantage of this is that the control has fewer errors to correct Figure 32 No addition of the cycle times ...

Page 85: ... synchronization 49 Figure 16 Embossing with position synchronization 49 Figure 17 Synchronizing to a stationary master 50 Figure 18 Synchronizing to a running master 50 Figure 19 Position displacement 51 Figure 20 Wiring diagram application example 52 Figure 21 Control behaviour with marker synchronization 59 Figure 22 Conveyor belt with marker synchronization 59 Figure 23 Initial start up with m...

Page 86: ...4 External 24 V DC supply 12 F FFVEL calc 75 Field bus control signals 20 interface 20 status signals 21 Fine setting of the gear ratio admixture 48 Fine setting of the position embossing patterns on mould 58 packaging 69 Fixed offset 77 Function description 4 Function diagrams for marker synchronization 60 position synchronization 50 speed synchronization 38 G Gear changing 40 Gear ratio denomina...

Page 87: ...pe 73 Slave marker quantity 76 Slave marker type 74 Slave markers 77 Slave position 79 Slave speed 79 Slave speed factor 77 Software version number 79 Speed synchronization 4 37 Standard RS485 Interface 17 Starting synchronization admixture 48 embossing patterns on mould 58 packaging 69 Status of Synchronization 79 Step time 77 Step width 77 Stopping synchronization admixture 48 embossing patterns...

Page 88: ...VLT 5000 Rev 2003 09 16 www danfoss com drives 175R0237 MG10N402 MG10N402 XREF__BC NOT LOADED ON RIP Operating Instructions Synchronizing Controller VLT 5000 FLUX ...

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