Danfoss MCO 305 User manual

MCO 305 Operating Instructions
MG.33.K2.02 – VLT is a registered Danfoss trademark 1
Contents

How to Read these Operating Instructions..............................3
How to Read these Operating Instructions .......................................................3
Available Literature for FC 300, MCO 305 and MCT 10 Motion Control Tool ...........4
Approvals ...................................................................................................5
Symbols and Conventions .............................................................................5
Abbreviations ..............................................................................................5
Abbreviations ..............................................................................................6

Safety Instructions and General Warnings ...............................7
High Voltage Warning ...................................................................................7
Safety Instructions.......................................................................................7
Before Commencing Repair Work ...................................................................8
Avoid Unintended Start.................................................................................8
Safe Stop of FC 302 .....................................................................................8
General Warning..........................................................................................8

How to Install ..........................................................................9
How to Get Started.......................................................................................9
System Overview.......................................................................................10
Commissioning Guide .................................................................................18
Basic MCO Parameter Settings .....................................................................18
Connecting and Testing the Encoder(s) .........................................................21
PID Controller Settings ...............................................................................22
Executing a Test Program............................................................................25

Optimizing the PID controller.................................................27
How the Control Process Works....................................................................27
Significance and Influence of the Controller Parameters...................................27
PID Factors ...............................................................................................29
Optimizing your Controller Settings Step-by-Step ...........................................31

How to Install the Application ................................................35
Download Application Program and Configuration ...........................................35
Backup and Restore ...................................................................................35
How to Connect and Run Multiple Drives........................................................36

MCO 305 Operating Instructions
2MG.33.K2.02 – VLT is a registered Danfoss trademark

General Specifications ............................................................ 37
Protection and Features ..............................................................................37
Technical Data...........................................................................................37
Supply Voltage Overview.............................................................................40

Troubleshooting .....................................................................41
Warnings and Error Messages ......................................................................41
APOSS Software Messages ..........................................................................46

Appendix ................................................................................ 47
Parameter Lists..........................................................................................47
Index .......................................................................................................54
Copyright ¤Danfoss A/S, 2007
Trademarks VLT is a registered Danfoss trademark.
Microsoft, MS, MS-DOS, Windows 2000, and Windows XP are either registered trademarks or
trademarks of the Microsoft Corporation in the USA and other countries.

MCO 305 Operating Instructions
MG.33.K2.02 – VLT is a registered Danfoss trademark 3
How to Read these Operating Instructions
How to Read these Operating Instructions
These Operating Instructions will help you get started, install, program, and troubleshoot your
Motion Control Option MCO 305. Please read these operating instructions in full and, in order to be able to
work with the system safely and professionally, particularly observe the hints and cautionary remarks.
Chapter How to Read these Operating
Instruction introduces the manual and informs
you about the approvals, symbols, and abbrevia-
tions used in this literature.
Page divider for ‘How to Read these Operating
Instructions’.
Chapter Safety Instructions and General
Warnings entail instructions on how to handle
the MCO 305 correctly.
Page divider for ‘Instructions and General
Warnings’.
Chapter How to Install informs you how to start
up the FC 300 with the 'MCO 305 step-by-step'.
This section offers you a quick general introduc-
tion which includes turning on the controller and
familiarizing yourself with it, as well as starting
operation of the control unit with the test
programs provided and the most important basic
settings.
Page divider for ‘How to Install’.

MCO 305 Operating Instructions
__ How to Read these Operating Instructions __
4MG.33.K2.02 – VLT is a registered Danfoss trademark
Chapter Optimizing the PID Controller pro-
vides all about the PID control parameters and
how to optimize the controller during one or more
test runs, for example, in order to achieve better
positioning results or shorter cycle times. Detailed
instructions on how to proceed can be found in
the section 'Ten steps for optimum control'.
Chapter How to Install the Application informs
about Download, Backup, and Restore features.
Page divider for ‘How to Optimize the PID
Controller’ and ‘How to Install the Application’.
Chapter General Specifications entails technical
data about MCO 305.
Page divider for ‘General Specifications’.
Chapter Troubleshooting assists you in solving
problems that may occur when installing
MCO 305.
Page divider for ‘Troubleshooting’.
Chapter Appendix provides information about parameters in clearly arranged lists. Please see the
Parameter Reference in the MCO 305 DesignGuide for more details.

Available Literature for FC 300, MCO 305 and MCT 10 Motion Control Tool

The MCO 305 Design Guide entails all technical information about the option board and customer
design and applications.
The VLT®AutomationDrive FC 300 Operating Instructions provide the necessary information for getting
the drive up and running.
The VLT®AutomationDrive FC 300 Design Guide entails all technical information about the drive and
customer design and applications.
The VLT®AutomationDrive FC 300 Profibus Operating Instructions provide the information required for
controlling, monitoring and programming the drive via a Profibus fieldbus.
The VLT®AutomationDrive FC 300 DeviceNet Operating Instructions provide the information required
for controlling, monitoring and programming the drive via a DeviceNet fieldbus.
The VLT®AutomationDrive FC 300 MCT 10 Operating Instructions provide information for installation
and use of the software on a PC.
Danfoss Drives technical literature is also available online at www.danfoss.com/drives.

MCO 305 Operating Instructions
__ How to Read these Operating Instructions __
MG.33.K2.02 – VLT is a registered Danfoss trademark 5

Approvals

Symbols and Conventions
Symbols used in this manual:
NB!:
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
*Indicates default setting.
Conventions
The information in this manual follows the system and uses the typographical features described below to
the greatest extent possible:
Menus and Functions
Menus and functions are printed italics, for example: Controller oParameters.
Commands and Parameters
Commands and parameter names are written in capitals, for example: AXEND and KPROP; Parameters are
printed in italics, for example: Proportional factor.
Parameter Options
Values for use to select the parameter options are written in brackets, e.g. [3].
Keys
The names of keys and function keys are printed in brackets, for example the control key [Cntl] key, or just
[Cntl], the [Esc] key or the [F1] key.

MCO 305 Operating Instructions
__ How to Read these Operating Instructions __
6MG.33.K2.02 – VLT is a registered Danfoss trademark

Abbreviations
Automatic Motor Adaptation AMA
Direct Current DC
Frequency Converter FC
Local Control Panel LCP
Master Unit MU
Millisecond ms
Minute min
Motion Control Option MCO
Motion Control Tool MCT
Parameter par.
Protective Extra Low Voltage PELV
Position Control Loop PID
Pulses per Revolution PPR
Quad-counts qc
Revolutions per Minute RPM
Second s
Switch normally closed nc
Switch normally open no
User Unit UU
Volts V

MCO 305 Operating Instructions
MG.33.K2.02 – VLT is a registered Danfoss trademark 7
Safety Instructions and General Warnings
MCO 305
Operating Instructions
Software version: 4.xx
These Operating Instructions can be used for the MCO 305 option board
with all FC 300 frequency converters with software version 4.0x.
The software version number can be seen from parameter 15-43.

High Voltage Warning
The voltage of the FC 300 is dangerous whenever the converter is connected to mains.
Incorrect fitting of the motor or FC 300 may cause damage to the equipment, serious injury or death.
Consequently, it is essential to comply with the instructions in this manual as well as local and national rules
and safety regulations.
At altitudes above 2 km, please contact Danfoss Drives regarding PELV.

Safety Instructions
Make sure the FC 300 is properly connected to earth.
Do not remove mains plugs or motor plugs while the FC 300 is connected to mains.
Protect users against supply voltage.
Protect the motor against overloading according to national and local regulations.

MCO 305 Operating Instructions
__ Safety Instructions and General Warnings __
8MG.33.K2.02 – VLT is a registered Danfoss trademark
Motor overload protection is not included in the default settings. To add this function, set par. 1-90
Motor thermal protection to value ETR trip or ETR warning. For the North American market:
ETR functions provide class 20 motor overload protection, in accordance with NEC.
The earth leakage current exceeds 3.5 mA.
The [OFF] key is not a safety switch. It does not disconnect the FC 300 from mains.

Before Commencing Repair Work
1. Disconnect FC 300 from mains.
2. Disconnect DC bus terminals 88 and 89.
3. Wait at least 4 minutes.
4. Remove motor plugs.

Avoid Unintended Start
While FC 300 is connected to mains, the motor can be started/stopped using digital commands, bus
commands, references or via the LCP.
Disconnect the FC 300 from mains whenever personal safety considerations make it necessary to avoid
unintended start.
To avoid unintended start, always activate the [OFF] key before changing parameters.
Unless terminal 37 is turned off, an electronic fault, temporary overload, a fault in the mains supply, or
lost motor connection may cause a stopped motor to start.

Safe Stop of FC 302
The FC 302 can perform the Designated Safety Function Uncontrolled Stopping by removal of power (as
defined by draft IEC 61800-5-2) or Stop Category 0 (as defined in EN 60204-1). It is designed and appro-
ved suitable for the requirements of Safety Category 3 in EN 954-1. This functionality is called Safe Stop.
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 of the FC 300 Design Guide MG.33.BX.YY must be
followed! The information and instructions of the Operating Instructions are not sufficient for a correct and
safe use of the Safe Stop functionality!

General Warning
Warning:
Touching the electrical parts may be fatal – even after the
equipment has been disconnected from mains.
Also make sure that all voltage inputs have been disconnected,
such as load-sharing (linkage of DC intermediate circuit), as well
as the motor connection for kinetic back-up.
Using VLT AutomationDrive FC 300 (at and below 7.5 kW):
wait at least xx minutes.
xx = The waiting time using the VLT AutomationDrive FC 300 is
different for different sizes: Please see period of waiting time xx in
the FC 300 Operating Instructions.

MCO 305 Operating Instructions
MG.33.K2.02 – VLT is a registered Danfoss trademark 9
How to Install

How to Get Started
Please consult the FC 300 Operating Instructions (MG.AX-XX) for correct installation of FC 300, this
instruction covers installation of MCO 305.
The installation procedure depends on whether the MCO 305 was delivered as an option for upgrading an
existing FC 300 or if it was preinstalled before delivery. Skip the next chapter (Mechanical installation) if the
MCO 305 was preinstalled:

Initialization to Default Settings
Initialize the frequency converter to default setting in two ways:
Recommended initialization (via par. 14-22):
1. Select par. 14-22
2. Press [OK]
3. Select “Initialization”
4. Press [OK]
5. Cut off the mains supply and wait until the
displays turns off.
6. Reconnect the mains supply – the frequency
converter is now reset.
NB!
MCO 305 programs and arrays are not
affected.
Par. 14-22 initializes all except:
14-50 RFI 1
8-30 Protocol
8-31 Address
8-32 Baud Rate
8-35 Minimum Response Delay
8-36 Maximum Response Delay
8-37 Max Inter-char Delay
15-00 to 15-05 Operating Data
15-20 to 15-22 Historic log
15-30 to 15-32 Fault log

MCO 305 Operating Instructions
__ How to Install __
10 MG.33.K2.02 – VLT is a registered Danfoss trademark
Manual initialization
1. Disconnect from mains and wait until the
display turns off.
2. Press [Status] – [Main Menu] – [OK] at the
same time:
3. Reconnect mains supply while pressing the keys.
4. Release the keys after 5 s.
5. The frequency converter is now programmed
according to default settings.
This method initializes all except:
15-00 Operating Hours
15-03 Power-up’s
15-04 Over temp’s
15-05 Over volt’s
NB!:
When you carry out manual initialization, you also reset serial communication and fault log
settings.
And all MCO 305 programs and arrays are deleted!

System Overview

Mechanical Installation
(Only relevant if the MCO 305 is delivered as option for upgrading an existing FC300)
Frame size A2 and A3

MCO 305 Operating Instructions
__ How to Install __
MG.33.K2.02 – VLT is a registered Danfoss trademark 11
Frame size A5, B1 and B2

Accessory Bag
Accessory bag A2 and A3 enclosures:

Installation kit A5 enclosure:
Installation kit B and C enclosure:
MCO 305 Operating Instructions
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12 MG.33.K2.02 – VLT is a registered Danfoss trademark

MCO 305 Operating Instructions
__ How to Install __
MG.33.K2.02 – VLT is a registered Danfoss trademark 13
Electrical Installation
All control cables must be screened and the cable screen must be connected to earth at both ends. It is
very important to use the correct cable for encoders to avoid noise problems, always follow the prescrip-
tions of the encoder supplier. See also FC 300 Design Guide (MG.33.AX.XX) for more information regarding
EMC correct cable installation.

MCO 305 Control Terminals
Frame size A2 and A3:
All MCO 305 terminals are located behind the C-
option terminal cover, see illustration.
Frame size A5, B1 and B2:
All MCO 305 terminals are located next to the
FC 300 control card. Remove the front cover to get
access, see illustration.

MCO 305 Operating Instructions
__ How to Install __
14 MG.33.K2.02 – VLT is a registered Danfoss trademark
MCO 305 control terminals are plug connectors with screw terminals; the terminal blocks are duplicated to
enable use of the same MCO 305 in all frame sizes. See illustration to locate the terminal blocks:
(1) is used with frame sizes A2 and A3,
(2) is used with frame sizes A5, B1 and B2:
X55 = Encoder 2
X56 = Encoder 1
X57 = Digital inputs
X58 = 24VDC supply
X59 = Digital outputs
X55
X56
X58
X59
(1) (2)
X57

MCO 305 Operating Instructions
__ How to Install __
MG.33.K2.02 – VLT is a registered Danfoss trademark 15

Terminal overview
Terminal
block
Terminal
number
Descriptive Name
Encoder 2 (Feedback)
1 +24V Supply
2 +8V Supply
3 +5V Supply
4 GND
5 A
6 A not
7 B
8 B not
9 Z / Clock
10 Z not / Clock not
11 DATA
X55
12 DATA not
Terminal
block
Terminal
number
Descriptive Name
Encoder 1 (Master)
1 +24V Supply
2 N/A (not available)
3 +5V Supply
4 GND
5 A
6 A not
7 B
8 B not
9 Z / Clock
10 Z not / Clock not
11 DATA
X56
12 DATA not
Terminal
block
Terminal
number
Descriptive 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
X57
10 Digital Input
Terminal
block
Terminal
number
Descriptive Name
Supply
1 +24V Supply
X58 2 GND
Terminal
block
Terminal
number
Descriptive Name
Digital outputs
1 Digital Output/Input
2 Digital Output/Input
3 Digital Output
4 Digital Output
5 Digital Output
6 Digital Output
7 Digital Output
X59
8 Digital Output

MCO 305 Operating Instructions
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16 MG.33.K2.02 – VLT is a registered Danfoss trademark

Connection Examples
5V incremental encoder (RS422) supplied by
MCO 305:
5 V incremental encoder (RS422) supplied by an
external power source:
24 V absolute encoder (SSI) supplied by
MCO 305:
24 V absolute encoder (SSI) supplied by an
external power source:

MCO 305 Operating Instructions
__ How to Install __
MG.33.K2.02 – VLT is a registered Danfoss trademark 17
Virtual master connection:
When more than 2 MCO 305 master encoder
interfaces are interconnected termination must be
on (par. 32-40 = ON) at both ends of the bus.
Termination must be off (par. 32-40 = OFF) in all
other MCO's.

MCO 305 Operating Instructions
__ How to Install __
18 MG.33.K2.02 – VLT is a registered Danfoss trademark

Commissioning Guide
This guideline is only describing basic configuration and optimizing of MCO 305, before starting the following
steps must be completed:
1. Basic commissioning of FC 300. NOTE: FC 300 must be optimized and have good control over the motor
and application before commissioning MCO 305! Guidelines can be found in FC 300 Operating
Instructions (MG.33.AX.XX).
2. Install the PC software tools (MCT 10 and APOSS)
3. Establish communication between PC and FC 300 using USB, RS485 or PROFIBUS DPV1.
Then follow these steps to set-up and optimize MCO 305:
1. Setting of basic MCO 305 parameters (groups 32-** and 33-**).
2. Connect and test encoder(s).
3. Optimize PID controller.
NB!:
Error 113 will show up right after power up if the FC 300 is not ready. The FC 300 is in the “Not
ready” state when:
it has an alarm (trip),
it is in hand mode, [Hand on] key,
local LCP stop is activated, [OFF] key,
there is no signal on input 37 safe stop (only FC 302).
Error 113 can only be reset using the ERRCLR command or with BREAK [Esc] in the PC software and only
when the FC 300 is in the “ready” state, which means none of the above may be true.
The FC 300 monitoring function can be switched off by selecting [0] in par. 33-82 Drive Status Monitoring.
Read the Safety Instructions before installing the drive.
Basic MCO Parameter Settings
The following parameters must always be checked and if necessary adjusted. Depending on the require-
ments of the application it might be necessary to adjust other parameters as well.
For the other parameters you can use the default settings at first and then optimize the controller as
needed at a later point in time with a Testrun.
The MCT 10 Set-up Software Tool will support you to set the parameters in Local Control Panel LCP.
For a detailed description of all parameters and there options please refer to the chapter Parameter
Reference.
Once the parameter settings are complete, it is recommended to save the settings.

MCO 305 Operating Instructions
__ How to Install __
MG.33.K2.02 – VLT is a registered Danfoss trademark 19

Setting of Encoder Parameters
Define the used type of encoder for the slave in
parameter group 32-0*.
These defaults are set:
32-0* Encoder 2 - Slave Default
32-00 Incremental Signal Type [1] RS422
32-01 Incremental Resolution 1024
32-02 Absolute Protocol [0] None
32-03 Absolute Resolution 8192
32-05 Absolute Encoder Data Length 25
32-06 Absolute Encoder Clock
Frequency
262000
32-07 Absolute Encoder Clock
Generation
[1] On
32-08 Absolute Encoder Cable Length 0
32-09 Encoder Monitoring [0] Off
The following parameters are only relevant for
synchronizing applications.
These defaults are set:
32-3* Encoder 1 - Master
32-30 Incremental Signal Type [1] RS422
32-31 Incremental Resolution 1024
32-32 Absolute Protocol [0] None
32-33 Absolute Encoder Resolution 8192
32-35 Absolute Encoder Data Length 25
32-36 Absolute Encoder Clock
Frequency
262000
32-37 Absolute Encoder Clock
Generation
[1] On
32-38 Absolute Encoder Cable Length 0
32-39 Encoder Monitoring [0] Off
32-40 Encoder Termination [1] On

Setting of Velocity Parameters
Define par. 32-80, the Maximum Velocity of the
shaft where the encoder is mounted in RPM. 32-8* Velocity & Acceleration Default
32-80 Maximum Velocity (Encoder) 1500
32-81 Shortest Ramp 1.000
NB!:
For synchronizing the setting must be at least the same as the maximum velocity of the master in
order to be able to synchronize. For position synchronizing it must even be higher so that the slave
can catch up lost position related to the master. All velocity commands (VEL, CVEL) are related to
this value.
Define par. 32-81 Shortest Ramp. That is the time from 0 to maximum velocity and from maximum velocity
to 0. All acceleration and deceleration commands (ACC, DEC) are related to this value.

MCO 305 Operating Instructions
__ How to Install __
20 MG.33.K2.02 – VLT is a registered Danfoss trademark

Setting of Home Parameters
Homing is not necessary in standard synchronization applications and applications using an absolute
encoder.
When using an incremental encoder the controller
must be run to home after being switched on.
During this process the reference switch defines
the position at which 0 is located and how the
FC 300 functions during a home run: input depends
on the application.
Define par. 33-03 Velocity of Home Motion: Home
speed is entered in % relative to the maximum
speed of the drive.
33-0* Home Motion Default
33-00 Force HOME [0] not forced
33-01 Zero Point Offset from
Home Position
0
33-02 Ramp for Home Motion 10
33-03 Velocity of Home Motion 10
33-04 Behavior during Home
Motion
[0] Reverse
+ Index

Setting of Synchronization Parameters
The following parameters are only relevant for
synchronizing applications:
Par. 33-10, 33-11: Synchronizing Factor Master
and Slave
The Synchronizing Factors Master and Slave must
be set according to the gear ratio between master
and slave encoder.
Example:
Both encoders have 1024 PPR, master is running
305 RPM and slave must run 1220 RPM.
par. 33-10 Syncfactor Master
par. 33-11 Syncfactor Slave
= 305 and
= 1220
Alternative:
par. 33-10 Syncfactor Master
par. 33-11 Syncfactor Slave
= 1
= 4
The following parameters are only relevant when using synchronizing with marker correction (SYNCM):
Par. 33-15, 33-16: Marker Number for Master and
for Slave
Marker Number for Master and Slave must be set
according to the ratio between the number of
marker signals from master and slave. A ratio of
1:1 means that each slave marker will be aligned
with each master marker. A ratio of 2:1 means that
each slave marker will be aligned with each second
master marker.
33-1* Synchronization Default
33-10 Synchronization Factor
Master (M:S)
1
33-11 Synchronization Factor Slave
(M:S)
1
33-15 Marker Number for Master 1
33-16 Marker Number for Slave 1
33-17 Master Marker Distance 4096
33-18 Slave Marker Distance 4096
33-19 Master Marker Type [0] Enc. Z pos.
33-20 Slave Marker Type [0] Enc. Z pos.
Par. 33-17, 33-18: Master and Slave Marker Distance
When using the encoder zero pulse as marker signal the distance between 2 markers is the resolution (qc)
of the encoder.
When external marker signals are used, the marker distance can be measured by means of the program
sample “Marker count” (see chapter program samples) if it is unknown.