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