Danfoss VLT 5000 Series User manual

SyncPos Motion Controller

VLT®5000 SyncPos option
MD.50.B2.02 – VLT is a registered Danfoss trade mark2
■VLT 5000 synchronising/positioning option
The SyncPos motion controller for VLT 5000 is an
integrated synchronising and positioning controller.
One controller can synchronise two axes. When
using the virtual master function and multiple
controllers it is possible to synchronise up to 32 axes
(even more when using repeaters).
The position controller is a single axis controller
which can perform relative or absolute positioning.
In addition to the synchronising and positioning
functions the programmable controller can perform
PLC like functions.
The SyncPos motion controller can be delivered as:
- Separate option card for updating VLT 5000
or
- Build into the VLT 5000
Ordering details can be found in the VLT 5000
Design Guide.
Synchronising of two axes with one SyncPos motion
controller
Synchronising of multiple axes using the virtual master function
■Application examples
The SyncPos motion controller combined with the
dynamic performance of VLT 5000 opens new
posibilities for using frequency converters in a wide
range of applications as for example:
- Bottle washing machines
- Palletizers
- Packaging machines
- Cranes
- Positioning on the fly for e.g. filling, cutting,
spray painting and drilling
- Indexing tables
- Storage systems
SyncPos Motion Controller
- Pick and Place systems
- Vibrating tables
- Material handling
- Film wrapping
- Conveyors

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MD.50.B2.02 –VLT is a registered Danfoss trade mark
VLT®5000 SyncPos option
■Function overview
General featuresGeneral features
General featuresGeneral features
General features
- Coverage of the entire VLT 5000 series; power range 0.37-500kW, voltage range
200V-500V.
- Use of standard AC motors
- Motion controller fits inside the VLT 5000 drive to preserve IP/NEMA rating
- No extra panel space required
- Standard user interface - settings and messages via the VLT 5000 local control
panel
- Utilizes the VLT 5000 series' field bus options, including PROFIBUS, DeviceNet
and Interbus
- Smooth change between three control modes: Closed loop speed control,
synchronizing and positioning
- Standard incremental and absolute encoder interface (RS422, line driver) up to
220 kHz
- Improved encoder resolution thanks to quadrature signals
Synchronizing functionsSynchronizing functions
Synchronizing functionsSynchronizing functions
Synchronizing functions
- Speed synchronizing
- Position (angle) synchronizing, with or without marker correction
- On-line adjustable gear ratio
- On-line adjustable position (angle) offset
- Encoder output with virtual master function for synchronization of multiple slaves
Positioning functionsPositioning functions
Positioning functionsPositioning functions
Positioning functions
- Home function
- Absolute positioning
- Relative positioning
- Marker related positioning
- Programmable speed profiles
- Hardware and software end limits
Programmable controller functionsProgrammable controller functions
Programmable controller functionsProgrammable controller functions
Programmable controller functions
Easy-to-use high level programming language (BASIC-like) featuring:
- Definition of user parameters on VLT 5000 local control panel
- Handling of digital and analog I/O
- Read/write access to VLT 5000 parameters
- Conditional/unconditional jumps
- Calculation, comparison, bit manipulation and logical gating
- Error handling routine
- Digital input interrupts
- Time controlled interrupts
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- Graphical PID controller optimizing tool
- Position teach-in function
- Parameter settings
- Program single stepping for debugging
- On-line help/manual
- Test programs
SyncPos Motion Controller

VLT®5000 SyncPos option
MD.50.B2.02 –VLT is a registered Danfoss trade mark4
■■
■■
■Option card layout:
Option card layout showing the position of connectors and dip switch.
Digital Inputs Master / Virtual Master
Digital Outputs Feedback
Terminal A2 A2 B2 B2 Z2 Z2
Incremental encoder A in A in B in B in Z in Z in
Absolute input encoder Clk out Clk out Data in Data in Not used Not used
Terminal A1 A1 B1 B1 Z1 Z1
Incremental encoder A in A in B in B in Z in Z in
Absolute encoder Clk out Clk out Data in Data in Not used Not used
Virtual master A out A out B out B out Z out Z out
■■
■■
■Input/Output data:
SyncPos Motion Controller
The control card inputs and outputs can be allocated for the SyncPos application program. Together with the
inputs and output of the SyncPos option card the available programmable inputs and outputs are thus:
2 Encoder inputs (one can be used as output).
3 Analogue inputs.
16 Digital inputs.
8 Digital outputs.
2 Digital/analogue outputs.
2 Relay outputs.
Detailed specification of the control card inputs and outputs can be found in the VLT 5000 design guide.

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MD.50.B2.02 –VLT is a registered Danfoss trade mark
VLT®5000 SyncPos option
■■
■■
■Technical data, continued
Terminals:
Type ................................................................................................................... Plugs with screw connections
Maximum cable size ............................................................................................................ 1.3 mm2 (AWG 16)
Digital inputs, MK3A:
Number of inputs which are used by SyncPos program ................................................................................ 8
Terminal designations .............................................................................................................................. I1 –I8
Voltage level....................................................................................................0 –24 V DC (PNP positive logic)
Voltage threshold logical “0”.................................................................................................................. 6 V DC
Voltage threshold logical “1”.............................................................................................................13.5 V DC
Maximum voltage ................................................................................................................................ 28 V DC
Input impedance........................................................................................................................................ 3 kΩ
Min. pulse duration (ON INT) ................................................................................................................. 1 msec
Galvanic isolation: All digital inputs are galvanically isolated by means of optocouplers,
but with the same common as the digital outputs.
Digital outputs, MK3C:
Number of outputs which are used by SyncPos program.............................................................................. 8
Terminal designations .......................................................................................................................... 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, page 10)
Encoder input 1, MK3B (master):
Terminal designations ................................................................................................. A1, A1, B1, B1, Z1, Z1.
Incremental:
Signal level...................................................................................................................................5 V differential
Signal type............................................................................................................................Linedriver, RS 422
Input impedance.............................................................................................. 140 Ω(Dip switch 1.1–4 = ON)
.......................................................................................................................12 kΩ(Dip switch 1.1–4 = OFF)
Maximum frequency ........................................................................................... 220 kHz (at 50 % duty cycle)
Phase displacement between A and B...............................................................................................90°±30°
Absolute:
Signal level...................................................................................................................................5 V differential
Signal type....................................................................................................................................................SSI
Data coding ...................................................................................................................................... Gray code
Data length............................................................................................................................................... 25 bit
Parity.......................................................................................................................................................... none
Clock frequency ....................................................................................................................... 105 or 262 kHz
Protocol ..................................................................................................................................................... Gray
Maximum positions per revolution ............................................................................................................. 8192
Maximum number of revolutions ............................................................................................................... 4096
SyncPos Motion Controller

VLT®5000 SyncPos option
MD.50.B2.02 –VLT is a registered Danfoss trade mark6
Encoder input 2, MK3D (slave):
Terminal designations ...................................................................................................A2, A2, B2, B2, Z2, Z2
Incremental:
Signal level...................................................................................................................................5 V differential
Signal type............................................................................................................................. Linedriver, RS422
Input impedance...................................................................................................................................... 140 Ω
Maximum frequency ........................................................................................... 220 kHz (at 50 % duty cycle)
Phase displacement between A and B...............................................................................................90°±30°
Absolute:
Signal level...................................................................................................................................5 V differential
Signal type....................................................................................................................................................SSI
Protocol ............................................................................................................................................ Gray code
Data length............................................................................................................................................... 25 bit
Parity.......................................................................................................................................................... none
Clock frequency ....................................................................................................................... 105 or 262 kHz
Maximum positions per revolution ............................................................................................................. 8192
Maximum number of revolutions ............................................................................................................... 4096
Encoder output, MK3B:
Terminal designations ...................................................................................................A1, A1, B1, B1, Z1, Z1
Signal type............................................................................................................................. Linedriver, RS485
Maximum frequency .............................................................................................................................150 kHz
Minimum frequency ................................................................................................................................150 Hz
Maximum number of slaves ........................................................................... 31 (more when using repeaters)
Maximum cable length ............................................................................................................................400 m
■■
■■
■Dip switch 1.1 –1.5
Switch
designation OFF ON
1.1 Option card must be supplied from an Option card is supplied from control card
external power supply (24 V) (24 V)
1.2 Terminating resistor not connected (Z channel) Terminating resistor connected (Z channel)
1.3 Terminating resistor not connected (B channel) Terminating resistor connected (B channel)
1.4 Terminating resistor not connected (A channel) Terminating resistor connected (A channel)
1.5 Option card must be supplied from an Option card is supplied from control
external power supply (Common) card (Common)
Default setting of switch 1.1 - 1.5 is ON.
SW. 1.2, 1.3 and 1.4 applies only to MK3B (the master encoder interface).
NB!
When using the virtual master function termination must be switched off (sw 1.2-1.4) in all options
except on the first and the last station connected in the network.
SyncPos Motion Controller
Encoder cable
Cable type………………………………………. ...............Twisted pair and screened. Note:Note:
Note:Note:
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 262 kHz clock.
(Tested with TR electronic encoder type CE-65 M 8192*4096 and appropriate cable prescribed by TR electronic)
Maximum allowed time delay between clock and data signal measured at the controller terminals
105kHz clock = 9 µsec
262kHz clock = 3.5 µsec

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MD.50.B2.02 –VLT is a registered Danfoss trade mark
VLT®5000 SyncPos option
Each digital input on the option card takes 8 mA.
Each digital output on the option card can supply up
to 0.7 A (external 24V-supply) depending on the
load.
The load from the 24 V supply (internal or external)
can be calculated as follows:
8 mA * number of digital inputs
+
Load on digital outputs
(mk3 C, O1 –O8)
+
load on 5 V supply
(mk3 B/D, 5 V/com)
+
Load on control card
(24 V supply, terminal 12/13 and
outputs, terminal 42/45)
■■
■■
■Supply voltages:
The option card is supplied by the internal 24 V DC
supply of VLT 5000, but as the available power is
limited it can be necessary to use an external 24 V
DC supply.
The 24 V DC supply of VLT 5000 can supply a total
of 420 mA 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 1.5.
SyncPos Motion Controller

VLT®5000 SyncPos option
MD.50.B2.02 –VLT is a registered Danfoss trade mark8
ABSOLUTE ENCODER
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■■
■Connection examples
The terminating resistors on both end of the
bus have to be switch on with dip switch
SW 1.2–4.
SyncPos Motion Controller
Master Slave
Master Slave

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MD.50.B2.02 –VLT is a registered Danfoss trade mark
VLT®5000 SyncPos option
SyncPos Motion Controller
Encoder connection for master-/slave sychronization
Encoder connection for positioning applications
Encoder connections for the synchronizing with
virtual master.

Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material.
Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such
alterations can be made without subsequential changes being necessary in specifications already agreed.
175R0308 VLT is a registered Danfoss trademarkMD.50.B2.02-