VLT 5000/5000 FLUX SyncPos Quick-Setup ■ Safety ...................................................................... 2 Chapter 2 ■ Introduction ........................................................... 3 Chapter 3 ■ Typical application example .................................. 4 Chapter 4 ■ Basic SyncPos information .................................. 6 Chapter 5 ■ Installing the SyncPos PC Software ................... 8 Chapter 6 ■ Checking encoder connections ...........................
Safety VLT 5000/5000 FLUX SyncPos Quick-Setup ■ The voltage of the frequency converter is dangerous whenever the equipment is connected to mains. Incorrect installation of the motor or the frequency converter may cause damage to the equipment, serious personal injury or death. Consequently, the instructions in this manual, as well as national and local rules and safety regulations, must be complied with. ■ Safety regulations 1.
VLT 5000/5000 FLUX SyncPos Quick-Setup Introduction ■ About this manual: How is it arranged? 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. It is important to have knowledge about operating a VLT 5000/5000 FLUX. Indicates a general warning Indicates something to be noted by the reader Indicates a high-voltage warning MG.10.Q1.
Typical application example VLT 5000/5000 FLUX SyncPos Quick-Setup ■ Description in brief The tire will enter the conveyor belt from the right. This, in turn, will start to run at the same speed as the previous conveyor belt. When the tire reaches the centering station it will stop. The tire will be centered and stays in the waiting position until the machine has finished measuring the "previous" tire.
VLT 5000/5000 FLUX SyncPos Quick-Setup Typical application example MG.10.Q1.
Basic SyncPos information VLT 5000/5000 FLUX SyncPos Quick-Setup ■ How SyncPos functions Let us explain the basic principle of SyncPos in brief: Determining parameters Factory settings are stored in the program for all parameters. These factory settings are active upon delivery. You can adjust all the parameters for your controller. These user parameters are permanently saved in the EEPROM and are valid for all programs.
VLT 5000/5000 FLUX SyncPos Quick-Setup ■ The SyncPos Window The following figure serves to explain the most important elements of the SyncPos Windows. Each window represents a SyncPos program which can be connected with a VLT. Thus, you can open at least the same number of edit windows as the number of controllers resp. VLTs you have selected. Symbol bar Click on the icons in the symbol bar to quickly select a function.
Installing the SyncPos PC Software VLT 5000/5000 FLUX SyncPos Quick-Setup . This section offers you a quick general introduction which includes turning on and familiarizing yourself with the program, how to set up a VLT with SyncPos motion controller using the test programs provided and the most important basic settings. NB! O.ERR 13 will show up right after power up if the VLT is not ready.
VLT 5000/5000 FLUX SyncPos Quick-Setup Press "ok" to confirm interruption of program. Choose parameter group Encoder. The factory default setting of encoder resolution is 500 as shown. Checking encoder connections Function of inputs and output must be selected in parameter group 3xx according to the required functions. Note that the default values are different from a drive without option. Please note that Dead Time Compensation in parameter 780 (not Flux) is set to OFF.
Checking encoder connections VLT 5000/5000 FLUX SyncPos Quick-Setup drive forward for example in local mode (Parameter 002 = ”Local”) then the position must count positive. If the position is counting negative you must swap A and B channels from the encoder or two motor phases. You can also turn the encoder by hand (the motor should not be connected!). The position is continuously registered in the communications window.
VLT 5000/5000 FLUX SyncPos Quick-Setup 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
10 steps to optimise the PID loop VLT 5000/5000 FLUX SyncPos Quick-Setup AV is the actual velocity AP is the actual position (calculated from encoder feedback) in qc (Quad Counts). CP is the current Setpoint position in qc. CV is the Setpoint velocity in qc/ms. (Position deviation) is calculated by CP–AP. NB! In SYNCV mode the PID controller is working with speed deviation instead of position deviation. Speed deviation is calculated by CV–AV.
VLT 5000/5000 FLUX SyncPos Quick-Setup Velocity Feed-forward FFVEL (36) The Velocity feed-forward factor is a scaling factor that is multiplied with the derivative of the setpoint position (the velocity of the setpoint). The result of this operation is added to the overall control signal. This feature is especially useful in applications where there is a good correlation between the control signal (the VLT speed reference), and the speed of the motor.
10 steps to optimise the PID loop VLT 5000/5000 FLUX SyncPos Quick-Setup ■ Optimizing your controller settings step-by-step For best results use the functions in the testrun menu for this purpose; these help you to evaluate and optimize the PID controller on the basis of graphs of the set and actual curves. However, we recommend only changing one value at a time and subsequently determining the improvement with a testrun..
VLT 5000/5000 FLUX SyncPos Quick-Setup FFVEL is now optimized, save the current value. Please note that some high inertia systems do not allow the use of FFVEL. 4. In systems with large inertia and/or rapid changes in the reference velocity it is a good idea to use and optimize the Acceleration feed-forward control (make sure the inertial load is connected when optimizing this parameter): Step 1) Execute a "TESTRUN" with KPROP=0, KDER=0, KINT=0, FFACC=0 and FFVEL at the optimized value calculated above.
10 steps to optimise the PID loop VLT 5000/5000 FLUX SyncPos Quick-Setup ... the tolerated position error is exceeded If the test run is constantly interrupted with the message “position error” set the parameter for the Tolerated position error POSERR (15) – within the tolerable limits– as large as possible. If the position error occur during the acceleration phase that suggests that the set acceleration cannot be achieved under the existing load conditions.
VLT 5000/5000 FLUX SyncPos Quick-Setup Error messages ■ VLT and SyncPos Motion Controller messages All messages are shown in the LCP display of the VLT in short and in the SyncPos software in plain text. You can find brief information on the error messages in the table or detailed information in the following section. ■ Table of Messages The tables contain the messages in numerical order. Letters following a % sign represent variables which can be used in plain text at the corresponding locations. O.
Error messages VLT 5000/5000 FLUX SyncPos Quick-Setup ■ SyncPos option messages in detail As in the table above, the messages are in numerical order. Here you can find additional information about possible causes and tips on troubleshooting. O.ERR_3 SyncPos Axis no. %bu not in system Cause An attempt has been made to find another axis which does not exist in the controller. (The program allows for input of axis numbers greater than 1 since it is configured for multi-axes applications.
VLT 5000/5000 FLUX SyncPos Quick-Setup Cause A motion command will cause / has caused the software limit switch to be activated. Tip Identification of attainment of software limit at a motion in the speed mode will only be made after the current position is identical to the software limit switch.
Error messages VLT 5000/5000 FLUX SyncPos Quick-Setup O.ERR_18 SyncPos Reset by CPU O.ERR_51 SyncPos Too many nested GOSUB commands Meaning The processor has been stopped and a re-set has automatically been executed (watchdog). Cause In the program, too many calls from one subroutine to another subroutine exist. The error usually occurs when there is a recurrent reference to one of the sub-programs in a subprogram. Cause Short term voltage drop, voltage peak or short circuit. O.
VLT 5000/5000 FLUX SyncPos Quick-Setup O.ERR_84 SyncPos Too many time interrupts Meaning The definition of an array in a DIM command does not correspond to an already existing array in the SyncPos option. Meaning Too many ON TIME or ON PERIOD commands were used within the program. Cause The fields are from older SyncPos programs. The current program has other definitions.
Error messages VLT 5000/5000 FLUX SyncPos Quick-Setup O.ERR_91 SyncPos Curve array wrong Meaning An incorrect or old array is defined in the DIM instruction for SETCURVE. Tip An old array may exist if the cnf file with all parameters and arrays has not been loaded into the CAM-Editor. An incorrect array could be caused by the following: • It was not created by the curve editor. • Previous version of a curve editor. Such an array must first be converted by the current curve editor (→ "LOAD" and "SAVE").
VLT 5000/5000 FLUX SyncPos Quick-Setup ■ Error in global parameter ... SyncPos Error in global parameter part of file. Meaning When re-saving a configuration ("CONTROLLER" → "PARAMETERS" → "RESTORE FROM FILE") the computer recognizes that the data in the array area is formatted incorrectly. Meaning When re-saving a configuration ("CONTROLLER" → "PARAMETERS" → "RESTORE FROM FILE") the computer recognizes that the data in the area of the global parameters is formatted incorrectly.
Error messages VLT 5000/5000 FLUX SyncPos Quick-Setup There are two interfaces to the SyncPos option: • 36 terminals on the option card • 24 terminals on the VLT control card ■ VLT control card terminals The terminals on the control card can be allocated for synchronizing and positioning functions if the following parameter settings are made: Digital inputs 16, 17, 18, 19, 27, 29, 32 and 33: It is always possible to read the status of the digital inputs from the SyncPos application program with the IN comm
VLT 5000/5000 FLUX SyncPos Quick-Setup Encoder interface 2 MK3D is a 8pole terminal block with 6 terminals for the encoder signals and 2 terminals with 5 V supply. Digital outputs MK3C is a 10pole terminal block with 8 digital outputs and 2 terminals for 24 V supply. The digital outputs are controlled by the SyncPos application program and are thus free programable. All the outputs can also be assigned functions. • Slave encoder input (incremental or absolute) for synchronizing.
Technical Data/Wiring examples VLT 5000/5000 FLUX SyncPos Quick-Setup ■ Technical data 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 ............................................
VLT 5000/5000 FLUX SyncPos Quick-Setup Encoder 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 262 kHz clock. (Tested with TR electronic encoder type CE-65 M 8192*4096 and appropriate cable prescribed by TR electronic.
Technical Data/Wiring examples VLT 5000/5000 FLUX SyncPos Quick-Setup ■ 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.
VLT 5000/5000 FLUX SyncPos Quick-Setup Encoder monitor master, channel A, B and Z: LED off = Short or open circuit LED green = Ok. Encoder monitor slave, channel A, B and Z: LED off = Short or open circuit LED green = Ok. 5V monitor: LED off = no 5V LED Green = 5V ok. CPU monitor: LED must flash at 1 Hz to indicate a running CPU system SW 1.1: SW 1.2: SW 1.3: SW 1.4: Connect(ON)/disconnect(OFF) 24 V from control card (see description of supply voltages).
Technical Data/Wiring examples VLT 5000/5000 FLUX SyncPos Quick-Setup The terminating resistors on both end of the bus have to be switch on with dip switch SW 1.3. 30 MG.10.Q1.
VLT 5000/5000 FLUX SyncPos Quick-Setup Technical Data/Wiring examples left: encoder connection for positioning applications below: encoder connection for master-/slave synchronization MG.10.Q1.
Technical Data/Wiring examples VLT 5000/5000 FLUX SyncPos Quick-Setup Encoder connections for the synchronizing with virtual master. 32 MG.10.Q1.
VLT 5000/5000 FLUX SyncPos Quick-Setup A About this manual .......................................................... 3 Acceleration feed-forward FFACC (37) .......................... 13 APOS .................................................................. 4, 8, 11 K KDER (12) ................................................................... 12 KILIM (21) .................................................................... 12 KINT (13) ..................................................................
Index VLT 5000/5000 FLUX SyncPos Quick-Setup O V O.ERR_3 ... xx ............................................................. 18 ON APOS .. GOSUB ................................................... 20 ON COMBIT .. GOSUB ................................................ 20 ON INT .. GOSUB ........................................................ 20 ON MAPOS .. GOSUB ................................................ 20 ON MCPOS .. GOSUB ................................................ 20 ON PARAM .. GOSUB ...
