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

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

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