Safety Regulation: MCO351 Positioning Controller

MCO351 Positioning Controller Contents
Contents
1. Safety Regulation 3
Approvals 3
Symbols 3
Disposal Instruction 3
High Voltage 4
Safety Instructions 4
Avoid Unintended Start 5
Safe Stop of FC 300 5
Safe Stop Installation (FC 302 and FC 301 - A1 enclosure only) 7
IT Mains 7
2. Introduction 9
Hardware 9
VLT Control Card Terminals 9
Technical Data 9
Introduction 9
Option Card Terminals 9
Encoder Monitor 10
Option Card Layout 11
General Technical Data 11
Description of the Electrical and Fieldbus Interface 13
Option Card X57 15
Option Card X59 16
3. Fieldbus Interface 17
Fieldbus Interface 17
Introduction 17
Data Layout 17
4. Programming 19
Description of Parameters 19
5. Application Examples 35
Application examples 35
Wiring diagram 36
Basic Setup 36
Parameter Settings 37
Timing of the Electromechanical brake (par. 19-10 to 19-12) 38
Setting of par. 32-11 and 32-12 38
Setting for the Homing Procedure (par. 33-00 to 33-04) 38
MG.33.R1.02 - VLT® is a registered Danfoss trademark 1

Contents MCO351 Positioning Controller
Programming positions (par. 19-23 to 19-28) 39

Software Limits (par. 33-41 to 33-44) 39
Setting par. 32-81 and 19-06 39
Other Settings 40
6. Troubleshooting 41
Frequently Asked questions 41
Error Messages 42
Glossary of Key Terms 44
Index 47
2 MG.33.R1.02 - VLT® is a registered Danfoss trademark

MCO351 Positioning Controller 1. Safety Regulation
1. Safety Regulation 1
1.1.1. Approvals
1.1.2. Symbols
Symbols used in these Operating Instructions.
NB!
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
∗ Indicates default setting
1.1.3. Disposal Instruction
Equipment containing electrical components may not be disposed of

together with domestic waste.
It must be separately collected with Electrical and Electronic waste
according to local and currently valid legislation.
The FC 300 AutomationDrive DC link capacitors remain charged after power has
been disconnected. To avoid electrical shock hazard, disconnect the FC 300 from
the mains before carrying out maintenance. When using a PM-motor, make sure it
is disconnected. Before doing service on the frequency converter wait at least the
amount of time indicated below:

1. Safety Regulation MCO351 Positioning Controller
1
FC 300 380 - 500 V 0.25 - 7.5 kW 4 minutes
11 - 75 kW 15 minutes
90 - 200 kW 20 minutes
250 - 400 kW 40 minutes
525 - 690 V 37 - 250 kW 20 minutes
315 - 560 kW 30 minutes
MCO 351 Positioning Controller for

VLT AutomationDrive FC 30x
Operating Instructions
Software version: 1.1x
These Operating Instructions can be used for all MCO 351 Positioning Controller for VLT Au-
tomationDrive FC 30x frequency converters with software version 1.1x.
The software version number can be seen from parameter 19-92.
1.1.4. High Voltage
The voltage of the frequency converter is dangerous whenever the frequency con-
verter is connected to mains. Incorrect installation or operation of the motor or
frequency converter may cause damage to the equipment, serious personal injury
or death. The instructions in this manual must consequently be observed, as well as
applicable local and national rules and safety regulations.
Installation in high altitudes

At altitudes above 2 km, please contact Danfoss Drives regarding PELV.
1.1.5. 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.
• Motor overload protection is not included in the default settings. To add this function,
set parameter 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.

1.1.6. General Warning

1
Warning:
Touching the electrical parts may be fatal - even after the equipment has been dis-
connected from mains.
Also make sure that other 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: wait at least 15 minutes.
Shorter time is allowed only if indicated on the nameplate for the specific unit.
Leakage Current
The earth leakage current from the FC 300 exceeds 3.5 mA. To ensure that the earth
cable has a good mechanical connection to the earth connection (terminal 95), the
cable cross section must be at least 10 mm2 or 2 times rated earth wires terminated
separately.
Residual Current Device
This product can cause a D.C. current in the protective conductor. Where a residual
current device (RCD) is used for extra protection, only an RCD of Type B (time de-
layed) shall be used on the supply side of this product. See also RCD Application
Note MN.90.GX.02.
Protective earthing of the FC 300 and the use of RCD's must always follow national
and local regulations.
1.1.7. Before Commencing Repair Work

1. Disconnect the frequency converter from mains
2. Wait for discharge of the DC-link. See period of time on the warning label.
3. Disconnect DC bus terminals 88 and 89
4. Remove motor cable
1.1.8. 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 Local Control Panel (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.
• An electronic fault, temporary overload, a fault in the mains supply, or lost motor con-
nection may cause a stopped motor to start. FC 300 with Safe Stop (i.e. FC 301 in A1
enclosure and FC 302) provides protection against unintended start, if the Safe Stop
Terminal 37 is on low voltage level or disconnected.
1.1.9. Safe Stop of FC 300

The FC 302, and also the FC301 in A1 enclosure, can perform the safety function Safe Torque
Off (As defined by IEC 61800-5-2) or Stop Category 0 (as defined in EN 60204-1).
FC 301 A1 enclosure: When Safe Stop is included in the drive, position 18 of Type Code must be
either T or U. If position 18 is B or X, Safe Stop Terminal 37 is not included!
Example:
Type Code for FC 301 A1 with Safe Stop: FC-301PK75T4Z20H4TGCXXXSXXXXA0BXCXXXXD0

1. Safety Regulation MCO351 Positioning Controller
It is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1. This
1 functionality is called Safe Stop. Prior to integration and use of Safe Stop in an installation, a
thorough risk analysis on the installation must be carried out in order to determine whether the
Safe Stop functionality and safety category are appropriate and sufficient. 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 fol-
lowed! The information and instructions of the Operating Instructions are not sufficient for a
correct and safe use of the Safe Stop functionality!

1.1.10. Safe Stop Installation (FC 302 and FC 301 - A1 enclosure only)
1
To carry out an installation of a Catego-
ry 0 Stop (EN60204) in conformance
with Safety Category 3 (EN954-1), fol-
low these instructions:
1. The bridge (jumper) between Termi-
nal 37 and 24 V DC must be re-
moved. Cutting or breaking the
jumper is not sufficient. Remove it
Illustration 1.1: Bridge jumper between terminal
entirely to avoid short-circuiting. See
37 and 24 VDC
jumper on illustration.
2. Connect terminal 37 to 24 V DC by a
short-circuit protected cable. The 24
V DC voltage supply must be inter-
ruptible by an EN954-1 Category 3
circuit interrupt device. If the inter-
rupt device and the frequency con-
verter are placed in the same instal-
lation panel, you can use a regular
cable instead of a protected one.
3. Unless the FC302 itself has protec-
tion class IP54 and higher, it must be
placed in an IP 54 enclosure. Conse-
quently, FC301 A1 must always be
placed in an IP 54 enclosure.
The illustration below shows a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN
954-1). The circuit interrupt is caused by an opening door contact. The illustration also shows how
to connect a non-safety related hardware coast.
Illustration 1.2: Illustration of the essential aspects of an installation to achieve a Stopping Category 0 (EN
60204-1) with safety Category 3 (EN 954-1).
1.1.11. IT Mains
Par. 14-50 RFI 1 can on FC 102/202/302 be used to disconnect the internal RFI capacitors from
the RFI filter to ground. If this is done it will reduce the RFI performance to A2 level.

2. Introduction MCO351 Positioning Controller

MCO351 Positioning Controller 2. Introduction
2. Introduction
2.1. Hardware 2
2.1.1. VLT Control Card Terminals
The terminals on the control card are allocated for positioning controller functions the following
parameter settings should therefore not be changed in synchronising mode (set-up 1):
Digital inputs 18, 19, 27, 32 and 33

Parameters 510–515 are set to No operation (default setting), then the inputs are ignored by the
control card but they are used as inputs for the positioning controller.
Analogue inputs 53, 54

Parameters 315, 316 and 317 are set to No function, then the inputs are ignored by the control
card but they are used as inputs to the positioning controller.
Digital/analogue outputs 42
Parameters 650 are set to: MCO 0 … 20 mA [52] analogue output
2.2. Technical Data

2.2.1. Introduction
Technical data on the control card terminals can be found in the VLT Automation Drive FC 300
Design Guide.
2.2.2. Option Card Terminals

There are two encoder interfaces, which cover the following functions:
• Feedback encoder input
• Secondary encoder input
Terminal X55 Terminal X56

Terminal Number Descriptive Name Terminal Number Descriptive Name
Encoder 2 (Feed- Encoder (Secon-
back) dary)
1 + 24 V Supply 1 + 24 V Supply
2 + 8 V Supply 2 NC
3 + 5 V Supply 3 + 5 V Supply
4 GND 4 GND
5 A 5 A
6 A not 6 A not
7 B 7 B
8 B not 8 B not
9 Z / Clock 9 Z / Clock
10 Z / Clock not 10 Z / Clock not
11 Data 11 Data
12 Data not 12 Data not

There are 2 digital input/output terminal blocks, 10 inputs and 8 outputs. (See figure below)
Terminal X57 Terminal X59
2 Terminal Number Descriptive Name

Digital Inputs
Terminal Number Descriptive Name
Digital Output
1 Digital Input 1 Digital Output
9 Digital Input
10 Digital Input
Terminal X59
Terminal Number Descriptive Name
24 V Supply
1 + 24 V Supply
2 GND
2.2.3. Encoder Monitor

Both encoder interfaces are equipped with a monitoring circuit that can detect open circuit as well
as short circuit of each encoder channel. Each encoder channel has a LED showing the status:
Green light means OK, no light means fault. An encoder fault will result in an ”Option error” 192
if encoder monitoring is activated via parameter 3239 (master) and 3209 (slave).

2.2.4. Option Card Layout

MCO 351 control terminals are plug connectors with screw terminals; the terminal blocks are
duplicated to enable use of the same MCO 351 in all frame sizes. See illustration to locate the
terminal blocks: 2
(1) is used with frame sizes A2 and A
(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
2.2.5. General Technical Data

− All inputs, outputs and supply voltages are protected against short circuit.
− All inputs, outputs and supply voltages are galvanic isolated from high voltages such as mains
supply and motor voltage (PELV).
− Encoder signals are monitored during operation and standstill.
− All MCO 351 parameters including user defined application parameters are accessible via the
FC 300 Local Control Panel.
− MCO 351 can be combined with other FC 300 options, namely PROFIBUS and DeviceNet inter-
face.
− All digital inputs and outputs are galvanic isolated from the internal electronics and can be
sourced from an external 24V power supply.
Connection Terminals:
Maximum cross section, rigid wire 1.5 mm2/AWG 16
Maximum cross section, flexible wire 1.5 mm2/AWG 16
Maximum cross section, wire with enclosed core 1.5 mm2/AWG 16
Minimum cross section 0.082/AWG 28
Digital inputs:
Number of programmable digital inputs 10
Terminal block X57
Terminal number 11),21),3,4,5,6,7,8,9,10
Logic PNP or NPN1)
Voltage level 0 - 24 V DC
Voltage level, logic '0' PNP < 5 DC
Voltage level, logic'1' PNP > 10 V DC
Voltage level, logic '0' NPN2) > 19 V DC
Voltage level, logic '1' NPN2) < 14 V DC
Maximum voltage on input 28 V DC
1) ) Selected in parameter 5-00 Digital I/O mode.
The digital inputs are galvanic isolated from the internal electronics and can be sourced by an
external 24V power supply.
Digital outputs:
Number of programmable digital outputs 8 (6)1
Terminal block X59
Terminal number 11), 21),3,4,5,6,7,8
Driver type push/pull

Logic PNP or NPN2)

Max. output current (sink or source) with internal power supply (total Σ) 40 mA
Max. output current (sink or source) with external power supply (per output) 100 mA
2 Terminals X59-1 and X59-2 can be programmed as input, parameter 33-60.
Combined Digital Inputs/Outputs:

Number of digital outputs which can be used as digital inputs 21)
Terminal block X59
Terminal number 1,2
Logic PNP or NPN2)
Voltage level, logic '0' PNP < 10 V DC
Voltage level, logic'1' PNP > 17 V DC
Voltage level, logic '0' NPN > 13 V DC
Voltage level, logic '1' NPN < 6 V DC
Maximum voltage on input 28 V DC
1) Terminals X59-1 and X59-2 can be programmed as input, parameter 33-60.
2) Selected in parameter 5-00 Digital I/O mode.
24 V DC Supply Output
Terminal block X58
Terminal number 1,2
Maximum load 65 mA
The internal 24V power supply can be disconnected via parameter 33-85, an external 24V power
supply must then be connected to X58-1 and X58-2.
Encoder Inputs
Number of encoder inputs 2
Terminal block X55 and X56
Terminal number 5,6,7,8,9,10,11,12
Input impedance 120Ω
Maximum voltage on inputs 5 V DC
Cable type Screened cable with a twisted pair of wires for each encoder channel1)
Incremental encoder type RS422/TTL
Maximum frequency 410 kHz
Phase displacement between A and B 90°±30°
Maximum cable length 300 m1)
Absolute encoder type SSI
Data coding Gray
Data length 12 - 37 bit
Clock frequency 78 kHz - 2 MHz1)
1) Always observe specifications/limitations prescribed by the encoder supplier.
2) 150 m cable is possible up to 500 kHz clock frequency, above 500 kHz cable length must be
limited further.
Encoder Output
Number of encoder outputs 1
Terminal block X56
Terminal number 5,6,7,8,9,10,11,12
Signal type RS 422Ω
Maximum frequency 410 kHz
Maximum number of slaves 31 (more with repeater)

Maximum cable length 400 m
Encoder Output
Number of supply voltages 3
Terminal block
Terminal number
X55 and X56
1,2,3,4 2
24 V, max load 250 mA1)
8 V, max load 250 mA1) 2)
5 V, max load 400 mA1)
1) This is maximum load when only one supply voltage is used; when 2 or 3 supply voltages are
used simultaneously the load must be reduced accordingly. The following must be observed:
load24V + load8V + load5V ≤ 6W and load8V + load5V ≤ 2W.
2) 8 V is only available at terminal block X55.
2.3. Description of the Electrical and Fieldbus Interface
Terminal Designation Description

12 24 V DC 24V power supply for switches etc. maximum load
200 mA
13 24 V DC 24V power supply for switches etc. maximum load
200 mA
18 Reference index Bit 0 Reference position index number bit 0 (least signifi-
(LSB) cant bit). Not used in fieldbus mode.
19 Reference index Bit 1 Reference position index number bit 1. Not used in
fieldbus mode.
20 GND Ground for 24V is normally bridged with Terminal 39,
but can be set to “OFF” by means of Switch SW 4 on
the control card.
27 Reset / ENABLE (error Errors are cleared on the rising edge (must be “0”
clear) min. 1 ms. to guarantee edge detection). Not used in
fieldbus mode. To enable operation, this input must
be maintained at “1” in either digital control mode or
fieldbus control mode.
29 Reference index Bit 4 Reference position index number bit 4 (most signifi-
(MSB) cant bit). Not used in fieldbus mode. Not used in FC
301.
fieldbus mode.
fieldbus mode.


01 COM; 240V AC/2A Common terminal for Relay 01.
02 Connect to electro-me- Normal Open Relay 01 is open (brake activated) dur-
chanical brake NO ing power off, and start-up of the FC30x. It is always
2 open after a “Quick Stop” procedure or in connection
with an error situation. Relay 01 only closes in con-
nection with motion procedures or if specified in
P715.
03 NC Normal Closed
04 COM; 240V AC/2A; 400V Common terminal for Relay 02.
DC/2A
05 Brake activated NC Normal Closed Relay 02 is closed to indicate an acti-
vated electromechanical brake. It is open to indicate
a deactivated electromechanical brake. Not used in
fieldbus control mode.
06 NO Normal Open
39 GND Ground for analogue inputs/outputs is normally
bridged with Terminal 20, but can be set to “OFF” by
means of Switch SW 4 on the control card.
50 10V DC 17mA Power supply for manual JOG inputs (terminal 53 and
54)
53 ± 10V-In Manual jog pos- When high (above 5V), the drive will travel with jog-
itive ging speed (P1916) and ramp (P1917) in the positive
direction. When low (below 5V), the drive will ramp
down and stop if no other motion procedure is acti-
vated. Jog positive has higher priority than Jog neg-
ative Not used in fieldbus mode.
54 ± 10V-In Manual jog neg- When high (above 5V), the drive will travel with jog-
ative ging speed (P1916) and ramp (P1917) in the nega-
tive direction. When low (below 5V), the drive will
ramp down and stop if no other motion procedure is
activated. Not used in fieldbus mode.

2.3.1. Option Card X57

1 Touch probe switch Interrupt triggered on the rising edge. If this signal
input goes high when no touch probe target position is 2
currently locked a new touch probe target position
is calculated and locked in memory.
2 Positive HW limit Interrupt triggered on the falling edge. Triggers a
switch input HW limit error and the drive is stopped according to
P1906.
3 Negative HW limit Interrupt triggered on the falling edge. Triggers a
switch input HW limit error and the drive is stopped according to
P1906.
4 HOME reference Active high. Marks the HOME position in the appli-
switch input cation.
5 Go to the refer- Active high. Upon activation the drive goes to the
enced target posi- specified target position. A low signal interrupts any
tion positioning sequence. Not used in fieldbus mode.
6 Reset home flag Active high. This input clears the home flag. This al-
lows the user to perform a second homing se-
quence. Not used in fieldbus mode.
7 Reset touch probe Active high. This input clears the touch probe posi-
position tion flag. The reset is necessary to carry out a touch
probe positioning command to a new target posi-
tion. Not used in fieldbus mode.
8 Quick stop Active low. This input activates the Quick Stop func-
tion. The drive is stopped according to the setting of
P1906. After that the electromechanical brake is al-
ways activated when the “Quick stop” input is acti-
vated regardless of the P1906 setting.
9 Go to HOME posi- While this input is high the drive executes the hom-
tion ing sequence. While this input is high no position or
jog operations are carried out. Any homing se-
quence is interrupted by a low state on this input.
Not used in fieldbus mode.
10 LATCH new refer- Active on the rising edge (must be “0” min. 1 ms. to
ence position index guarantee edge detection): Latches reference posi-
number tion index number specified on terminal 18, 19, 29,
32, 33 into memory. Digital output 4 – 8 is changed
to mirror the new reference index specified when
using digital input control. Not used in fieldbus
mode.

2.3.2. Option Card X59
2 1 Homing completed Active high. This output is always high if an absolute

encoder is used.
2 Referenced position reached Active high. This output is set when the target posi-
tion is reached according to the setting of P3347.
3 Error occurred Active high. This output is set every time an error
occurs. It is cleared every time a successful error
clear is carried out. This output will remain high as
long as the Power recovery function is selected
(P1908) and active.
4 Reference index bit 0 Active high. Mirror of the currently locked-in refer-
ence index bit 0. Not used in fieldbus mode.

MCO351 Positioning Controller 3. Fieldbus Interface
3. Fieldbus Interface
3.1. Fieldbus Interface

3.1.1. Introduction 3
This section is only relevant if the frequency converter is equipped with a Fieldbus
interface (option) as well as the Positioning controller.
The Positioning controller can be controlled via the digital/analogue inputs or via fieldbus. The
control source can be selected in parameter 19-04. There can only be one control source at a time
meaning that the digital/analogue inputs are inactive when fieldbus is selected as control source
and visa versa. The only exceptions are listed in the digital interface section. In fieldbus mode it
is possible to specify only the target position and velocity. If the acceleration and deceleration
PCDs are left blank then the last used acceleration and deceleration chosen via a quickbus is used.
This enables the use of PPO type 4.
3.1.2. Data Layout

Control and status signals are transferred via the so-called process data channel (PCD) of the
various fieldbus interfaces. The telegram structure and the available number of data words de-
pends on the fieldbus used, please refer to the manual of the fieldbus option in use for further
details. The below example is based on the layout of a PROFIBUS telegram, the so-called PPO:
Example using PROFIBUS PPO type 5:

3. Fieldbus Interface MCO351 Positioning Controller
Fieldbus Control Signals

Fieldbus Fieldbus Mode Corresponding Input
[word.bit]
1.1 Quick bus go to target (↑) N\A
1.2 Reset error (↑) 27
1.3 Go to home / Stop positioning (↑) / Go to position 9
3
(↓)
1.4 Read new trajectory index (↑) 10
1.5 Automatic (↑) / manual(↓)mode 5
1.6 Reset home status (↑) 6
1.7 Reset touch probe position (↑) 7
1.8 Quick stop (↓) 8
1.9 Positive jog (↑) 53
1.10 Negative jog (↑) 54
1.11 Quick Bus Type Absolute (↑) N\A
1.12 Quick Bus Type Relative (↑) N\A
1.13 Quick Bus Type Touch Probe positive (↑) N\A
1.14 Quick Bus Type Touch Probe negative (↑) N\A
1.15 Teach in (via LCP or fieldbus) (↑) KEYPAD “Back” & “Cancel”
1.16 Change sign on Quick Bus Target Position (↑) N\A
2 Quick Bus Target Position(MSB) N\A
3 Quick Bus Target Position (LSB) N\A
4 Quick Bus Target Velocity N\A
5 Quick Bus Target Acceleration N\A
6 Quick Bus Target Deceleration N\A
7.1 Reference index bit 0 (LSB) (↑) 18
7.2 Reference index bit 1 (↑) 19
7.6 Reference index bit 5 (Fieldbus MSB) (↑) N\A
Fieldbus Status Signals

Fieldbus Fieldbus Mode Corresponding Output/Parameter
[word.bit]
1.1 Homing done (↑) 1
1.2 Referenced position reached (↑) 2
1.3 Error occurred (↑) 3
1.4 Electro-mechanical brake output (↑) 04
1.5 Touch probe position locked (↑) N/A
1.6 Watchdog output (toggling) N/A
1.7 Positive hardware limit (↑) N\A
1.8 Negative hardware limit (↑) N\A
2.1 Current index bit 0 (LSB) (↑) 4
2.2 Current index bit 1 (↑) 5
2.6 Current index bit 5 (Fieldbus MSB) (↑) N\A
3 Actual Position (MSB) 3450 (MSB)
4 Actual Position (LSB) 3450 (LSB)
5 Error Status Par. 19-93

MCO351 Positioning Controller 4. Programming
4. Programming
4.1. Description of Parameters

19-00 VLT local mode
Option: Function:
[0] * Pos control
[1] VLT control By setting this parameter to 1 the VLT changes to setup “2” 4
Manual running of the VLT is now possible.
19-01 Endless positioning

Range: Function:
0 [0...1] Set this parameter to “1” if drive must perform positioning con-
tinuously in one direction. Remember to also set parameter
POWER RECOVERY, par. 33-43 and par. 33-44 to “0”.
19-02 Block reversal

Option: Function:
[0] * No blocking Selecting “0” disables the function.
[1] Block reverse By selecting “1” it is defined as an error situation (“Reverse op-
eration prohibited” – ERROR STATUS = 12) if the drive is moving
in reverse direction.
[2] Block forward By selecting “2” it is defined as an error situation (“Forward op-
eration prohibited” – ERROR STATUS = 13) if the drive is moving
in forward direction.
19-03 Touch probe delay

Range: Function:
0 [1...1000,000 ms] This parameter enables for compensation in any fixed delay
there may be in the touch probe.
19-04 Control source

Range: Function:
0 [0...1] Choose control source for pos. controller. Enter “0” for digital
inputs or “1” for field¬bus control.
19-05 User APOS setting

Range: Function:
0 [-1,073,741,824 … At power-up if FORCE HOME (par. 33-00) is “0” the actual po-
1,073,741,824] sition is equal the value set here.

4. Programming MCO351 Positioning Controller
19-06 Error behaviour

Option: Function:
[0] * Electronic brake This parameter determines the behaviour of the drive after an
error is detected.
If “0” is selected the drive will ramp down to standstill with the
shortest possible ramp (P3281). After achieving standstill it will
activate the electronic brake according to the setting of COAST
DELAY. If the drive is coasted at any point during ramp down
4 (e.g. due to an OVER CURRENT trip) the drive will immediately

activate the brake and coast the drive.
[1] Mechanical brake If “1” is selected the drive will immediately activate the brake
and coast the drive.
The brake is always activated after an error situation (or quick stop) regardless of
the AUTO BRAKE CTRL setting.
19-07 Error reset

Option: Function:
[0] * No reset The parameter automatically resets to “0” when the error is
successfully cleared.
[1] Reset error By setting this parameter to “1” it is possible to clear the error
flag (provided that the reason for the error is not still present).
19-08 Power-recovery
Option: Function:
[0] disabled When the power recovery function is disabled (0), it is not pos-
sible to drive the application by any means (neither jogging nor
positioning) as long as the application is outside the HW or SW
limits. The only way to recover from this situation is to move the
application by hand.
[1] * enabled When the power recovery function is activated (1) however it is
possible to make a “partial reset“ of the limit error (ERROR STA-
TUS = 2/3/4/5) whereby it will be possible to use the jogging
function to drive the application out of the HW or SW limit area.
It is not possible to drive the application otherwise by means of
homing, positioning or jogging (in the wrong direction), as long
as the application is still within the HW or SW limit area. The
“error occurred” output will remain high to indicate that these
restrictions are in effect. As soon as the application is moved
outside the HW or SW limit area the error is automatically
cleared and the “error occurred” signal goes low to indicate that
normal operation is now restored.

19-09
Option: Function:
[0] Disabled When the automatic brake control function is disabled, the drive
controls the application also at standstill.
[1] * Enabled When the automatic brake control function is enabled, the elec-
tromechanical brake is automatically activated every time the
application has been at standstill for a time period specified in
parameter 19-12. This is especially useful in hoist applications
where the motor could overheat if it has to deliver full torque at
standstill for a prolonged period of time.
4
19-10 Coast delay
Range: Function:
200 ms [0...1,000 ms] Used in conjunction with the automatic brake control function.
The coast delay is the delay after activating the electro-me-
chanical brake before disabling the controller and coasting the
drive. Useful in hoisting applications where the load would oth-
erwise have a tendency to drop a little after each stop because
the activation of the brake is slower than the deactivation of the
drive.
19-11 BRAKE DELAY

Range: Function:
200 ms [0...1,000 ms] Used in conjunction with the automatic brake control function.
The brake delay is the delay after activating the control and
magnetising the motor before the brake is deactivated. Useful
in applications with (typically large) motors that take a longer
time to be fully magnetised than the time it takes for the electro-
mechanical brake to deactivate.
19-12 Hold delay

Range: Function:
0s [0...10,000 s] Used in conjunction with the automatic brake control function.
The hold delay is a waiting period in which the brake is not ac-
tivated even though the application is at standstill. Useful in
applications where a sequence of fast positioning commands is
followed by longer standstill periods.
19-13 Brake wear limit

Range: Function:
0 [0 ( = disabled) … Setting a value higher than “0” (disabled) the drive defines an
1,073,741,824 UU] error situation (“Brake wear limit exceeded” – ERROR STATUS
= 7) if the drive moves more than the number of UU specified
in this parameter while the electronic brake is activated.

19-14 Motor/encoder gear nominator

Range: Function:
1 [1...1,000] If the encoder is mounted on a gear where 5 revolutions of the
motor correspond to 2 revolutions of the encoder, GEAR NUM
should be set to “5” (the number of motor revolutions) and
GEAR DEN should be set to “2” (the number of encoder revo-
lutions). If the encoder is mounted directly on the motor shaft
this parameter setting should remain at “1”.
4 19-15 Motor/encoder gear denominator

Range: Function:
1 [1...1,000] See the description of GEAR NUM. If the encoder is mounted
directly on the motor shaft this parameter setting should remain
at “1”.
19-16 Maximum jog velocity

Range: Function:
100 [1...999,999 ERPM] The maximum speed allowed while jogging the application is
ERPM specified in terms of Encoder Revolutions Per Minute (ERPM).
NB!
This setting must never exceed a value that is approx. 5% lower than the value in
par. 32-80.
19-17 Jog ramp time

Range: Function:
5,000 [50...100,000 ms] This parameter specifies both the ramp-up time as well as the
ms ramp-down time used during jogging. The ramp time is defined
as the time in milliseconds it would take to ramp from standstill
to the maximum allowed velocity 3280.
19-18 Jogl Velocity Scaling

Range: Function:
0 [0...1] If 1, the scale velocity will be scaled by MOT ENC GEAR NUM/
DEN
19-19 FFVEL auto-calculation

Option: Function:
[0] * Disabled
[1] FFVEL enabled Setting this parameter to “1” will prompt the program to calcu-
late the optimal setting of parameter velocity feed forward.

[2] FFVEL + PID enabled Setting this parameter to “2” will prompt the program to calcu-
late the optimal setting of parameter velocity feed forward,
proportional, derivative and integral factor.
P3280 Maximum Velocity
P3200 OR 3202 encoder type
P3201 OR 3203 encoder resolution
P1914 motor/encoder gear ratio numerator
P1915 motor/encoder gear ratio denominator
NB!
If any one of these parameters are changed, prompt a recalculation, since the op-
4
timum value of the regulation parameters will have changed.
19-20 Factory reset

Option: Function:
[0] * Disabled The parameter automatically resets to “0” when the reset is
successfully carried out.
[1] Enabled By setting this parameter to “1” it is possible to reset all param-
eter values to default. This also resets all trajectory data.
19-21 Link LCP input to index

Option: Function:
[0] * disabled The function is deactivated when set to “0”. This is necessary
when programming a position number different from the one
loaded into the PLC memory.
[1] * enabled When activating this function (1) INDEX NUMBER will be auto-
matically updated with the last position reference number that
has been loaded into memory. This enables to operator to see
what position reference is currently given by the PLC system.
19-23 Index number

Range: Function:
0 [0 … 31 Specify which position data that should be displayed in par.
0 … 63 in fieldbus 19-24 to par.19-28. Whenever this number is changed the cur-
mode] rent values of the Index Parameters are stored in memory under
the previously specified index number. After that, the values of
the index parameters are updated with the data stored in mem-
ory relevant to the newly specified index number.
19-24 Index target position

Range: Function:
0 [-1,073,741,824 … The meaning of this parameter depends on the position type
1,073,741,824 UU] specified in TRAJECTORY TYPE.
If TRAJECTORY TYPE = 0, the value of this parameter refers to
an absolute position (relative to the fixed HOME position).

If TRAJECTORY TYPE = 1 and the last position was obtained

through jogging, the value of this parameter is a position rela-
tive to that position. If the last position was reached as a result
of a positioning command, then the value of this parameter
specifies a position relative to the last target position (whether
it was reached or not).
If TRAJECTORY TYPE = 2 the application will move in the pos-
itive direction until a touch probe position is defined. If a touch
probe position is already defined the application will move di-
rectly to that position.
4 A touch probe position is defined as the position at which the
“touch probe switch” input goes high plus the value of TARGET
POSITION.
A touch probe position is cleared by a high signal on the “reset
touch probe position” input. The output “Touch probe position
locked” is high if a touch probe position is defined. If TRAJEC-
TORY TYPE = 3 the application will move in the negative direc-
tion until a touch probe position is defined. If a touch probe
position is already defined the application will move directly to
that position.
NB!
This parameter is automatically updated depending on INDEX NUMBER.
19-25 Index ramp up time

Range: Function:
5,000 [50....100,000 ms] This setting is relevant during positioning with the current tra-
jectory index. The index ramp up time is defined as the time in
milliseconds it would take to ramp from standstill to the maxi-
mum allowed velocity (P3280).
NB!
19-26 Index ramp down time

Range: Function:
5,000 [50....100,000 ms] This setting is relevant during positioning with the current tra-
jectory index. The index ramp down time is defined as the time
in milliseconds it would take to ramp from the maximum allowed
velocity (P3280) to standstill.
NB!

19-27 Index maximum velocity

Range: Function:
100 [1...999.999 ERPM] This setting is relevant during positioning with the current tra-
ERPM jectory index.
NB!
This parameter is automatically updated depending on INDEX NUMBER. The setting
should never exceed a value that is approx. 5% lower than the value calculated in
P32-80. 4
19-28 Index trajectory type

Option: Function:
[0] * absolute
[1] Relative
[2] Touch probe positive
[3] Touch probe negative
The function of this parameter setting is described under TARGET POSITION.
NB!
19-29 Parameter save

Option: Function:
[0] * No action This parameter automatically resets to “0” when the data is
successfully stored.
[1] SAVE EEPROM Trajectory data is not automatically stored in EEPROM and will
thus not automatically be available after power-down and pow-
er-up. To permanently store changes made to trajectory this
parameter must be set to “1”.
19-30 Main screen setup save

Option: Function:
[0] * No action Mains screen setup is not automatically stored in EEPROM and
will thus not automatically be available after power-down and
power-up.
This parameter automatically resets to “0” when the data is
successfully stored.
[1] SAVE EEPROM To permanently store changes made to the main screen setup
this parameter must be set to “1”.

19-91 Software version

Range: Function:
110 [110] The text in this parameter shows the current version number of
the Positioning Controller program.
19-92 New Index

Range: Function:
0 [0...31 Currently latched index number
4 0...63
mode]
in fieldbus
19-93 Error status

Option: Function:
[0] * 0 = OK READ-ONLY PARAMETER: The current error code is displayed in
1 = Homing needed this parameter
2 = Pos. HW limit
3 = Neg. HW limit
4 = Pos. SW limit
5 = Neg. SW limit
6 = VLT not running
7 = Brake wear limit
8 = Quick stop
9 = PID error too big
12= Rev. operation
13= Fwd. operation
92= Encoder hard-
ware error
32-00 Incremental Signal Type

Option: Function:
[0] * None Set up the incremental encoder type here. If an absolute Type
is used, this Parameter MUST be set to 0!
[1] RS422
[2] Sinusoidal 1Vpp
NB!
When switching from a setting of absolute encoder to a setting of incremental en-
coder, the home flag is automatically cleared. A homing procedure afterwards is
necessary before any positioning commands can be executed.
32-01 Encoder resolution

Range: Function:
1024 [1...1,000,000 pul- If an incremental encoder is used its resolution must be entered
ps.* ses] here in pulses per revolution (not quad-counts per revolution).

32-02 Absolute Protocol

Option: Function:
[0] * None Set up the absolute encoder type here. If an absolute Type is
used, Parameter 3200 MUST be set to 0! If you select any ab-
solute encoder the home flag is instantly set high, thus no
homing is required preceding a positioning command. A possible
leap in the position data can be detected if it is larger than the
encoder resolution/2. The correction is made by means of an
artificial position value which is calculated from the last velocity.
If the error continues for more than 100 read-outs (> 100 ms),
there will be no further correction which will then lead to a tol- 4
erated position error exceeded.
[4] SSI
[5] SSI with filter
32-03 Encoder resolution

Range: Function:
1024 [1...1,000,000 pul- If an absolute encoder is used its resolution must be entered
ps.* ses] here in pulses per revolution (not quad-counts per revolution).
32-10 Positive Direction

Option: Function:
This parameter is used to specify which encoder direction is
considered positive. When changing this setting the current ac-
tual position (P3450) will also change sign.
[1] * No action 1 = standard, position is counting positive when the drive is

running forward.
[2] Reference Reversed 2 = as “1”, but with opposite sign of the reference to the drive.
This can be used as alternative to swapping two motor phases
if direction of motor rotation is wrong.
[3] User units reversed 3= position is counting negative when the drive is running for-
ward.
[4] Uu and Ref reversed 4 = as “3”, but with opposite sign of the reference to the drive.
This can be used as alternative to swapping two motor phases
if direction of motor rotation is wrong.
32-11 User unit denominator

Range: Function:
1* [1 … 1,073,741,823] Par. 32-12 and par. 32-11 together define the ratio between
User Units (UU) and quad-counts (QC). The setting of this pa-
rameter is illustrated in the description of par. 32-11.

The target positions stored in memory is defined according to the settings of par.
32-12/par. 32-11, so changing the par. 32-12/par. 32-11 ratio might require that up
to 32 positions must be reprogrammed to achieve the same result as before the
change.
32-12 User unit numerator

Range: Function:
1* [1 … 1,073,741,823] Par. 33-12 and par. 32-11 together define the ratio between
4 User Units (UU) and quad-counts (QC). This parameter can be
illustrated with the following example:
By measurement it has been determined that 1000 mm of travel
correspond to 16345 QC (quad-counts). Now instead of defining
the target positions in QC but rather in mm, the setting of par.
32-12 must be 16345, and the setting of par. 32-11 must be
1000.
NB!
The target positions stored in memory is defined according to the settings of par.
32-12/par. 32-11, so changing the par. 32-12/par. 32-11 ratio might require that up
to 32 positions must be reprogrammed to achieve the same result as before the
change.
32-60 Proportional gain

Range: Function:
30* [1...100,000] The proportional gain is the factor that is multiplied with the PID
tracking error to produce the proportional part of the output
frequency. The higher the setting of this parameter the “harder”
is the resulting control.
NB!
Too high a setting of this parameter will cause the controller to become unstable.
32-61 Derivative gain

Range: Function:
0* [1...100,000] The derivative gain is the factor that is multiplied with the
change in the PID tracking error to produce the derivative part
of the output frequency. The higher the setting of this param-
eter the “harder” is the resulting control. The derivative gain has
best effect if the encoder is mounted directly on the motor and
an encoder with good resolution (4096 pulses/rev) is used.
NB!

32-62 Integral gain

Range: Function:
0* [1...100,000] The integral gain is the factor that is multiplied with the inte-
grated PID tracking error to produce the integral part of the
output frequency. The main function of the integral part is to
provide zero steady-state tracking error. The higher the setting,
the faster the application will reach a zero steady-state tracking
error. The dynamic tracking error however increases with in-
creasing setting of this parameter.
4
NB!
32-63 Limit integral part

Range: Function:
1,000* [0...100,000] Here it is possible to clamp the integral part of the PID output.
A setting of 1000 corresponds to 100% of the maximum allowed
reference specified in parameter 303.
32-64 Limit PID output

Range: Function:
1,000* [0...100,000] Here it is possible to clamp the total output of the PID controller.
A setting of 1000 corresponds to 100 % of the maximum al-
lowed reference specified in parameter 303.
32-65 Feed Forward Velocity Gain

Range: Function:
0* [0...100,000] The velocity feed-forward gain is the factor that is multiplied
with the set-point (desired trajectory) velocity to produce the
feed-forward part of the output frequency. The function of the
feed-forward part is to provide a fast (and fairly accurate) start-
ing point for the calculation of the output frequency.
NB!
To get the fastest and most stable controller response this parameter should be set
optimally. For this purpose parameter 19-19 gives access to a function that auto-
matically calculates the optimal setting of this parameter.
32-66 Feed-forward acceleration gain

Range: Function:
0* [0...100,000] The acceleration feed-forward gain is the factor that is multi-
plied with the set-point acceleration to produce the feed-for-
ward part of the output frequency.

32-67 Maximum tolerated PID error

Range: Function:
20,000 [1...1,073,741,823 The PID track error is defined as the difference between the
qc* qc] internal controller set-point and the actual position. The better
tuning of the PID controller (par. 32-60 to 32-66) the lesser the
PID track error.
At every sample time the current track error is compared with
the setting of par. 32-67. It is defined as an error situation (“PID
4 track error too big” - par. 19-93 = 9) if the track error is bigger
than the setting of par. 32-67. After tuning the PID controller
optimally this parameter should be set to a value approx. 50 %
larger than the maximum observed value of par. 34-56.
NB!
The unit is quad-counts (QC) not user units (UU).
32-69 PID sample interval

Range: Function:
1 ms* [1...1000 ms] The sampling frequency of the controller can be adjusted in this
parameter. Normally, the fastest possible setting (1 ms) is pref-
erable, but in cases with low resolution of the feedback signal it
is a good idea to set this parameter at a slightly higher value.
32-80 Maximum allowed velocity

Range: Function:
1,500 [1 … 100,000 ERPM] When performing a FFVEL autocalculation, the maximum ve-
ERPM locity allowed is calculated on the basis of par. 303, par.19-14,
1* par. 19-15 and the result is presented in this parameter.
32-81 Quick ramp time

Range: Function:
1,000 [50...3600000 ms] The quick ramp time is defined as the time to ramp down from
ms* the maximum velocity to standstill. The quick ramp time is used
when the quick stop function is activated or an error has occur-
red.
32-82 Ramp type

Option: Function:
[0] * Linear This parameter MUST be set to 0 for the Positioning Controller.
[1] * S-Ramp

33-00 Force HOME

Option: Function:
[0] * Home not forced
[1] * Home forced If this parameter is set to 1, homing has to be carried out before
any positioning can take place.
33-01 Home offset

Range:
0 UU*
Function:
[-1,073,741,824, … This parameter defines an offset to the “zero” (HOME) position.
4
1,073,741,823 UU] Any change in this setting will immediately affect the actual po-
sition displayed in par. 34-50.
33-02 Home ramp time

Range: Function:
10 ms* [1...1000] The home ramp time is defined as the time in milliseconds it
would take to ramp from stand¬still to the maximum allowed
velocity par. 32-80).
33-03 Home velocity

Range: Function:
100 [–(value in P3280)… The home velocity is entered here. Notice that the sign of the
ERPM* (value in P3280) velocity determines the direction in which the homing sequence
ERPM] will be performed.
33-04 Home type

Option: Function:
[0] * The drive moves to the reference switch (Input 4) with home
velocity (P3303), then reverses and slowly (at 30% of home
velocity) leaves the switch, subsequently moves to the next in-
dex pulse. The HOME position is defined as that index position.
[1] * Like “0” but without the search for the index position. Instead
the HOME position is defined as the position at which the ref-
erence switch goes low. After defining the HOME position the
drive is then ramped down with the home ramp (P3302) and
stopped.
[2] * Like “0” but without reversing before leaving the reference
switch. Rather the movement is slowly continued in the same
direction out of the switch.
[3] * Like “1” but without the search for the index position. Instead
the HOME position is defined as the position at which the ref-
erence switch goes low. After defining the HOME position the
drive is then ramped down with the home ramp (P3302) and
stopped.

33-41 Negative software limit

Range: Function:
-500,0 [-1,073,741,824 … If the actual position (par. 34-50) goes below the value specified
00 * 1,073,741,823 UU] in this parameter an error situation is defined (par. 19-93 = 5)
and handled according to the setting of the “Error behaviour”
parameter (par. 19-06).
33-42 Positive software limit

4 Range: Function:
-500,0 [-1,073,741,824 … If the actual position (par. 34-50) exceeds the value specified
00 * 1,073,741,823 UU] in this parameter an error situation is defined (par. 19-93 = 4)
and handled according to the setting of the “Error behaviour”
parameter (par. 19-06).
33-43 Negative SW limit active

Range: Function:
0* [0...1] Enter “0” to disable negative software limit switch. This should
be done only when not positioning within two fixed limits.
33-44 Positive SW limit active

Range: Function:
0* [0...1] Enter “0” to disable positive software limit switch. This should
be done only when not positioning within two fixed limits.
NB!
Either both or none of the SW limits must be active. Only activating one border is
not valid. When Limits have been activated or deactivated, switch the drive off and
on.
33-45 Actual position

Range: Function:
0* [–2,000,000,000 … READ-ONLY PARAMETER:
2,000,000,000 UU] This parameter displays the latest position obtained from the
feedback encoder.
33-47 Target position window

Range: Function:
0* [0 UU (< P726) … During a positioning sequence the “Referenced position
10000 UU] reached” output (X59 2) is set according to this parameter.
If the setting of this parameter is “0” then the “Referenced po-
sition reached” output goes high immediately when the internal
PID target position is equal to the requested target position. If
the setting of this parameter is larger than “0” i.e. “200” then
the “Referenced position reached” output goes high when the
actual position (par. 34-50) is within ±200 UU of the requested
target position.

34-40 Actual inputs

Range: Function:
000000 [00000000000 / During a positioning sequence the “Referenced position
000000 111111111111] reached” output (X59 2) is set according to this parameter.
* READ-ONLY PARAMETER:
This parameter displays the last read status of the digital input
on the option card (X57). The status of the digital inputs on the
VLT5000 control card is accessible via par. 16-60.
4
34-56 PID tracking error
Range: Function:
0* [–2,000,000,000 … During a positioning sequence the “Referenced position
2,000,000,000 UU] reached” output (X59 2) is set according to this parameter.
READ-ONLY PARAMETER:
The current PID tracking error is displayed in this parameter in
user units.

5. Application Examples MCO351 Positioning Controller

MCO351 Positioning Controller 5. Application Examples
5. Application Examples
5.1. Application examples
The drawing below shows a layout of a pallet conveyor system. Loaded pallets are coming from
four different product lines via the pallet inlet conveyors. Each pallet must be transported from
one of the four inlet conveyors to the one of the two outlet conveyors. To do this a movable pallet
conveyor cart is used.
A typical work process could be:

1. Moving the (empty) pallet conveyor cart to pallet inlet no. 1 to pick up a loaded pallet.
2. Waiting until the pallet is successfully transferred to the cart.
3. Moving to pallet outlet no. 2.
4. Waiting until the pallet is successfully transferred to the outlet conveyor and so on…

5.1.1. Wiring diagram
NB!
Please note that input 29 is not available in FC 301. This means that only 16 positions
can be selected via digital inputs in FC 301.
5.1.2. Basic Setup

First, check the motor connection. Please be aware that the mechanical brake control cannot be
trusted during this basic setup, therefore control brake externally from the option until setup is
finished. Also ensure that the motor can rotate freely without causing damage or injury to per-
sonal.
1. Remove all signals to inputs . Only Input 27(coast), I8 (q-stop), I3 (HW limit) and I2 (HW
limit) must be connected and high.
2. Select “Off” Mode
3. Input the motor name plate data in P120-125 and activate the “Automatic Motor Adap-
tation” function in P129.
4. Press the [Hand On] button on the FC control panel and wait for the AMA to be comple-
ted.
5. Goto “Hand on” mode and set the frequency for a low positive value, for example +3 Hz
in the reference value, please note that motor should now rotate.
6. If the motor rotates in the wrong (negative) direction then exchange the motor phases.

7. When using an incremental encoder:

Setup Incremental Signal Type par. 32-00 to the type needed. Set up the resolution of
the encoder in par. 32-01.
When using an absolute encoder:
Setup Incremental Signal Type par. 32-00 to “0”, Absolute Protocol P2302 to your type
of encoder and Absolute Resolution par. 32-03 matching the resolution of your encoder.
Set up databit and clock settings for absolute encoder in parameters 32-05 through
32-08.
8. Press the [STATUS] button on the LCP. Now the following values appear in the upper
line of the display: RPM and Actual Position.
9. Rotate the slave drive motor shaft manually in the positive directionNow the display
should show an ascending count of the actual position.
10. If the count is descending with an incremental encoder, exchange the feedback encoder
track A by B and A/ by B/. If there is no counting in the display then check the wiring of
5
the encoder. When you have tested the encoders and the wiring of motor and encoders,
continue as follows:
11. Select “Auto On” mode on the FC control panel.
12. Reset any error by toggling input 27.
Now you come to the test run:
13. Drive the application back and forth by closing the contacts on terminal 53 (positive
direction) or terminal 54 (negative direction). Watch the PID track error via P3456 display
during these tests.
Now you can optimise the controller:
14. Optimise the Feed forward velocity P3265 by following the procedure described in the
parameter list for the FFVEL auto-calculation function.
15. If the track error after entering “2” in parameter P3456 is within specification, when
jogging, there is no reason to optimise any further, move to step 21.
16. Increase the P-portion P3260. After each change you should make a test run to find the
right setting. If the drive becomes unstable or if a message is given about over-voltage
or over-current, then reduce the value in parameter P3260 to about 70-80% of the set
value.
17. Increase the other PID parameters P3261 (if needed) by following the same approach.
Read the description concerning these parameters in the parameter list.
5.1.3. Parameter Settings

Now determine the parameter settings fitting this application. The following list of parameters can
be determined right away:

Parameter no.
32-61 to 62-67 Determined during optimising of the PID controller
32-10 Default (“1”)
32-00 Incremental encoder used (“1”)
32-01 Encoder resolution (“4096”)
32-82 Trapeze ramps must be used (“0”)
19-14 Default (encoder mounted directly on motor) (“1”)
19-15 Default (encoder mounted directly on motor) (“1”)
19-16 Default (“100”)
19-17 Default (“1500”)
33-01 Default (“0”)
19-02 Default (“0”)
19-03 Default (“0”)
5
5.1.4. Timing of the Electromechanical brake (par. 19-10 to 19-12)
If the application is not equipped with an electromechanical brake, par. 19-10 to 19-12 are not
very important. Then, however, it is very important to set par. 19-09 to “0” to enable the drive
also at standstill.
This application is equipped with mechanical brakes to allow it to stop rapidly even if the drive is
somehow prevented from stopping the motor (damaged motor cables, damaged or short-circuited
motor, inverter overload and so on).
Par. 19-10 to 19-12 is provided to time the interaction between the mechanical brake and the
drive. A description of these parameters can be found in the parameter list above. In this appli-
cation the default values of COAST DELAY and BRAKE DELAY is used (200 ms) but the HOLD
DELAY setting is changed to 30 seconds to minimise wear of the brake.
5.1.5. Setting of par. 32-11 and 32-12

Distances are measured in quad-counts (QC) but defined in millimetres. Therefore, it is necessary
to measure how many QC correspond to how many millimetres. To do this the cart is first moved
as far to the left as possible by activating the “Manual jog negative” input (terminal 54). The
position is then marked on the application and the corresponding value of par. 34-50 is noted.
Then the cart is moved as far to the right as possible by activating the “Manual jog positive” input
(terminal 53). The travelled distance in mm is now measured from the position of the mark to the
position of the cart. Likewise the distance in QC is calculated by subtracting the current value of
P3450 from the noted value of P3450. In this example it is measured that 871380 QC correspond
to 4000 mm.
To prevent eventually overflow the parameters values are a factor 10 smaller than the measured
QC and mm so par. 32-12 is set to “87138” and par. 32-11 is set to “400”. Positions will now be
displayed and entered in millimetres. Settings like par. 32-12 set to “43569” and par. 32-11 set
to ”200” will also give the positions in millimetres.
5.1.6. Setting for the Homing Procedure (par. 33-00 to 33-04)

The HOME ramp setting (par. 33-02) is reduced to the lowest allowable setting to get the fastest
HOMING procedure possible. The HOME velocity setting, however, should never be very high to
enable a precise result of the homing procedure, and because the exact position is not known
during homing, it is not advisable to go with a very high velocity for safety reasons. The default
setting of par. 33-03 at 100 encoder revolutions per minute (approx. 1/15th of the max. velocity)

is therefore maintained in this application. The default homing type defined in par. 33-04 is also
maintained.
The resulting homing sequence is illustrated below.
5.1.7. Programming positions (par. 19-23 to 19-28)

The program positions the conveyor cart in front of the various inlets and outlets. Different ac-
celeration and deceleration is allowed between the different positions. An empty pallet cart can
be accelerated as fast as possible while this is not allowed when transporting a fully loaded pallet.
Different settings for each position are available because every position is programmed
The different positions are programmed using par. 19-23 to 19-28 as interface. First, the appli- 5
cation must be homed to get at fixed reference for measuring (and entering) the positions.
When this is done the first position is programmed:
a. Par. 19-23 is set to “1” either directly or by using the digital inputs and the “link” func-
tionality of par. 19-21.1
b. The position is programmed in P1924 either directly on the LCP or by using the “TEACH-
IN” functionality (simply use the jog inputs (54, 53) to drive the application to the desired
position, then press the [Back] and [Cancel] buttons to store that position in memory).
1
c. The individual ramp and velocity settings for this position is specified in P1925-P1927.1
d. For trajectory type “absolute” is selected in par. 19-28 set to (“0”). 1
The following table shows the complete list of settings for each of the 6 target positions.
19-23 19-24 19-25 19-26 19-27 19-28

1 40000 900 900 500 0
2 80000 2000 2000 500 0
3 150000 900 900 500 0
4 220000 900 900 500 0
5 260000 2000 2000 500 0
6 330000 900 900 500 0
5.1.8. Software Limits (par. 33-41 to 33-44)

The software limits are placed just in front of the hardware limit switches with a distance to the
hardware limit switches that allows for the cart to be stopped with the shortest allowable ramp
before the HW limit switch is activated.
The settings are: par. 33-41 = “370000” and

par. 33-42 = “-10000”.
5.1.9. Setting par. 32-81 and 19-06

If the pallet cart is transporting a loaded pallet and travelling at its top speed, it is not allowed to
simply activate the electromechanical brake (all the products on the pallet would be scattered
across to floor because of the deceleration). So if a “safety cage” or other safety device is opened
and the “quick stop” input is activated, the drive should ramp down with the appropriate ramp
and then activate the safety brake. This functionality is achieved by setting par. 19-06 to “0” and
tuning par. 32-81 to the lowest allowable setting.

5.1.10. Other Settings

The maximum PID track error was brought down to approximately +/- 100 QC during the opti-
mising sequence described above. Therefore, it is an indication of an error, if the PID track error
should suddenly grow larger than approximately +/- 200 QC. Thus par. 32-67 Maximum tolerated
PID error is set at “200”.
The maximum tolerated travel of the brake before replacement is estimated at 4 mm so Brake
wear limit is set to “4”.
If the application for some reason should ever go into the not allowed area beyond the SW limits
it should be possible to bring the application back into the allowed area by resetting the limit error
and using the jog inputs. This is achieved by setting par. 19-08 Power-recovery to “1”. The allowed
5 position tolerance is defined to be +/- 10 mm in this application so P3347 Target position window
is set to “10”.

MCO351 Positioning Controller 6. Troubleshooting
6. Troubleshooting
6.1. Frequently Asked questions

Q1:
When I have a “PID TRACK ERROR TOO BIG” error (par. 798=“9”), the inverter also trips on
ALARM 13 (OVER CURRENT).
A1:
a) Check that the velocity setting (par. 723 for jogging and par. 738/par. 742 for positioning) is
at least 5% lower than the maximum allowed velocity calculated in par. 799. Either lower the
velocity (par. 723 or par. 742) setting or raise the maximum allowed velocity (par. 799) by setting
a higher value of par. 205 - please see Q2.
b) The quick stop ramp time (par. 719) could be too short. Try to increase the setting.
6
Q2:
How do I adjust the maximum allowed velocityin par. 32-80?
A2:
You need to raise the setting of par. 303. Doing this will also affect the performance of the pa-
rameters par. 32-60 to 32-66. Smaller changes to par. 303 may not have any noticeable effect on
most of these parameters but par. 32-65 should always be recalculated using the auto-calculation
function par. 19-19.
Q3:
The inverter frequently trips on ALARM 7 (DC LINK OVERVOLTAGE) while ramping down.
A3:
a) Use a higher ramp time setting (par. 719 for “quick stop”, par. 724 for jogging and par. 738/
par. 741 for positioning).
b) If a lower ramp time is required a brake resistor should be installed.
Q4:
The inverter frequently trips on ALARM 13 (OVER CURRENT) while ramping up
A4:
a) The ramp settings may require too much torque. Try to determine which operation (“quick
stop”, manual move or positioning) caused the trip, and then set the corresponding ramp time
(par. 719 for “quick stop”, par. 724 for jogging and par 738/par. 741 for positioning) with a higher
ramp time setting.
b) The PID controller settings may be unstable – re-optimise the PID controller parameters (par.
702-709).

6. Troubleshooting MCO351 Positioning Controller
Q5:
The correct target position is reached, but the PID tracking error (P797) is too big while the drive
moves.
A5:
Harder settings of the PID controller may be required – re-optimise the PID controller parameters
(par. 702-709).
Q6:
The option sometimes seems to forget changes to trajectory data.
A6:
Changes to trajectory data values are not stored after power-down unless par. 777 (STORE DA-
TA) is activated before power-down.
6 6.2. Error Messages

All messages are shown in P789 in the VLT 5000 LCP display. You can find detailed information,
additional notes on possible causes of errors as well as tips for clearing errors in the following
section.
P19-93 - 0: Status OK. No errors detec-

ted.
Meaning
No errors detected.
P19-93 - 1: Homing needed
Meaning
The user has issued a positioning command to a certain position while the home position is not
defined.
NOTE: The error must be cleared and a homing sequence successfully completed before the next
position command is issued to the application.
P19-93 - 2: Positive hardware limit ex-
ceeded
Meaning
The positive hardware switch input has been activated.
Causes
The application has hit the positive limit marker switch. Alternatively, the connection to the limit
switch has been lost or the limit switch is defective.
P19-93 - 3: Negative hardware limit ex-
ceeded
Meaning
The negative hardware switch input is activated.
Causes
The application has hit the negative limit marker switch. Alternatively, the connection to the limit
switch has been lost or the limit switch is defective

P19-93 - 4: Positive software limit ex-

ceeded
Meaning
A motor command will cause / has caused the software limit switch to be activated. The maximum
limit is specified in P744.
Note
Before the error can be cleared the application must be moved back from the limit. If “power
recovery” is enabled in P736, this can be done through an error reset and a negative jog (input
54).
P19-93 - 5: Negative software limit ex-
ceeded
Meaning
A motor command will cause / has caused the software limit switch to be activated. The minimum
limit is specified in P745.
Note
Before the error can be cleared the application must be moved back form the limit. If “power
recovery” is enabled in P736 this can be done through an error reset and a positive jog (input 53).
6
P19-93 - 6: VLT not running
Meaning
The motor was not magnetised in a situation where it should have been. The electromechanical
brake is immediately activated in this case regardless of the settings in P718 and P725.
Causes
While the motor was holding/driving the load, the drive either tripped, connection to terminal 27
was lost, or the [STOP] button was pressed on the LCP.
P19-93 - 7: Brake wear limit exceeded
Meaning
This error message is given if the drive has moved more than the allowed number of user units
specified in P735 while the electronic brake was activated.
Causes
The mechanical brake is worn and should be replaced in the near future or the limit specified in
P735 is too low.
P19-93 - 8: Quick stop input activated
Meaning
The quick stop input has been activated. As a safety precaution of the electromechanical brake is
activated according to the setting of P725 and the drive is coasted regardless of the setting of
P715. Normal operation is resumed if the error is cleared.
P19-93 - 9: Controller (PID) tracking er-
ror too big
Meaning
The difference between the desired set-point position and the actual position read via the encoder
feedback has exceeded the limit specified in P726.
Causes
Several reasons may exist:
1. The encoder is not properly connected. Check the encoder connection.
2. The encoder is counting positive in the wrong direction. Switch A and B channels if nec-
essary.
3. The PID controller settings are not properly optimised. Follow the instructions for opti-
mising.
4. The limit specified in P726 may be too low.

P19-93 - 12: Reverse operation prohibi-

ted
Meaning
The drives have been operated in reverse direction while this was not allowed according to the
setting of P734.
P19-93 - 13: Forward operation prohibi-
ted
Meaning
The drives have been operated in forward direction while this was not allowed according to the
setting of P734.
P19-93 - 92: Error from encoder moni-
toring
Meaning
Open or short circuit in accordance with the displayed LED. An error will be displayed even if no
encoder is connected and the monitor is active (P3209 = 1).
6 6.3. Glossary of Key Terms

Incremental encoder
This is an encoder system that picks up the speed and the direction of rotation and transmits on
the appropriate configuration. The number of tracks, and thus the number of signals, indicate the
properties of the encoder system. There are single-track systems that deliver a pulse signal de-
pendent on the speed as well as a fixed direction signal. Dual-track systems deliver two pulse
signals that are offset 90 degrees. By evaluating the two tracks, the direction signal is also ob-
tained. Three-track encoders deliver, as well as the two tracks of the dual-track encoder, an
additional “zero-track”. This emits a signal when the zeros transit is passed through.
Illustration 6.1: Incremental Encoder Signals Illustration 6.1: Incremental Encoder Signals
Quad counts
Through edge detection, a quadrupling of the increments is produced by both tracks (A/B) of the
incremental encoder. This improves the resolution.

Illustration 6.1: Derivation of quad counts
Absolute value encoder 6

This is a special form of encoder, as it indicates not only the speed and direction of rotation but
also the absolute physical position. This is communicated via transfer of the position in parallel
form or in the form of a telegram in serial form. Absolute value encoders also come in two versions:
Single-Turn encoders supply an absolute position via a specific quantity, or via a freely-definable
number of rotations.
ERPM
The speed is defined in relation to the RPM of the encoder. To underline this the term “encoder
revolutions per minute” is chosen as unit.
AMA
Automatic Motor Adaptation - function in P129.
Motor/encoder gear ratio
Since the encoder is not necessarily mounted on the motor itself, the relationship between the
nominal motor speed in RPM and the nominal encoder speed in ERPM must be specified.
Track error
The PID track error is defined as the difference between the internal controller set-point and the
actual position. The track error is specified in UU and is displayed in P3456.NOTE! The maximum
tolerated PID error is entered in P3267 in QC.

Input 10 is the latch reference index input in digital control mode. PCD 1.4 is the latch reference
index input in fieldbus control mode.
Input 1 is the touch probe input.
Input 7 is the reset touch probe input in digital control mode. PCD 1.7 is the reset touch probe
input in fieldbus control mode.
NB!
A delay in the touch probe sensor will make the target position drift. This means the
target position will become larger than stated in parameter 1924. To compensate
for this please specify a delay value in parameter 1903. Only a constant delay can
be compensated for, and not a variable delay.

MCO351 Positioning Controller Index
Index
A
Absolute Protocol 26
Actual Inputs 32
Adjust The Maximum Allowed Velocity 41
Alarm 13 41
Alarm 7 41
An Application Example 35
Approvals 3
Automatic Brake Control 20
B
Basic Setup 36
Block Reversal 19
C
Control Source 19
D
Dc Link Overvoltage 41
Digital Inputs: 11
Digital Outputs 11
Disposal Instruction 3
E
Earth Leakage Current 4
Encoder Monitor 10
Encoder Resolution 26
Error Behaviour 20
Error Reset 20
F
Factory Reset 23
Feed Forward Velocity Gain 29
Feed-forward Acceleration Gain 29
Ffvel Auto-calculation 22
Fieldbus Control Signals 18
Fieldbus Interface 17
Fieldbus Status Signals 18
Force Home 30
G
General Warning 5
H
Hardware 9
Hold Delay 21
Home Offset 31
Home Ramp Time 31
Home Type 31
Home Velocity 31
I
Incremental Signal Type 26
Index Maximum Velocity 25
Index Number 23
Introduction

Index MCO351 Positioning Controller
J
Jog Ramp Time 22
L
Leakage Current 5
Limit Integral Part 29
Limit Pid Output 29
M
Maximum Jog Velocity 22
Maximum Tolerated Pid Error 30
Motor Overload Protection 4
Motor/encoder Gear Denominator 22
Motor/encoder Gear Nominator 21
N
Negative Software Limit 31
O
Option Card Layout 11
Option Card Terminals 9
Option Card X57 15
P
Pallet Conveyor System 35
Pid Sample Interval 30
Pid Track Error Too Big 41
Pid Tracking Error 33
Positive Direction 27
Positive Software Limit 32
Power-recovery 20
Proportional Gain 28
Q
Quick Ramp Time 30
R
Ramp Down Time 24
Ramp Type 30
Ramp Up Time 24
Repair Work 5
Residual Current Device 5
S
Safe Stop 5
Safety Instructions 4
Safety Regulations 3
Sample Interval 30
Software Version 4
Store Data 42
Supply Voltages 11
Symbols 3
T
Technical Data 9
Terminals 9
Touch Probe Delay 19
Trajectory Type 25

MCO351 Positioning Controller Index
Troubleshooting 41
U
Unintended Start 5
User Apos Setting 19
User Unit Denominator 27
User Unit Numerator 28
V
Vlt Control Card Terminals 9
Voltage Level 11, 12
W
Wiring Diagram 36

Safety Regulation: MCO351 Positioning Controller

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MCO351 Positioning Controller Contents

MG.33.R1.02 - VLT® is a registered Danfoss trademark 1

Programming positions (par. 19-23 to 19-28) 39

2 MG.33.R1.02 - VLT® is a registered Danfoss trademark

Indicates a general warning.

Indicates a high-voltage warning.

∗ Indicates default setting

1.1.3. Disposal Instruction

Equipment containing electrical components may not be disposed of

MG.33.R1.02 - VLT® is a registered Danfoss trademark 3

MCO 351 Positioning Controller for

1.1.4. High Voltage

Installation in high altitudes

1.1.5. Safety Instructions

4 MG.33.R1.02 - VLT® is a registered Danfoss trademark

1.1.6. General Warning

1.1.7. Before Commencing Repair Work

1.1.8. Avoid Unintended Start

1.1.9. Safe Stop of FC 300

MG.33.R1.02 - VLT® is a registered Danfoss trademark 5

6 MG.33.R1.02 - VLT® is a registered Danfoss trademark

MG.33.R1.02 - VLT® is a registered Danfoss trademark 7

8 MG.33.R1.02 - VLT® is a registered Danfoss trademark

Digital inputs 18, 19, 27, 32 and 33

Analogue inputs 53, 54

2.2. Technical Data

2.2.2. Option Card Terminals

Terminal X55 Terminal X56

MG.33.R1.02 - VLT® is a registered Danfoss trademark 9

Terminal X57 Terminal X59

2 Terminal Number Descriptive Name

2.2.3. Encoder Monitor

10 MG.33.R1.02 - VLT® is a registered Danfoss trademark

2.2.4. Option Card Layout

2.2.5. General Technical Data

MG.33.R1.02 - VLT® is a registered Danfoss trademark 11

Logic PNP or NPN2)

Combined Digital Inputs/Outputs:

12 MG.33.R1.02 - VLT® is a registered Danfoss trademark

Maximum cable length 400 m

2.3. Description of the Electrical and Fieldbus Interface

Terminal Designation Description

MG.33.R1.02 - VLT® is a registered Danfoss trademark 13

Terminal Designation Description

14 MG.33.R1.02 - VLT® is a registered Danfoss trademark

2.3.1. Option Card X57

Terminal Designation Description

MG.33.R1.02 - VLT® is a registered Danfoss trademark 15

2.3.2. Option Card X59

Terminal Designation Description

2 1 Homing completed Active high. This output is always high if an absolute

16 MG.33.R1.02 - VLT® is a registered Danfoss trademark

3.1. Fieldbus Interface

3.1.2. Data Layout

MG.33.R1.02 - VLT® is a registered Danfoss trademark 17

Fieldbus Control Signals

Fieldbus Status Signals

18 MG.33.R1.02 - VLT® is a registered Danfoss trademark

4.1. Description of Parameters