SyncPos Motion Controller

VLT® 5000 SyncPos option

■ VLT 5000 synchronising/positioning option Synchronising of two axes with one SyncPos motion
SyncPos Motion Controller

The SyncPos motion controller for VLT 5000 is an controller

integrated synchronising and positioning controller.

One controller can synchronise two axes. When

using the virtual master function and multiple
controllers it is possible to synchronise up to 32 axes
(even more when using repeaters).

The position controller is a single axis controller

which can perform relative or absolute positioning.

In addition to the synchronising and positioning

functions the programmable controller can perform
PLC like functions.

The SyncPos motion controller can be delivered as:

- Separate option card for updating VLT 5000
or
- Build into the VLT 5000
Ordering details can be found in the VLT 5000
Design Guide.

Synchronising of multiple axes using the virtual master function

■ Application examples
The SyncPos motion controller combined with the - Pick and Place systems
dynamic performance of VLT 5000 opens new - Vibrating tables
posibilities for using frequency converters in a wide - Material handling
range of applications as for example: - Film wrapping
- Conveyors
- Bottle washing machines
- Palletizers
- Packaging machines
- Cranes
- Positioning on the fly for e.g. filling, cutting,
spray painting and drilling
- Indexing tables
- Storage systems
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 VLT® 5000 SyncPos option

SyncPos Motion Controller

■ Function overview
General features
- Coverage of the entire VLT 5000 series; power range 0.37-500kW, voltage range
200V-500V.
- Use of standard AC motors
- Motion controller fits inside the VLT 5000 drive to preserve IP/NEMA rating
- No extra panel space required
- Standard user interface - settings and messages via the VLT 5000 local control
panel
- Utilizes the VLT 5000 series' field bus options, including PROFIBUS, DeviceNet
and Interbus
- Smooth change between three control modes: Closed loop speed control,
synchronizing and positioning
- Standard incremental and absolute encoder interface (RS422, line driver) up to
220 kHz
- Improved encoder resolution thanks to quadrature signals

Synchronizing functions
- Speed synchronizing
- Position (angle) synchronizing, with or without marker correction
- On-line adjustable gear ratio
- On-line adjustable position (angle) offset
- Encoder output with virtual master function for synchronization of multiple slaves

Positioning functions
- Home function
- Absolute positioning
- Relative positioning
- Marker related positioning
- Programmable speed profiles
- Hardware and software end limits

Programmable controller functions

Easy-to-use high level programming language (BASIC-like) featuring:
- Definition of user parameters on VLT 5000 local control panel
- Handling of digital and analog I/O
- Read/write access to VLT 5000 parameters
- Conditional/unconditional jumps
- Calculation, comparison, bit manipulation and logical gating
- Error handling routine
- Digital input interrupts
- Time controlled interrupts

W indows based pr ogramming softwar

programming softwaree featuring:
- Graphical PID controller optimizing tool
- Position teach-in function
- Parameter settings
- Program single stepping for debugging
- On-line help/manual
- Test programs

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 VLT® 5000 SyncPos option

■ Option card layout:

SyncPos Motion Controller

Option card layout showing the position of connectors and dip switch.

■ Input/Output data:

The control card inputs and outputs can be allocated for the SyncPos application program. Together with the
inputs and output of the SyncPos option card the available programmable inputs and outputs are thus:

2 Encoder inputs (one can be used as output).

3 Analogue inputs.
16 Digital inputs.
8 Digital outputs.
2 Digital/analogue outputs.
2 Relay outputs.

Detailed specification of the control card inputs and outputs can be found in the VLT 5000 design guide.

Digital Inputs Master / Virtual Master

Digital Outputs Feedback

Terminal A1 A1 B1 B1 Z1 Z1
Incremental encoder A in A in B in B in Z in Z in
Absolute encoder Clk out Clk out Data in Data in Not used Not used
Virtual master A out A out B out B out Z out Z out

Terminal A2 A2 B2 B2 Z2 Z2
Incremental encoder A in A in B in B in Z in Z in
Absolute input encoder Clk out Clk out Data in Data in Not used Not used

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 VLT® 5000 SyncPos option

SyncPos Motion Controller

■ Technical data, continued

Terminals:
Type ................................................................................................................... Plugs with screw connections
Maximum cable size ............................................................................................................ 1.3 mm2 (AWG 16)

Digital inputs, MK3A:

Number of inputs which are used by SyncPos program ................................................................................ 8
Terminal designations .............................................................................................................................. I1 – I8
Voltage level .................................................................................................... 0 – 24 V DC (PNP positive logic)
Voltage threshold logical “0” .................................................................................................................. 6 V DC
Voltage threshold logical “1” ............................................................................................................. 13.5 V DC
Maximum voltage ................................................................................................................................ 28 V DC
Input impedance ........................................................................................................................................ 3 kΩ
Min. pulse duration (ON INT) ................................................................................................................. 1 msec
Galvanic isolation: All digital inputs are galvanically isolated by means of optocouplers,
but with the same common as the digital outputs.

Digital outputs, MK3C:

Number of outputs which are used by SyncPos program .............................................................................. 8
Terminal designations .......................................................................................................................... O1 – O8
Voltage level ................................................................................................................................... 0 – 24 V DC
Maximum load .............................................................................................. 0.7A (with external power supply)
Update rate ........................................................................................................................................... 1 msec
Galvanic isolation: All digital outputs are galvanically isolated by means of optocouplers,
but with the same common as the digital inputs.

External 24 V DC supply:
(see VLT 5000 manual, page 10)

Encoder input 1, MK3B (master):

Terminal designations ................................................................................................. A1, A1, B1, B1, Z1, Z1.
Incremental:
Signal level ................................................................................................................................... 5 V differential
Signal type ............................................................................................................................ Linedriver, RS 422
Input impedance .............................................................................................. 140 Ω (Dip switch 1.1–4 = ON)
....................................................................................................................... 12 kΩ (Dip switch 1.1–4 = OFF)
Maximum frequency ........................................................................................... 220 kHz (at 50 % duty cycle)
Phase displacement between A and B ............................................................................................... 90° ±30°
Absolute:
Signal level ................................................................................................................................... 5 V differential
Signal type .................................................................................................................................................... SSI
Data coding ...................................................................................................................................... Gray code
Data length ............................................................................................................................................... 25 bit
Parity .......................................................................................................................................................... none
Clock frequency ....................................................................................................................... 105 or 262 kHz
Protocol ..................................................................................................................................................... Gray
Maximum positions per revolution ............................................................................................................. 8192
Maximum number of revolutions ............................................................................................................... 4096

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 VLT® 5000 SyncPos option

Encoder input 2, MK3D (slave):

SyncPos Motion Controller

Terminal designations ................................................................................................... A2, A2, B2, B2, Z2, Z2

Incremental:
Signal level ................................................................................................................................... 5 V differential
Signal type ............................................................................................................................. Linedriver, RS422
Input impedance ...................................................................................................................................... 140 Ω
Maximum frequency ........................................................................................... 220 kHz (at 50 % duty cycle)
Phase displacement between A and B ............................................................................................... 90° ±30°
Absolute:
Signal level ................................................................................................................................... 5 V differential
Signal type .................................................................................................................................................... SSI
Protocol ............................................................................................................................................ Gray code
Data length ............................................................................................................................................... 25 bit
Parity .......................................................................................................................................................... none
Clock frequency ....................................................................................................................... 105 or 262 kHz
Maximum positions per revolution ............................................................................................................. 8192
Maximum number of revolutions ............................................................................................................... 4096
Encoder 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)
Maximum allowed time delay between clock and data signal measured at the controller terminals
105kHz clock = 9 µsec
262kHz clock = 3.5 µsec
Encoder output, MK3B:
Terminal designations ................................................................................................... A1, A1, B1, B1, Z1, Z1
Signal type ............................................................................................................................. Linedriver, RS485
Maximum frequency ............................................................................................................................. 150 kHz
Minimum frequency ................................................................................................................................ 150 Hz
Maximum number of slaves ........................................................................... 31 (more when using repeaters)
Maximum cable length ............................................................................................................................ 400 m

■ Dip switch 1.1 – 1.5

Switch
designation OFF ON
1.1 Option card must be supplied from an Option card is supplied from control card
external power supply (24 V) (24 V)
1.2 Terminating resistor not connected (Z channel) Terminating resistor connected (Z channel)
1.3 Terminating resistor not connected (B channel) Terminating resistor connected (B channel)
1.4 Terminating resistor not connected (A channel) Terminating resistor connected (A channel)
1.5 Option card must be supplied from an Option card is supplied from control
external power supply (Common) card (Common)
Default setting of switch 1.1 - 1.5 is ON.
SW. 1.2, 1.3 and 1.4 applies only to MK3B (the master encoder interface).

NB!
When using the virtual master function termination must be switched off (sw 1.2-1.4) in all options
except on the first and the last station connected in the network.

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 VLT® 5000 SyncPos option

SyncPos Motion Controller

■ Supply voltages:
The option card is supplied by the internal 24 V DC Each digital input on the option card takes 8 mA.
supply of VLT 5000, but as the available power is Each digital output on the option card can supply up
limited it can be necessary to use an external 24 V to 0.7 A (external 24V-supply) depending on the
DC supply. load.
The 24 V DC supply of VLT 5000 can supply a total
of 420 mA including the load on the control card The load from the 24 V supply (internal or external)
(terminal 12, 13 and output 42 and 45). can be calculated as follows:

The 5 V output on the option card is generated from 8 mA * number of digital inputs
the 24 V supply. The maximum power on the 5 V +
side is 5 V * 280 mA = 1.4 W, this corresponds to Load on digital outputs
app. 60 mA on the 24 V side. (mk3 C, O1 – O8)
+
When an external 24 V DC voltage source is used load on 5 V supply
the internal 24 V supply from the control card must (mk3 B/D, 5 V/com)
be disconnected, this is done by opening switch 1.1 +
and 1.5. Load on control card
(24 V supply, terminal 12/13 and
outputs, terminal 42/45)

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 VLT® 5000 SyncPos option

■ Connection examples
SyncPos Motion Controller

ABSOLUTE ENCODER

Master Slave

Master Slave

The terminating resistors on both end of the

bus have to be switch on with dip switch
SW 1.2–4.

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 VLT® 5000 SyncPos option

SyncPos Motion Controller

Encoder connection for positioning applications Encoder connection for master-/slave sychronization

Encoder connections for the synchronizing with

virtual master.

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

175R0308 MD.50.B2.02- VLT is a registered Danfoss trademark