- Wahlberg Light & Motion Design
Contents
1. A rule of thumb is to only adjust one PID variable at a time The extended mode is especially useful for initial tuning of the system here you can get PID values on DMX channels 7 10 EXT MODE PIDS afterwards you can save the values see the menu control mode on page 11 A good start is to use the examples here below You can also initially to set P 1000 I 0 D 0 and S 1000 Set the motor to run from one position to another then you can adjust the P value You adjust the value to where the motor will still be able to run at full speed After adjusting the P value adjust the S value The S value should also be adjusted to make the motor be able to run at full speed Now you will have found the slowest regulation that still will allow full speed this is a good starting point After this a bigger S value will result in faster regulation A lower S value will result in slower regulation but with the chosen P value it will also reduce the max speed When the P and S values is chosen the I and D value can be used to fine tune the regulation Thus correct adjusting of the PID will only be possible if the maximum motor speed and the feedback are chosen according to the rules on page 4 If it is not possible get the motor to reach the wanted position i e if the motor will run back and forth over the selected position and never stop This may be because of the setup itself i e if a tacho gives too many pulses to the regulation2. Control mode The display shows DMX CONTROL MI M1 refers to the actual mode START CHAN 1 It can also be controlled manually MANUAL CONTROL MS refers to the actual mode M5 Control mode Expanded view Expanded view is activated by holding the DOWN button for approx 5 seconds Here it is possible to watch the different parameters P ACTUAL POSITION D DELTA POSITION W WANTED DMX POSITON S SPEED Holding the DOWN button for further 5 seconds will reveal the received DMX values in the menu The value is shown in the menu as this CH1 CH2 CH3 CH4 CH5 CH6 CH7 CH8 If in extended mode holding the DOWN button for further 5 seconds will reveal the extended mode values in the menu These values are shown in the menu for different EXT MENU EXT MENU ACCDCC ACC Acceleration DCC Deceleration EXT MENU PIDS P PID P value I PID I value D PID D value S PID S value In the extended mode value menu holding down BN for approximately 5 seconds will save the values selected by DMX This makes it easy to adjust e g PID values and save them to the AC Motor Controllers memory Menu navigation mode Top Line shows MENU NAVIGATE In menu navigate mode the different parameters can be changed e g DMX address PID setup etc In menu navigate mode the motor is stopped and DMX input has no effect the motor can be moved by the MAN FWD REV menu though Menu mode change MENU NAVIGATE The top line of the display is showing
3. DMX CONTROL MI Push the buttons OB amp DOWN and hold them for 3 seconds Now the top line of the display should show MENU NAVIGATE MENU DMX CONTROL Go back to the starting position and activate DMX control The top line of the display is showing MENU NAVIGATE Push the buttons GB amp DOWN and hold them for 3 seconds Now the top line of the display is showing DMX CONTROL MI WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 11 Navigate the menu The top line of the display is showing MENU NAVIGATE Push the buttons UP or to go up and down in the menu choices The bottom line of the display is showing DMX ADDR 1 Adjusting menu parameters The top line of the display is showing MENU NAVIGATE The bottom line of the display is showing DMX ADDR 1 Push ENT to change the DMX ADDR value The top line of the display is showing EDIT MENU VALUES The bottom line of the display is showing DMX ADDR 1 Save changed value The top line of the display is showing EDIT MENU VALUES The bottom line of the display is showing DMX ADDR 270 Push ENT to change the top line to SAVING 1 20 Then press and hold BENT The top line of the display counts up to 20 then shows OK SAVING OK The Value is now saved in the memory Adjustable parameters Range Default MAN SPEED Speed for manual driving 100 6000 500 MAN FWD REV Run the motor manual from the menu MOTOR FWD MOTOR REV STOP DMX AD
4. DMxX channel 4 Motor Enable between 50 and 55 to enable the motor output DMX channel 5 Manual FWD Mode 2 4 Reset FWD only active in mode 3 amp 4 DMxX channel 6 Manual REV Mode 2 4 Sets the TAC RANGE in mode 4 E g the motor shaft connected to a potentiometer running to the middle position at 40 speed set DMX channels approximately to DMX channel 1 50 DMX channel 2 0 DMX channel 3 40 DMX channel 4 52 between 50 55 E g the motor shaft connected to a tacho TAC RANGE 40000 Running to position 30000 at full speed set DMX channels approximately to DMX channel 1 75 DMX channel 2 0 DMX channel 3 100 DMX channel 4 51 between 50 55 Mode 5 Manual control no DMX channels is in use DMX channels 7 10 varies for extended mode WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 1 Mode setup The motor controller has 5 different control modes The different modes determine which kind of motor feedback and which type of motor regulation is used Here are the main features Mode 1 Mode 2 Mode 3 Mode 4 Free run motor can run forward and reverse at variable speeds and it can stop The limit switch FWD and REV is active meaning activating the FWD limit switch will stop the motor from running forward and likewise for REV Positioning with analog feedback Position and direction can be controlled The position
5. show At times the regulation needs to be smooth and at other times it needs to be as fast as possible during a show Will not have any effect in mode 1 When the PIDS parameters have been found they can be saved to the memory of the motor controller by pressing the ENT button in the extended mode menu DMX channel 7 PID P only active when EXT MODE PIDS Channel 7 is used to adjust the P value of the PID motor regulation 0 100 sets the P value P channel7 in multiplied with 50 E g 10 gt P 500 20 gt P 1000 DMX channel 8 PID I only active when EXT MODE PIDS Channel 8 is used to adjust the I value of the PID motor regulation 0 100 sets the I value I channel 8 in multiplied with 50 E g 7 gt I 350 30 gt I 1500 DMX channel 9 PID D only active when EXT MODE PIDS Channel 9 is used to adjust the D value of the PID motor regulation 0 100 sets the D value D channel 9 in multiplied with 50 E g 35 gt D 1750 40 gt D 2000 DMX channel 10 PID S only active when EXT MODE PIDS Channel 10 is used to adjust the S value of the PID motor regulation 0 100 sets the S value S channel 10 in multiplied with 50 E g 22 gt S 1100 40 gt S 2000 WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 10 MENU The menu structure is divided into two different areas for safer motor control
6. A high value on channel 1 gives a high position A low value on channel 1 gives a low position on the motor DMX channel 2 Position fine 16 bit DMX channel This is the fine position of the motor This channel together with channel 1 makes up a 16 bit position on the motor Channel 2 is used to fine tune the position DMX channel 3 Speed Channel 3 is used to control the speed or the maximum speed of the motor If channel 3 is 0 the motor will not run If channel 3 is 50 the motor will run at 50 speed DMX channel 4 Motor Enable 50 and 55 for the motor to turn Channel 4 is used as an extra security channel The value on channel 4 needs to be between 50 and 55 for the motor to run All other values make the motor stop All other values will also reset any error shown DMX channel 5 Manual FWD Mode 2 4 Reset FWD only active in mode 3 amp 4 Channel 5 is used to manual move the motor forward When channel 5 is in use it will run the motor FWD until it hits the limit switch FWD In mode 3 and 4 the position is reset Setting DMX channel 5 to 0 resets the position 10 100 makes the motor run forward at variable speed 10 low speed 100 full speed WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 9 DMX channel 6 Manual REV Mode 2 4 calculates a new TAC RANGE in mode 4 Channel 6 is used to manual move the motor reverse When channel 6
7. MIN REV Minimum speed reverse Range 0 1000 The motor minimum speed for the reverse direction The motor is allowed to run at different minimum speed for each direction this is to differentiate between different mechanical loads for forward and reverse see SP MIN FWD Set this value to a speed where the motor will still run reverse at full load ACC RAMP Acceleration ramp Range 50 10000 ACC RAMP sets the accelerations ramp on the motor control in 1 min sec ACC RAMP values of 500 is slow and 10000 is very fast acceleration DEC RAMP Deceleration ramp Range 50 10000 DCC RAMP sets the decelerations ramp on the motor control in 1 min sec If the ramp is set too steep the motor controller can shut shuts down and issues the error message Overvoltage DEC RAMP value of 500 is slow deceleration and 10000 is very fast NOM SPEED The motor nominal speed setting Range 100 6000 The motor nominal speed value is the speed of the motor without load the motor controller needs to know this value to correctly control the motor This NOM SPEED value is found on the motor name plate See also NOM FREQ below E g The name plate reads 1400RPM at 50Hz then set NOM SPEED to 1400 amp NOM FREQ to 50 NOM FREQ Motor nominal frequency setting Range 50 or 60 The motor nominal frequency is the frequency at which the motor nominal speed is given Found on the motor name plate Most times both a speed at 50 and 60 Hz is given See also NOM SPEED above
8. TAC RANGE sets the working range pulses of the motor This is only used with tacho feedback mode 3 4 E g with 20 tacho pulses on the motor and a gearing of 1 28 gives 1 round 20 28 560 pulses in TAC RANGE 50 rounds 50 20 40 5600 in TAC RANGE Tacho range is limited to 50 000 If you want to have longer range you have to raise the tacho divider see TAC DIVIDE below TAC DIVIDE Tacho pulse divider Range 1 512 Define the divider for the tacho feedback Used for adjusting the pulse number so the AC Motor Controller regulator does not get overrun E g Tacho directly on the motor 1024 pulses per round 1 024 pulses Gearing of 50 1 one round on the gearing output shaft 51 200 pulses Rounds on the gearing output shaft 40 rounds 2 048 000 pulses To have less than 50 000 pulses the divider needs to be 64 1 024 50 40 2 048 000 which means with a 64 divider pulses is 2 048 000 64 32 000 This is within range Set TAC DIVIDE 64 and TAC RANGE 32 000 LIM RESET Limit switch position reset Range 1 4 Defines which activated limit switch resets the tacho position NONE Do not reset the tacho position by any limit switch FWD Resets the position to TAC RANGE RES OFFSET if the FWD limit switch is activated REV Resets the position to 0 RES OFFSET if the reverse limit switch is activated FWD RE Resets if either of the limit switches is activated see FWD and REV above E g LIM RESET FWD TAC RANGE 30000 and RES OF
9. TORQUE Motor torque setup Range 0 42 TORQUE sets the maximum torque of the motor 0 normal power and 42 is the highest motor torque To high a TORQUE setup can result in overheating the motor at continually use SPEED BOOST Motor speed boost Range 50 400 This is used to be able to raise the maximum RPM of the motor If a motor nominal is set to 1400 at 50 Hz raising the SPEED BOOST to 200 will enable the motor run double the RPM 1400 x 200 2800 Not all AC motors are capable of running faster than nominal frequency Most AC motor though can run at twice the original speed PID P I D and S Are all parameters for adjusting the motor control The PID regulation regulates the motor speed until the position has been reached The PID regulation is only used for mode 2 4 See Tuning the PID on page 5 or searching the internet for PID tuning this will reveal several thousands of sources of information on PID regulation and tuning A very useful rule of thumb is to only change one PID value at a time PID P PID regulator Power setup Range 50 5000 PIDI PID regulator Integrate setup Range 0 5000 PID D PID regulator Differentiate setup Range 0 5000 PIDS PID regulator S setup Range 50 5000 WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 15 PRECISION Precision Range 1 500 The precision parameter is used to adjust the positioning system This parameter sets how accurate the p
10. You can raise the TAC DIVIDE this will decrease the amount of data to the regulation but have in mind that it will also decrease the precision of the positioning E g Setting TAC DIVIDE to 8 will work if you have a 1400 RPM motor with 1024 pulses rev mounted directly on the motor shaft Examples of PID setup E g with 20 pulses on the motor shaft Motor speed nominal 2800 RPM Feedback Tacho with 20 pulse round mounted on the motor shaft Set PID values P 1000 I 1000 D 1500 S 500 E g with 28 1 gearing and 10 turn potentiometer Motor speed nominal 1400 RPM Gearing 28 1 Feedback 10 turn potentiometer mounted on the gearing shaft Set PID values P 500 I 1000 D 1000 S 1000 E g with 28 1 gearing and tacho with 1024 pulse round Motor speed nominal 1400 RPM Gearing 28 1 Feedback Tacho with 1024 pulse round mounted on the gearing shaft Set PID values P 600 I 2000 D 1000 S 600 WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 5 Connecting the AC Motor Controller Limit Switch i Pin 1 GND Relay Output Fmergeney syn Pin 2 Limit SW FWD Pin 1 NO Pin 1 GND Pi imi Pin 2 NC in 3 Limit SW REV Pin 2 Emergency in Pin 4 GND Pin 3 COM Pin 3 No Connection POWER SUPPLY 400 VAC AC MOTOR AC motor 3 PHASES C OTO 3 PHASES 1 NULL CONTROLLER Star Delta 1 GROUND Lighting Desk with Analog Ref
11. plate NOM FREQ this is the frequency at which the RPM is found on the motor name plate SPEED BOOST boost the nominal speed from 50 400 default 100 No speed boost E g typed on a motor name plate is 2800RPM at 50Hz Then set NOM SPEED 2800 NOM FREQ 50 and SPEED BOOST 100 Setting up DMX values Setup MAX SPEED to the maximum speed you want the motor to run E g In the example above the MAX SPEED is set to 2800 but you only want the motor be allowed to run 2000 RPM then you set MAX SPEED 2000 But if you want the same motor to run at maximum 3000 RPM then set SPEED BOOST to 110 and set MAX SPEED to 3000 Most but not all AC motors will run up to 200 faster than the nominal speed some even faster Setting up feedback There is some ground rules that should be followed when choosing feedback and where to mechanically mount this feedback Potentiometer feedback Too fast changes in the analog input will make it impossible for the motor regulation to regulate the motor to stop at a specific position As arule if you want the motor regulation to use the maximum motor speed the minimum time for the potentiometer to travel from one end to other should not be less than one second This can be calculated by the following equation POTENTIOME TER GEARING x RPM 2 60 x GEARING ls E g 1 10 turn potentiometer mounted on a 1 100 gearing with a 1400 RPM motor 10 x 1400 60 x 100 2 33
12. sink on the bottom of the AC Motor Controller to direct some of the heat away If a heat sink it is not enough a fan can be used to force air over the heat sink to make sure the temperature stays below 70 C 158 F If an error has occurred it can be reset by toggling the emergency stop or by setting DMX channel 4 to 0 Technical specifications Power supply 360 460V AC 47 63 Hz 3 phase incl null amp earth Power consumption total max 2500W Motor voltage 3 phase 400V AC Freq regulated 16 KHz switch freq Motor 3 phase AC motor 400VAC up to 2200W 4 5A see Note 1 DMX control signal DMX 512 DMX channels 4 10 channels Position sensor 2 channel tacho sensor potentiometer input 1 10Kohm Ambient temperature range 0 40 C 32 104 F Weight 2 Kg 4 4Lbs Dimension H L W 125 345 105 mm 4 9 13 6 4 2 Inch WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 17 WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 18 Cheat sheet Mode overview Mode 1 Free run Mode 2 Analog Feedback Mode 3 Tacho Feedback Mode 4 Tacho Feedback with TAC RANGE adjustment Mode 5 Manual Tacho 0 REV Tacho 1 FWD Analog Speed DMX channels Mode 1 DMXX channel 1 Direction 0 25 Mode 2 4 DMX channel 1 Position 16 bit DMX channel DMX channel 2 Position fine 16 bit DMX channel Mode 1 4 DMX channel 3 Maximu
13. Channel 7 at 10 gt ACC RAMP 1000 gt slow acceleration Channel 8 at 100 gt DCC RAMP 10000 gt fast deceleration PIDS DMX Channel 7 10 adjusts the PIDS values for the PID motor regulation This is used in mode 2 4 to setup the motor regulation See PID menu for details PID P Channel 7 multiplied by 50 PIDI Channel 8 multiplied by 50 PID D Channel 9 multiplied by 50 PIDS Channel 10 multiplied by 50 The new values are calculated by multiplying the DMX percentage with 50 E g Channel 7 at 20 gt PID P 1000 Channel 8 at 10 gt PID I 500 Channel 9 at 30 gt PID D 1500 Channel 10 at 10 gt PID S 500 The PIDS extended mode is especially useful for initial tuning of the system WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 13 AN FWD LIM Analog Forward Limit Range 50 10000 This is the forward analog position limit Only used in mode 2 Analog Feedback It is used to limit the range the motor can move meaning if set to 5000 max DMX value will only let the motor run from 50 to 5000 see also AN REV LIM AN REV LIM Analog Reverse Limit Range 50 10000 This is the reverse analog position limit Only used in mode 2 Analog Feedback It is used to limit the range the motor can move meaning if set to 2500 minimum DMX value will only let the motor run 10000 to 2500 see also AN FWD LIM TAC RANGE The motor working range Range 0 50 000 The
14. DR DMX start address 1 506 1 CTRL MODE Control Mode 1 5 1 EXT MODE Extended Mode 1 2 NONE AN FWD LIM Analog position forward limit 0 10000 9900 AN REV LIM Analog position reverse limit 0 10000 100 TAC RANGE Motor range in tacho mode 0 50000 20000 TAC DIVIDE Tacho divider 1 512 1 LIM RESET Limit switch to reset the position 1 4 NONE RES OFFSET Reset offset value 0 4000 0 SPEED MAX Maximum speed 100 15000 1400 SP MIN FWD Minimum speed FWD 0 1000 150 SP MIN REV Minimum speed REV 0 1000 150 ACC RAMP Accelerations ramp 50 10000 2500 DEC RAMP Decelerations ramp 50 10000 4800 NOM SPEED Motor nominal speed 100 6000 1400 NOM FREQ Motor nominal frequency 50 or 60 50 TORQUE Motor torque setup 0 42 0 SPEED BOOST Motor speed boost 50 400 100 PIDP PID regulator Power setup 50 5000 1000 PID I PID regulator Integrator setup 0 5000 600 PID D PID regulator Differentiate setup 0 5000 0 PIDS PID regulator S setup 50 5000 850 PRECISION Precision 1 500 100 RELAY Relay output 1 6 DMX OFF REL DELAY Relay delay 0 250 0 3 FACTORY Restore to factory settings MAN SPEED and MAN FWD REV is used for manual control of the motor WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 12 Detailed explanation of all parameters MAN SPEED Speed for manual driving Range 100 6000 MAN SPEED sets the speed for manual driving the motor 6000 sets the maximum speed
15. ELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 19
16. FSET 1000 If the FWD limit switch at some point activates the FWD limit switch it will reset the position to 30000 1000 This will run the position 1000 pulses reverse from the limit switch In this way the limit switch would only be reached if a problem occurs and if this happens it will automatically reset to its correct position again RES OFFSET Set the reset position offset Range 0 4000 Set some distance between the position where to reset and the operational range This can be used to run away from the limit switch after a limit switch reset If RES OFFSET 1000 reaching FWD limit switch LIM RESET FWD or FWD RE will reset to 1000 tacho pulses away from the limit switch See also LIM RESET above SPEED MAX Maximum speed Range 100 15000 SPEED MAX sets the speed for mode 1 and the maximum speed for mode 2 4 If set to 1000 it means the motor run at 1000 RPM when DMX speed is set to full SPEED MAX can be used lower the maximum speed e g while learning the system WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 14 SP MIN FWD Minimum speed forward Range 0 1000 The motor minimum speed for the forward direction The motor is allowed to run at different minimum speed for each direction this is to differentiate between different mechanical loads for forward and reverse see SP MIN REV Set this value to a speed where the motor will still run forward at full load SP
17. direction Pin 3 Tacho Input 1 Tacho output B or A dependent of the wanted direction Pin 4 5V Output Tacho sensor power 5volt Pin 5 12V Output Tacho sensor power 12volt The tacho sensor output 2 pulses corresponding to the speed and the direction The tacho sensors can be found in many different variants a tacho sensor output pulses on the two output pins A and B Tacho sensors is made in a wide range of variants from 2 to 10 000 pulses per round Most important is that the tacho sensor ARM or AXLE should be mechanically connected to the motor movement so the tacho sensor gives signal pulses when the motor moves With tacho sensor feedback a reset of the position is needed at power up The motor position reset can be done by running the motor forward with channel 5 until the forward limit switch has been reached setting channel 5 to 0 resets the motor It is also possible to reset the position directly if one of the limit switches is activated see the LIM RESET menu on page 16 The tacho sensor output A and B is used as input for the AC Motor Controller The tacho sensor used must operate at 5V or 12V Mode 3 or mode 4 is used to positions the motor from the tacho pulses Relay output The relay output can be used to activate a motor brake system See DELAY and REL DELAY for options for the relay output Pinout Relay sensor connections Pin 1 NC Normally Closed Pin 2 NO Normally Open P
18. erence Tacho input Reference DMX output Potentiometer input Pin 1 GND Pin 1 GND Pin 1 GND Pin 2 Tacho input 0 A Pin 2 Data Pin 2 Svolt Pin 3 Tacho input 1 B Pin 3 Data Pin 3 Analog input Pin 4 5 volt Pin 5 12 15 volt Figure 2 Connections to the AC Motor Controller Power supply The AC Motor Controller connects to 400V AC through the 5 pole 16A CEE male connector It is also necessary to mount both Null and Earth After connecting the power a start up screen is displayed it includes the software and hardware version and after that this screen appears DMX CONTROL MI START CHAN 1 DMX DMX is connected to the male 5 pole XLR connector The DMX LED will light constantly when receiving a DMX signal and it will blink when no DMX are received Pinout DMX IN DMX OUT Pin 1 GND Pin 1 GND Pin 2 Data Pin 2 Data Pin 3 Data Pin 3 Data Pin4 NC Pin 4 NC Pin 5 NC Pin 5 NC Emergency stop switch If the emergency stop switch is activated pin 1 and pin 2 are disconnected the red ERROR LED will light The emergency stop switch is connected to the female 3 pole XLR connector Pin 1 and Pin 2 should be connected to each other otherwise the motor will not run Pinout Pin 1 GND Pin 2 Emergency stop Pin 3 NC WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk Limit switch These inputs s
19. erwritten WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 16 LED Functions DMX LED The DMX lamp will light steady green when receiving a DMX signal The DMX lamp will blink green if no DMX signal is present Error LED The error LED will light red if there is an error Le if an emergency stop is present Reset error is done by toggling the emergency switch or by setting DMX channel 4 to 0 When the Error LED lights red there will also be an error description in the display Error codes AC Motor Controller will not start Check if the AC Motor Controller is connected to mains display shows nothing power incl Null and Earth The AC Motor Controller will not Check DMX connection start DMX lamp is blinking The motor will not run DMX LED Check limit switch inputs are connected is steady green The motor stops running after some The surrounding temperature has made the AC Motor time Controller to hot above 70 C 158 F so it has turned off the motor output Reactivate the output by toggling the emergency stop or by setting DMX channel 4 to 0 Note 1 The AC Motor Controller is designed to positioning a motor When running a motor continuously the AC Motor Controller can become very hot Above 70 C 158 F it will disable the motor output If the AC Motor Controller motor output disables because of over temperature you can mount a heat
20. in 3 COM Common WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk DMX Control When the AC Motor Controller is connected to power a DMX lightdesk and when the Limit Switches and Emergency Stop Switch inputs has been connected to GND the motor controller is ready for use and can be controlled from the lightdesk DMX channel description Mode Free run DMX channel 1 0 9 STOP 10 39 REV 40 69 STOP 70 100 FWD DMX channel 2 Not used DMX channel 3 Maximum speed DMX channel 4 Motor Enable between 50 and 55 to enable the motor output Mode 2 4 DMX channel 1 Position 16 bit DMX channel DMX channel 2 Position fine 16 bit DMX channel DMX channel 3 Maximum speed DMxX channel 4 Motor Enable between 50 and 55 to enable the motor output DMX channel 5 Manual FWD Mode 2 4 Reset FWD only active in mode 3 amp 4 DMxX channel 6 Manual REV Mode 2 4 Sets the TAC RANGE in mode 4 DMxX channel 7 Used in the extended DMX mode for Acceleration and PID P DMX channel 8 Used in the extended DMX mode for Deceleration and PID I DMX channel 9 Used in the extended DMX mode for and PID D DMxX channel 10 Used in the extended DMX mode for and PID S Mode 5 Manual control no DMX channels is in use DMX channel 1 Position 16 bit DMX channel This channel together with channel 2 makes up a 16 bit position on the motor
21. ing a new range with DMX TAC RANGE First reset the forward position then find the reverse position Run the motor reverse with channel 6 to the reverse reset position Setting DMX channel 6 to 0 calculates a new TAC RANGE The new TAC RANGE is calculated as the tacho pulses between forward reset position and the position reached with channel 6 subtracted RES OFFSET x 2 WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 2 E g resetting forward with channel 5 to the maximum forward position Set channel 5 to 50 motor speed moving the motor forward until the limit switch is reached Then reverse the motor to the most reverse position Set channel 6 to 50 speed and run the motor reverse until reverse limit switch is reached setting channel 6 to 0 recalculates the TAC RANGE The TAC RANGE is calculated from the forward limit switch to the reverse limit switch where the motor controller has counted 23731 tacho pulses between the two points RES OFFSET here is set to 1000 then the calculation of the new TAC RANGE 23731 2x1000 21731 This range is instantly saved in the motor controller As a safety precaution set the mode back to mode 3 Mode 5 MANUAL CONTROL Direction and speed can be controlled with manual pushbuttons and a potentiometer Manual reverse is achieved by connecting Tacho Input 0 to GND Manual forward is achieved by connecting Tacho Input I to GND The mo
22. is calculated from the analog feedback The limit switches will stop the motor if activated Manual forward on channel 5 manual reverse on channel 6 is active Positioning with tacho feedback Position and direction can be controlled The limit switches will stop the motor if activated The motor controller calculates the position from the tacho feedback Manual forward on channel 5 is active It is also used for resetting Manual reverse on channel 6 is active Resetting the forward position Run the motor to the forward reset position with channel 5 Setting DMX channel 5 to 0 resets the position The position after reset is set to TAC RANGE RES OFFSET Positioning with tacho feedback TAC RANGE reset with channel 5 and 6 Position and direction can be controlled The limit switches will stop the motor if activated Manual forward on channel 5 is active It is also used for resetting Manual reverse on channel 6 is active Mode 4 is intended to be used as an easy way of setting a new tacho range this could be at the initial motor system setup or if the mechanical range is changed After a new range has been set it is recommended to switch back to mode 3 to not risk changing the TAC RANGE under normal DMX control Resetting the forward position Run the motor to the forward reset position with channel 5 Setting DMX channel 5 to 0 resets the position The position after reset is set to TAC RANGE RES OFFSET Sett
23. is in use it runs the motor in reverse until it hits the limit switch REV In mode 4 the position is reset and anew TAC RANGE is calculated The new range is the tacho pulses between forward position set by channel 5 and reverse position set by channel 6 10 100 makes the motor run recverse at variable speed 10 low speed 100 full speed Extended Mode EXT MODE ACCDCC The ADCDCC mode is used to adjust the acceleration and the deceleration parameters at setup or during a show Sometimes a movement needs to be fast one place in the show and slow some other time in the same show When the acceleration and deceleration parameters have been found they can be saved to the memory of the motor controller by pressing the ENT button in the extended mode menu It is only advisable to change the acceleration and deceleration variables during a show in Free run mode DMX channel 7 Acceleration only active when EXT MODE ACCDCC Channel 7 is used to adjust the acceleration of the motor regulation 0 100 sets the acceleration 0 lowest acceleration 100 highest acceleration DMX channel 8 Deceleration only active when EXT MODE ACCDCC Channel 8 is used to adjust the deceleration of the motor regulation 0 100 sets the deceleration 0 lowest deceleration 100 highest deceleration EXT MODE PIDS The PIDS mode is used to adjust the PIDS parameters at setup or adjusting them during a
24. m speed DMX channel 4 Motor Enable between 50 and 55 to enable the motor output Mode 2 4 DMX channel 5 Manual FWD Mode 2 4 Reset FWD only active in mode 3 amp 4 DMxX channel 6 Manual REV Mode 2 4 Sets the TAC RANGE in mode 4 Extended mode ACCDCC DMX channel 7 Used for the extended DMX mode i e acceleration DMxX channel 8 Used for the extended DMX mode i e deceleration Extended mode PIDS DMX channel 7 PID P DMX channel 8 PID I DMX channel9 PID D DMX channel 10 PID S Motor setup NOM SPEED RPM found on the motor name plate NOM FREQ the frequency corresponding to the RPM on the motor name plate 50 60Hz MAX SPEED the maximum RPM set by DMX Connecting the AC Motor Controller Emergency Switch Pin 1 GND Pin 2 Emergency in Pin 3 No Connection POWER SUPPLY 400 VAC 3 PHASES 1 NULL 1 GROUND Lighting Desk with DMX output Pin 1 GND Pin 2 Data Pin 3 Data Limit Switch Pin 1 GND Pin 2 Limit SW FWD Pin 3 Limit SW REV Pin 4 GND AC MOTOR CONTROLLER Analog Reference Potentiometer input Pin 1 GND Pin 2 Svolt Pin 3 Analog input Relay Output Pin 1 NO Pin 2 NC Pin 3 COM AC motor 3 PHASE Star Delta Tacho input Reference Pin 1 GND Pin 2 Tacho input 0 A Pin 3 Tacho input 1 B Pin4 5 volt Pin 5 12 15 volt WWW WAHLBERG DK TELEPHONE 45 86 18 1420 C
25. ositioning system stops at the wanted position Low values give precise positioning and a high value gives a less precise positioning The precision value determines when the regulation may stop the motor E g when precision set to 100 the motor regulation stops when the wanted position and the actual position gets within 100 pulses from each other see the values on the expanded menu when finding a position see page 11 RELAY Relay output Range 1 6 Setup the relay output It has the following options OFF the relay is always off ON the relay is on when power is applied to the AC Motor Controller BROFF the relay turns off when the motor stops BRON the relay turns on when the motor stops DMXOFF the relay turns off only when DMX speed 0 DMX ON the relay turns on only when DMX speed 0 E g 1 The relay output BROFF set to release a motor brake whenever the motor speed is more than 0 2 The relay output DMXOFF set to release a motor brake whenever the DMX speed is more than 0 REL DELAY Relay delay Range 0 250 REL DELAY sets the seconds of delay time for the relay output The value is shown in seconds with one decimal so a value of 0 3 300ms delay E g RELAY DMXOFF and REL DELAY 0 5 turns the relay on when the DMX speed is not 0 and releases the relay 0 5 seconds after DMX speed is set to 0 again FACTORY Restores the original the factory settings All settings DMX address and so on will be ov
26. this will work just fine 2 1 turn potentiometer on the same setup as above 1x 1400 60 x 100 0 233 For setup number 2 you probably have to limit the max speed to regulate to a position without overshooting Tacho feedback Too fast changes in the regulation system will make it impossible for the motor regulation to regulate the motor to stop at a specific position The maximum number of pulses per second should be less than 1000 This can be calculated by the following equation TACHO IMPULSES x RPM 60 x GEARING lt 1000 pulses sec onds E g Nominal motor RPM 2800 80 pulse revolution tacho sensor on a 100 1 gearing gives us 2800 x 1024 100 x 60 37 pulses seconds This is okay for the regulation but it may not be precise enough for your positioning see the tacho input on page 8 It would be better to have 1024 pulses revolution tacho which gives 478 pulses s WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 4 Tuning the PID The PID values P Decreasing P will slow down the regulation It will also reduce the maximum speed if decreased to much I Increasing I slows down the regulation Only if P and S is set approprietly D Increasing D slows down the regulation Only if P and S is set approprietly S Increasing S will slow the regulation down It will also reduce the maximum speed if increased to much PID values are only used in Mode 2 4
27. tiometer A potentiometer would be mechanically connected to the motor shaft maybe through a gearbox Pinout Potentiometer Pin 1 GND potentiometer pin 1 Pin 2 5V supply potentiometer pin 3 Pin 3 Analog input potentiometer pin 2 middle pin Many different variants of potentiometers can be used single turn and multiturn or sliding potentiometers dependent on how they can be mechanically mounted The multiturn potentiometers can have 1 to 78 rounds The main thing using potentiometers as feedback is that the potentiometer ARM or AXIS should be connected to the motor movement so when the motor moves the potentiometer follows the movement and feeds the motor position back into the AC Motor Controller through the analog input The value of the potentiometer resistance should be between 1K and 10K ohms Mode 2 positions the motor from the analog feedback value Hint Care needs to be taken not to run the motor out over the potentiometers inner mechanical boundaries as it will destroy the potentiometer The limit switches will stop the motor if they are activated WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk Tacho input The tacho input is used for position feedback from a tacho sensor that is mechanically connected to the motor shaft Pinout Tacho sensor connections Pin 1 GND GND Pin 2 Tacho Input 0 Tacho output A or B dependent of the wanted
28. to 6000 RPM and 100 sets the minimum speed MAN UP DWN Manuel driving the motor MAN UP DWN is used for manual control of the motor Pressing the UP button makes the Rollup run up unless the limit switch is activated Pressing the DOWN button makes the Rollup run down unless the limit switch is activated The Rollup will stop if the Emergency Switch is activated DMX ADDR DMX start address Range 1 506 DMX start address defines which DMX address the motor controller reacts on The AC Motor Controller uses minimum 6 DMX channels CTRL MODE Control Mode Range 1 5 The AC Motor Controller has five different control modes Mode 1 to Mode 5 Mode 1 The motor runs free run without positioning Mode2 Positioning mode with analog feedback e g potentiometer Mode 3 Positioning mode with tacho feedback Mode 4 Positioning mode with tacho feedback and range set Mode 5 Manual mode no DMX used EXT MODE Extended DMX Mode Range 1 2 In the expanded view in the display it is possible to save the ACC and DCC or PIDS values to memory see page 11 NONE No extended DMX channels in use ACCDCC DMX Channel 7 sets the acceleration and DMX channel 8 sets the deceleration This is used to setup acceleration and deceleration ramps ACC RAMP is overridden by the DMX percentage value of channel 7 times 100 DEC RAMP is overridden by the DMX percentage value of channel 8 times 100 The new value is calculated by multiplying the DMX percentage with 100 E g
29. top the motor movement in direction of the respective limit switch Placing the limit switches strategic at the outer positions of the maximum operating range forces the motor to stop in the outer limit positions The display will show a message for the limit switch in the FORWARD LIMIT Control Mode menu Shown here for the forward limit switch SWITCH ACTIVATED This message will not be shown in the expanded view this is done to be able to see the position values while resetting see page 11 The limit switch connects to the 4 pole XLR connector The limit switch for the forward movement is connected to pin 1 and 2 The limit switch for the reverse movement is connected to pin 3 and 4 When the limit switch FWD is disconnected from GND the motor stops the forward motion When the limit switch REV is disconnected from GND the motor stops the reverse motion Pinout Pin 1 GND Pin 2 Limit Switch Forward Pin 3 Limit Switch Reverse Pin 4 GND Motor connection The tree phased motor connects to the AC Motor Controller on the female 5 pole 16A CEE connector 230VAC 400VAC motors needs to be connected in Y formation also called star formation 400VAC 600VAC motors needs to be connected in Delta formation u 11 Pinout Pin L1 Phase 1 Pin L2 Phase 2 Pin L3 Phase 3 PinN NC GND Earth motor cable shield Delta Y N Analog reference The analog reference can be used for position feedback from a poten
30. tor speed is adjusted with the voltage on analog input 0 5VDC Adjusting the motor speed can be easily done by connecting a potentiometer between GND and 5V and connecting the potentiometer middle pin 2 to the Analog Input Pin 3 Analog Reference Potentiometer input Pin 1 GND Pin2 5 volt Pin 3 Analog input Potentiometer Tacho input Reference Pin1 GND Reverse Forward Pin 2 Tacho input 0 A Pushbutton Pushbutton Pin 3 Tacho input 1 B Pin4 5 volt Pin 5 12 15 volt Figure 1 Connection for direction and speed controlled with buttons potentiometer E g we have a turntable we want to turn in one direction at the push on a button We want it to turn at one specific speed but we need to adjust the speed to determine at which speed it should turn Placing a potentiometer on the Analog Reference and placing a pushbutton between GND Pin 1 and Tacho 1 Pin 3 will enable us to du just that See figure 1 WWW WAHLBERG DK TELEPHONE 45 86 18 1420 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk 3 Getting started with the AC Motor Controller The Limit Switch and the Emergency Switch inputs needs to be connected to GND for the motor to run Setting up the motor parameters The motor parameters can be found on the motor name plate It is very important to correctly setup the following parameters for the motor to run properly NOM SPEED the nominal motor RPM found on the motor name
31. wahlberg LIGHT amp MOTION DESIGN J gerg rdsgade 152 05A DK 8000 Aarhus C DENMARK WWW WAHLBERG DK AC Motor Controller 2200W User Manual WWW WAHLBERG DK TELEPHONE 45 86 18 14 20 CELL PHONE 45 40 52 20 88 EMAIL mads wahlberg dk April 2011 AC Motor Controller features The AC Motor Controller is an advanced motor regulation with various control inputs It has inputs for DMX signal tacho sensors and potentiometers emergency stop and limit switches The motor controller controls a 3 phase AC motor of maximum 2200W The motor is controlled by a frequency inverter which controls the speed and force of the motor The frequency inverter is controlled by a control circuit where a microprocessor control and monitor the motor another microprocessor receives the DMX signal DMX channels used for controlling the motor For a more detailed description see page 9 Mode 1 Free run DMX channel 1 0 9 stop 10 39 REV 40 69 STOP 70 100 FWD DMxX channel 2 Not used DMxX channel 3 Speed DMxX channel 4 Motor Enable between 50 and 55 to enable the motor output E g Running the motor in reverse with 50 speed set DMX values to DMX channel 1 20 between 10 39 DMX channel 2 not used DMX channel 3 50 DMxX channel 4 53 between 50 55 Mode 2 4 DMX channel 1 Position 16 bit DMX channel DMX channel 2 Position fine 16 bit DMX channel DMX channel 3 Maximum speed
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