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MLP-TRIM User Manual (840KB PDF)

1. entree enne 3 3 Keypad LOCKOUT A aa eee s 3 5 Control Parameters 3 7 Direct Mode estat tee a 3 8 Master 7 97 tnnt nnne niin 3 9 Follower Rt oi PEE tet E da ted 3 19 MOG DE 3 38 Inverse Master 3 43 Inverse Follower 3 45 Acceleration Deceleration 44 408540000 3 47 EDT 3 48 5a a a i rasen ale 3 52 3 54 3 55 Logic Control uc tor ri 3 57 logic Inputs e Ee a eoe ERR SERM EUREN eta 3 58 Logic OUTPUTS s m ete bee ele e rd 3 61 Monitor Parameters uiii een tte esie e odes 3 63 en 3 64 Output Monitoring u e en eater i aere tea 3 67 Performance Monitoring 444 3 68 inna eene 3 70 Serial Communications 404 2 2 3 73 Using Serial 3 74 Communications Software 3 76 Troubleshooting ori 4 1 Diagnostics len 4 3 Troubleshooting 4 1
2. 4 17 MLP Trim Wiring Connections without Relays G 1 Relay Start Stop Wiring Connections G 2 Start Stop for Regen with Armature Contactor G 3 Start Stop for Non Regen with Armature Contactor G 4 Two Channel Start Stop Lead Follower Logic G 5 vii viii Table 3 1 Table 3 2 Table 3 3 Table 3 4 Table 3 5 Table 3 6 Table 3 7 Table 3 8 Table 3 9 Table 3 10 Table 3 11 Table 3 12 Table 3 13 Table 3 14 Table 3 15 Table 3 16 Table 3 17 Table 3 18 Table 3 19 Table 3 20 Table 3 21 Table 3 22 Table 3 23 Table 3 24 Table 3 25 Table 3 26 Table 3 27 Table 3 28 Table 3 29 Table 3 30 Table 3 31 Table 3 32 Table 3 33 Table 3 34 Table 3 35 List of Tables Basic Keypad Entry 3 4 Default Direct Mode Control Parameters 3 8 Entering Direct Mode Control Parameters 3 8 Default Master Scaling Control Parameters 3 10 Entering Master Scaling Control Parameters 3 10 Entering Master Setpoint Control Parameters 3 11 Master Mode Control Parameters Example 3 12 Default Scaling Control Parameters 3 13 Entering Master Scaling Analog Feedback Parameters 3 1
3. RPM Feedback Open Loop y Direct Enable i Inverse Scaling si Display Mode Follower Gain Integral rcd Derivative Trim Authority Device Address ______ Baud Rate y Character Format Control Mask Drive Enable Logic Offset Null f Offset Authority y Offset Polarity EE Setpoint Lockout Mask Analog Input Allocation Analog Input Zero ______ O y oH Please record what the relevant Monitor Parameters display when the problem occurs Code Description Tach Lead Frequency Pulse Error Count Feedback Frequency Deviation Error Ramped Reference Spd Command Output Trim Output Active Scaling Mode Keypad Error Alarm Status x ee O Scaled Reference tl 73 GE i 7 Displayed Code Description Displayed Control State Logic Inputs Group A Logic Inputs Group B Logic Outputs EEPROM Status Serial Comm Error Frequency Overflow Limit Status A D Input A D Input Adjusted Software Code Rev Software Part Number APPENDIX G WIRING DIAGRAM EXAMPLES DANGER This diagram is for conceptual purposes only Use safety equipment Make wiring connections carefully Incorrect use of equipment or connections can cause injury or death 5V DI 1 5V Ext Pwr Supply LEAD SE u Feedback u 2 Freq RUN Run
4. Response Tuning Scaling Formats Setpoints Engineering Units Accel Decel Frequency Inputs Control Inputs Caution MLP TRIM SPECIFICATIONS 0196 Set Speed 10 millisecond control loop update Separately adjustable Gain Integral and Derivative parameters for stability and response Direct Direct set of Speed Command Out analog Master Absolute Setpoint entry Follower Ratio Setpoint calculation Offset Ratio plus analog offset Inverse Master Absolute Inverse Setpoint entry Inverse Follower Inverse Ratio Setpoint calculation Six Total 2 Master 2 Follower 1 Direct 1 Jog Engineering Unit Setpoint and Display 0 to 600 0 seconds 74HC14 Schmitt Trigger Vin MAX 24 VDC Vin LOW 1 0 VDC Logic Low Vin HIGH gt 3 5 VDC Logic High 0 30 KHz Feedback amp Lead 4 99 Pullup to 5V Optically Isolated 74HC14 Schmitt Trigger Vin MAX 24 VDC Vin LOW 1 0 VDC Logic Low Vin HIGH 3 5 VDC Logic High 4 99 Pullup to 5V Optically Isolated Run R Stop F Stop Jog Master Follower Setpoint Select Scroll Up Scroll Down Do not exceed 5VDC on the I O Power Input J5 pins 1 2 or equipment damage will occur A 1 Analog Input Status Outputs Speed Command Aux Supply Serial Interface Power Requirements Line Loss Operating Temperature Storage Temperature Humidity A 2 0 10 VDC Range 33
5. 1 apo 0 joeuq opo Me uo uo Iso 3 91 92 5 Troubleshooting Diagnostics Troubleshooting PROM Chip Replacement DIAGNOSTICS This section describes how to use the diagnostic routines to verify that the MLP Trim is operating properly as well as to identify any MLP Trim problems The diagnostic routines are run independently with the MLP Trim temporarily disconnected from your system Begin diagnostics with the Clear 4 procedure then run tests 1 6 Each of the tests can be performed without repeating the Clear 4 procedure unless you exit diagnostics If you need to verify the integrity of the MLP Trim relative to your system refer to the Troubleshooting Troubleshooting section If the information in this section does not solve your problem consult Contrex Technical Support 763 424 7800 or 800 342 4411 Clear 4 To Begin the Diagnostic Procedure To begin the diagnostic procedure turn the MLP Trim off and disconnect it from your system Turn the power on the MLP Trim while simultaneously pressing Clear and 4 on the keypad The MLP Trim defaults to RAM Test 1 The Diagnostic indicator and the number 1 are visible on the left side of the LED display If you did not see this indicator you are not in diagnostics The example below shows the diagnostic indicator and test number on the LED display Diagnostic Indicator Test Number RAM Test 1 To T
6. Acceleration Time See Appendix C CP 16 Alarms See Appendix C CP 10 11 12 13 14 or 15 Calibration Calibration matches the analog output of the MLP Trim with the analog input of the motor drive It also zero and spans the analog input Closed loop A system that is controlled by manipulating the output based on error setpoint feedback Closed Loop Compensation A mathematical term for a control algorithm that resolves PID Software the control error feedback setpoint to zero Output Kp X Error Error dt dError dt PID represents Proportional Integral Derivative Code Select Key Press this key prior to entering a Parameter Code either a Control Parameter or a Monitor Parameter Control Command Send The Control Command Send allows the host computer to control the operating functions of the MLP Trim that are associated with the Logic inputs Run Stop Setpoint Select and Master Follower Control Parameters Control Parameters allow you to enter data that is unique to your system e g encoder resolution Lead to Follower ratios and modify the MLP Trim s operation for your specific application e g maximum RPMs setpoints acceleration deceleration ramp rates There are Control Glossary 3 Data Inquiry Deceleration Time Dedicated Keys Derivative Digital Motor Controller Direct Mode Direct Enable Direct Setpoint Display Test Glossary 4 Parameters for Direct mo
7. MP 42 PULSE ERROR COUNT The Pulse Error Count indicates the difference between the Lead and Feedback pulses received during the Follower mode of operation It is an indicator of the position error between the lead and follower devices This error is cleared to zero when the MLP Trim enters the stop state MP 44 DEVIATION ERROR Deviation MP 44 displays the difference between the Ramped Reference MP 46 and the Feedback Frequency MP 43 measured in units of hertz pulses per second Deviation MP 44 is not averaged or filtered it is the ten millisecond frequency calculation prior to the display update MP 45 SCALED REFERENCE The Scaled Reference MP 45 is the scaled setpoint number converted to hertz It is the calculated value that is input to the Acceleration Deceleration routine This parameter may display numbers that are larger than 9999 These larger values are displayed with two decimal places For example 10 000 hertz is displayed as 10 00 MP 46 RAMPED REFERENCE The Ramped Reference MP 46 is the calculated output of the Acceleration Deceleration routine in hertz It is the setpoint input to the PID compensation routine This parameter may display numbers that are larger than 9999 These larger values are displayed with two decimal places For example 10 000 hertz is displayed as 10 00 MP 47 SPEED COMMAND OUTPUT The Speed Command Output MP 47 displays the level of calibrated full scale analog o
8. has potentiometer speed control MOTOR DRIVE remove the potentiometer connections and wire the Speed Do not connect the Drive Isolated Common to other Command Output to the logic commons potentiometer wiper input The MLP Trim s isolated common should Figure 2 17 Speed Command Out always be connected to the drive common Digital Output 1 J6 pin 15 17 The Digital Output 1 can be programmed to activate as a function of various alarm conditions or as a function of the drive enable logic Refer to CP 10 for functional allocation of Digital Output 1 NOTE This is an open collector relay driver For specification details see References Appendix MLP Trim Specifications Use an external DC power supply to power the relays Free wheeling diodes are incorporated internally in the MLP Trim and do not need to be added externally 16 Digital Output 2 J6 pin 16 17 The Digital Output 2 can be programmed to activate as a function of various alarm conditions or as a function of the drive enable logic Refer to CP 11 for functional allocation of Digital Output 2 NOTE This is an open collector relay driver Use an external DC power supply to power the relays Free wheeling diodes are incorporated internally in the MLP Trim and do not need to be added externally V DO EXTERNAL DIG OUT1 DIG OUT2 BREIT Common 50V Max Figure 2 18 Digital Output 1 and Digital Output 2 Auxiliary DC Power J1 pin 1 2
9. ling Monitor Parameters also confirm the wiring and the tuning as well as assist with troubleshooting MPs can be accessed at any time during the MLP Trim s operation including during Run Jog R Stop and F Stop There are four categories of Monitor Parameters Input Monitoring Output Monitoring Performance Monitoring and Status Monitoring Numeric Keys Use the numeric keys to enter a Parameter Code for either a Control Parameter CP or a Monitor Parameter MP or to enter a value for a Control Parameter Use the Enter key after each entry Use the Clear key to delete your entry Open Loop A system that is controlled without feedback Operating State The systems status within a mode of operation such as Run R Stop F Stop or Jog Glossary 7 Output Monitoring Output Test Outputs Parameters Parameter Code Parameter Send Parameter Value Performance Monitoring PROM Chip PROM Test PPR Feedback Glossary 8 Speed Command Output MP 47 Logic Outputs MP 56 Tests the Logic Outputs Speed Command Out Dig_Out1 Dig_Out2 Parameters are divided into two classifications Control Parameters CP and Monitor Parameters MP The numbered code that represents a Parameter Use the Parameter Send to change any of the MLP Trim s Control Parameters in Serial Communications Parameter values are pre loaded in the factory however you can modify Control Parameter values with operational data that i
10. peo ve dd cao IW qd 8MOJJOFJ 5n 3 6 4 AGOW H3MOT1OJ 09 Je 049 N a 2 xen ve dd X ise uiodies 1 99 Jeau p TY v d9 xXoeqpee4J v d9 yoeqpes4 0497 eran odes 49 Seyy 02 09 na iseihurodies 24 AGOW H31SVIN ZH je19U9H yoeq 9947 09 001 001 Yd asyo ranty niu y AueodjasyO Auounvesyo 16 42 0 99 8 99 88 42 42 9 99 2227 es Nau 13 Ydd Wdy ZH gt 16 42 0 99 6 42 135440 APPENDIX C PARAMETER SUMMARY NUMERIC QUICK REFERENCE CP 01 MASTER SETPOINT 1 The Engineering Units value that you want your system to operate at when Master Setpoint 1 CP 01 is active If the Master Setpoint is equal to the Master Engineering Units CP 20 then the system will run at its maximum RPMs Max RPM Feedback CP 34 The factory default Master Setpoint Control Parameters are set at 0 CP 02 MASTER SETPOINT 2 The Engineering Units value that you want your system to operate at when Master Setpoint 2 CP 02 is active If the Master Setpoint is equal to the Master Engineering Units CP 20 then the system will run at
11. D 1 Lead page 3 19 C 5 D 1 PROM Chip page Glossary 8 Index 10 Chip Replacement page 4 16 Test page 4 10 Glossary 8 R R Stop page 3 58 Input page 2 10 RAM Test page 4 4 4 10 Glossary 9 Ramped Error page C 3 D 1 Ramped Reference page C 7 E 1 Remote Control of the MLP Trim page 3 73 Revision Log page H 1 Ring Kits page Glossary 9 RPM Feedback page Glossary 9 RPM Lead page Glossary 9 RS485 page 3 73 Run page 3 59 Glossary 9 Input page 2 9 S Scaled Error page 3 D 1 Scaled Reference page C 7 E 1 Scaling page Glossary 9 Scroll Down Input page 2 13 Scroll Up Input page 2 13 Serial Communications page 3 73 Glossary 10 ASCII Messages page 3 76 Binary Messages page 3 76 Connections page 2 18 Control Command Send page 3 82 Data Inquiry page 3 86 Error page 3 75 C 11 E 1 Multidrop Installation page 2 17 Parameter Send page 3 77 Service Policy page Warranty 3 Setpoint Select Input page 2 12 Setup Calibration page 2 19 Mounting the MLP Trim page 2 3 Wiring page 2 5 Software Code Revision page C 17 E 1 Index 11 Design Communications page 3 76 Part Number page C 17 E 1 Specifications MLP Trim page 1 Speed Command Out page 3 67 C 7 E 1 Output page 2 15 Status Monitoring page 3 70 Glossary 10 Support Technical See Technical Support T Tach page 3 68 C 5 E 1 Technical Support page ii 4 3 4 11 Test Random Access Memory page 4 4 The Key
12. JOG Jog R STOP R Stop Speed F STOP F Stop Command Out MST FOL SETPT SCRL_UP SCRL_DWN COM v DO DIG OUT1 DIG OUT2 COM ANAL IN COM J6 AL DIGITAL OUTPUTS N IN Figure G 1 MLP Trim Wiring Connections without Relays DANGER This diagram is for conceptual purposes only Use safety equipment Make wiring connections carefully Incorrect use of equipment or connections can cause injury or death Line Neut Armature Contactor DI 5V Ext COM Pwr Supply LEAD FQ FDBK FQ Feedback COM Freq RUN KJ Run K J JOG K J Jog R STOP R Stop F STOP KR F Stop Speed COM K FS Command Out MST FOL SETPT SCRL_UP SCRL_DWN COM V DO DIG OUT1 DIG OUT2 COM ANAL IN COM H3MOd ov ANAL DIGITAL DIGITAL FREQ IN OUTPUTS INPUTS INPUTS Figure G 2 Relay Start Stop Wiring Connections DANGER This diagram is for conceptual purposes only Use safety equipment Make wiring connections carefully Incorrect use of equipment or connections can cause injury or death 12 Volt Power Supply Line Armature Contactor Figure G 3 Start Stop for Regen with Armature Contactor 5V Ext Pwr Supply cg m FDBK_FQ Feedback 2 Freq RUN Run JOG Jog R STOP R Stop F STOP F Sto 5 Mst FOL SETPT SCRL UP SCRL COM L DIG OUTI 108 Di com
13. MP 41 displays the frequency of the Lead Frequency Input J6 pin 1 in units of hertz pulses per second The Lead Frequency MP 41 is not averaged or filtered it is the ten millisecond frequency calculation prior to the display update Because the Lead Frequency MP 41 is not averaged or filtered and because of sensor irregularities it may appear less stable than Tach MP 40 Numbers that are larger than 9999 are displayed with two decimal places For example 10 000 hertz is displayed like the figure below in MP 43 MP 43 FEEDBACK FREQUENCY The Feedback Frequency MP 43 displays the frequency of the Feedback Frequency input J6 pin 2 in units of hertz pulses per second The Feedback Frequency MP 43 is not averaged or filtered it is the ten millisecond frequency calculation prior to the display update Because the Feedback Frequency MP 43 is not averaged or filtered and because of sensor irregularities it may appear less stable than Tach MP 40 Numbers that are larger than 9999 are displayed with two decimal places For example 10 000 hertz is displayed as follows Two Decimal Places MP 54 LOGIC INPUTS GROUP A The Logic Inputs A displays the status of the Run Jog R Stop and F Stop digital inputs The number 1 indicates an open or logic high level The number 0 indicates a closed or logic low level shorted to common In the example below Jog is the open or logic high level Code Run J6
14. R Stop F Stop Master or Follower Setpoint Select Scroll Up Scroll Down See Appendix C CP 66 One of four operating states Jog increases the RPMs at the acceleration rate that is specified in Acceleration Time CP 16 until the Jog Setpoint CP 05 is achieved When Jog is terminated there is no deceleration time the drive motor comes to an immediate stop Tests the Keypad The two digit Parameter Code is displayed on the left LED Display The Parameter Code s value is displayed on the right LED display This value can be up to four digits F Stop R Stop Run Jog Setpoint Select Master Follower Scroll Up Scroll Down Master Mode A stand alone control of a single motor The scaling format allows the operator to enter a setpoint in Engineering Units The MLP Trim compares the sensor shaft feedback to the scaled setpoint and calculates any speed error When the MLP Trim finds speed error the control algo rithm adjusts the Speed Command analog output and reduces the error to zero Master Setpoints See Appendix C CP 01 and CP 02 Max RPM Feedback See Appendix C CP 34 Max RPM Lead See Appendix C CP 33 Mode of Operation The scaling method that is used to operate your system e g Direct mode Master mode Follower mode Offset mode Inverse Master mode or Inverse Follower mode Monitor Parameters Monitor Parameters MPs monitor the performance of the MLP Trim and the system which the MLP Trim is control
15. The 5 volt output J1 pin 1 is a DC regulated output that can be used to power encoders or other auxiliary equipment that is used in conjunction with the MLP Trim If this output is used it will nullify optical isolation WARNING Do not exceed the maximum current output of 150 mA for 5 VDC Exceeding the maximum current output can damage the MLP Trim SERIAL COMMUNICATIONS NOTE The installation of this motor control must conform to area and local electrical codes See The National Electrical Code NEC Article 430 published by the National Fire Protection Association or The Canadian Electrical Code CEC Use local codes as applicable The Serial Communications interface on the MLP Trim complies with EIA Standard RS 485 A for balanced line transmissions This interface allows the host computer to perform remote computer parameter entry status or performance monitoring and remote control of the MLP Trim See Operations Serial Communications for information on using Serial Communications The MLP Trim is designed to use with an isolated RS232 to RS485 converter Figure 2 19 illustrates a multidrop installation of the Serial Communications link and Figure 2 20 illustrates the Serial Communications connections Isolated 85232 to 85485 Figure 2 19 MLP Trim Multidrop Installation Isolated RS232 to RS485 Converter TXD TXD COM RXD RXD MLP Trim 1 MLP Trim 2 1 Shield only at
16. This is the two character access address for the MLP Trim Character 4 Error Code If there are errors in the transmission that MLP Trim receives from the host computer the Error Code will display them Use Table 3 57 to convert the ASCII code to binary The binary code can be decoded as follows Bit7 Always 0 Bit6 Always 1 Bit5 1 Data was out of minimum maximum range Bit4 1 Checksum or Decimal Point Error Invalid Parameter Code Bit3 1 Receive buffer filled before ETX received or Message Format Error Bit2 1 Parameter Data Bit1 1 Error BitO 1 2 Always 0 Note The MLP Trim will only accept data if there are no errors The ASCII error code Binary code 1000000 indicates that the Host Transmission contains no errors Characters 5 6 Parameter Number The Control Parameter code is sent back to the host computer from the MLP Trim Characters 7 through 10 DATA The Control Parameter data that was requested is sent back to the host computer from the MLP Trim For an interpretation of the MP 50 through MP 56 and CP 73 data refer to Table 3 58 For the ASCII to binary conversion refer to Table 3 57 Character 11 Data Format Character 11 indicates the decimal location and polarity of the data that was transmitted in characters 7 through 10 Use the following codes to indicate decimal location and polarity 2 Format Code Forma
17. warranties whether of merchantability or otherwise except as to title other than those set forth above which are expressly made in lieu of all other warranties shall apply to any devise sold by Contrex Inc Contrex Inc reserves the right to change or improve its devices without imposing any obligation upon Contrex Inc to make changes or improvements in previously manufactured devices This warranty statement is a summary of Contrex Inc s policy Further limits of liability are contained in the Contrex Inc s purchase order acknowledgments and invoices Index Index A AC Power Input page 2 8 Acceleration Time page C 4 D 1 Acceleration Deceleration page 3 47 Glossary 3 Active Scaling Mode page 3 70 C 8 E 1 Alarm Format page 3 52 C 2 C 3 D 1 Status page 3 71 C 9 E 1 Alarms grouped page 3 52 Analog Feedback Follower Mode page 3 31 Master Mode page 3 13 Analog Input Input page 2 14 Analog Lead Follower Mode page 3 28 Analog Setpoint Follower Mode page 3 34 Master Mode page 3 16 Appendix A page A 1 Appendix B page B 1 Appendix C page C 1 Appendix D page D 1 Appendix E page E 1 Appendix F page F 1 Appendix G page G 1 Appendix H page H 1 ASCII Serial Communications Messages page 3 76 Auxiliary DC Power Output page 2 16 B Baud Rate page 3 74 C 14 D 2 Binary Serial Communications Messages page 3 76 C Calibration page 2 19 Analog Input page 2 23 Index 3 De
18. 2 3 Device These characters are the access address of the MLP Trim This number identifies individual MLP Trims on a multidrop system The MLP Trim will accept data only if this number matches the MLP Trim s address CP 70 with the exception of a 00 address The 00 address is universally accepted by all of the MLP Trims that are on the RS485 Serial Communications Interface Character 4 Message Type This character should always be 3 78 Character 5 6 Parameter Number These characters identify the Control Parameter that you want to change i e 16 2 CP 16 Characters 7 through 10 DATA These characters transmit the new value for a Control Parameter that you want to change The Data must be within the range specified in Appendix D Character 11 Data Format Character 11 indicates the decimal location and polarity of the data that was transmitted in characters 7 through 10 Use the following codes to indicate decimal location and polarity o 2 Format XXXX XXX X XX XX X XXX XXXX XXX X XX XX X XXX NOOA Codes 0 through 7 are valid for 20 CP 21 All other Code Parameters have either fixed or derived decimal locations and must use Code 0 Code 8 does not apply to the parameter send Character 12 ETX Always use the ASCII character to terminate the character string Example of Paramet
19. 2 7 J6 pins 1 3 Lead Frequency page 2 8 J6 pins 10 13 Setpoint Select page 2 12 J6 pins 11 13 Scroll Up page 2 13 J6 pins 12 13 Scroll Down or Open Closed Loop page 2 13 J6 pins 15 17 Dig Out1 page 2 15 J6 pins 16 17 Dig Out2 page 2 16 J6 pins 18 19 Analog In page 2 14 J6 pins 2 3 Feedback Frequency page 2 9 J6 pins 4 8 Run page 2 9 J6 pins 5 8 Jog page 2 10 2 14 J6 pins 6 8 R Stop page 2 10 J6 pins 7 8 F Stop page 2 11 J6 pins 9 13 Master Follower page 2 11 2 13 Jog page 3 55 3 60 Glossary 6 Jog Input page 2 10 2 14 Jog Setpoint page 3 55 C 1 D 1 K Keypad Basic Entry page 3 4 Error page 3 70 C 8 E 1 Lockout page 3 5 C 17 D 2 Mask page 3 5 Record of your Password page 3 6 Operation page 3 3 Test page 4 6 Glossary 6 Keys Code Select page 3 3 Glossary 3 Dedicated page 3 3 Index 7 Numeric page 3 3 Glossary 7 Setpoint page 3 3 Tach page 3 3 Up Down Scroll page 3 3 Glossary 10 L Lead Frequency page 3 64 C 6 E 1 Input page 2 8 LED Display page 3 3 Glossary 6 Limits page 3 54 LOC page 3 5 Logic Inputs page 3 58 Glossary 6 Inputs Group A page 3 65 C 10 E 1 Inputs Group B page 3 65 C 10 E 1 Output page 3 61 Outputs page 3 67 C 11 E 1 Logic Control page 3 57 Low Alarm page 3 D 1 Master Follower Input page 2 11 Master Engineering Units page 3 9 C
20. 4095 3000 2000 1000 Press Clear to exit the test Press Code Select to exit diagnostics 10 In addition to diagnostic tests 1 6 the MLP Trim automatically performs two power up diagnostic routines during every Power Up RAM TEST Random Access Memory The MLP Trim performs a pattern read write test on RAM If RAM fails 5 Is displayed The test will stop if a failure is detected Press Clear to exit the test IF the RAM is good the MLP Trim will begin the PROM test PROM TEST The MLP Trim performs a checksum comparison on the PROM If the test fails 3 is displayed The test stops if a failure is detected Press Clear to exit the test If the PROM is good exit is automatic The MLP Trim will begin the initialization routines and normal operation TROUBLESHOOTING This section contains four troubleshooting flowcharts to help you resolve four possible system operating problems The four scenarios that are addressed by the flowcharts are Motor Does Not Stop Motor Does Not Run Motor Runs at Wrong Speed Motor Runs Unstable If you need to verify the integrity of the MLP Trim independently refer to the Troubleshooting Diagnostics section If these troubleshooting procedures do not solve your problem perform a Clear 7 as follows Make a record of your current Control Parameter values When you perform the Clear 7 procedure all Control Parameters return to
21. 5 ANALIN COM 6 DANGER This diagram is for conceptual purposes only Use safety equipment Make wiring connections carefully Incorrect use of equipment or connections can cause injury or death Line Neut F Stop Start l_ Armature M1 AUX1 Contactor 5V DI 5V Ext com Pwr Supply LEAD FQ FDBK FQ Feedback LZ Freq RUN Run JOG R STOP R Stop Speed z F Stop Command MST FOL SETPT SCRL UP SCRL_DWN COM 20 2 Die OE pia our2 O a ANAL IN Sz i lt J6 Figure G 4 Start Stop for Non Regen with Armature Contactor DANGER This diagram is for conceptual purposes only Use safety equipment Make wiring connections carefully Incorrect use of equipment or connections can cause injury or death 5V DI 5VExt COM Pwr Supply g FDBK_FQ Feedback 2 RUN Run JoG Jog R STOP R Stop Speed F STOP F Stop Command 5 m COM Out MST FOL Setpoint SETPT Select SCRL UP SCRL DWN COM d v_Do E DIG our g our2 Z ANAL IN J6 5V DI Lead 0 LEAD FQ Frequency FDBK FQ Feedback 2 RUN Run JoG Jog R STOP R Stop d F STOP 2 F Stop Comm
22. 84 CP 21 Parameter Name Parameter Value Name Analog Input Allocation Follower Engineering Units CP 34 Max RPM Feedback CP 31 PPR Feedback Note Parameter Value Setting CP 84 to a value of 1 allocates the analog input to be used as the lead signal Enter the Follower Engineering Unit value for an analog lead level of 10 0 volts and feedback of Max RPM Feedback CP 34 This is typically a value of 1 000 Enter the maximum operating RPMs measured at the feedback sensor shaft Enter the resolution of the follower feedback sensor The Max RPM Lead CP 33 and PPR Lead CP 30 control parameters used for scaling Follower mode with a frequency lead are ignored when using analog lead scaling 29 30 Follower Mode Analog Lead Example The following example demonstrates Follower mode scaling using analog lead A pump delivers 20 0 gallons per minute of ingredient A when the pump motor rotates at 1800 RPM A second pump delivers 40 0 gallons per minute of ingredient B when the pump motor rotates at 1800 RPM A potentiometer connected to the analog input of the MLP Trim produces a 10 0 volt signal when the pump A lead motor rotates at 1800 RPM The following motor B has an encoder feedback of 30 PPR The Fol lower setpoint is to reflect the flow ratio in gallons minute of ingredient B to ingredient A Table 3 21 Follower Mode Lead Allocation Example CP Parameter Name Value Remarks C
23. CP 64 page 3 68 C 13 D 1 Index 4 CP 65 page 3 48 13 D 1 CP 66 page 3 48 C 13 D 1 CP 67 page 3 48 C 13 D 2 CP 69 page C 13 D 2 CP 70 page 3 74 C 14 D 2 CP 71 page 3 74 C 14 D 2 CP 72 page 3 75 C 14 D 2 CP 73 page 3 75 C 14 D 2 CP 74 page C 15 D 2 CP 75 page 3 38 C 15 D 2 CP 76 page 3 39 C 15 D 2 CP 77 page 3 39 C 15 D 2 CP 79 page 3 5 C 15 D 2 CP 84 page 3 13 3 16 3 28 3 31 3 34 3 38 16 D 2 CP 85 page 16 D 2 CP 86 page 2 23 C 16 D 2 CP 98 page 3 5 C 16 Control State page 3 71 C 9 E 1 D Data Inquiry page Glossary 4 Serial Communications page 3 86 Deceleration Time page C 4 D 1 Dedicated Keys page Glossary 4 See also Keys Dedicated Derivative page 3 48 C 13 D 2 Deviation page 3 69 C 3 C 7 E 1 Device Address page 3 74 C 14 D 2 Diagnostics page 4 3 Automatic Test Routines page 4 10 Digital Motor Controller page Glossary 4 Digital Output 1 Output page 2 15 Digital Output 2 Output page 2 16 Direct Enable page 3 8 C 12 D 1 Direct Mode page 3 8 Glossary 4 Direct Setpoint page 3 8 C 2 D 1 Display Mode Follower page 3 68 C 13 D 1 Display Test page 4 5 Glossary 4 Drive Enable page Glossary 5 Logic page C 15 D 2 E EEPROM page Glossary 5 EEPROM Status page 3 72 C 11 E 1 Index 5 Enclosure Mounting and Housing the MLP Trim page 2 3 Engineering Units page Glossary 5 F F Stop page 3 58 Glossary 5 Input
24. Closure Display RUN J6 4 JOG J6 5 R STOP J6 6 F STOP J6 7 MASTER FOLLOWER J6 9 SETPOINT SELECT J6 10 SCROLL UP J6 11 SCROLL DOWN J6 12 Press CLEAR to exit the test Press CODE SELECT only if you want to exit diagnostics Output Test 5 To Test the Logic Outputs Press the UP or DOWN scroll keys until the diagnostic indicator and the number 5 are visible on the left side of the LED display Only the diagnostic indicator and the number 5 will be visible on the LED display during this test To run this test connect the outputs to a pull up resistor and either a meter or LED or connect the outputs to a relay and either lights or sound Press Enter to start the test Press keys 1 2 to activate the outputs Press To Activate 1 Dig Out1 2 Dig Out2 Press Clear to exit the test Press CODE SELECT only if you want to exit diagnostics Output Test 6 Test the Speed Command Output Press the UP or DOWN scroll keys until the diagnostic indicator and the number 6 are visible on the left side of the LED display Only the diagnostic indicator and the number 6 will be visible on the LED display during this test To run this test attach a scope probe between J3 1 and 2 Press Enter to start the test The test will step through the DAC bits for Speed Command Output as follows 0 1000 2000 3000
25. Control Parameters 3 55 Entering Jog Control Parameters 3 55 Default Drive Enable Logic Control Parameters 3 61 Entering Drive Enable Logic Control Parameters 3 62 Parameter Send Host 3 77 Parameter Send MLP Trim Response 3 80 Control Command Send Host Transmission 3 82 Control Command Send MLP Trim Response 3 84 Data Inquiry Host Transmission 3 86 Data Inquiry MLP Trim Response 3 88 ASGII to Binary icit ea 3 90 Binary to Monitor Parameters 3 91 NOTES Introduction Introducing the MLP Trim Examples of MLP Trim Applications INTRODUCING THE MLP TRIM The MLP Trim is a highly accurate digital motor controller It has advanced embedded software that is capable of solving a great variety of speed control tasks It operates as either a stand alone control of a single motor Master mode as a part of a complex multi drive system Follower mode or Follower mode with analog trim Offset mode The MLP Trim is ideal for motor control applications where your present open loop or rudimentary closed loop operations are inaccur
26. Example A Example B is discussed in the following section Example demonstrates how scaling and setpoint Control Parameters are entered for a typical Follower mode of operation that uses a setpoint based on a percentage setpoint The Lead pump delivers 20 gallons minute of ingredient A The Lead motor s is running at a maximum RPM of 1800 and the Lead sensor shaft is equipped with a 60 tooth Ring kit The Follower pump delivers 10 gallons minute of ingredient B The Follower motor is running at a maximum RPM of 1800 and the Follower sensor shaft is equipped with a 60 tooth Ring kit Follower Setpoint 1 will be set so that when the Lead pump delivers 20 gallons minute of ingredient A the Follower will deliver 10 gallons minute of ingredient B Setpoint 2 will be set so when the Lead pump delivers 10 gallons minute of ingredient A the Follower pump will delivers 7 gallons minute of ingredient B Table 3 18 shows the Control Parameters that would be entered in the MLP Trim for Example B To find the ratio for the Follower Engineering Units CP 21 for Example B Follower E U at Max Follower RPM 10 Follower E U CP 21 100 50 Lead E U at Lead RPM 20 10 gal min The Follower Engineering Units when the Follower is operating at maximum RPM Divided by 20 gal min The Lead Engineering Units when the Lead is operating at maximum RPM Multiplied by 100 96 equals 50 Follower Engineering Units CP 21 as a percen
27. KQ Input Impedance 12 Bit Resolution 0 196 Linearity Error Typical 0 05 Drift Error Typical Isolated Mode 0 2 Drift Error Typical Non Isolated Mode Open Collector Driver ULN2003 50 VDC max 200 mA continuous 500 mA peak Optically Isolated Dig Out1 Dig Out2 0 to 10 VDC Span Pot Adjustable 5 to 12 VDC Optically Isolated 45 596 150 mA Max non isolated RS485 300 to 9600 Baud Full parameter access and control 115 1596 model 3200 1936 230 15 model 3200 1937 50 60 Hz 0 1 Amp 70 mSec ride through 0 to 55 C Int Enclosure 0 to 40 C Ext Enclosure 25 to 70 C 0 to 9595 non condensing Physical Dimensions Faceplate Rating Environment Altitude Weight 4 0 inches height 4 0 inches width 6 0 inches depth Interior Panel Nema 4 4X 12 13 65 MLP Trim shall be installed in a pollution degree 2 macro environment To 3 300 Feet 1000 meters 49 ounces A 3 4 5 FORMULAS APPENDIX B Use the following formulas to calculate Speed Control War J9MO0JIOJ azaan 3 2 rese dd ZH ve d9 pea xen d9 X v d9 jurodies Olo A du xen ve d9 X v d9 w odjes T 1 ta yoeqpes
28. Master Setpoint 1 CP 20 Master Engineering 20 0 This is the Engineering Unit value Units that would be present if the analog input were at 10 0 volts CP 34 Max RPM Feedback 1800 The maximum operating RPM of the feedback shaft 60 CP 31 PPR Feedback Feedback sensor resolution Follower Mode The Follower mode of operation is the most frequently used mode of operation It is a multi motor operation in which the entire process can be controlled by any number of motors and MLP Trims The MLP Trim allows you to control your system in Follower Engineering Units e g Follower to Lead ratio or percentage of RPMs gallons per minute feet per minute The Follower Engineering Units that you want the system to operate at are entered into the two available Follower Setpoints 03 and CP 04 However before the MLP Trim can determine how to operate at these setpoints you must enter Scaling Control Parameters into the MLP Trim Scaling is a convenient method for translating the relationship of the Lead and Follower motor RPMs into Follower Engineering Units Scaling Control Parameters give the MLP Trim the following information Max RPM Lead 33 Measured at the Lead sensor shaft this number is the maximum RPMs at which the Lead will operate in your system Max RPM Feedback CP 34 Measured at the sensor shaft this number is the maximum RPMs at which you want the follower to operate when the Lead is operating at its max
29. Mode Example 2 3 42 Default Inverse Master Control Parameters 3 43 Entering Inverse Master Control Parameters 3 43 Inverse Master Mode Control Parameters Example 3 44 Default Inverse Follower Control Parameters 3 45 Entering Inverse Follower Control Parameters 3 45 Table 3 36 Table 3 37 Table 3 38 Table 3 39 Table 3 40 Table 3 41 Table 3 42 Table 3 43 Table 3 44 Table 3 45 Table 3 46 Table 3 47 Table 3 48 Table 3 49 Table 3 50 Table 3 51 Table 3 52 Table 3 53 Table 3 54 Table 3 55 Table 3 56 Table 3 57 Table 3 58 Inverse Follower Mode Control Parameters Example 3 46 Default Master or Follower Accel Decel Control Parameters 3 47 Entering Master or Follower Accel Decel Control Parameters 3 47 Default Master or Follower Tuning Control Parameters 3 48 Entering Master or Follower Tuning Control Parameters 3 49 Default Zero Error Loop Control Parameters 3 50 Entering Zero Error Loop Control Parameters 3 51 Default Alarm Control Parameters 3 52 Entering Alarm Control Parameters 3 53 Default Limit Control Parameters 3 54 Entering Limit Control Parameters 3 54 Default Jog
30. Mode Feedback Allocation Example CP Parameter Name Value Remarks CP 84 Analog Input 2 Allocates The analog input as the Allocation feedback source Master Engineering 20 0 This is the Engineering Unit value Units that would be present if the analog input were at 10 0 volts 01 Master Setpoint 1 The desired Master Setpoint 1 CP 02 Master Setpoint 2 17 5 desired Master Setpoint 2 15 16 Master Mode Analog Setpoint The MLP Trim can be scaled for Engineering Unit setpoint entry and Tach display operation using the analog input for the setpoint The following Control Parameters give the MLP Trim the necessary information for analog setpoint operation in Master mode Analog Input Allocation CP 84 Setting CP 84 Analog Input Allocation to a value of 4 or 5 allocates the analog input to be used as Master Setpoint 1 or Master Setpoint 2 respectively Master Engineering Units CP 20 The actual value of the Master Engineering Units if the system were to operate with an analog setpoint level of 10 0 volts This is the maximum calibrated analog input level refer to Installation Setup Calibration Analog Input Calibration Note The analog input does not need to operate to 10 0 volts full scale to be used for setpoint replacement Max RPM Feedback CP 34 This is the maximum RPM of the feedback sensor shaft during system operation This number should be the same as the maximum operating speed set du
31. RPM Lead Enter the maximum operating RPMs measured at the lead sensor shaft PPR Lead Enter the resolution of the lead sensor Follower Mode Analog Setpoint Example The following example demonstrates Follower mode scaling using analog setpoint A pump delivers 20 0 gallons per minute of ingredient A when the pump motor rotates at 1750 RPM A second pump delivers 60 0 gallons per minute of ingredient B when the pump motor rotates at 1750 RPM A potentiometer connected to the analog input of the MLP Trim produces a 10 0 volt signal when the pump B and pump A motors rotate at 1750 RPM The lead motor A has an encoder feedback of 1000 PPR The feedback motor is equipped with a 60 tooth ring kit sensor The Follower Setpoint 1 is to reflect the flow ratio in gallons minute of ingredient B to ingredient A Table 3 27 Follower Mode Setpoint Allocation Parameter Name Value Remarks CP 84 Analog Input Allocates the analog input as the Allocation Follower Setpoint 1 CP 21 Follower This is the Engineering Unit value Engineering Units that is present if the analog input were at 10 0 volts and the lead and feedback at max RPM 60 0 gal min an B 3 000 20 0 gal min ingredient A CP 34 Max RPM Feedback 1750 The maximum operating RPM of the feedback shaft CP 31 PPR Feedback The resolution of the feedback sensor CP 33 Max RPM Lead 1750 The maximum operating RPM of the lead shaft CP 30 PPR Lead 1000 The resolution of the
32. Recovery Multiplier determines the rate at which the pulse error position is reduced to zero This parameter multipied by the pulse error count is the amount by which the speed setpoint is adjusted every 100 milliseconds Table 3 41 Default Zero Error Loop Control Parameters CP Parameter Name Parameter Value 0 CP 19 Lead Pulse Limit CP 29 Recovery Multiplier Table 3 42 Entering Zero Error Loop Control Parameters Parameter Name Parameter Value Lag Pulse Limit Enter the desired lag behind in position pulse limit Lead Pulse Limit Enter the desired lead ahead in position pulse limit Recovery Multiplier Enter the desired position recovery rate After the Control Parameters for Tuning have been entered you can enter the Control Parameters for the Alarms for either the Master or the Follower mode Alarms and limits are discussed in the following section 51 52 Alarms The Control Parameters for Alarms are identical for both the Master and the Follower modes of operations By entering values in the Control Parameters for the Alarms CP 12 CP 13 CP 14 CP 15 you can establish circumstances under which the MLP Trim will alert you to potential operating problems The Alarm 1 Format CP 10 and Alarm 2 Format CP 11 can be set to activate at any combination of low speed high speed ramped error or scaled error conditions Alarm 1 Format is used to control Dig Out1 J6 pins 15 17 Alarm 2 Format is u
33. Setpoint Select J6 pins 10 13 The Master and Follower setpoints are determined by the Setpoint Select CONTROL input combined with the Master PARAMETER A ORA Follower Input For access to Master Control Parameters 1 and 2 and Follower Control Parameters 3 and 4 g CONTROL refer to the chart below PARAMETER 2 OR 4 Figure 2 13 Setpoint Select Setpoint Select Open Setpoint Select Closed Master Follower Input Open Master Control Parameter 1 Master Control Parameter 2 Master Follower Input Closed Follower Control Parameter 3 Follower Control Parameter 4 Scroll Up J6 pins 11 13 The Scroll Up input increments the active setpoint The active setpoint will be incremented whether or not it is being currently displayed There two methods to increment the g SCROLL UP active setpoint using the Scroll Up input Each closure of the input increments the active setpoint one engineering unit Also if the Scroll Up input is maintained closed the active setpoint will be incremented one engineering unit every half second Figure 2 14 Scroll Up Scroll Down or Open Closed Loop J6 pins 12 13 SCROLL DOWN The function of this input is determined by CP 60 If CP 60 is set to 1 this input functions as the Scroll Down input If CP 60 is set to 2 this input functions as the Open Closed Loop input Figure 2 15 Scroll Down The Scroll Down input decrements the active setpoint
34. The active setpoint will be decremented whether or not it is being currently displayed There are two methods to decrement the active setpoint using the Scroll Down input Each closure of the input decrements the active setpoint one engineering unit Also If the Scroll Down input is maintained closed the active setpoint will be decremented one engineering unit every half second The Open Closed Loop input determines the basic manner in which the control algorithm operates In the Closed Loop position J6 pin 12 open the control algorithm adjusts the speed command output to reduce the error to zero Setpoint minus feedback In the Open Loop position J6 pin 12 shorted to 13 the speed command output is adjusted in response to the setpoint changes only and feedback and error are ignored Analog Input J6 pins 18 19 The Analog Input can be used for frequency or setpoint replacement in the Master and Follower modes of operation or the offset input in the Signal Offset mode of operation Refer to CP 84 for discussion on the functional allocation of the analog input Figure 2 16 Analog Input OUTPUTS Speed Command Out J3 pins 1 2 Speed Command Out is an isolated analog output signal that is sent to SIGNAL INPUT the motor drive to control the speed of the motor Wire the Speed DRIVE COMMON Y Command Out into the speed signal input of the drive If the motor drive Speed Command Out a
35. accessible through the MLP Trim s front panel keypad are also accessible through the Serial Communications Interface The host computer sends a twelve character record to the MLP Trim to establish the link and the MLP Trim responds with either a conformation or an error message Once the MLP Trim responds the host computer can send additional transmissions All of the MLP Trim s messages use the USA Standard Code for Information Interchange ASCII The host computer sends three types of messages Parameter Send To change CPs Control Command Send To control operating states Data Inquiry To monitor CPs and MPs These three message types their character level descriptions in binary and ASCII as well as the MLP Trim s response record are outlined in the sections that follow Parameter Send Use the Parameter Send to change any of the MLP Trim s Control Parameters Table 3 51 Parameter Send Host Transmission DEV DEV MSG PAR 4 PAR DATA DATA DATA DATA DATA DESC STX 10s 15 105 15 10005 1005 10s 15 FORM os s os os os os oo 07 The following is description of the Parameter Send Host Transmission Characters Character 1 STX This is the first character in the character string None of the other characters will be recognized without this character prefix Always use the ASCII STX character it enables the MLP Trim s receive buffer Characters
36. analog input level refer to Installation Setup Calibration Analog Input Calibration Note The analog input does not need to operate to 10 0 volts full scale to be used for the setpoint replacement Max RPM Feedback CP 34 This is the maximum RPM of the feedback sensor shaft during system operation This number should be the same as the maximum operating speed set during step 7 of the calibration procedure PPR Feedback CP 31 The number of gear teeth or encoder lines on the follower feedback sensor per revolution Max RPM Lead CP 33 This is the maximum RPM of the lead sensor shaft during system operation PPR Lead CP 30 The number of gear teeth or encoder lines on the lead sensor per revolution Table 3 25 Default Scaling Control Parameters CP Parameter Name CP 30 PPR Lead Parameter Value 35 36 Table 3 26 Entering Follower Scaling Analog Setpoint Parameters Parameter Name Parameter Value Analog Input Allocation Setting CP 84 to a value of 6 or 7 allocates the analog input to be used as the Follower Setpoint 1 or Follower Setpoint 2 respectively Follower Engineering Units Enter the Follower Engineering Unit value for an analog setpoint level of 10 0 volts with a lead of Max RPM Lead CP 33 and feedback of Max RPM Feedback CP 34 Max RPM Feedback Enter the maximum operating RPMs measured at the feedback sensor shaft PPR Feedback Enter the resolution of the feedback sensor Max
37. and the motor drive set up before you enter the Direct Control Parameters Refer to Installation Setup Calibration The Direct Setpoint CP 06 is entered as a percentage of the MLP Trim s calibrated full scale Speed Command output To enable or disable Direct mode use the Direct Enable CP 61 The factory default Control Parameters for the Direct mode are found in Table 3 2 To modify the default parameters refer to Table 3 3 Table 3 2 Default Direct Mode Control Parameters CP Parameter Name Parameter Value Direct Enable Table 3 3 Entering Direct Mode Control Parameters CP Parameter Name Parameter Value Direct Setpoint Enter the percentage of the calibrated full scale Speed Command output at which you want your system to operate Direct Enable Enter 1 to enable the Direct Mode Enter 0 to disable the Direct Mode Master Mode The Master or stand alone mode of operation is a single motor operation In this simple mode of operation the entire process is controlled by a single motor and one MLP Trim Caution To avoid damage to your system the MLP Trim must be calibrated and the motor drive set up before you enter the Master Control Parameters Refer to Installation Setup Calibration The MLP Trim allows you to control your system in Master Engineering Units e g RPMs gallons per hour feet per minute The Master Engineering Units at which you want the system to operate are entered into the two
38. attempt to maintain a speed at or above this RPM level CP 09 MAXIMUM LIMIT This parameter sets the maximum level of operation in the Run state It is possible to enter a setpoint above this limit however the control will always attempt to maintain a speed at or below this RPM level CP 10 ALARM 1 FORMAT By entering alarm Control Parameters you can establish circumstances under which the MLP Trim will alert you to potential operating problems The alarm can be wired to activate a warning light a warning sound or to shut down the system under specified conditions Alarm Format CP 10 determines which alarm conditions will activate the Dig Out1 output using the values that are entered in Low Alarm CP 12 High Alarm CP 13 Ramped Error Alarm CP 14 and Scaled Error Alarm CP 15 0 No Alarm 8 Scaled Error 1 Low Alarm 9 Low Alarm or Scaled Error 2 High Alarm 10 High Alarm or Scaled Error 3 Low Alarm or High Alarm 11 Low Alarm or High Alarm or Scaled Error 4 Ramped Error 12 Ramped Error or Scaled Error 5 Low Alarm or Ramped Error 13 Low Alarm or Ramped Error or Scaled Error 6 High Alarm or Ramped Error 14 High Alarm Ramped Error or Scaled Error 7 Low Alarm or High Alarm 15 Low Alarm or High Alarm or Ramped Error or or Ramped Error Scaled Error 16 Drive Enable CP 11 ALARM 2 FORMAT By entering alarm Control Parameters you can establish circumstances under which the MLP Trim will alert yo
39. factory default Control Parameters for the standard Follower Mode are found in Table 3 34 To modify these default parameters refer to Table 3 35 Table 3 34 Default Inverse Follower Control Parameters CP Parameter Name Parameter Value Inverse Scaling 1 Standard Scaling Follower E U Table 3 35 Entering Inverse Follower Control Parameters CP Parameter Name Parameter Value Inverse Scaling Enter 2 for Inverse Scaling Follower E U Enter the Engineering Units if the system were to operate at the Max RPM Lead CP 33 and the Max RPM Feedback CP 34 46 Inverse Follower Mode Example The Inverse Follower Mode Example demonstrates how the scaling and setpoint Control Parameters are entered for a typical Inverse Follower mode of operation In a wire machine twisiting application the Follower twists the wire as the Lead pulls the wire When the Follower is at the maximum revolutions per minute of 1800 RPM and the Lead is at the maximum revolutions per minute of 2000 RPM then the twist length lay is at 2 0 inches The Follower motor uses a 1200 PPR encoder and the Lead motor shaft is equipped with a 60 tooth ring kit Follower Setpoint 1 is setup for the twist lay of 2 0 inches Follower Setpoint 2 is setup for a twist lay of 5 0 inches Table 3 36 shows the scaling Control Parameters that would be entered in the MLP Trim for this example Table 3 36 Inverse Follower Mode Control Parameters Example CP Parameter Na
40. is in R Stop or F Stop however Run cannot be activated when the MLP Trim is in Jog Run has the third highest operating state priority Scaling Scaling Control Parameters supply the MLP Trim with the information that it needs to calculate the ratio of RPM s to Engineering Units and run at the entered setpoint Glossary 9 Scroll Up Down Keys Serial Communications Status Monitoring Glossary 10 These keys change the active setpoint value even if the active setpoint is not displayed in the LED display Each time you press the Scroll Up key the active setpoint will increase by one increment Each time you press the Scroll Down key the active setpoint value will decrease by one increment Press and hold the key to automatically scroll through the increments or decrements The MLP Trim can interface with a host computer through a RS485 Serial Communications Interface This interface allows the host computer to perform remote computer parameter entry status or performance monitoring and remote control of the MLP Trim Active Scaling Format Keypad Error Alarm Status Limit Status Control State Appendices Appendix A MLP Trim Specifications Appendix B Formulas Appendix C Parameter Summary Numeric Quick Reference Appendix D Control Parameter Reference Appendix E Monitor Parameter Reference Appendix F Fax Cover Sheet Appendix G Wiring Diagram Examples Appendix H Revision Log APPENDIX
41. is the Open Closed Loop input CP 61 DIRECT ENABLE In the Direct mode of operation the Speed Command output from the MLP Trim that is connected to the motor drive can be set directly Direct mode is an open loop mode of operation Use Direct Enable CP 61 to either enable or disable the Direct mode Enter 1 to enable the Direct Mode Enter 0 to disable the Direct Mode Code Enabled CP 62 INVERSE SCALING Use Inverse Scaling CP 61 to select either the Standard or the Inverse setpoint scaling format Enter 2 for Inverse Scaling Enter 1 for Standard Scaling Code Inverse Scaling CP 64 DISPLAY MODE FOLLOWER In the Follower mode of operation Display Mode Follower CP 64 determines how the data will display in Tach CP 40 Enter 2 to display the ratio of feedback to lead in E U Follower Enter 1 to display the feedback in E U s Time Master CP 65 GAIN PROPORTIONAL To achieve an acceptable level of speed error adjust Gain CP 65 until the system stabilizes With Integral CP 66 and Derivative CP 67 set to 0 reduce the Gain CP 65 value until the System becomes unstable then increase it slightly until the system stabilizes Reduced values will increase Gain To verify the stability of the speed changes you can access Tach through either the Tach key or the Tach MP 40 CP 66 INTEGRAL In systems that require greater accuracy it may be necessary to adjust the value of Integral CP 66 to
42. its maximum RPMs or Max RPM Feedback CP 34 The factory default Master Setpoint Control Parameters are set at 0 CP 03 FOLLOWER SETPOINT 1 The Engineering Units value that you want your system to operate at when Follower Setpoint 1 CP 03 is active The Follower setpoint values are the ratio of Follower speed to Lead speed 04 FOLLOWER SETPOINT 2 The Engineering Units value that you want your system to operate at when Follower Setpoint 2 CP 04 is active The Follower setpoint values are the ratio of Follower speed to Lead speed 05 JOG SETPOINT In Jog Setpoint CP 05 enter the RPM at which you want your system to operate when it is in Jog Jog increases the RPMs at the acceleration rate that you specified in Acceleration Time CP 16 until the Jog Setpoint CP 05 is achieved When Jog is terminated there is no deceleration time the drive comes to an immediate stop CP 06 DIRECT SETPOINT Use the Direct Setpoint CP 06 to set the drive output that is used when the MLP Trim is in the Direct Mode of operation Direct mode is an open loop mode of operation Scaling Acceleration Deceleration and closed loop compensation PID software are not involved in the Direct mode The Direct mode is used in conjunction with the Run and Stop controls CP 08 MINIMUM LIMIT This parameter sets the minimum level of operation in the Run state It is possible to enter a setpoint below this limit however the control will always
43. lead sensor 38 Offset Mode Offset mode is a variation of Follower mode In Offset mode an additional quantity offset term is added to or subtracted from the standard calculated follower scaled reference The quantity of the offset term is determined by the analog input level and three additional scaling parameters offset null offset authority and offset polarity A common use for Offset mode is dancer pot control on a web follower operation In this application the dancer pot is brought into the analog input of the MLP Trim to provide an offset to the web follower operation The following Control Parameters give the MLP Trim the necessary information for Offset mode Analog Input Allocation CP 84 Setting CP 84 Analog Input Allocation to a value of 3 establishes the Offset mode of operation Follower Engineering Units CP 21 The actual value of the Follower Engineering Units when the lead and feedback are operating at their maximum speeds i e Max RPM Lead CP 33 and Max RPM Feedback CP 34 This entry is typically the ratio of the maximum feedback RPM to the maximum lead RPM Max RPM Feedback CP 34 This is the maximum RPM of the feedback sensor shaft during system operation This number should be the same as the maximum operating speed set during step 7 of the calibration procedure PPR Feedback CP 31 The number of gear teeth or encoder lines on the feedback sensor per revolution Max RPM Lead CP 33
44. lockout however Control Parameters can not be changed during lockout The Clear 7 procedure will default Keypad Lockout CP 98 unlocked CAUTION Make certain that you record your password as it becomes transparent once you have entered it If you forget your password you can use the Clear 7 procedure to revert back to the default ULOC unlocked Please note however that the Clear 7 procedure will revert all of the Control Parameters back to their original default values and you will lose any changes that you have made to the Control Parameters Therefore make certain that you have recorded all Control Parameter changes in the space provided in Appendix D before you use the Clear 7 procedure Refer to Troubleshooting Troubleshooting for instructions on the Clear 7 procedure MP 99 SOFTWARE CODE REVISION Software Code Revision MP 99 displays the code revision number of the MLP Trim software PROM MP 00 SOFTWARE PART NUMBER Software Part Number MP 00 displays last four digits of the software part number for the MLP Trim The first four digits of the part number are assumed to be 1000 18 5 APPENDIX D CONTROL PARAMETER REFERENCE USER DESCRIPTION MAX DEFAULT aizel DE UNITS Master Setpoint 1 Master Setpoint 2 Follower Setpoint 1 Follower Setpoint 2 Jog Setpoint Direct Setpoint Minimum Limit Maximum Limit Alarm 1 Format Alarm 2 Format Low Alarm High Alarm Ramped Error A
45. maximum RPM of 1725 The motor shaft is equipped with a 30 tooth Ring kit The Master Engineering Units are gallons per minute Master Setpoint 1 will be setup to pump 10 gallons per minute when it is the active setpoint Master Setpoint 2 will be setup to pump 5 gallons per minute when it is the active setpoint Table 3 7 shows the scaling Control Parameters that would be entered in the MLP Trim for this example Table 3 7 Master Mode Control Parameters Example CP 02 Master Setpoint 2 5 0 After the Scaling and the Master Setpoints for your system have been entered you can enter the Acceleration Deceleration Control Parameters for the Master mode The Acceleration Deceleration Control Parameters are identical for both the Master and the Follower modes of operations Acceleration Deceleration is discussed in Operation Control Parameters Acceleration Deceleration Master Mode Analog Feedback The MLP Trim can be scaled for Engineering Unit setpoint entry and Tach display operation using the analog input for the feedback signal The following Control Parameters give the MLP Trim the necessary information for analog feedback operation in Master mode Analog Input Allocation CP 84 Setting CP 84 Analog Input Allocation to a value of 2 allocates the analog input to be used as the feedback source Master Engineering Units CP 20 The actual value of the Master Engineering Units if the system were to operate with an analog fe
46. of gear teeth or encoder lines on the lead sensor per revolution Table 3 22 Default Scaling Control Parameters Parameter Name Parameter Value CP 84 Analog input Allocation Input Allocation CP 21 Follower Engineering Units 1 000 CP 33 Max RPM Lead 2000 Table 3 23 Entering Follower Scaling Analog Feedback Parameters Parameter Parameter Value P CP 84 Analog Input Allocation Setting CP 84 to a value of 2 allocates the analog input to be used as the feedback signal CP 21 Follower Engineering Units Enter the Follower Engineering Unit value for an analog feedback level of 10 0 volts and lead of Max RPM Lead CP 33 CP 33 Max RPM Lead Enter the maximum operating RPMs measured at the lead sensor shaft CP 30 PPR Lead Enter the resolution of the lead sensor Note The Max RPM Feedback CP 34 and PPR Feedback CP 31 control param eters used for scaling Follower mode with a frequency lead are ignored when using analog feedback scaling 32 Follower Mode Analog Feedback Example The following example demonstrates Follower mode scaling using analog feedback A pump delivers 20 0 gallons per minute of ingredient A when the pump motor rotates at 1800 RPM A second pump delivers 10 0 gallons per minute of ingredient B when the pump motor rotates at 1800 RPM A tachometer connected to the analog input of the MLP Trim produces a 10 0 volt signal when the pump B follower motor rotates at 18
47. one end of the cable 2 If you need to terminate the communication line then terminate it at the unit which is the furthest away from the converter A 100 ohm 1 2 Watt resistor will usually terminate successfully Refer to EIA Standard 5485 for more information Figure 2 20 MLP Trim Serial Communications Connections CALIBRATION Calibration matches the Speed Command analog output of the MLP Trim with the analog input of the motor drive Calibration is accomplished in two steps The first step is to set up the motor drive The second step is to calibrate the MLP Trim to the motor drive so that the speed is adjusted to the maximum operating speed Calibration also zero and spans the analog input The MLP Trim must be properly installed prior to calibration Refer to nstallation Setup Mounting and Installation Setup Wiring Z N DANGER Hazardous voltages Can cause severe injury death or damage to the equipment Make adjustments with caution MOTOR DRIVE SET UP Put the MLP Trim in R Stop by opening the R Stop input J6 pins 6 8 Refer to Installation Setup Wiring Inputs R Stop Set the drive s acceleration and deceleration potentiometers to their fastest rates minimum ramp time The goal is to make the drive as responsive as possible which allows the MLP Trim to control the speed changes If the drive has a maximum speed span potentiometer set it to the highest setting at whic
48. page 2 11 2 13 Fax Cover Sheet page F 1 Feedback Frequency page 3 64 C 6 E 1 Input page 2 9 Follower Engineering Units page 3 19 C 4 D 1 Follower Mode page 3 19 Glossary 5 Application page 1 5 Example page 3 22 Follower Setpoint 1 page C 1 D 1 Follower Setpoint 2 page C 1 D 1 Formulas page B 1 Frequency Overflow Counter page 3 72 C 12 E 1 G Gain page 3 48 C 13 D 1 Glossary page Glossary 3 H Hardwired page Glossary 5 High Alarm page 3 71 C 3 D 1 Host Computer Interface page 3 73 3 76 Housing the MLP Trim page 2 3 How to Enter a Parameter Code page 3 4 Enter a Parameter Value Control Parameter page 3 4 Replace the PROM Chip page 4 16 Use Serial Communications page 3 74 Use the Setpoint Key page 3 4 Use the Tach Key page 3 4 Use the Up Down Scroll Keys page 3 4 Power page 2 7 Input Monitoring page 3 64 Glossary 5 Test page 4 7 Glossary 6 Inputs page Glossary 6 Wiring page 2 7 Index 6 Installation Calibration page 2 19 Mounting the MLP Trim page 2 3 Wiring page 2 5 Integral page 3 48 C 13 D 1 Interface with a Host Computer page 3 73 3 76 Internal Control Structure of the MLP Trim page 3 68 Inverse Follower Mode page 3 45 Inverse Master Mode page 3 43 Inverse Scaling page 3 43 3 45 C 12 J J1 pins 1 2 Aux Power page 2 7 2 16 J3 pins 1 2 Speed Command Out page 2 15 J4 pins 1 2 3 AC Power page 2 8 J5 pins 1 2 I O Power page
49. password becomes transparent once you have entered it If you forget your password you can use the Clear 7 procedure to revert back to the default ULOC unlocked Please note however that the Clear 7 procedure will revert all of the Control Parameters back to their original default values and you will lose any changes that you have made to the Control Parameters Therefore make certain that you have recorded all Control Parameter changes in the space provided in Appendix D before you use the Clear 7 procedure Refer to Troubleshooting Troubleshooting for instructions on the Clear 7 procedure If you are uncertain how to enter a Control Parameter review the Operations Keypad section Record your numeric Keypad Lockout password here CONTROL PARAMETERS Parameters are divided into two classifications Control Parameters CP and Monitor Parameters MP The numbered code that represents the Parameter is the Parameter Code The operational data is the Parameter s value Control Parameter 05 50 Parameters Monitor Parameter 40 200 arbitrary Parameter Code Parameter Value This section is about Control Parameters Monitor Parameters are explained in Operation Monitor Parameters The MLP Trim comes factory pre loaded with a complete set of default Control Parameters values The majority of these default settings are suitable for most applications and do not require modification Control Parameters allow you to enter
50. reduce any remaining speed error In systems with low inertia the speed error will be reduced more quickly if you enter low values in Integral CP 66 An entry that is too low however can create instability or overshoot the setpoint before reaching the correct value Generally use larger entries for Integral CP 66 on systems with a large inertia While switching between the high and low setpoints decrease the Integral s default value of 2000 until the speed error is reduced within an acceptable time frame To verify the stability of the speed changes you can access Tach through either the tach key or the Tach MP 40 CP 67 DERIVATIVE In systems with a very large inertia use Derivative CP 67 to reduce the overshoot from the integral term Decrease the value of Derivative CP 67 until the overshoot is acceptable The System may operate erratically or become unstable if the value of Derivative CP 67 is too small CP 69 TRIM AUTHORITY Trim Authority determines how much influence the PID term has on the control output If stability cannot be obtained through the standard tuning procedure reduce CP 69 until stable tuning is achieved CP 70 DEVICE ADDRESS Device Address CP 70 is the physical address of the MLP Trim which can be set from 1 to 32 Each individual MLP Trim on a multidrop RS485 communications link needs a unique Device Address The address 00 will be globally accepted by all of the MLP Trims on a communications li
51. 00 RPM The lead motor A has an encoder feedback of 1000 PPR The Follower setpoint is to reflect the flow ratio in gallons minute of ingredient B to ingredient A Table 3 24 Follower Mode Feedback Allocation Example Parameter Name Value Remarks CP CP 84 Analog Input 2 Allocates the analog input as the Allocation feedback source CP 21 Follower This is the Engineering Unit value Engineering Units that is present if the analog input were at 10 0 volts and the lead at Max RPM Lead 10 0 gal min ingredient B 0 500 20 0 gal min ingredient A CP 33 Max RPM Lead 1800 The maximum operating RPM of the lead shaft CP 30 PPR Lead 1000 The resolution of the lead sensor 33 Follower Mode Analog Setpoint The MLP Trim can be scaled for Engineering Unit setpoint entry and Tach display operation using the analog input for the setpoint The following Control Parameters give the MLP Trim the necessary information for analog setpoint operation in the Follower mode Analog Input Allocation CP 84 Setting CP 84 Analog Input Allocation to a value of 6 or 7 allocates the analog input to be used as Follower Setpoint 1 CP 03 or Follower Setpoint 2 CP 04 respectively Follower Engineering Units CP 21 The actual value of the Follower Engineeing Units if the system were to operate with an analog setpoint level of 10 0 volts when the lead and feedback are at their maximum operating RPMs This is the maximum calibrated
52. 1 PROM chip Replacement 4 16 GOSS ANY Glossary 1 Glossary dee e eco ie nena a Glossary 3 1 Appendix MLP Trim 1 Appendix B Formulas 1 Appendix C Parameter Summary numeric quick reference C 1 Appendix D Control Parameter Reference D 1 Appendix E Monitor Parameter E 1 Appendix MLP Trim Fax Cover Sheet F 1 Appendix Wiring Diagram Examples sese G 1 Appendix Revision 0 0 H 1 Warranty 1 SetvICe PollGy was ae Hab eb Warranty 3 Waran Warranty 4 Index M Index 1 ET Index 3 vi Figure 1 1 Figure 1 2 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Figure 2 10 Figure 2 11 Figure 2 12 Figure 2 13 Figure 2 14 Figure 2 15 Figure 2 16 Figure 2 17 Figure 2 18 Figure 2 19 Figure 2 20 Figure 3 1 Figure 3 2 Figure 4 1 Figure 4 2 Figure 4 3 Figure 4 4 Figure 4 5 Figure G 1 Figure G 2 Figure G 3 Figure G 4 Figure G 5 List of Illustrations MLP Trim Master Mod
53. 1 BAUD RATE There are six different baud rates data rates for the MLP Trim Enter the number for the required function as listed below 1 300 Baud 2 600 Baud 3 1200 Baud 4 2400 Baud 5 4800 Baud 6 9600 Baud CP 72 CHARACTER FORMAT The MLP Trim uses three different character formats Enter the number for the required format as listed below 1 8 Data Bits No One Stop Bit 2 7 Data Bits Even Parity One Stop Bit 3 8 Data Bits No Parity Two Stop Bits CP 73 CONTROL MASK The Serial Communications can control some of the digital input functions Enter the number for the required functions as listed below 0 F Stop only 1 F Stop Run R Stop 2 F Stop Master Follower Setpoint Select 3 All of the Above MP 58 SERIAL COMMUNICATIONS ERROR Serial Communications Error identifies errors in the last transmitted message that was sent to the MLP Trim by the host computer The mode that displays a number 1 indicates the error In the example below Invalid Parameter Code is the error Code Structure Error Parity Framing No ETX No STX Invalid Parameter Code Invalid Parameter Data or Out of Data Min Max Range Control Mask Error Communications Software Design The MLP Trim Serial Communications Interface uses a polling technique to establish a link with the host computer With the exception of Keypad Lockout CP 98 all of the Control Parameters and Monitor Parameters that are
54. 101 1001110 1001111 1010000 1010001 1010010 1010011 1010100 1010101 1010110 1010111 1011000 1011001 1011010 1011011 1011100 1011101 1011110 1011111 ONC XK lt lt gt lt gt 0 m r 1100000 1100001 1100010 1100011 1100100 1100101 1100110 1100111 1101000 1101001 1101010 1101011 1101100 1101101 1101110 1101111 1110000 1110001 1110010 1110011 1110100 1110101 1110110 1110111 1111000 1111001 1111010 1111011 1111100 1111101 1111110 1111111 1281956 juiodies 04 HASEN 9015 4 86 esn uH M01 ul JON 1102 1022 0015 4 esn ul uH JON 0105 0105 dois y M01 02 1 00 1urodies UBI uno Jersey 1ewojo4 Buipuodsauo pue dols H ON ung ung ON y IH peeds MO 1103207 10 ON jnoeui nu3 103201 Jo ON ON anen ON 04 any annoy epo
55. 1936 operates on 115 VAC 15 0 1 Amp 50 60 Hz The MLP Trim model 43200 1937 operates on 230 VAC 4 1596 0 1 Amp 50 60 Hz Fuse L1 for 115VAC applica tions Fuse L1 and L2 for 230VAC applications Use 1 Amp 250V normal blow fuses Lead Frequency J6 pins 1 3 The Lead Frequency is a pulse train input that the MLP Trim uses to determine the speed of the lead motor For signal level specifications refer to References Appendix A MLP Trim Specifications L1 Neutral or L2 GND PE Figure 2 5 Input Power Signal Common Figure 2 6 Lead Frequency Feedback Frequency J6 pins 2 3 The Feedback Frequency is a pulse train input that the MLP Trim uses to determine the speed of the follower motor For signal level specifications Common refer to References Appendix A MLP Trim Specifications Signal Figure 2 7 Feedback Frequency DANGER If the Feedback Frequency is lost the MLP Trim will command a 100 Speed Out and the motor will run at 100 capacity This can cause severe injury death or equipment damage Run J6 pins 4 8 When the Run input J6 pin 4 is momentarily shorted to common the MLP Trim enters Run As a momentary input Run is internally latched and does not need to be maintained by an operator device NOTE Close the R Stop and F Stop inputs prior to entering Run If you are only using one of the Stop inputs wire short the other Stop input to common or th
56. 2 digits up to 4 digits Led Display Code Select Key nn Dedicated Keys en Numeric Keys Up Down Scroll Keys Clear Key Figure 3 1 The MLP Trim Front Panel KEYPAD LOCKOUT Keypad Lockout CP 98 displays the present status of the keypad lockout When the keypad is locked then LOC is displayed Code HE When the Keypad is unlocked then ULOC is displayed Code PS To lock out the keypad enter a numerical password between 1 and 9999 in Keypad Lockout CP 98 then press the enter key This numerical password will flash briefly on the screen then the screen will display LOC To unlock the keypad enter the same numerical password in Keypad Lockout CP 98 The number will flash briefly on the screen and then the screen will display ULOC Control Parameters and Monitor Parameters may be monitored during lockout however Control Parameters can not be changed during lockout The Clear 7 procedure will default Keypad Lockout CP 98 to ULOC unlocked CP 79 Setpoint Lockout Mask determines which setpoints are disabled when the keypad is locked out If CP 79 is set to 0 then none of the setpoints CP 01 through CP 04 are disabled If CP 79 is set to 1 then all four of the setpoints are disabled If CP 79 is set to 2 then CP 02 and CP 04 are disabled while CP 01 and CP 03 remain enabled CAUTION Make certain that you record your password in the space provided on page 3 6 as your
57. 21 enter a number that will represent the setpoint Engineering Units when the Lead and Follower are operating at the maximum desired RPM This number is usually the ratio of Max RPM Feedback CP 34 to Max RPM Lead CP 33 When this number is also entered as a setpoint CP 03 or CP 04 the Follower will operate at Max RPM Feedback CP 34 when the Lead is at Max RPM Lead CP 33 CP 29 RECOVERY MULTIPLIER The Recovery Multiplier determines the rate at which the pulse error position is reduced to zero This parameter multiplied by the pulse error count is the amount by which the speed setpoint is adjusted every 100 milliseconds CP 30 PPRLEAD PPR Lead CP 30 is the number of gear teeth or number of encoder lines on the Lead sensor per revolution pulses per revolution CP 31 FEEDBACK PPR Feedback CP 31 is the number of gear teeth or number of encoder lines on the Follower feedback sensor per revolution pulses per revolution CP 33 MAX RPM LEAD Measured at the Lead sensor shaft Max RPM Lead CP 33 is the maximum RPMs at which the Lead will operate your system This number is not to be confused with the full capacity at which the Lead is capable of running A system is not generally run at full capacity CP 34 MAX RPM FEEDBACK Measured at the sensor shaft Max RPM Feedback CP 34 is the maximum RPMs at which you want your system to operate and is not to be confused with the full capacity at which your System is capa
58. 4 D 1 Master Mode page 3 9 Glossary 7 Application page 1 4 Example page 3 12 Master Setpoint 1 page C 1 D 1 Master Setpoint 2 page C 1 D 1 Max RPM Feedback page 3 9 3 19 C 5 D 1 Max RPM Lead page 3 19 C 5 D 1 MLP Trim Example of Application page 1 4 Internal Structure page 3 68 Introducing the page 1 3 Mounting See Mounting the MLP Trim Operation See Operation Mode of Operation page Glossary 7 Monitor Parameter Reference List page E 1 Monitor Parameters page 3 7 3 63 Glossary 7 MP 00 page C 17 E 1 MP 40 page 3 68 C 5 E 1 MP 41 page 3 64 C 6 E 1 MP 42 page 3 68 C 6 E 1 MP 43 page 3 64 C 6 E 1 MP 44 page 3 69 C 7 E 1 Index 8 MP 45 page 3 69 7 1 46 3 69 7 1 47 3 67 7 1 MP 48 page 3 69 7 1 MP 50 page 3 70 8 1 MP 51 page 3 70 8 E 1 52 3 71 9 1 MP 53 page 3 71 9 1 MP 54 page 3 65 10 1 55 3 65 10 1 MP 56 page 3 67 C 11 E 1 MP 57 page 3 72 C 11 E 1 MP 58 page 3 75 C 11 E 1 MP 59 page 3 72 C 12 E 1 MP 83 page 3 72 C 16 E 1 MP 87 page 3 66 C 17 E 1 MP 88 page 3 66 C 17 E 1 MP 99 page C 17 E 1 Monitor the Performance of the MLP Trim page 3 68 Motor Does Not Run page 4 13 Does Not Stop page 4 12 Runs at Wrong Speed page 4 14 Runs Unstable page 4 15 Motor Drive Set Up page 2 20 Mounting the MLP Trim page 2 3 Multidr
59. 4 Master Mode Feedback Allocation Example 3 15 Default Scaling Control Parameters 3 16 Entering Master Scaling Analog Setpoint Parameters 3 17 Master Mode Setpoint Allocation Example 3 18 Default Follower Scaling Control Parameters 3 20 Entering Follower Scaling Control Parameters 3 20 Entering Follower Setpoint Control Parameters 3 21 Follower Mode Control Parameters Example A 3 24 Follower Mode Control Parameters Example 3 27 Default Scaling Control Parameters 3 28 Entering Follower Scaling Analog Lead Parameters 3 29 Follower Mode Lead Allocation Example 3 30 Default Scaling Control Parameters 3 31 Entering Follower Scaling Analog Feedback Parameters 3 32 Follower Mode Feedback Allocation Example 3 33 Default Scaling Control Parameters 3 35 Entering Follower Scaling Analog Setpoint Parameters 3 36 Follower Mode Setpoint Allocation 3 37 Default Scaling Control Parameters 3 39 Entering Offset Scaling Analog Setpoint Parameters 3 40 Offset
60. 6 Parameter Number The Control Parameter code is sent back to the host computer from the MLP Trim Characters 7 through 10 DATA The Control Parameter data is sent back to the host computer from the MLP Trim Character 11 Data Format The Data Format character is sent back to the host computer from the MLP Trim Character 12 ETX The return message is always terminated with the ASCII character 81 Control Command Send The Control Command Send allows the host computer to control the operating functions of the MLP Trim that are associated with the digital inputs Run Stop Setpoint Select and Master Follower Table 3 53 Control Command Send Host Transmission n rers ee pes DEV DEV MSG PAR 4 PAR DATA DATA DATA DATA DATA DESC STX 10s 15 105 is 10005 1005 10s 15 FORM E o RUN The following is description of the Control Command Send Host Transmission Character 1 STX This is the first character in the character string None of the other characters will be recognized without this character prefix Always use the ASCII STX character it enables the MLP Trims receive buffer Characters 2 3 Device These characters are the access address of the MLP Trim This number identifies individual MLP Trims a mutltidrop system The MLP Trim will accept data only if this number matches the MLP Trim s address C
61. Contrex Inc has a staff whose primary responsibility is service both factory service and field on site service Personnel of this department are usually available for service on a 24 hour notice To facilitate quicker handling of service requests either written or by phone such requests should be directed to the Contrex Inc Technical Services Department Service Charges Contrex Inc reserves the right to charge for all services performed at the customers request with the exception of factory service performed under warranty All on site service is charged at flat rate per diem rates plus expenses Any Contrex Inc product developing defects as defined in the warranty during its effective period will be repaired or replaced without charge providing it is shipped prepaid to Contrex Inc 8900 Zachary Lane North Maple Grove Minnesota 55369 Spare Parts Contrex Inc will usually have an adequate inventory of spare parts and circuit boards for all standard products However purchasers are encouraged to maintain a nominal supply of spare parts to insure immediate on site accessibility Instruction Manuals Instructions for installation maintenance and troubleshooting are included in manuals that are provided with the equipment Repairs may be performed in the field by competent customer personnel but in order to not invalidate the warranty they must be made in strict accordance with published instructions and
62. F MLP TRIM APPLICATIONS Figure 1 1 is an example of a Master mode of operation for a pump application The scaling format allows the operator to enter a setpoint in Engineering Units of gallons per minute The MLP Trim compares the sensor shaft feedback to the scaled setpoint and calculates any speed error When the MLP Trim finds speed error the control algorithm adjusts the Speed Command Out to the motor drive and reduces the error to zero Motor Drive Motor Pus Sensor N Feedback Frequency MLP Trim Figure 1 1 MLP Trim Master Mode Figure 1 2 is an example of the Follower mode of operation in a pump application scaling format allows the operator to enter the setpoint as a ratio of ingredient B to ingredient A The MLP Trim compares the setpoint ratio to the Follower sensor shaft feedback and Lead sensor shaft feedback to calculate any speed error When the MLP Trim finds speed error the control algorithm adjusts the Speed Command Out to the motor drive and reduces the error to zero Lead Motor Drive MLP Trim Feedback Frequency A Ingredient A Sensor 9 gt gt 0 Final Product Pump N Lead Motor Follower Motor Drive MLP Trim Feedback Frequency Follower Motor gt Sensor 9 Q me gt Pump Q Ingredient B Figure 1 2 MLP Trim Follower Mode 5 Installation Setup Mounting Wiring Inpu
63. MLP Trim User Manual 0001 0129 Revision B Technical Assistance If you have comments or questions concerning the operation of the MLP Trim please call us A member of our Technical Support Staff will be happy to assist you Ask for Technical Support 763 424 7800 or 1 800 342 4411 Contrex 8900 Zachary Lane North Maple Grove Minnesota 55369 Copyright 1999 Contrex MN DANGER Improper installation 1 cause severe injury death or damage to your system Integrate this motion control unit into your system with caution Operate this motion control unit only under the conditions prescribed in this manual Any other use shall be deemed inappropriate Comply with the National Electrical Code and all applicable local and national codes Table of Contents Introduction 1 1 Introducing the MLP Trim 1 3 Examples of MLP Trim 1 4 Installation Setup anna 2 1 MOUNINO reu tee D e ide EI eet Md 2 3 WIEIDQ s iiio o EA a MEM EE nius 2 5 eS 2 7 he Dea a tt Met n c be t 2 15 Serial Communications 2 17 CAND FAL OM a ae tec 2 19 Motor Drive Set 2 20 MLP Trim 2 21 Analog Input Calibration 2 23 Meet ie 3 1 Keypad Operation
64. ONLY AFTER obtaining approval of the Technical Service Department such repairs are usually limited to the replacement of circuit boards and major subassemblies not the repair of these items OEM Service In many instances Contrex Inc products are sold to the original equipment manufactures or integrators for inclusion in larger systems In such cases the obligations of Contrex Inc extend only to that original purchaser It is the latter s responsibility to handle any service required by his customer the end user Such problems can usually be solved by field replacement of complete units OEM s are encouraged to buy and maintain a supply of loaners for this purpose Contrex Inc will provide factory overhaul service at nominal charges to support that OEM Users of Contrex Inc products that were acquired as components of larger systems may buy service or spare parts directly from Contrex Inc at standard prices but they must appeal through the OEM for warranty service If Contrex Inc encounters trouble in the field which appears to be the result of fault or inadequacy of the system Contrex Inc reserves the right to recover service charges from the party that authorized the service activity Warranty 3 WARRANTY Contrex Inc guarantees this device against defects in workmanship and materials for a period of one 1 year from the date of purchase Any parts or components that fail during the warranty peri
65. Open the Run input Short the Jog input to common Jog must be sustained to remain active RUN JoG R STOP F STOP 4 COMMON J Maintain Closed Logic Outputs Drive Enable activates the motor drive based on the Ramped Reference MP 46 and the feedback The Ramped Reference 46 is the calculated setpoint that is output from the Acceleration Deceleration routine Dig Out1 or Dig Out2 can be used as the Drive Enable output depending on the setting of CP 10 and CP 11 respectively Drive Enable Logic CP 74 determines which conditions of the Ramped Reference MP 46 and feedback will control the Drive Enable output The factory defaults for Drive Enable Logic CP 74 are found in Table 3 49 To modify these default parameter refer to Table 3 50 If you are uncertain how to enter a Control Parameters review the Operations Keypad section Table 3 49 Default Drive Enable Logic Control Parameter CP Parameter Name Parameter Value CP 74 Drive Enable Logic 0 61 62 Table 3 50 Entering Drive Enable Logic Control Parameter Parameter Name Parameter Value CP 10 Alarm 1 Format CP 11 Alarm 2 Format CP 74 Drive Enable Logic Enter 16 to allocate Dig Out1 as the drive enable output Enter 16 to allocate Dig Out2 as the drive enable output Enter 0 in CP 74 to deactivate the drive enable output output high when the Ramped Reference is zero and activate the drive enable output ou
66. P 05 is correct MP 50 MP 50 0010 Master 0100 Follower Setpoint is correct Yes MP 45is Correct MP 46 is Correct Yes MP 47 is Zero Check Drive Wiring Enter Correct Scaling Problem Corrected No Enter Correct Setpoint No Motor Does Not Run Flowchart MP 50 0001 Direct CP 06 is correct Yes Consult Tech Support 1 800 342 4411 Motor Runs at Wrong Speed MP 50 50 50 0010 Master L 0100 Follower Lo 0001 Direct No No Setpoint is correct CP 06 is correct Enter Correct Setpoint MP 45 is correct Repeat Calibration Procedure MP 46 is Enter Correct correct Scaling MP 48 is Negative Problem Corrected Consult Tech Support 1 800 342 4411 Problem Corrected Decrease Max Speed Increase Max Speed Figure 4 3 Motor Runs at Wrong Speed Flowchart Motor Runs Unstable Change CP 61 to 1 and Run in Direct Mode Motor Still Unstable Change CP 61 to run in Master Mode Check Drive Calibration Repeat Tuning Procedure Problem Corrected Consult Tech Support 1 800 342 4411 Figure 4 4 Motor Runs Unstable Flowchart PROM CHIP REPLACEMENT The PROM Programmable Read Only Memory chip is the software for the MLP Trim See Figure 4 5 for the PROM s locati
67. P 70 with the exception of a 00 address The 00 address is universally accepted by all MLP Trims that are on the RS485 Serial Communications Interface Character 4 Message Type This character should always be 1 Characters 5 6 Parameter Number These characters should always be 0 Characters 7 through 8 DATA These characters should always be 0 Characters 9 10 DATA 01 F Stop 02 R Stop 03 Run 04 Enable Master Mode 05 Enable Follower Mode 06 Not in Use 07 Not in Use 08 Not in Use 09 Not in Use 10 Enable Setpoint 1 3 11 Enable Setpoint 2 4 12 Not in Use 13 Not in Use 14 Not in Use 15 Not in Use Character 11 Data Format This character should always be 0 Character 12 ETX Always use the ASCII character to terminate the character string Table 3 54 Control Command Send Response BEZ BEE DEV DEV ERROR PAR PAR DATA DATA DATA DATA DATA DESC STX 10s 15 CODE 10s 15 1000s 100s 10s 1s FORM DREIER The following is a description of the Control Command Send MLP Trim Response Characters Character 1 STX This is the first character in the character string Characters 2 3 Device This is the two character access address for the MLP Trim Character 4 Error Code If there are errors in the transmission that the MLP Trim receives from the host computer the Erro
68. P 84 Analog Input 1 Allocates The analog input as the Allocation lead source CP 21 Follower This is the Engineering Unit value Engineering Units that would be present if the analog input were at 10 0 volts and the feedback at Max RPM Feedback 40 0 gal min ingredient B 2 000 20 0 gal min ingredient A CP 34 Max RPM Feedback 1800 The maximum operating RPM of the feedback shaft CP 31 PPR Feedback 30 The resolution of the feedback sensor Follower Mode Analog Feedback The MLP Trim can be scaled for Engineering Unit setpoint entry and Tach display operation using the analog input for the feedback signal The following Control Parameters give the MLP Trim the necessary information for analog feedback operation in the Follower mode Analog Input Allocation CP 84 Setting CP 84 Analog Input Allocation to a value of 2 allocates the analog input to be used as the feedback source Follower Engineering Units CP 21 The actual value of the Follower Engineering Units if the system were to operate with an analog feedback level of 10 0 volts and a lead of Max RPM Lead CP 33 This is the maximum calibrated analog input level refer to Installation Setup Calibration Analog Input Calibration Note The analog input does not need to operate to 10 0 volts full scale to be used for analog feedback Max RPM Lead CP 33 This is the maximum RPM of the lead sensor shaft during system operation PPR Lead CP 30 The number
69. Pin 4 Jog J6 Pin 5 R Stop J6 Pin 6 F Stop J6 Pin 7 MP 55 LOGIC INPUTS GROUP B The Logic Inputs B displays the status of the Master Follower Setpoint Select Scroll Up and Scroll Down digital inputs The number 1 indicates an open or logic high level The number 0 indicates a closed or logic low level shorted to common In the example below Setpoint Select is the open or logic high level Code Master or Follower J6 Pin 9 Setpoint Select J6 Pin 10 Scroll Up J6 Pin 11 Scroll Down J6 Pin 12 66 MP 87 A DINPUT The A D Input parameter MP 87 displays the value of the analog input in percent of full scale XXX X before it is zero and span adjusted MP 88 A DINPUT ADJUSTED The A D Input Adjusted parameter MP 88 displays the value of the analog input in percent of full scale after it is zero and span adjusted The A D Input Adjusted value is the value used for scaling the setpoint replacement frequency replacement and offset functions Output Monitoring These MPs monitor the MLP Trim s outputs MP 47 SPEED COMMAND OUT The Speed Command Out MP 47 displays the level of calibrated full scale analog output to the motor drive pin 1 The Speed Command Out 47 is displayed as a percentage 100 represents 100 of the calibrated full scale analog output MP 56 OUTPUTS The Logic Outputs MP 56 displays the status of the Dig Out1 and the Dig Out2 o
70. This is the maximum RPM of the lead sensor shaft during system operation PPR Lead CP 30 The number of gear teeth or encoder lines on the lead sensor per revolution Offset Null CP 75 Offset Null is used to determine the analog input level where the offset term is zero has no influence Offset Authority CP 76 Offset Authority determines the quantity of the offset term amount of influence for a given analog input level Offset Polarity CP 77 Offset Polarity determines if the offset term is added or subtracted from the follower scaled reference If CP 77 is set to 1 additive analog input voltages greater than CP 75 Offset Null will cause an increase in the follower speed Analog input voltages less than Offset Null will cause a decrease in follower speed If CP 77 is set to 2 subtractive analog input voltages greater than CP 75 Offset Null will cause an decrease in the follower speed Analog input voltages less than Offset Null will cause a increase in follower speed Table 3 28 Default Scaling Control Parameters CP Parameter Name Parameter Value CP 84 Analog Input Allocation CP 21 Follower Engineering Units Max RPM Feedback PPR Feedback CP 33 Max RPM Lead CP 30 PPR Lead CP 75 Offset Null CP 76 Offset Authority CP 77 Offset Polarity 40 Table 29 Entering Offset Scaling Analog Setpoint Parameters CP Parameter Name Parameter Value CP 84 Analog Input Allocation Setting CP 84
71. and caue M 7 usr FOL Master Out MST FO Follower EU Setpoint SCRL UP Select SCRL_DWN COM d v_Do E g DIG ouri S our L ANAL IN COM ANA IN J6 Figure G 5 Two Channel Start Stop Lead Follower Logic 5 REVISION LOG APPENDIX H Jenueui y JO uoisi eJ jueJuno sow y eui esn eJeu si Jeym UCU si uoisi eJ j jou 00 90 18649 EN ojeq JequinN el Seller uoisi eH 093 enuen H 1 5 Warranty Service Policy Warranty SERVICE POLICY Contrex Inc recognizes that with each sale of its product there are certain product obligations This document defines the limits of such obligations and provides guidelines for the performance of related services Applicability This Service Policy shall apply to all product sales of Contrex Inc However it may be modified by mutual consent Thus whenever an accepted proposal contains wording inconsistent with this policy the proposal will prevail with respect to specific sale or series of sales involved Applicability of this policy is also somewhat limited in cases where products are sold to an OEM for resale to user See paragraph below entitled OEM Service Service Personnel
72. and setpoint information for Example B 27 28 Follower Mode Analog Lead The MLP Trim can be scaled for Engineering Unit setpoint entry and Tach display operation using the analog input for the lead signal The following Control Parameters give the MLP Trim the necessary information for analog lead operation in Follower mode Analog Input Allocation CP 84 Setting CP 84 Analog Input Allocation to a value of 1 allocates the analog input to be used as the lead source Follower Engineering Units CP 21 The actual value of the Follower Engineering Units if the system were to operate with an analog lead level of 10 0 volts and a feedback of Max RPM Feedback CP 34 This is the maximum calibrated analog input level refer to Installation Setup Calibration Analog Input Calibration Note The analog input does not need to operate to 10 0 volts full scale to be used for analog lead Max RPM Feedback CP 34 This is the maximum RPM of the feedback sensor shaft during system operation This number should be the same as the maximum operating speed set during step 7 of the calibration procedure PPR Feedback CP 31 The number of gear teeth or encoder lines on the follower feedback sensor per revolution Table 3 19 Default Scaling Control Parameters CP Parameter Name Parameter Value CP 21 Follower Engineering Units 1 000 CP 34 Max RPM Feedback S Table 3 20 Entering Follower Scaling Analog Lead Parameters CP
73. at or above CP 16 ACCELERATION TIME Acceleration Time CP 16 controls the rate of speed change in response to setpoint changes This Control Parameter applies to both the Master and Follower modes of operation Enter the desired number of seconds to increase the motor speed from 0 to 2000 RPMs 17 DECELERATION TIME Deceleration Time CP 17 controls the rate of speed change in response to setpoint changes This Control Parameter applies to both the Master and Follower modes of operation Enter the desired number of seconds to decrease the setpoint in the range of 2000 to 0 RPMs CP 18 LAG PULSE LIMIT The Lag Pulse Limit sets a maximum pulse error for the lagging follower is behind in position feedback pulses that are maintained in the zero error loop It may not always be desirable to recover all of the position error lag CP 19 LEAD PULSE LIMIT The Lead Pulse Limit sets a maximum pulse error for the leading follower is ahead in position feedback pulses that are maintained in the zero error loop It may not always be desirable to recover all of the position error lead CP 20 MASTER ENGINEERING UNITS The actual value of the Master Engineering Units CP 20 if the system were to operate at the desired maximum RPMs refer to CP 34 This is not to be confused with the setpoint which is the Master Engineering Units at which you want the system to operate CP 21 FOLLOWER ENGINEERING UNITS In Follower Engineering Units CP
74. ate or where there is inadequate load regulation The MLP Trim adds accurate digital control to virtually any AC DC Servo Flux Vector or Clutch drives The MLP Trim is also at the forefront in digitally accurate Follower applications See Figure 1 1 and Figure 1 2 for examples of Master and Follower applications The MLP Trim is unique among its competition because the MLP Trim has preprogramed software that integrates with your system with little effort from you The MLP Trim will also allow you to enter data that is unique to your system s specific needs e g maximum RPMs setpoints acceleration deceleration ramp rates Using Control Parameters CPs this data is entered through either the MLP Trim s integrated keypad or though a host computer via the RS485 Serial Communications port In addition to the Control Parameters that allow you to customize for your systems specific needs MLP Trim s Monitor Parameters MPs allow you to monitor your system s performance The MLP Trim s multiple scaling formats allow you to enter the setpoints and monitor speed in the Engineering Units e g RPMs gallons per hour feet per minute that are unique to your system Among the MLP Trim s advanced capabilities is the flexibility to preset up to four setpoint entries Integrating the MLP Trim s applied intelligence with your system puts precise speeds and perfect synchronization at your fingertips quickly easily and cost effectively EXAMPLES O
75. available Master Setpoints CP 01 and CP 02 However before the MLP Trim can determine how to operate at those setpoints you must enter Scaling Control Parameters into the MLP Trim Scaling is a convenient method for translating the relationship of the motor RPMs into Master Engineering Units The Scaling Control Parameters give the MLP Trim the following information Max RPM Feedback CP 34 Measured at the sensor shaft this number is the maximum RPMs at which you want your system to operate This number is identical to the maximum operating speed that you set in step 7 of the calibration procedure PPR Feedback CP 31 The number of gear teeth or number of encoder lines on the feedback sensor per one revolution pulses per revolution Master Engineering Units CP 20 The actual value of the Master Engineering Units if the system were to operate at the maximum RPMs that you entered in Max RPM Feedback CP 34 The factory default Control Parameters for Scaling are found in Table 3 4 To modify the default parameters refer to Table 3 5 Information on setpoint entry follows Table 3 5 10 Table 3 4 Default Master Scaling Control Parameters Parameter Name Parameter Value CP 34 Max RPM Feedback 2000 CP 20 Master Engineering Units 2000 Table 3 5 Entering Master Scaling Control Parameters CP Parameter Name Parameter Value Max RPM Feedback Enter the maximum desired RPMs measured at the sensor shaft CP 31 PPR Fe
76. ble of running A system is not generally run at full capacity This number is identical to the maximum operating speed that you set in step 7 of the calibration procedure MP 40 TACH In the Master mode Tach MP 40 will display the feedback in Master Engineering Units CP 20 In the Follower mode Tach MP 40 will display either the E U s Time or the feedback to Lead ratio in Follower Engineering Units CP 21 depending on the value in Display Mode Follower CP 64 In Jog or the Direct mode Tach MP 40 will display the feedback in RPMs The feedback is read by the MLP Trim every ten milliseconds The readings are summed then averaged for one second before the Tach is displayed MP 41 LEAD FREQUENCY The Lead Frequency MP 41 displays the frequency of the Lead Frequency Input J6 pin 1 in units of hertz pulses per second Lead Frequency MP 41 is not averaged or filtered it is the ten millisecond frequency calculation prior to the display update Because Lead Frequency MP 41 is not averaged or filtered and because of sensor irregularities it may appear less stable than Tach MP 40 Numbers that are larger than 9999 are displayed with two decimal places For example 10 000 hertz is displayed like the figure in Feedback Frequency MP 43 42 PULSE ERROR COUNT The Pulse Error Count indicates the difference between the Lead and Feedback pulses received during the Follower mode of operation It is an indication of the positio
77. control must conform to area and local electrical codes See The National Electrical Code NEC Article 430 published by the National Fire Protection Association or The Canadian Electrical Code CEC Use local codes as applicable Power J5 pins 1 2 For isolated operations the Frequency Inputs J6 pins 1 2 3 the Digital Inputs J6 pins 4 13 the 45VDC Digital Outputs J6 pins 14 17 and External Analog Input J6 pins 18 19 require Power g Input J6 p req Supply an external source of 5VDC power CAUTION The MLP Trim is shipped from the factory non isolated with J1 and J5 jumpers Do not connect the External Power Supply You must remove the J1 and J5 Common to Earth Ground jumpers before you connect the External Power Supply or you can Figure 2 3 Power Isolated damage the equipment The external supply should be free of ripple and noise to prevent analog signal bounce Do not exceed 5VDC on the I O Power input Use the Auxiliary Power Output J1 pins 1 2 to supply power to non isolated operations The MLP Trim is shipped from the factory with the wiring in the non isolated operation NOTE The MLP Trim should be wired in the isolated mode when using the analog input for precision appli cations setpoint or frequency replacement References Appendix A MLP Trim Specifications Figure 2 4 Power Non Isolated AC Power J4 pins 1 2 3 The MLP Trim model 3200
78. data that is unique to your system e g encoder resolution Lead to Follower ratios and modify the MLP Trim for your specific needs e g maximum RPMS setpoints acceleration deceleration ramp rates by entering a parameter value The MLP Trim is designed to execute either the Direct mode of operation the Master stand alone mode of operation or the Follower mode of operation The values that you enter in the relevant Control Parameters as well as the manner in which you wire and calibrate your MLP Trim determine which of the modes of operation your MLP Trim is set up for The mode of operation that you use is determined by your systems operational requirements The following subsections demonstrate how to enter Control Parameters for the Direct mode Master stand alone mode or the Follower mode of operation In addition Control Parameters for speed change stability warning methods and fast forward are addressed in the subsections on Acceleration Deceleration Tuning Alarms and Jog Direct Mode In the Direct mode of operation the Speed Command output from the MLP Trim that is connected to the motor drive can be set directly Direct mode is an open loop mode of operation Scaling Acceleration Deceleration and closed loop compensation PID software are not involved in the Direct mode The Direct mode is used in conjunction with the Run and Stop controls Caution To avoid damage to your system the MLP Trim must be calibrated
79. de Master stand alone mode the Follower mode Offset mode Acceleration Decelera tion Tuning Alarms and Jog The MLP Trim comes factory pre loaded with a complete set of default Control Parameters Use the Data Inquiry to request the current value for Parameters i e Control Parameters or Monitor Param eters in serial communications See Appendix C CP 17 The Setpoint key and the Tach key are shortcut keys The Setpoint key accesses the active setpoint variable directly and the Tach key accesses the tach variable directly rather than manually entering the Code Parameter See Appendix C CP 67 A precision motor controller that uses digital compensation technology In the Direct mode of operation the analog Speed Com mand from the MLP Trim that is connected to the motor drive can be set directly Direct mode is an open loop mode of operation Scaling Acceleration Deceleration and closed loop compensation PID software are not involved in the Direct mode The Direct mode is used in conjunction with the Run and Stop controls See Appendix C CP 61 See Appendix C CP 06 Tests the LED Display Panel Segments Drive Enable Drive Enable activates the motor drive based on the Ramped Reference MP 46 and the feedback The Ramped Reference is the calculated setpoint that is output from the Acceleration Deceleration routine See Appendix C CP 74 Engineering Units E U Master Engineering Units are the units of m
80. e 1 4 MLP Trim Follower 1 5 MLP Trim Cutout Dimensions and Mounting Guide 2 2 MLP Trim General Wiring Guide 2 4 Power 2 7 Power 2 7 eO RA e Ree e RR 2 8 Lead Frequency nn 2 8 Feedback Frequency 2 9 at 2 9 os ots tees d ie coy ed tor teen 2 10 R SIOD indi ga c e d eet 2 10 joo ED 2 11 Master or 2 11 Setpoint 2 12 S6toll Jp eoe 2 13 Scrol DOWD tdt fh se coe o es 2 13 Analog Inp t een ie 2 14 Speed Command 2 15 Digital Output 1 and Digital Output 2 2 16 MLP Trim Multidrop Installation 2 2 2 17 MLP Trim Serial Communications Connections 2 18 MLP Trim Front Panel 2 3 4 MLP Trim Internal Structure 3 68 Motor Does Not Stop Flowchart 4 12 Motor Does Not Run Flowchart 4 13 Motor Runs at Wrong Speed Flowchart 4 14 Motor Runs Unstable Flowchart 4 15 PROM
81. e MLP Trim will not enter Figure 2 8 Run Run Jog J6 pins 5 8 Jog is a maintained input When Jog is closed the MLP Trim sends a Speed Command Out signal to the drive at the selected jog speed As a maintained input Jog is only active when the operator device is closed NOTE Close the R Stop and F Stop inputs and open the Run input prior to entering Jog If you are only using one of the Stop inputs wire short the other Stop input to Figure 2 9 Jog common or the MLP Trim will not enter Jog R Stop J6 pins 6 8 R Stop is a momentary input When itis opened the MLP Trim ramps to a zero Speed Command Out at the specified deceleration rate As a momentary input R Stop is internally latched and does not need to be maintained by an operator device Figure 2 10 R Stop 10 F Stop J6 pins 7 8 F Stop is a momentary input When it is open the MLP Trim stops immediately zero RPM and ignores the specified deceleration rate As a momentary input F Stop is internally latched and does not need to be maintained by an operator device Master Follower J6 pins 9 13 This input determines the MLP Trim s mode of operation and resulting scaling formula that the control algorithm uses The MLP Trim is in Master mode when the circuit is open and Follower or Offset mode if the circuit is shorted to the common Figure 2 11 F Stop MASTER FOLLOWER Figure 2 12 Master Follower
82. ead sensor shaft pulses per revolution CP 34 Max RPM Feedback Enter the maximum desired RPM of the Follower motor measured at the Follower feedback sensor shaft 33 PPR Lead Enter the number of gear teeth or encoder lines on the Lead sensor 31 PPR Feedback Enter the number of gear teeth or encoder lines on the Follower feedback sensor CP 21 Follower Engineering Units Enter the Engineering Units value if the Lead CP 33 is operating at maximum RPM and the Follower CP 34 is operating at maximum RPM With your scaling established you can enter values for Follower Setpoints 1 and 2 03 CP 04 The value that you enter for a setpoint is the ratio of the Follower E U s at which you want to operate the system divided by the E U s that the Lead is operating at Follower E U desired Setpoint Lead E U operation You can toggle between the two setpoints if you have wired the Setpoint Select accordingly Setpoint Select located at J6 pins 10 13 determines which of the two setpoints is active The factory preset default Follower Setpoints 1 and 2 CP 03 and CP 04 are set at 0 To modify these default parameters refer to Table 3 16 Table 3 16 Entering Follower Setpoint Control Parameters CP Parameter Name Parameter Value Follower Setpoint 1 Divide the Follower E U that you want by the Lead E U that the Lead is operating at and enter that value Follower Setpoint 2 Divide the Follo
83. ead this section prior to wiring the MLP Trim to ensure that you make the appropriate wiring decisions NOTE The installation of this motor control must conform to area and local electrical codes See The National Electrical Code NEC Article 430 published by the National Fire Protection Association or The Canadian Electrical Code CEC Use local codes as applicable Use a minimum wire gauge of 18 AWG Use shielded cable to minimize equipment malfunctions from electrical noise Keep the AC power wiring J4 physically separated from all other wiring on the MLP Trim Failure to do so could result in additional electrical noise and cause the MLP Trim to malfunction A hand operated supply disconnect device must be installed in the final applica tion The primary disconnect device must meet EN requirements Inductive coils on relay contactors solenoids that are on the same AC power line or housed in the same enclosure should be suppressed with an RC net work across the coil For the best results use resistance r values of 50 ohms and capacitance c values of 0 1 microfarads Install an AC line filter or isolation transformer to reduce excessive EMI noise such as line notches or spikes on the AC power line DANGER Hazardous voltages Can cause severe injury death or damage to the equipment The MLP Trim should only be installed by a qualified electrician NOTES INPUTS NOTE The installation of this motor
84. easure that your system operates at such as RPMs gallons per hour feet per minute Follower Engineering Units is the number that will represent the setpoint when the Lead and Follower are operating at maximum capacity See Appendix C CP 20 and CP 21 EEPROM The EEPROM is where the default Control Parameters are stored This is not to be confused with the PROM chip which is the software for the MLP Trim F Stop One of four operating states F Stop brings the MLP Trim s speed command analog output to an immediate zero F Stop has priority over the other operating states Follower Mode A complex multi drive system The scaling format allows the operator to enter the setpoint as either a ratio or percentage The MLP Trim compares the setpoint ratio or percentage to the Follower sensor shaft feedback and Lead sensor shaft to calculate any speed error When the MLP Trim finds speed error the control algorithm adjusts the Speed Command analog output and reduces the error to zero Gain See Appendix C CP 65 Hardwired Inputs that are wire shorted rather than using push buttons or switches Input Monitoring Lead Frequency MP 41 Feedback Frequency MP 43 Logic Inputs Group A MP 54 Logic Inputs Group B MP 55 Glossary 5 Input Test Inputs Integral Jog Keypad Test LED Display Logic Inputs Glossary 6 Tests the Logic Inputs AC Power Power Lead Frequency Feedback Frequency Run Jog
85. edback Enter the number of gear teeth or encoder lines on the sensor per one revolution pulses per revolution Master Engineering Units Enter the Master Engineering Units value if the system were to operate at the maximum desired RPMs entered in CP 34 Now that your scaling has been established you can enter a value for Master Setpoints 1 and 2 The value that you enter for a setpoint is the Engineering Units E U s that you want to operate your system at The factory default Control Parameters for Master Setpoint 1 and 2 are set at 0 To modify these default parameters refer to Table 3 6 You can toggle between the two setpoints if you have wired the Setpoint Select accordingly Setpoint Select located at J6 pins 10 13 determines which of the two setpoints is active Table 3 6 Entering Master Setpoint Control Parameters CP Parameter Name Parameter Value Enter the Master Engineering Units value that you want your system to operate at when Setpoint 1 is active Master Setpoint 1 Enter the Master Engineering Units value that you want your system to operate at when Setpoint 2 is active Master Setpoint 2 An example of the Master mode of operation is demonstrated on the following page 11 12 Master Mode Example The following example demonstrates how scaling and setpoint Control Parameters are entered for a typical Master mode of operation A pump delivers 15 gallons minute when the motor runs at a
86. edback level of 10 0 volts This is the maxi mum calibrated analog input level refer to Installation Setup Calibra tion Analog Input Calibration Note The analog input does not need to operate to 10 0 volts full scale to be used for analog feedback Table 3 8 Default Scaling Control Parameters Parameter Name Parameter Value Master Engineering Units 2000 13 14 Table 3 9 Entering Master Scaling Analog Feedback Parameters Parameter Name Parameter Value CP 84 Analog Input Allocation Enter a value of 2 to allocate the analog input as the feedback source Master Engineering Units Enter the Master Engineering Unit value for an analog feedback level of 10 0 volts Note The Max RPM Feedback CP 34 and PPR Feedback CP 31 control parameters used for scaling Master mode with frequency feedback are ignored when using analog feedback scaling Master Mode Analog Feedback Example The following example demonstrates Master mode scaling using analog feedback A pump delivers 20 0 gallons per minute when the pump motor rotates at 1800 RPM A tachometer connected to the pump motor produces a 10 0 volt signal when the motor rotates at 1800 RPM Master Setpoint 1 will be setup for an operation of 12 0 gallons per minute Master Setpoint 2 will be setup for an operation of 17 5 gallons per minute Table 3 10 shows the scaling Control Parameter that would be entered for the above System operation Table 3 10 Master
87. een entered you can enter the Control Parameters for Tuning either the Master or the Follower mode The tuning Control Parameters are identical for both the Master and the Follower modes of operations Tuning is discussed in the following section Tuning If your system is unstable or the speed error is unacceptable tuning stabilizes speed error differences between the setpoint and feedback You can achieve a stable system using conservative tuning Control Parameter values however the speed error may be unacceptable On the other hand aggressive tuning Control Parameter values may cause the system to become unstable The goal is to reduce the speed error to the level that you want yet maintain the system s stability To achieve an acceptable level of speed error reduce the Gain CP 65 until the system becomes unstable then increase slightly until the system stabilizes In systems that require greater accuracy it may be necessary to adjust the Integral CP 66 to reduce any remaining speed error In systems with low inertia the speed error will be reduced more quickly if you enter low values in CP 66 An entry that is too low however can create instability or overshoot the setpoint before reaching the correct value Generally use larger entries for CP 66 on systems with a large inertia Sometimes performance can be improved in systems with a large inertia by lowering the Derivative CP 67 If stability cannot be obtained with the above t
88. en the Ramped Reference is not zero CP 75 OFFSET NULL Offset Null is used to determine the analog input level where the offset term is zero has no influence CP 76 OFFSET AUTHORITY Offset Authority determines the quantity of the offset term amount of influence for a given analog input level CP 77 OFFSET POLARITY Offset Polarity determines if the offset term is added or subtracted from the follower scaled reference CP 79 SETPOINT LOCKOUT MASK Setpoint Lockout Mask determines which setpoints are disabled when the keypad is locked out If CP 79 is set to 0 then none of the setpoints CP 01 through CP 04 are disabled If CP 79 is set to 1 then all four of the setpoints are disabled If CP 79 is set to 2 then CP 02 and CP 04 are disabled while CP 01 and CP 03 remain enabled MP 83 LIMIT STATUS Limit Status MP 83 displays the status of the Minimum Limit CP 08 and the Maximim Limit CP 09 functions A 1 in the display digit location for the respective function indicates that function is limiting Code Not Used Min Limit Max Limit Not Used CP 84 ANALOG INPUT ALLOCATION CP 84 allocates the analog input to the desired function Allocation is accomplished by entering one of the following codes into 84 0 Not Used 1 Lead Frequency Replacement 2 Feedback Frequency Replacement 3 Offset Function 4 Setpoint 1 Replacement 5 Setpoint 2 Replacement 6 Setpoint 3 Replacement 7 S
89. er Send A new Acceleration Time of 52 3 seconds is sent to the MLP Trim at address 4 ASCII character string STX0431605230ETX Note The character string has no spaces between the integers 79 Table 3 52 Parameter Send MLP Trim Response DEV DEV ERROR PAR PAR DATA DATA DATA DATA DATA DESC STX 10s 15 105 15 10005 1005 10s 15 FORM ee os ee The following is a description of the Parameter Send MLP Trim Response Characters Character 1 STX This is the first character in the character string Characters 2 3 Device This is the two character access address for the MLP Trim Character 4 Error Code If there are errors in the transmission that MLP Trim receives from the host computer the Error Code will display them Use Table 3 57 to convert the ASCII code to binary The binary code can be decoded as follows Bit 7 Always 0 Bit 6 Always 1 Bit 5 1 Data was out of minimum maximum range Bit 4 1 Checksum or Decimal Point Error Invalid Parameter Code Bit 3 1 Receive buffer filled before ETX received or Message Format Error Bit 2 1 Invalid Parameter Data Bit 1 1 Error Bit 0 1 Always 0 Note The MLP Trim will only accept data if there are no errors The ASCII error code Binary code 1000000 indicates that the Host Transmission contains no errors Characters 5
90. est Random Access Memory Clear 4 will automatically default to RAM Test 1 The diagnostic indicator and the number 1 will be visible on the left side of the LED display To enter this test from another diagnostic test press the UP or DOWN scroll keys until the number 1 is visible in the left side of the LED display Press Enter to start the test If RAM fails 5 is displayed The test will stop if a failure is detected Press Clear to exit the test IF the RAM is good the MLP Trim will display 0 0 0 0 Press Clear to exit the test Press CODE SELECT only if you want to exit diagnostics Display Test 2 To Test the LED Display Panel Segments Press the UP or DOWN scroll keys until the diagnostic indicator and the number 2 are visible on the left side of the LED display Press Enter to start the test The MLP Trim will quickly run through all of the display variations Watch each of the display variations carefully for missing segments For example a nine with missing segments could look like a seven The MLP Trim will display the following 00 0000 0 0 0 0 0 0 11 1111 1 1 1 1 1 1 22 2222 2 2 2 2 2 2 33 3333 3 3 3 3 3 3 44 4444 4 4 4 4 4 4 55 5555 5 5 5 5 5 5 66 6666 6 6 6 6 6 6 777777 7 7 7 7 7 7 88 8888 8 8 8 8 8 8 99 9999 9 9 9 9 9 9 0005 0 3 0 0 Qa aaaa a a a a The right side of the LED display will be blank af
91. etpoint 4 Replacement CP 85 ANALOG INPUT ZERO CP 85 is used to zero adjust the analog A D input during calibration The value displayed in CP 85 is the percent XXX X of full range A D voltage input 86 ANALOG INPUT SPAN CP 86 is used to span adjust the analog A D input during calibration The value displayed in 86 is the percent of full range A D voltage input 87 A DINPUT A D Input parameter MP 87 displays the value of the analog input in percent of full scale XXX X before it is zero and span adjusted MP 88 A D INPUT ADJUSTED MP 88 displays the value of the analog input in percent of full scale XXX X after it is zero and span adjusted The A D Input Adjusted value is the value used for scaling the setpoint replacement frequency replacement and offset functions CP 98 KEYPAD LOCKOUT Keypad Lockout CP 98 displays the present status of the keypad lockout When the keypad is locked then LOC is displayed When the Keypad is unlocked then is displayed To lock out the keypad enter a numerical password between 1 and 9999 in Keypad Lockout CP 98 This numerical password will flash briefly on the screen then the screen will display LOC To unlock the keypad enter the same numerical password in Keypad Lockout CP 98 The number will flash briefly on the screen and then the screen will display ULOC Control Parameters and Monitor Parameters may be monitored during
92. finition page Glossary 3 MLP Trim page 2 21 2 23 Character Format page 3 75 C 14 D 2 Clear 4 page 4 3 Clear 7 page 4 11 Closed Loop page 1 3 Glossary 3 Closed Loop Compensation page Glossary 3 Connections Serial Communications page 2 18 Contrex Host page 3 73 Control Command Send page Glossary 3 Serial Communications page 3 82 Control Mask page 3 75 C 14 D 2 Control Paramerters CP 86 page 2 23 Control Parameter Reference List page D 1 Control Parameters page 3 7 3 34 Glossary 3 CP 01 page 3 9 3 10 3 11 3 44 C 1 D 1 CP 02 page 3 9 3 10 3 11 3 44 C 1 D 1 CP 03 page 3 19 3 21 3 27 3 46 C 1 D 1 CP 04 page 3 19 3 21 3 27 3 46 C 1 D 1 CP 05 page 3 55 C 1 D 1 CP 06 page 3 8 C 2 D 1 CP 08 page 3 54 C 2 D 1 CP 09 page 3 54 C 2 D 1 CP 10 page 3 52 C 2 C 3 D 1 CP 11 page 3 52 C 3 D 1 CP 12 page 3 52 C 3 D 1 CP 13 page 3 52 C 3 D 1 CP 14 page 3 52 C 3 D 1 CP 15 page 3 52 C 3 D 1 CP 16 page 3 47 C 4 D 1 CP 17 page 3 47 C 4 D 1 CP 18 page 3 50 C 4 D 1 CP 19 page 3 50 C 4 D 1 CP 20 page 3 9 3 13 3 16 C 4 D 1 CP 21 page 3 19 3 28 3 31 3 38 C 4 D 1 CP 29 page 3 50 C 5 D 1 CP 30 page 3 19 3 31 3 34 3 38 C 5 D 1 CP 31 page 3 9 3 16 3 19 3 28 3 34 3 38 C 5 D 1 CP 33 page 3 19 3 31 3 34 3 38 C 5 D 1 CP 34 page 3 9 3 16 3 19 3 28 3 34 3 38 C 5 D 1 CP 60 page C 12 D 1 CP 61 page 3 8 C 12 D 1 CP 62 page 3 43 3 45 C 12
93. h the motor drive is capable of running The maximum speed at which you want the system to operate will be controlled by the MLP Trim If the drive has a zero speed potentiometer adjust it to eliminate any motor creep If the drive has an IR compensation potentiometer set it at minimum Each motor drive has settings that are unique to its particular model Adjust any remaining drive settings according to the manufacturer s recommendations MLP TRIM CALIBRATION 1 Make sure that the MLP Trim is still in R Stop If the MLP Trim is not in R Stop then put it in R Stop by opening the R Stop logic input J6 pins 6 8 Refer to nstallation Setup Wiring Inputs R Stop Enter the resolution PPRs of the feedback sensor in the Feedback Control Parameter CP 31 by entering the following on the keypad Press Code Select Enter 31 PPR Feedback Press Enter Enter the Pulses Per Revolution PPR of the feedback sensor Press Enter The Tach for the Direct mode is now scaled Set the MLP Trim s maximum speed potentiometer located on the rear as far counter clockwise as it will turn This is the minimum speed setting Enable the MLP Trim s Direct mode by entering the following on the keypad Press Code Select Enter 61 Direct Enable Press Enter Enter 1 Press Enter Put the MLP Trim into Run by deactivating shorting the R Stop input J6 pins 6 8 and the F Stop input J6
94. hieved When Jog is terminated there is no Deceleration Time CP 17 the drive comes to an immediate stop The factory default Control Parameter for Jog is found in Table 3 47 To modify this default parameter refer to Table 3 48 Table 3 47 Default Jog Control Parameters CP Parameter Name Parameter Value Table 3 48 Entering Jog Control Parameters CP Parameter Name Parameter Value CP 05 Jog Setpoint Enter the RPM at which you want your system to operate when it is in Jog For information on the Jog Logic Input refer to Logic Control Logic Inputs Jog 55 56 5 LOGIC CONTROL This section addresses the four digital inputs and two digital outputs that control the MLP Trim s and connected drive s operating state The four digital inputs are F Stop R Stop Run and Jog When the MLP Trim is powered up it defaults to R Stop If either Run or Jog have been hardwired the MLP Trim will operate in either Run or Jog instead of R Stop Run is hardwired by shorting Run R Stop and F Stop to common Jog is hardwired by shorting Jog R Stop and F Stop to common The motor drive is activated by the Drive Enable logic control The sections that follow demonstrate how to use the digital inputs and outputs Caution Do not use the AC line power to start or stop the system Use the Digital Inputs to start or stop the system Logic Inputs F Stop has priority over the other operating states F Stop bri
95. imum RPMs This number is identical to the maximum operating speed that you set in step 7 of the calibration procedure PPR Lead CP 30 The number of gear teeth or number of encoder lines on the Lead sensor per revolution pulses per revolution PPR Feedback CP 31 The number of gear teeth or number of encoder lines on the Follower feedback sensor per revolution Follower Engineering Units CP 21 Enter a number that will represent the setpoint Engineering Units when the Lead and Follower are operating at their maximum RPMs This number is usually either the ratio of Max RPM Feedback CP 34 to Max RPM Lead CP 33 or the ratio of Follower to Lead Engineering Units at maximum desired RPM When this number is also entered as a setpoint CP 03 or CP 04 the Follower will operate at maximum desired RPM when the Lead is at maximum desired RPM 20 The factory default Control Parameters for Scaling are found on Table 3 14 To modify these default parameters refer to Table 3 15 If you are uncertain how to enter a Control Parameter review the Operations Keypad section Table 3 14 Default Follower Scaling Control Parameters CP Parameter Name Parameter Value CP 33 Max RPM Lead 2000 CP 34 Max RPM Feedback 2000 CP 21 Follower Engineering Units Table 3 15 Entering Follower Scaling Control Parameters Parameter Name Parameter Value CP 33 Max RPM Lead Enter the maximum operating RPM of the Lead motor measured at the L
96. irst character in the character string None of the other characters will be recognized without this character prefix Always use the ASCII STX character it enables the MLP Trims receive buffer Characters 2 3 Device These characters are the access address of the MLP Trim This number identifies individual MLP Trims on a mutltidrop system The MLP Trim will accept data only if this number matches the MLP Trim s address CP 70 with the exception of a 00 address The 00 address is universally accepted by all MLP Trims that are on the RS485 Serial Communications Interface Character 4 Message Type This character should always be 2 Characters 5 6 Parameter Number This is the Control Parameter code i e enter 16 for CP 16 Characters 7 through 10 DATA These characters should always be 0 Character 11 Data Format This character should always be 0 Character 12 ETX Always use the ASCII character to terminate the character string 87 Table 3 56 Data Inquiry MLP Trim Response IE ee DEV DEV PAR PAR DATA DATA DATA DATA DATA DESC STX 10s 15 105 15 10005 1005 10s 15 FORM ee SEs ee ee The following is a description of the Data Inquiry MLP Trim Response Characters Character 1 STX This is the first character in the character string Characters 2 3 Device
97. isable the MLP Trim s Direct mode by entering the following on the keypad Press Code Select Enter 61 Direct Enable Press Enter Enter 0 Press Enter 10 Put the MLP Trim in R Stop by opening the R Stop input J6 pins 6 8 ANALOG INPUT CALIBRATION The analog input is factory calibrated for zero and span levels at 0 10 VDC If it is necessary to field calibrate the analog input follow these procedures Zero Adjust 1 Enter CP 85 Analog Input Zero by entering the following on the keypad Press Code Select Enter 85 Press Enter 2 Place zero volts short on the analog input J6 pins 18 19 3 Press the decimal point key The display should now read between 0 0 and 1 0 This step zero adjusts the analog input Span Adjust 1 Enter CP 86 Analog Input Span by entering the following on the keypad Press Code Select Enter 86 Press Enter 2 Place 10 0 VDC on the analog input J6 pins 18 19 3 Press the decimal point key The display should now display a value from 90 0 to 100 0 for a 10 VDC input This step span adjusts the analog input 24 NOTES Operation Keypad Operation Keypad Lockout Control Parameters CP Direct Mode Master Mode Follower Mode Offset Mode Inverse Master Mode Inverse Follower Mode Acceleration Deceleration Tuning Alarms Limits Jog Logic Control Logic Inputs Logic Outputs Monitor Parameters MP Input Monitoring Output Monitoring Pe
98. it that displays a number 1 is the active control state of the MLP Trim In the example below Run is the active control state Code 72 MP 57 EEPROM STATUS The Control Parameters are stored in the EEPROM memory chip EEPROM Status MP 57 displays the status of the EEPROM memory chip The number 0 indicates no failure The number 1 indicates a write verify error In the event of an error call Technical Support at 612 424 7800 or 1 800 342 4411 MP 59 FREQUENCY OVER FLOW COUNTER The Frequency Over Flow Counter MP 59 is a counter that increments each time the frequency input to the MLP Trim causes an overflow To reset the counter to 0 press the Clear key MP 83 LIMIT STATUS Limit Status MP 83 displays the status of the Minimum Limit CP 08 and the Maximum Limit CP 09 functions A 1 in the display digit location for the respective function indicates that function is limiting Not Used Min Limit Max Limit Not Used Code SERIAL COMMUNICATIONS The MLP Trim can interface with a host computer through a RS485 Serial Communications Interface This interface allows the host computer to perform remote Control Parameter entry status or performance monitoring and remote control of the MLP Trim Refer to Using Serial Communications in this section If you are using the Contrex Host software your communications network is user ready and does not require any software programming Contrex Hos
99. lamp attachments wire routing and heat convection Insert the MLP Trim through the door panel cutout until the gasket and bezel are flush with the door panel see Figure 2 1 Slide the mounting clamps into the slots that are located on the top and bottom of the MLP Trim Tighten the mounting screws until the MLP Trim is mounted securely in the NEMA Electrical Enclosure Do not overtighten Z Z 2661 0026 WII d IN OWA 062 esf 3d QN5 C WOO WOO 10 Aiadns zino oia omas Xe nog 0 5 Vi Od A WOO 1102125 _____ NMG THOS dn 1104256 H dn 1405 199195 191938 _ a O 103 150 ANG 2 J49MOJIJOJ 6 WOO SIS Aud SIS 8 dois 4 ae j U dois uH OTO BE dors O raro INOO 1 T 4osuas NOS EE T 915 z qu aL oravan Josueg woo 7T EN WOO le119S 68058 AouenbeJ4 mE i peo Ast Id AS 9r Aiddng ast ae OGASt 9661 0026 WUL ATN OVA GLL es WIRING This section contains the input output and serial communications wiring information for the MLP Trim Please r
100. larm Scaled Error Alarm Acceleration Time Deceleration Time Lag Pulse Limit Lead Pulse Limit Master Eng Units Follower Eng Units Recovery Multiplier PPR Lead PPR Feedback Max RPM Lead Max RPM Feedback Open Loop Direct Enable Inverse Scaling Display Mode Follower Gain Proportional Integral LB DESCRIPTION MAX DEFAULT Derivative Trim Authority Device Address Baud Rate Character Format Control Mask Drive Enable Logic Offset Null Offset Authority Offset Polarity Setpoint Lockout Mask Analog Input Allocation Analog Input Zero Analog Input Span Keypad Lockout D m 20 UNITS APPENDIX E MONITOR PARAMETER REFERENCE DESCRIPTION Tach ENG Lead Frequency HZ Pulse Error Count PULSES Feedback Frequency HZ Deviation Error HZ Scaled Reference HZ Ramped Reference HZ Speed Command Output 96 Trim Output DAC BITS Active Scaling Mode CODED Keypad Error CODED Alarm Status CODED Control State CODED Logic Inputs Group A CODED Logic Inputs Group B CODED Logic Outputs CODED EEPROM Status CODED Serial Comm Error CODED Frequency Overflow Counter COUNTS Limit Status CODED A D Input A D Input Adjusted Software Code Revision Software Part Number 5 APPENDIX F MLP TRIM FAX COVER SHEET Date Contrex Technical Support Fax Number 1 763 424 8734 From Name Ext Company Telephone Fax We have MLP Trim s
101. me Parameter Value CP 62 Inverse Scaling 2 CP 30 PPR Lead CP 31 PPR Feedback 5 0 CP 04 Follower Setpoint 2 After the Scaling and the Follower Setpoints for your system have been entered you can enter the Acceleration Deceleration Control Parameters for the Inverse Follower mode Acceleration Deceleration is discussed in the following section Acceleration Deceleration Acceleration Deceleration CP 16 and CP 17 control the rate of speed change in response to setpoint changes These parameters apply to both the Master and Follower modes of operation The MLP Trim comes factory pre loaded with default Control Parameters for Acceleration Deceleration Generally these default settings are suitable for most applications and do not require modification The factory default Control Parameters for Timing are found in Table 3 37 To modify these default parameters refer to Table 3 38 Table 3 37 Default Master or Follower Acceleration Deceleration Control Parameters CP Parameter Name Parameter Value 5 0 Deceleration Time Table 3 38 Entering Master or Follower Acceleration Deceleration Control Parameters CP Parameter Name Parameter Value Acceleration Time Enter the desired number of seconds to increase the motor speed from 0 to 2000 RPMs Deceleration Time Enter the desired number of seconds to decrease the motor speed from 2000 to 0 RPMs After the Control Parameters for Acceleration Deceleration have b
102. n error between the lead and follower devices This error is cleared to zero when the MLP Trim enters the stop state MP 43 FEEDBACK FREQUENCY The Feedback Frequency MP 43 displays the frequency of the Feedback Frequency Input J6 pin 2 in units of hertz pulses per second Feedback Frequency MP 43 is not averaged or filtered it is the ten millisecond frequency calculation prior to the display update Because Feedback Frequency MP 43 is not averaged or filtered and because of sensor irregularities it may appear less stable than Tach MP 40 Numbers that are larger than 9999 are displayed with two decimal places For example 10 000 hertz is displayed as follows Two Decimal Places MP 44 DEVIATION ERROR Deviation MP 44 displays the difference between the Ramped Reference MP 46 and the Feedback Frequency MP 43 measured in units of hertz pulses per second Deviation is not averaged or filtered it is the ten millisecond frequency calculation prior to the display update MP 45 SCALED REFERENCE The Scaled Reference MP 45 is the scaled setpoint number converted to hertz It is the calculated value that is input to the Acceleration Deceleration routine This parameter may display numbers that are larger than 9999 These larger values are displayed with two decimal places For example 10 000 hertz is displayed as 10 00 MP 46 RAMPED REFERENCE The Ramped Reference 46 is the calculated output of the Accelera
103. ngs the MLP Trim s Speed Command output to an immediate Zero To activate F Stop Open the F Stop Input F Stop is latched and does not need to be maintained to remain active F STOP COMMON Open Momentarily R Stop has the second highest operating priority R Stop decelerates the Speed Command output to Zero using the Deceleration Time CP 17 To activate R Stop Short the F Stop input to common Open the R Stop input R Stop is latched and does not need to be maintained to remain active R STOP R STOP F STOP COMMON Open Momentarily Run has the third highest operating priority Run ramps to the scaled setpoint speed using the Acceleration Time CP 16 Run can be activated when the MLP Trim is in R Stop or F Stop however Run cannot be activated when the MLP Trim is in Jog To activate Run Short the F Stop and R Stop inputs to common Open the Jog input Short the Run input to common Run is latched and does not need to be maintained to remain active RUN JOG R STOP F STOP COMMON Close Momentarily 59 60 Jog has the least operating priority Jog ramps to the Jog Setpoint CP 05 using the Acceleration Time CP 16 When Jog is terminated the MLP Trim brings the Speed Command output to an immediate Zero Unlike the other inputs Jog is not latched and must be sustained to remain active To activate Jog Short the F Stop and R Stop inputs to common
104. nits CP 21 as a ratio of Follower to Lead To find Follower Setpoint 1 CP 03 for Example Follower E U desired 15 Setpoint 1 z z 3 Lead E U operation 5 15 gal min The Follower Engineering Units gallon per minute at which you want the Follower to operate do not confuse this with the full capacity gal min that the Follower is capable of pumping Divided by 5 gal min The Lead Engineering Units that the Lead is operating at do not confuse this with the full capacity that the Lead is capable of operating at Equals Follower Setpoint 1 CP 03 value Co e To find Follower Setpoint 2 CP 04 for Example Follower E U desired 22 5 Setpoint 2 z 4 50 Lead E U operation 5 22 5 gal min Follower Engineering Units gallon per minute at which you want the Follower to operate do not confuse this with the full capacity gal min that the Follower is capable of pumping Divided by 5 gal min The Lead Engineering Units gallon per minute that the Lead is operating at do not confuse this with the full capacity that the Lead is capable of pumping Equals gt Follower Setpoint 2 CP 04 value 24 Table 3 17 Follower Mode Control Parameters Example e CP 04 Follower Setpoint 2 4 50 The will adjust and monitor the speed of the Follower motor to achieve the desired gallons minute This completes the scaling and setpoint information for
105. nk however they will not send a response message back to the host computer when this global address is used CP 71 BAUD RATE There are six different baud rates data rates for the MLP Trim Enter the number for the required function in Baud Rate CP 71 as listed below 1 300 Baud 2 600 Baud 3 1200 Baud 4 2400 Baud 5 4800 Baud 6 9600 Baud CP 72 CHARACTER FORMAT The MLP Trim uses three different character formats Enter the number for the required format in Character Format CP 72 as listed below 1 8 Data Bits One Stop Bit 2 7 Data Bits Even Parity One Stop Bit 3 8 Data Bits No Parity Two Stop Bit CP 73 CONTROL MASK The Serial Communications can control some of the logic input functions Enter the number for the required functions in Control Mask CP 73 as listed below 0 F Stop only 1 F Stop Run R Stop 2 F Stop Master Follower Setpoint Select 3 All of the above 74 DRIVE ENABLE Drive Enable Logic CP 74 determines which conditions of the Ramped Reference MP 46 the feedback will control the Drive Enable logic Enter 0 to deactivate the Drive Enable output output high when the Ramped Reference is zero and activate the Drive Enable output output low when the Ramped Reference is not zero Enter 1 to deactivate the Drive Enable output when both the Ramped Reference and the feedback are zero and activate the Drive Enable output wh
106. od will be replaced or repaired without charge This guarantee is void if the device has been damaged by improper installation or operation tampering careless handling or accident When a device fails to function in accordance with standards set forth in the instruction manual the purchaser should contact an authorized representative of Contrex Inc 8900 Zachary Lane North Maple Grove Minnesota 55369 Whether repairs will take place in the field or at the factory will be solely the prerogative of Contrex Inc If inspection reveals defects that are caused by faulty materials or workmanship Contrex Inc reserves the right to either replace the device or rebuild the device using new or refurbished warranted parts and components In either instance the device that is returned to the purchaser meets full factory standards for new device performance If there is less than 90 days remaining on the warranty period at the time of the repair the warranty will extend to 90 days after the repair Parts and services outside the scope of this Warranty 4 warranty will be available at Contrex Inc current market price Contrex s liability for a device or it s use whether in warranty or not shall not in any instance exceed the cost of correcting the defects of the device Contrex Inc assumes no responsibility for damage to property or injuries to persons from improper use of this device No express warranties and no implied
107. on on the CPU Board To replace the PROM chip Make a record of your current Control Parameter values the replacement chip contains default values that will replace your current values when you perform the Clear 7 step Turn off the power to the MLP Trim Remove the back panel Pull out the CPU board Ground yourself Static electricity can damage the PROM Locate the PROM chip and carefully pry the PROM from the socket Alternate between the two corners as noted in figure 4 5 Carefully install the replacement PROM in the socket by lining up the beveled corner of the PROM chip with the beveled corner of the socket Apply even pressure until the PROM is seated NOTE Incorrect placement can damage the PROM Replace the CPU board e Replace the back panel Press the Clear key and 7 key then continue to press the keys while you apply power to the MLP Trim The Clear 7 procedure restores the factory default settings and automatically performs the Power Up diagnostic routines Reenter your Code Parameters values Insert Tool Insert Tool Beveled Corner Figure 4 5 PROM Location 18 5 Glossary GLOSSARY Acceleration Deceleration Acceleration Time CP 16 and Deceleration Time CP 17 control the rate of speed change in response to setpoint changes These parameters apply to both the Master and Follower modes of operation
108. op Installation Serial Communications page 2 17 Offset Mode page 3 38 Example page 3 41 Open Loop page 1 3 Glossary 7 Open Closed Loop Input page 2 13 Operating State page Glossary 7 Operating States F Stop page 3 58 Jog page 3 60 R Stop page 3 58 Run page 3 59 Operation Acceleration Deceleration page 3 47 Alarms page 3 52 Control Parameters page 3 7 Direct Mode page 3 8 Index 9 Follower Mode page 3 19 Example page 3 22 Input Monitoring page 3 64 Inverse Follower Mode page 3 45 Example page 3 46 Inverse Master Mode page 3 43 Example page 3 44 Jog page 3 55 Keypad Operation page 3 3 Limits page 3 54 Logic Control page 3 57 Logic Inputs page 3 58 Logic Outputs page 3 61 Master Mode page 3 9 Example page 3 12 Monitor Parameters page 3 63 Offset Mode page 3 38 Example page 3 41 Output Monitoring page 3 67 Performance Monitoring page 3 68 Serial Communications page 3 73 Communications Software Design page 3 76 Using Serial Communications page 3 74 Status Monitoring page 3 70 Tuning page 3 48 Output Monitoring page 3 67 Glossary 8 Test page Glossary 8 Test 5 page 4 8 Test 6 page 4 9 Wiring page 2 15 Parameter page 3 7 Glossary 8 Code page 3 7 3 63 Glossary 8 Send page 3 77 Glossary 8 Summary Reference List page C 1 Value page 3 7 3 63 Glossary 8 Performance Monitoring page 3 68 Glossary 8 PPR Feedback page 3 9 3 19 C 5
109. output to activate High Alarm Enter the RPMs at or above which you want the alarm output to activate Ramped Error Alarm Enter the RPM Deviation between the Ramped Reference and the feedback that will activate the alarm output Scaled Error Alarm Enter the RPM Deviation between the Scaled Reference and the feedback that will activate the alarm output 53 54 Limits The MLP Trim has the ablity to limit both the minimum and maximum operating speed when in the Run state The following control parameters are used by the MLP Trim for limit control Minimum Limit CP 08 This parameter sets the minimum level of operation in the Run state It is possible to enter a setpoint below this limit however the control will always attempt to maintain a speed at or above this RPM level Maximum Limit CP 09 This parameter sets the maximum level of operation in the Run state It is possible to enter a setpoint above this limit however the control will always attempt to maintain a speed at or below this RPM level Table 3 45 Default Limit Control Parameters Parameter Name Parameter Value Maximum Limit 2000 Table 3 46 Entering Limit Control Parameters CP Parameter Name Parameter Value Enter the desired minimum operating RPM Maximum Limit Enter the desired maximum operating RPM Jog Jog increases the RPMs at the acceleration rate that you specified in Acceleration Time CP 16 until the Jog Setpoint CP 05 is ac
110. pad page 4 6 The LED Display Panel Segments page 4 5 The Logic Inputs page 4 7 The Logic Outputs page 4 8 The Speed Command Output page 4 9 Trim Output page C 7 E 1 Troubleshooting page 4 11 Motor Does Not Run page 4 13 Motor Does Not Stop Flowchart page 4 12 Motor Runs at Wrong Speed page 4 14 Motor Runs Unstable page 4 15 Tuning page 3 48 Glossary 9 U ULOC page 3 5 Warranty page Warranty 4 Wiring Connections Relay Start Stop page G 2 Connections without Relays page G 1 Examples page G 1 General Diagram page 2 4 Inputs page 2 7 Outputs page 2 15 Start Stop for Non Regen with Armature page G 4 Start Stop for Regen with Armature page G 3 Two Channel Start Stop Lead or Follower page G 5 Z Zero Error Loop page 3 50 Index 12
111. pins 7 8 and then activating shorting the Run input J6 pins 4 8 Although the motor is now in Run it will have zero speed until you adjust the Direct Setpoint in the next step Gradually set the MLP Trim s Direct Setpoint to 90 by entering the following on the keypad Press Code Select Enter 6 Direct Setpoint Press Enter Enter 10 Press Enter Enter 20 Press Enter Continue to gradually increase these increments by ten until you reach 90 Since there are no acceleration deceleration ramps in Direct mode a sudden increase to 90 could cause damage in some systems Turn the MLP Trim s maximum speed potentiometer clockwise until the drive motor s RPMs are at the maximum operating speed at which you want the system to operate The maximum operating speed is the same speed that you will enter in Max RPM Feedback CP 34 to scale for the Master mode of operation Refer to Operation Control Parameters Master Mode Check the speed RPMs by pressing the key If the lowest setting on the MLP Trim s maximum speed potentiometer still exceeds the maximum speed at which you want the system to operate then adjust the maximum speed span potentiometer on the motor drive until the desired speed is reached Put the Direct Setpoint back to 096 by entering the following on the keypad Press Code Select Enter 6 Direct Setpoint Press Enter Enter 0 Press Enter D
112. r Code will display them Use Table 3 57 to convert the ASCII code to binary The binary code can be decoded as follows Bit 7 Always 0 Bit 6 Always 1 Bit 5 1 Data was out of minimum maximum range Bit 4 1 Checksum or Decimal Point Error Invalid Parameter Code Bit 3 1 Receive buffer filled before ETX received or Message Format Error Bit 2 1 Invalid Parameter Data Bit 1 1 Parity Error Bit 0 1 Always 0 Note The MLP Trim will only accept data if there are no errors The ASCII error code Binary code 1000000 indicates that the Host Transmission contains no errors Characters 5 6 Parameter Number These characters will always be 0 Characters 7 through 10 DATA These characters will always be 0 Character 11 Data Format This character will always be 0 Character 12 ETX The return message is always terminated with the ASCII character 85 Data Inquiry Use the Data Inquiry to request the current value for Parameters i e Control Parameters or Monitor Parameters Table 3 55 Data Inquiry Host Transmission ner 1 2 os fe e DEV DEV MSG PAR PAR DATA DATA DATA DATA DATA DESC STX 10s 15 105 is 10005 1005 10s 15 FORM je 8 The following is description of the Data Inquiry Host Transmission Characters Character 1 STX This is the f
113. ratio of the follower web speed to lead web speed A dancer pot is placed on a web take up between the lead and follower nip rolls When the potentiometer is in its desired neutral position the analog voltage level is 6 0 volts or 60 096 of the 10 0 volt analog full scale Web operation is optimized by subtracting 15 0 of full scale feedback from the scaled reference when the analog input is at full scale 10 0 volts 42 CP CP 84 CP 21 CP 34 CP 31 CP 33 CP 30 75 76 77 Table 3 30 Offset Mode Example Parameter Name Value Analog Input Allocation 1 000 Max RPM Feedback 1800 PPR Feedback Max RPM Lead 1800 PPR Lead Offset Null 600 3 Offset Authority Offset Polarity 2 Follower Engineering Units Remarks Allocates The analog input as the Offset input This is the Engineering Unit value that is present if the lead and feedback at max RPM The maximum operating RPM of the feedback shaft The resolution of the feedback sensor The maximum operating RPM of the lead shaft The resolution of the lead sensor The neutral dancer pot position The authority of the dancer offset term The offset is subtracted from the scaled reference Inverse Master Mode The Inverse Master Mode is a variation of the Master Mode The Inverse Master Mode has an inverted setpoint If you increase the value of the setpoint CP 01 or CP 02 then the motor speed will dec
114. rease Inverse Mode setpoints generally use engineering units of time With the Inverse Scaling CP 62 set to 2 enter values in the Master Setpoints CP 01 and CP 02 that represent the E U at which you want the system to operate The higher the setpoint value the slower the motor speed Inversely the lower the setpoint value the higher the motor speed The MLP Trim comes factory pre loaded with the default Control Parameters for the standard Master Mode These default settings are not suitable for Inverse applications and require modification The factory default Control Parameters for the standard Master Mode are found in Table 3 31 To modify these default parameters refer to Table 3 32 Table 3 31 Default Inverse Master Control Parameters CP Parameter Name Parameter Value Inverse Scaling 1 Standard Scaling Master E U Table 3 32 Entering Inverse Master Control Parameters CP Parameter Name Parameter Value Inverse Scaling Enter 2 for Inverse Scaling Master E U Enter the Master Engineering Units value if the system were to operate at the maximum RPMs entered in CP 34 44 Inverse Master Mode Example The Inverse Master Mode Example demonstrates how scaling and setpoint Control Parameters are entered for a typical Inverse Master mode of operation It takes 10 seconds to move a product through a heat treat oven when the conveyor motor is running at 1500 RPM The conveyor motor shaft is equipped with a 60
115. rformance Monitoring Status Monitoring Serial Communications Using Serial Communications Communications Software Design KEYPAD OPERATION The front panel of the MLP Trim is an easy to use keypad that gives you direct access to the Parameters Control Parameters and Monitor Parameters by entering the Parameter Code You can also use the keypad to change the value of a Control Parameter The keypad has keys for Code Select Enter Clear and Scroll Up Down It also has numeric keys and two dedicated keys Setpoint and Tach The LED display is the above the keys Figure 3 1 displays the location of the keys and LED display on the keypad Table 3 1 demonstrates basic keypad entry The keypad functions as follows Code Select Key Numeric Keys Dedicated Keys Scroll Up Down Keys LED Display Press this key prior to entering a Parameter Code either a Control Parameter or a Monitor Parameter Use the numeric keys to enter a Parameter Code for either a Control Parameter CP or a Monitor Parameter MP or to enter a value for a Control Parameter Use the Enter key after each entry Use the Clear key to delete your entry The Setpoint key and the Tach key are shortcut keys The Setpoint key accesses the active setpoint variable directly and the Tach key accesses the tach variable directly rather than manually entering the Code Parameter These keys will change the active setpoint value even if that setpoint is not displayed in
116. ring step 7 of the calibration procedure PPR Feedback CP 31 The number of gear teeth or encoder lines on the follower feedback sensor per revolution Table 3 11 Default Scaling Control Parameters CP Parameter Name Parameter Value CP 84 Analog Input Allocation CP 20 Master Engineering Units CP 34 Max RPM Feedback 2000 Table 3 12 Entering Master Scaling Analog Setpoint Parameters CP Parameter Name Parameter Value CP 84 Analog Input Allocation CP 20 Master Engineering Units CP 34 Max RPM Feedback CP 31 PPR Feedback Setting CP 84 to a value of 4 or 5 allocates the analog input to be used as Master Setpoint 1 or Master Setpoint 2 respectively Enter the Master Engineering Unit value for an analog setpoint level of 10 0 volts and feedback RPM of GP 34 Enter the maximum operating RPMs measured at the feedback sensor shaft Enter the resolution of the feedback sensor 17 18 Master Mode Analog Setpoint Example The following example demonstrates Master mode scaling using analog setpoint A pump delivers 20 0 gallons per minute when the pump motor rotates at 1800 RPM The pump motor is equipped with a 60 tooth ring kit feedback sensor The pump will run at 20 0 gallons per minute with an analog input of 10 volts Table 3 13 Master Mode Setpoint Allocation Example CP Parameter Name Value Remarks 84 Analog Input Allocates the analog input as Allocation
117. s unique to your system Tach Deviation Error Pulse Error Count Scaled Reference Ramped Reference Trim Output The PROM Programmable Read Only Memory chip is the software for the MLP Trim This is not to be confused with the EEPROM which is were the default Control Parameters and Monitor Parameters are stored One of the two power up diagnostic routines that the MLP Trim automatically performs during every Power Up See Appendix C CP 31 PPR Lead See Appendix C CP 30 Tuning Tuning stabilizes speed error differences between the setpoint and feedback Ring Kits Ring Kits are flange motor mounted sensors that measure the pulses per revolution PPR of the motor shaft R Stop One of four operating states R Stop uses Deceleration Rate CP 17 to decelerate the Speed Command analog output to zero R Stop has the second highest operating state priority RAM Test Tests Random Access Memory This test can be run as part of the diagnostic tests It is also one of the two power up diagnostic routines that the MLP Trim automatically performs during every Power Up RPM Feedback The speed of the feedback sensor in revolutions per minute RPM Lead The speed of the lead sensor in revolutions per minute Run One of four operating states Run ramps to the scaled setpoint speed using the acceleration and deceleration rate values in Acceleration Time CP 16 and Deceleration Time CP 17 Run can be activated when the MLP Trim
118. sed to control Dig Out2 J6 pins 16 17 The alarm outputs can be wired to activate a warning light a warning sound or to shut down the system under specified conditions The MLP Trim comes factory pre loaded with default Control Parameters for Alarms These default parameter values are set for widely generic conditions that generally will not activate the alarm This allows you to either operate your system unfettered by the alarm or design your own alarm conditions that are unique to your system The factory default Control Parameters for the Alarms are found in Table 3 43 To modify these default parameters refer to Table 3 44 Table 3 43 Default Alarms Control Parameters CP 13 High Alarm 2000 CP 14 Ramped Error Alarm 2000 CP 15 Scaled Error Alarm 2000 Table 3 44 Entering Alarms Control Parameters Parameter Name Parameter Value Alarm 1 Format Alarm 1 Format CP 10 determines which alarm conditions will activate the Dig Out output using the values that are entered in Low Alarm CP 12 High Alarm CP 13 Ramped Error Alarm CP 14 and Scaled Error Alarm CP 15 Refer to Appendix C Alarm 2 Format Alarm 2 Format CP 11 determines which alarm conditions will activate the Dig Out2 output using the values that are entered in Low Alarm CP 12 High Alarm CP 13 Ramped Error Alarm CP 14 and Scaled Error Alarm CP 15 Refer to Appendix C Enter the RPMs at or below which you want the alarm
119. t XXXX 9 XX XX X XXX XXXX XXX X XX XX X XXX ON Codes 0 through 7 are valid for 20 and CP 21 Code 8 is valid for MP 41 MP 43 MP 45 and 46 other Code Parameters have either fixed or derived decimal locations and must use Code 0 For codes 9 multiply characters 7 through 10 by ten Character 12 ETX The return message is always terminated with the ASCII character 90 0000000 0000001 0000010 0000011 0000100 0000101 0000110 0000111 0001000 0001001 0001010 0001011 0001100 0001101 0001110 0001111 0010000 0010001 0010010 0010011 0010100 0010101 0010110 0010111 0011000 0011001 0011010 0011011 0011100 0011101 0011110 0011111 Table 3 57 ASCII to Binary ASCII Binary 5 Binary ASCII Binary ASCII Binary Bit7 Bit 1 Bit 7 Bit 1 Bit7 Bit 1 Bit 7 Bit 1 0100000 0100001 0100010 0100011 0100100 0100101 0100110 0100111 0101000 0101001 0101010 0101011 0101100 0101101 0101110 0101111 0110000 0110001 0110010 0110011 0110100 0110101 0110110 0110111 0111000 0111001 0111010 0111011 0111100 0111101 0111110 0111111 N XxE E c omJouozzm xc rgommoou G 1000000 1000001 1000010 1000011 1000100 1000101 1000110 1000111 1001000 1001001 1001010 1001011 1001100 1001
120. t of Follower to Lead 26 To find Follower Setpoint 1 CP 03 for Example Follower E U desired Setpoint 1 z 100 Lead E U operation 10 gal min The Follower Engineering Units gallons minute of ingredient B at which you want the Follower to operate do not confuse this with the full capacity that the Follower is capable of pumping Divided by 20 gal min The Lead Engineering Units gallons minute of ingredient A that the Lead is operating at do not confuse this with the full capacity that the Lead is capable of operating at Multiplied by 100 96 Equals 50 Follower Setpoint 1 CP 03 value To find Follower Setpoint 2 CP 04 for Example B Follower E U desired Setpoint 2 z x 100 Lead E U operation 7 gal min The Follower Engineering Units gallons minute of ingredient B at which you want the Follower to operate do not confuse this with the full capacity that the Follower is capable of pumping Divided by 10 gal min The Lead Engineering Units gallons minute of ingredient A that the Lead is operating at do not confuse this with the full capacity that the Lead is capable of operating at Multiplied by 100 Equals 70 Follower Setpoint 2 CP 04 value Table 3 18 Follower Mode Control Parameters Example e 04 Follower Setpoint 2 70 0 The MLP Trim will adjust and monitor the speed of the motors to achieve the desired gallons minute That completes the scaling
121. t software is available through your distributor If you are designing your own software refer to Communications Software Design in this section Once the software is installed you are ready to establish a link through the Serial Communications Interface 74 Using Serial Communications This section describes how to use the Serial Communications Before you can apply this section The MLP Trim must be interfaced with a host computer through a RS485 Serial Communications Interface The host computer must have the Contrex Host software or its equivalent installed The MLP Trim comes factory pre loaded with default Control Parameters for Serial Communications Setup These Control Parameters physically set up the MLP Trim to accommodate the RS485 Serial Communications Interface Generally the default settings are suitable for most applications and do not require modification The factory default Control Parameters for Serial Communications Setup are found in Appendix D These default parameters can be modified using the Serial Communications Interface CP 70 DEVICE ADDRESS The MLP Trim has a physical address which can be set from 1 to 32 Each individual MLP Trim on a multidrop 5485 communications link needs a unique Device Address The address 00 will be globally accepted by all of the MLP Trims on a communications link however they will not send a response message back to the host computer when this global address is used CP 7
122. t2 logic outputs number 1 indicates an inactive or de energized logic high level The number 0 indicates active or energized logic low level In the example below Dig Out2 is the inactive or de energized logic high level Code 4 Dig Out1 J6 Pin 15 Dig Out2 J6 Pin 16 Not Used Not Used MP 57 EEPROM STATUS The Control Parameters are stored in the EEPROM memory chip EEPROM Status MP 57 displays the status of the EEPROM memory chip The number 0 indicates no failure The number 1 indicates a write verify error In the event of an error call Technical Support at 612 424 7800 or 1 800 342 4411 MP 58 SERIAL COMMUNICATIONS ERROR Serial Communications Error MP 58 identifies errors in the last transmitted message that was sent to the MLP Trim by the host computer The mode that displays a number 1 indicates the error In the example below Invalid Parameter Code is the error Code Structure Error Parity Framing No ETX STX Invalid Parameter Code Invalid Parameter Data or Out of Data Min Max Range Control Mask Error MP 59 FREQUENCY OVER FLOW COUNTER The Frequency Over Flow Counter MP 59 is a counter that increments each time the frequency input to the MLP Trim causes an overflow To reset the counter to 0 press the Clear key CP 60 OPEN LOOP If CP 60 is set to 1 then the J6 Pin 12 input acts as the Scroll Down input If CP 60 is set to 2 then this input
123. ter the MLP Trim has completed the display variations The MLP Trim automatically exits the test Press CODE SELECT only if you want to exit diagnostics Keypad Test 3 Test the Keypad Press the UP or DOWN scroll keys until the diagnostic indicator and the number 3 are visible on the left side of the LED display Press Enter to start the test The MLP Trim displays the number 15 for the Enter key Press each of the keypad keys and verify against the following list Press Display 0 1 1 2 2 3 3 4 4 5 5 6 6 F 7 8 8 9 9 CODE SELECT 10 SETPOINT 11 TACH 12 A 13 v 14 ENTER 15 CLEAR No display If Clear is functioning pressing Clear will take you out of the Keypad test If Clear is not functioning it will not take you out of the test and the number of the prior key will remain on the LED display Press Clear to exit the test Press CODE SELECT only if you want to exit diagnostics Input Test 4 To Test the Logic Inputs Press the UP or DOWN scroll keys until the diagnostic indicator and the number 4 are visible on the left side of the LED display Press Enter to start the test The LED display will be blank unless an input has been shorted If an input has been shorted it s number will display For example if the number three appears in the display then R Stop has been shorted To test an input short that input and open all of the other inputs Input
124. that are used for Serial Communication Hookup Yes Brief Description of the Problem We are transmitting pages including this Cover Sheet a copy of Appendix D with the User Record completed a sketch of the system that the MLP Trim is integrated with Please turn the page to record any CPs that you have changed from the default value gt Please record the Control Parameters that you changed from the default value Codes Description User Codes Description User Record Record CP 01 CP 02 03 04 05 06 08 09 10 11 12 13 14 15 16 17 18 19 20 21 29 30 31 33 34 60 61 62 64 65 66 67 Master Setpoint 1 i ail Master Setpoint2 Follower Setpoint 1 Follower Setpoint2 _____ Jog Setpoint f Direct Setpoint Minimum Limit Maximum limit 1 Alarm 1 Format Alarm 2 Format CP 69 Low Alarm 70 High Alarm _____ CP 71 Ramped Error Alarm 72 Scaled Error Alarm __ CP 73 Acceleration Time 74 Deceleration Time CP 75 Lag Pulse Limit 76 Lead Pulse Limit 77 Master Eng Units 79 Follower Eng Units CP 84 Recovery Multiplier CP 85 PPR Lead ______ 86 2 Max RPM Lead
125. the LED Display Each time you press the scroll up key the active setpoint will increase by one increment Each time you press the scroll down key the active setpoint value will decrease by one increment It will also automatically scroll through the increments or decrements if you hold the key down The two digit Parameter Code is displayed on the left LED Display The Parameter Code s value is displayed on the right LED display This value can be up to four digits Table 3 1 Basic Keypad Entry To Enter a Parameter Code Press Code Select Enter a Parameter Code For a Control Parameter or Monitor Parameter Press Enter within 15 seconds The Parameter Code and it s current value are displayed on the LED display The Parameter Code decimal point is illuminated To Enter a Parameter Value Follow the steps to enter a Parameter Code For Control Parameters only Monitor Enter a new value Use the numeric keys Parameters can not be changed Press Enter within 15 seconds manually The Parameter Code decimal point turns Off To Use the Tach Key Press Tach The scaled Engineering Unit Feedback is displayed To Use the Setpoint Key Press Setpoint The active setpoint and its value are displayed To Use the Up Down Press the Up scroll key to increase the active setpoint value Scroll Keys Press the Down scroll key to decrease the active setpoint value Parameter Code Parameter Value
126. their default values Turn off the power to the MLP Trim Press the Clear key and the 7 key then continue to press these keys while you apply power to the MLP Trim The Clear 7 procedure restores the factory default settings and automatically performs the Power Up diagnostic routines Reenter the values for your Code Parameters If the information in this section does not solve your problem consult Contrex Technical Support 763 424 7800 or 800 342 4411 Motor Does Not Stop MP 53 MP 53 7 53 7 MP 53 1000 F Stop 0100 R Stop 0010 Run 0001 Jog J6 Pin 5 is shorted to common Remove wire at J3 Pin 1 J6 Pin 4 is Measure voltage with shorted to respect to J3 Pin 2 common Voltage 0 Wiring to Drive Motor Drive Calibration is correct is correct Problem Corrected Open J6 pin 4 and J6 pin 6 Open J6 Pin 5 Consult Tech Beben Support N 1 800 342 4411 orrecte Figure 4 1 Motor Does Not Stop Flowchart MP 53 53 1000 F Stop kpo R Stop Yes J6 Pin 7 is J6 Pin 6 is shorted shorted to common to common Yes Short J6 Pin 7 to common Short J6 Pin 6 to common Problem Corrected Consult Tech Support Figure Motor Does Not Run Enter Correct Yes Jog Setpoint Yes 4 2 No MP 53 MP 53 ooto Rur No Yes Yes C
127. tion Deceleration routine in hertz It is the setpoint input to the PID compensation routine This parameter may display numbers that are larger than 9999 These larger values are displayed with two decimal places For example 10 000 hertz is displayed as 10 00 MP 47 SPEED COMMAND OUTPUT The Speed Command Output MP 47 displays the level of calibrated full scale analog output to the motor drive J3 pin 1 Speed Command Output is displayed as a percentage 100 represents 100 of the calibrated full scale analog output MP 48 TRIM OUTPUT The Trim Output MP 48 is the calculated output of the PID Compensation routine The Trim Output added to the feedforward equals the Speed Command Output MP 47 The Trim Output MP 48 is represented in DAC Digital to Analog Converter bits for example 4096 equals 10096 output 2048 equals 5096 output MP 50 ACTIVE SCALING MODE Active Scaling Mode MP 50 displays a number 1 to indicate the active scaling mode In the example below Master Mode is the active scaling mode Code Direct Mode Master Mode Follower Mode Offset Mode Inverse MP 51 KEYPAD ERROR If a Control Parameter entry has been rejected Keypad Error MP 51 will ascertain the reason that it was rejected The digit that displays a number 1 is the error In the example below Above Maximum Allowed Value is the error Code Invalid Code Parameter Above Maximum Allowed Value Below Minimum Allowed Value Entr
128. to a value of 3 allocates the analog input to be used an offset CP 21 Follower Engineering Units The desired Follower Engineering Units when the lead and feedback are operating at their maximum speeds i e Max RPM Lead CP 33 and Max RPM Feedback CP 34 CP 34 Max RPM Feedback Enter the maximum operating RPMs measured at the feedback sensor shaft CP 31 PPR Feedback Enter the resolution of the feedback sensor Max RPM Lead Enter the maximum operating RPMs measured at the lead sensor shaft PPR Lead Enter the resolution of the lead sensor Offset Null Enter the analog level as a percent of the full scale analog level where no offset is desired This value can be found in CP 88 A D Input Adjusted with the dancer pot placed in the zero neutral position Offset Authority Enter into CP 76 the percent of full scale feedback that is desired when the analog input is at full range Offset Polarity Enter 1 if the offset is to be added to and 2 if itis to be subtracted from the scaled reference Offset Mode Analog Setpoint Example The following example demonstrates Offset mode scaling using analog setpoint The lead nip motor on a web has a maximum operating speed of 1800 RPM and is equipped with a 60 tooth ring kit sensor The follower motor on the same web matches the line web speed when it is rotating at 1800 RPM It also is equipped with a 60 tooth ring kit sensor The following setpoint is entered as the
129. tooth ring kit Set Master Setpoint 1 CP 01 so that the product is in the oven for 20 seconds Set Master Setpoint 2 CP 02 so that the product is in the oven for 15 seconds Table 3 33 shows the scaling Control Parameters that would be entered in the MLP Trim for this example Table 3 33 Inverse Master Mode Control Parameters Example CP Parameter Name Parameter Value After the Scaling and the Master Setpoints for your system have been entered you can enter the Acceleration Deceleration Control Parameters for the Inverse Master mode Acceleration Deceleration is discussed in Operation Control Parameters Acceleration Deceleration The following section demonstrates how to enter Control Parameters for the Inverse Follower mode of operation Inverse Follower Mode The Inverse Follower Mode is a variation of the Follower Mode The Inverse Follower Mode has an inverted setpoint If you increase the value of the setpoint CP 03 or CP 04 then the ratio of Follower speed to Lead speed will decrease With the Inverse Scaling CP 62 set to 2 enter values in the Follower Setpoints CP 03 and CP 04 that represent the E U at which you want the system to operate The higher the setpoint value the lower the Follower to Lead ratio speed The MLP Trim comes factory pre loaded with the default Control Parameters for the standard Follower Mode These default settings are not suitable for Inverse applications and require modification The
130. tput low when the Ramped Reference is not zero Enter 1 in CP 74 to deactivate the drive enable output when both the Ramped Reference and the feedback are zero and activate the drive enable output when the Ramped Reference is not zero 5 Parameters are divided into two classifications Control Parameters CP and Monitor Parameters MP The numbered code that represents the Parameter is the Parameter Code The operational data is the Parameter s value Control Parameter 05 50 Parameters Monitor Parameter 40 Parameter Code Parameter Value 200 arbitrary This section is about Monitor Parameters Control Parameters are explained in Operation Control Parameters The MLP Trim has a number of Monitor Parameters MPs that monitor the performance of the MLP Trim and your system troubleshoot for problems and confirm the wiring and tuning MPs can be accessed at any time during the MLP Trim s operation including during Run Jog R Stop and F Stop Note Monitor Parameters are status indicators only you can not directly affect a MP There are four categories of Monitor Parameters Input Monitoring Output Monitoring Performance Monitoring Status Monitoring In the subsections that follow the Monitor Parameters are listed according to these categories 64 Input Monitoring These MPs monitor the MLP Trim s inputs MP 41 LEAD FREQUENCY The Lead Frequency
131. ts Outputs Serial Communications Calibration Motor Drive Setup MLP Trim Calibration Analog Input Calibration CUTOUT ee 5 us From the rear of the door panel to the back of the connectors Figure 2 1 MLP Trim Cutout Dimensions and Mounting Guide MOUNTING This section contains instructions for mounting the MLP Trim in the door panel of a NEMA Industrial Electrical enclosure The MLP Trim is packaged in a compact 1 4 DIN Vertical Instrument Enclosure that mounts easily in the door of your Industrial Electrical Enclosure The Electrical Enclosure must have an IP54 rating or higher to comply with CE installations To mount the MLP Trim 1 The NEMA Industrial Electrical Enclosure that will house the MLP Trim must conform to the following environmental conditions Temperature 0 55 degrees C Internal NEMA enclosure temperature Humidity 0 95 RH non condensing Environment Pollution degree 2 macro environment Altitude To 3300 feet 1000 meters NOTE Allow adequate spacing between the MLP Trim and other equip ment to provide for proper heat convection Placing the MLP Trim too close to adjacent equipment could cause the interior ambient temperature to exceed 55 degrees C Spacing requirements depend on air flow and enclosure construction 2 The dimensions for the door panel cutout are 3 65 03 x 3 65 03 see Figure 2 1 Allow two inches of clearance on all sides of the cutout for mounting c
132. u to potential operating problems The alarm can be wired to activate a warning light a warning sound or to shut down the system under specified conditions Alarm Format CP 11 determines which alarm conditions will activate the Dig Out2 output using the values that are entered in Low Alarm CP 12 High Alarm CP 13 Ramped Error Alarm CP 14 and Scaled Error Alarm CP 15 0 No Alarm 8 Scaled Error 1 Low Alarm 9 Low Alarm or Scaled Error 2 High Alarm 10 High Alarm or Scaled Error 3 Low Alarm or High Alarm 11 Low Alarm or High Alarm or Scaled Error 4 Ramped Error 12 Ramped Error or Scaled Error 5 Low Alarm or Ramped Error 13 Low Alarm or Ramped Error or Scaled Error 6 High Alarm or Ramped Error 14 High Alarm Ramped Error or Scaled Error 7 Low Alarm or High Alarm 15 Low Alarm or High Alarm or Ramped Error or or Ramped Error Scaled Error 16 Drive Enable CP 12 LOW ALARM Low Alarm CP 12 is the RPMs at or below which you want the Alarm output to activate CP 13 HIGH ALARM High Alarm CP 13 is the RPMs at or above which you the want Alarm output to activate 14 RAMPED ERROR ALARM The Ramped Error Alarm CP 14 is the RPM deviation between the ramped reference and the feedback that will activate the Alarm output at or above CP 15 SCALED ERROR ALARM The Scaled Error Alarm CP 15 is the RPM deviation between the scaled reference and the feedback that will activate the Alarm output
133. uning procedure reduce the Trim Authority CP 69 and repeat the tuning procedure The MLP Trim comes factory pre loaded with default Control Parameters for Tuning These default settings are suitable for most applications and do not require modification The factory preset default tuning Control Parameters are found in Table 3 39 To modify these default parameters refer to Table 3 40 Table 3 39 Default Master or Follower Tuning Control Parameters CP Parameter Name Parameter Value CP 65 Gain Proportional 9000 CP 69 Trim Authority Table 3 40 Entering Master Follower Tuning Control Parameters CP Parameter Name Parameter Value With Integral 66 set to 0 reduce 22569 Gain Proportional the Gain CP 65 until the system becomes unstable then increase it slightly until the system stabilizes Reduced values will increase Gain To verify the stability of the speed changes you can access Tach through either the Tach key or the Monitor Parameter for Tach MP 40 CP 66 Integral While switching between the high and low setpoints decrease the Integral s default value of 2000 until the speed error is reduced within an acceptable time frame To verify the stability of the speed changes you can access Tach through either the tach key or the Monitor Parameter for Tach MP 40 CP 67 Derivative The Derivative should not be adjusted in most systems However sometimes in the larger inertia systems
134. utput to the motor drive J3 pin 1 Speed Command Output is displayed as a percentage 100 represents 100 of the calibrated full scale analog output MP 48 TRIM OUTPUT The Trim Output MP 48 is the calculated output of the PID Compensation routine The Trim Output MP 48 added to the Feedforward equals the Speed Command Output MP 47 The Trim Output is represented in DAC Digital to Analog Converter bits where 4096 equals 100 output 2048 equals 50 output etc Status Monitoring These MPs monitor the status of the MLP Trim s modes of operation and operating states MP 50 ACTIVE SCALING MODE The digit that displays a number 1 is the Active Scaling Mode MP 50 In the example below Master Mode is the active Scaling mode Code Direct Mode Master Mode Follower Mode Offset Mode Inverse MP 51 KEYPAD ERROR If a Control Parameter entry has been rejected Keypad Errors MP 51 will ascertain the reason that it was rejected The digit that displays a number 1 is the error In the example below Above Maximum Allowed Value is the error Code Invalid Code Parameter Above Maximum Allowed Value Below Minimum Allowed Value Entry Timeout or Keypad Lockout 52 ALARM STATUS The digit that displays a number 1 is the active Alarm In the example below High Speed Alarm is the active alarm Code Low Speed Alarm High Speed Alarm Ramped Error Scaled Error MP 53 CONTROL STATE The dig
135. utputs The number 1 indicates an inactive or de energized logic high level The number 0 indicates an active or energized logic low level In the example below Dig Out2 is the inactive or de energized logic high level Code Dig Out1 J6 Pin 15 Dig Out2 J6 Pin 16 Not Used Performance Monitoring Performance Monitor Parameters monitor the performance of the MLP Trim and your system Figure 3 2 is a block diagram of the internal control structure of the MLP Trim and the Performance Monitor Parameters Active Feedforward Scaling MP 50 RENE Scaled o Reference Deviation Lead 44 Frequency Master Speed Command MP 41 R 4 Out MP 47 gt Follower Reference 46 Feedback Frequency MP 43 Feedback Tach Scaling MP 40 Figure 3 2 MLP Trim Internal Structure 40 TACH Tach MP 40 is the feedback displayed in scaled Engineering Units or RPM In the Master mode Tach MP 40 will display the feedback in Master Engineering Units CP 20 In the Follower mode Tach MP 40 will display either the E U s Time or the feedback to Lead ratio in Follower Engineering Units CP 21 depending on the value in Display Mode Follower CP 64 In Jog or the Direct mode Tach MP 40 will display the feedback in RPMs The feedback is read by the MLP Trim every ten milliseconds The readings are summed then averaged for one second before the Tach is displayed
136. wer E U that you want by the Lead E U that the Lead is operating at and enter that value Examples of the Follower mode of operation are demonstrated on the following pages Follower Mode Examples A and B Example A demonstrates how scaling and setpoint Control Parameters are entered for a typical Follower mode of operation that uses a ratio setpoint The Lead pump delivers 10 gallons minute when the motor is running at a maximum RPM of 1725 The Lead sensor shaft is equipped with a 60 tooth Ring kit The Follower pump delivers 30 gallons minute when the motor is running at a maximum RPM of 1800 The Follower sensor shaft is equipped with a 30 tooth Ring kit Follower Setpoint 1 will be set so that when the Lead pump delivers 5 gallons minute the Follower pump will deliver 15 gallons minute Follower Setpoint 2 will be set so that when the Lead pump delivers 5 gallons minute the Follower pump will deliver 22 5 gallons minute Table 3 17 shows the Control Parameters that would be entered in the MLP Trim for Example A To find the ratio for the Follower Engineering Units CP 21 for Example A Follower E U at Max Follower RPM 30 Follower E U CP 21 z 3 Lead E U at Max Lead RPM 10 30 gal min The Follower Engineering Units when the Follower is operating atthe maximum RPM Divided by 10 gal min The Lead Engineering Units when the Lead is operating at maximum RPM Equals e e Follower Engineering U
137. y Timeout or Keypad Lockout MP 52 ALARM STATUS Alarm Status MP 52 displays a number 1 to indicate the active alarm In the example below High Speed Alarm is the active alarm Code Low Speed Alarm High Speed Alarm Ramped Error Scaled Error MP 53 CONTROL STATE Control State MP 53 displays a number 1 to indicate the active control state of the MLP Trim In the example below Run is the active control state Code MP 54 LOGIC INPUTS GROUP A The Logic Inputs Group A MP 54 displays the status of the Run Jog R Stop and F Stop logic inputs The number 1 indicates an open or logic high level The number 0 indicates a closed or logic low level shorted to common In the example below is the open or logic high level Code Run J6 Pin 4 Jog J6 Pin 5 R Stop J6 Pin 6 F Stop J6 Pin 7 MP 55 LOGIC INPUTS GROUP B The Logic Inputs Group B MP 55 displays the status of the Master Follower Setpoint Select and Scroll logic inputs The number 1 indicates an open or logic high level The number 0 indicates a closed or logic low level shorted to common In the example below Setpoint Select is the open or logic high level Code Master or Follower Dn Pin 9 Setpoint Select J6 Pin 10 Scroll Up J6 Pin 11 Scroll Down J6 Pin 12 56 5 The Logic Outputs MP 56 displays the status of the Dig Out1 and Dig Ou
138. you can improve performance by lowering the Derivative term to the point of instability and then increasing it incrementally until the system stabilizes CP 69 Trim Authority Trim Authority determines how much influence the PID term has on the control output If stability cannot be obtained through the standard tuning procedure reduce CP 69 until stable tuning is achieved Setting CP 69 to zero will make the MLP Trim operate in open loop feedforward only 49 Zero Error Loop The MLP Trim has the ability to eliminate any long term speed error in the follower mode This is equivalent to maintaining a follower position relative to the lead This is accomplished by keeping track of all the scaled lead and follower sensor pulses and then adjusting the setpoint to the speed control loop to eliminate any error The following control parameters are used by the MLP Trim for zero error control Lag Pulse Limit CP 18 The Lag Pulse Limit sets a maximum pulse error for the lagging fol lower is behind in position feedback pulses that are maintained in the zero error loop It may not always be desirable to recover all of the position error lag Lead Pulse Limit CP 19 The Lead Pulse Limit sets a maximum pulse error for the leading follower is ahead in position feedback pulses that are maintained in the zero error loop It may not always be desirable to recover all of the position error lead Recovery Multiplier CP 29 The

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