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MS332 Operation Manual - Electro

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2. seb gt p CONTROLLED OUTPUT i 9 T umadico NN LL Lt SELECT SWITCH FEEDBACK ENCODER SIGNAL 11171 Control Theory Open loop analog output formula The Jog mode analog output voltage obeys the following formula Vout V 90 DAC V 0 DAC Jog set point RPM Var01 00 V 0 DAC Jog set point The Jog mode set point should always be entered in feedback encoder RPM units Desc Oper Mode Sect page 5 bA02 XX 101801 MS332 Physical Installation Section Standard Panel Mount Installation The MS332 comes standard with 2 mounting brackets for through hole panel mounting Panel Cutout Dimensions Panel Cutout Thru Hole Dimensions in inches Note Maximum panel thickness 0 5 in 1 27 cm Installation Remove the 2 Standard Mounting Brackets from MS332 Slide MS332 rear terminals first into the control panel cut out Replace the Standard Mounting Brackets and tighten screws do not overtighten CONTROL PANEL CABINET DOOR ETC B INSERTING STANDARD MOUNTING BRACKETS x REAR TERMINALS LEFT SIDE VIEW FRONT PANEL OF SENSE i OF MS332 MS332 REMOVING STANDARD VI Vi Vi E MOUNTING BRACKETS E VI tt ALLOW A MINIMUM 1 5 INCHES CLEARANCE ON ALL SIDES Phys Install Sect page 1 bA02 XX 031301 Optional Side Mount Bracket Installation The optional Side Mount Bracket provides alternatives to standard panel mounting s
3. g A m X a A m m jaa m md um gn 4 UE A UU a oou uy A a Switch 9 9 9g m m m x 9 yy m m m x x wite gd 9 A A A 8 3 9 A A A 2 8 Purpose Se 2d d amp amp amp lt lt Se d Jd amp amp F amp F lt lt Ip l l l l l l l l l l l l l l A A a a Switch o o Position Z Z Oo O v v Switch Number 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 pull ups pUll dOWnsS Ref Sect page 33 bA02 XX 101701 Encoder Index Inputs Dip Switches cont Encoder Index and Aux input DIP Switches Each used input must have its pull up and pull down DIP switches configured for the type of device driving it Each unused input must also be properly configured Configure each Encoder Index and Aux input DIP switch according to the following table Driving Device Pull up DIP Pull down Notes Switch DIP Switch NPN ON OFF Input provides pull up to 12C PNP OFF ON Input provides pull down to Ground C TTL CMOS Gate OFF OFF Hi Z input Daisy chained Lead OFF OFF Hi Z input doesn t load signal or provide encoder any type pull up or pull down None unused input OFF ON Pulls unused input to Ground C Encoder Index Aux input circuitry MS33 12 Vdc internal Pull down Pull up 12 1 Reset able FUSE From Encoder Index or Aux device Ground C Special notes on DIP Switches
4. The set point to feedback RPM relationship is given by the equation FbRPM Set point Var01 00 Var01 01 Var01 00 Process Max Feedback Encoder RPM sets the maximum feedback encoder RPM for the process This is the maximum steady state feedback encoder RPM at which the process runs not accounting for overspeed needed to close the loop at maximum set point It is the expected nominal feedback encoder RPM for Master Mode when the set point is maximum Var01 01 Process Max Feedback Encoder RPM in User Units configures the user units of feedback encoder RPM for Master Mode set points speed set point scroll steps feedback encoder velocity display and npn output speed threshold parameters Set Var01 01 to Var01 00 s value converted to user units To use RPM user units set Var01 01 equal to Var01 00 During operation the set point may be set to any value from 0 to Var01 01 Desc Oper Mode Sect page 1 bA02 XX 101801 Ratio Follower Mode Description Input Hardware Ratio Follower mode uses quadrature output incremental encoders on both the lead and follower shafts Operation Ratio Follower mode controls follower motor speed causing the feedback encoder to precisely follow the lead encoder according to the speed ratio set point The set point sets the proportionality between the lead and follower shaft speeds When using a bidirectional drive and motor the feedback encoder follows the lead encoder in either dire
5. 1024 Var07 14 pieces and adding the pieces one per loop update into the PID s phase difference error PID loop is updated 1024 times per second Externally determined phase difference errors arise by two mechanisms 1 Index Follower mode index phase measurement 2 Master and Ratio Follower mode Advance Retard Scroll mechanism Variable 07 14 Phase Change Release Time Enter the time over which the phase difference error is introduced into the PID The allowed range for Var07 14 values is 0 01 gt 100 0 in seconds Note The Phase Change Release Time is not the same as Var03 01 Integral Time Constant Var07 14 Phase Change Release Time sets the time over which an externally determined phase difference error is smoothly introduced into the PID Var03 01 Integral Time Constant determines the PID s phase difference error correction rate Note In this context phase changes refers to changes apart from the corrections made in the normal course of maintaining correct speed and phase Similarly externally determined phase difference error refers to mechanisms of determining error apart from the normal cumulative mechanism based on encoder quadrature phases The closed loop PID performs its normal phase error measurements and corrections 1024 times per second Ref Sect page 38 bA02 XX 101701 Operational Variables cont Active Set point Selection The Master Ratio Follower and Index Follower modes each h
6. Reverse Note Each function code except code 0 can be assigned to only one Switch Input at a time If you attempt to assign a function code that is already assigned to another Switch Input the front panel ERR led lights up and your code is not accepted To proceed with the change the desired function code must first be un assigned from the other Switch Input Note The statuses of the Switch Inputs 0 through 7 can be displayed on the Display Window See Reference Section Display Display Window Variable for details Ref Sect page 30 bA02 XX 101701 Scrolling Scroll Vars 07 07 to 07 10 Set point Scroll Advance Retard Scroll Scrolling allows the user to continuously increment or decrement certain quantities in real time without entering the Change Variable Change Set point Menus Scrolled quantities take immediate effect when the MS332 is running Run Stop switch closed Fast Stop switch open if assigned the Analog Output responds as the quantity changes When Scroll is accessed the display window changes from displaying real time information as selected by Var05 00 to the scrollable quantity s value This quantity then begins to periodically increase or decrease by the appropriate mode determined scroll step For the first 2 seconds of scroll the quantity is stepped once per 250 msec After the first 2 seconds the quantity is stepped once per 20 msec The quantity continues to scroll for as long as
7. optional Analog Output 1 e 7 i 7 12 Vdc C Encoder Index Pwr pois ries ito baie Switch Input 4 10 Vdc Ref 8 8 e Feedback Chan A Ground C 10 Vdc Ref gnd e 9 Feedback Chan B xir ce ee eo eyes Switch Input 5 Feedback Index Menor ee Switch Input 6 Aux Input 0 optional Ground C aa ana Aa EPE oie Switch Input 7 Aux Input 1 optional yr ere KOSER E A NPN Out Protect Cathode DDD DD DODD HDD HDHD ODGHO e e TX NPN Output 0 9 TX d d NPN Output 1 L3 Earth Ground e pas NPN Output 2 L2 Neutral e xa 2 2 i d NPN Output 3 L1 Line e Ground B 222 22z2zzz2z 2 Ground C Bottom Edge of MS332 Appendix Section page 9 bA02 XX 032601
8. 1 2 3 Write a nonzero Jog Mode speed setpoint value into Var06 12 address 46120 The value is not important as long as it is no larger than the Process Maximum Feedback Encoder RPM of Var01 00 address 41000 The Feedback Encoder should turn View the Average Feedback PPI address 31110 This is the average of the last 32 measured Feedback PPI values The displayed Average Feedback PPI will initially change as more measured Feedback PPI values are included in the running average if the measured values are not equal to Var01 07 Wait for at least 33 Feedback Index pulses to occur This ensures the Feedback PPI averaging buffer contains only measured Feedback PPI values At this point the displayed Feedback PPI value should have settled down to a stable value Write the displayed Average Feedback PPI value address 31110 into Var01 07 address 41070 Un configure Jog Mode restore previous PPI measurement averaging 1 2 3 Open the MS332 Run Switch Un assign the Jog Switch Input function from the Switch Input by writing 0 to the corresponding Switch Input function assignment variable Example If you previously wrote 1 Jog to Var07 03 address 47030 assigning Jog to Switch Input 4 write 0 to it now to un assign Jog from it Restore the previous PPI measurement averaging setting by writing the previous value into Var01 09 address 41090 Ref Sect page 59 bA02 XX 101701 Serial Communications cont
9. Flashes when selecting the Password Definition variable Keypad Security Menu Flashes when selecting the Password Input variable Keypad Security Menu Flashes when selecting the temporary Percent of DAC variable in the Analog Output Calibration utility Diagnostic Menu Flashes when selecting the Encoder Pulses per Index Learn utility i e Pulses per Index Learn Diagnostic Menu Pr is displayed along with the selected variable s mnemonic and the right most digit flashes Change Variable Menu 1 Flashes when processing i e resetting the variables in the Factory Default Reset utility Diagnostic Menu 2 Flashes when processing i e learning teaching a Pulses per Index value in the Encoder Pulses per Index Learn utility Diagnostic Menu Flashes when testing the Right arrow key in the Keypad diagnostic Diagnostic Menu Flashes when selecting the SCALE variable in the Analog Output Calibration utility Diagnostic Menu Flashes when selecting the Security Definition variable Keypad Security Menu Flashes when selecting the Switch Inputs diagnostic Diagnostic Menu SP is displayed along with the selected set point s mnemonic and the right most digit flashes Change Set point Menu Flashes when testing the SETPT Set point key in the Keypad diagnostic Diagnostic Menu Appendix Section page 2 bA02 XX 032601 Mnemonics Glossary Display Window messages cont SUrE n SUrE
10. LdRPM Set point Var01 00 Var01 03 Var01 04 Var01 03 Process Max Lead Encoder RPM must be set to the maximum expected lead encoder RPM of the lead process Var01 00 Process Max Feedback Encoder RPM sets the maximum feedback encoder RPM for the follower process This is the maximum steady state follower process feedback encoder RPM not accounting for overspeed to close the loop at maximum set point It is the expected nominal feedback encoder RPM when the lead encoder is running at process maximum RPM Var01 03 and the Ratio Follower set point is maximum Var01 04 Process Max Feedback Encoder RPM Process Max Lead Encoder RPM in User Units configures the user units of the feedback lead encoder RPM ratio for Ratio Follower set points feedback lead encoder velocity ratio display and npn output velocity ratio threshold parameters Set Var01 04 to Var01 00 Var01 03 converted to user units To use unitless RPM ratio user units set Var01 04 equal to Var01 00 Var01 03 During operation the Ratio Follower set point may be set to any value from 0 to Var01 04 Desc Oper Mode Sect page 2 bA02 XX 101801 Index Follower Mode Description Input Hardware Index Follower mode uses lead and follower quadrature output incremental encoders and lead and follower index pulse devices An Index pulse signal is usually triggered by an event such as an object passing by a proximity sensor Operation Index follower m
11. Pc Dac is 000 0 b Use the Analog Output Calibration Utility to set the Scale to turn the feedback encoder at Var01 00 Process Maximum Feedback Encoder RPM while Pc Dac is 090 0 See Reference Section Keypad Keypad Menus Diagnostic Menu Analog Output Calibration Utility for details on calibration Operational Variables a Var03 00 PID Tuning Proportional Gain Enter the default value of 32 for an initial value Adjustments will be made later in step 9 b Var03 01 PID Tuning Integral Time Constant Enter the default value of 2 0s for an initial value Adjustments will be made later in step 9 c Var03 02 PID Tuning Derivative Gain Enter the default value of 0 to disable derivative compensation d Var03 04 Zero Lead Speed PID Control Enter the code to select desired zero lead speed PID operation The factory default is code 0 See Reference Section Operational Variables PID Compensation for details on PID Vars e Var07 00 Switch Input 1 Function Assignment Variable Enter code 8 to assign the Closed loop Open loop Switch Input Function to Switch Input 1 f Var07 12 Open loop Configuration Enter 2 to configure the Closed loop Open loop Switch Input Function to open only the index loop Note The Closed loop Open loop Switch Input Function is used here to temporarily disable index correction during set up PID adjustments and troubleshooting This switch input assignment and configuration along with the closed s
12. SETPT DIAG L ENTER w ij gt RUN SE TACH PROG STOP SPD ERR Keypad MS332 MOTION CONTROLLER The VAR key is used to access the Change Variable Menu Press the VAR key to enter the Change Variable Menu Press again to exit the Change Variable Menu The SETPT key is used to access the Change Set point Menu Press the SETPT key to enter the Change Set point Menu Press again to exit the Change Set point Menu The DIAG key is used to access the Diagnostic Menu Press the DIAG key to enter the Diagnostic Menu Press again to exit the Diagnostic Menu Note Holding this key pressed while AC power is applied to the MS332 resets all variables to their factory default values much the same as the Factory Default Reset Utility see Diagnostic Menu The Decimal Point key is used to access the Keypad Security Menu Press the key to enter the Keypad Security Menu Press again to exit the Keypad Security Menu This key is also used to change a variable or set point s decimal point position while in the Change Variable or Change Set point Menus The ENTER key is used to access save a selected security program variable set point or diagnostic utility while in the Keypad Security Change Variable Change Set point or Diagnostic Menus The RIGHT and LEFT ARROW keys select which digit to edit on the display while in the Change Variable Change Set point and Keypad Security Menus Th
13. Tach pros BUN SET o LED s Display Window All of the status led s are lit except for the ERR led o e o e O S 21 od ce 29 1 Display Window shows the mnemonic SUrE n or SUrE y with the right most digit flashing The initial display mnemonic upon entering level two is SUrE n Valid Keys Press the following keys to confirm SETPT Press L amp J or v to toggle between SUrE n or SUrE y Press while SUrE_y is displayed to proceed to level three and reset Note Pressing while SUrE n is displayed results in no action other than lighting the ERR led VAR ENTER E gigg BG OR Press to exit the Diagnostic Menu and return to level zero Invalid Keys Pressing vs er lt or Ce results in no action other than lighting the ERR error led Ref Sect page 18 bA02 XX 101701 Keypad Menus Diagnostic Menu cont Factory Default Reset Utility cont Level Three EXECUTE RESET This level resets all the variables to their factory defaults Pressing in level two while SUrE_y is displayed advances the menu to level three and commences reset Two mnemonics are displayed in level three First the mnemonic PrOCES is displayed flashing while the variables are resetting Note PrOCES is displayed for only a very brief time since reset only takes a second or so Then the mnemonic dOnE is displayed indicating the variables have been
14. Variable 01 02 Feedback Encoder PPR Enter the feedback encoder s Pulses Per Revolution value Ref Sect page 34 bA02 XX 101701 Encoder Index Inputs Encoder Variables cont Variable 01 03 Process Maximum Lead Encoder RPM Ratio Follower and Index Follower modes Enter the maximum expected lead encoder RPM for the process This value may be known or it may have to be converted from lead process units into lead RPM Variable 01 04 Process Max Feedback Encoder RPM Process Max Lead Encoder RPM in User Units See Reference Section Operational Variables Set points and Set point Units for details on Var01 04 Variable 01 05 Lead Encoder PPR Ratio Follower and Index Follower modes Enter the lead encoder s Pulses Per Revolution value Variable 01 06 Follower Mode Configuration Ratio Follower and Index Follower modes The user must select the Follower mode Ratio or Index needed for their application Select from the table Var01 06 CODE Selected Follower mode Ratio Follower mode Index Follower mode Variable 01 07 Feedback PPI Index Follower mode Enter the number of Feedback Encoder Pulses per Feedback Index Pulse Variable 01 08 Lead PPI Index Follower mode Enter the number of Lead Encoder Pulses per Lead Index Pulse Variable 01 12 No Feedback Response Configuration Master Ratio Follower and Index Follower modes Variable 01 12 configures the MS332 s r
15. index phasing and effective index pulses Ref Sect page 41 bA02 XX 101701 Operational Variables cont Acceleration and Deceleration Ramps Under certain circumstances the MS332 uses linear volts verses time ramp functions to transition the analog output to a new voltage This linear voltage transition produces a corresponding motor speed transition It is important to understand what is and isn t meant by ramps in this manual Ramps in the context of this manual are linear volts verses time functions executed by the MS332 apart from the normal closed loop speed speed ratio and phase control mechanisms For example a follower mode scenario where the lead encoder speed transitions from one speed to another while the MS332 follows is not a ramp in the sense of the MS332 s ramp mechanisms and variables Here the MS332 follows the lead never suspending its normal following mechanism Similarly a scenario invoking a motor drive s independent speed control ramping functionality is also not a ramp in the sense of the MS332 s ramp mechanisms and variables because speed control is taken away from the drive s analog input and therefore away from the MS332 Ramp time variables Var02 00 Var02 04 Time values are entered into the ramp variables Var02 00 Var02 04 These ramp variables work together with Var01 00 Process Max Feedback Encoder RPM to determine the ramp rates RPMs per second The acceleration and deceleration ra
16. with the lead running Observe the follower behavior at the top of the acceleration ramp and while it runs steady state If the feedback follower encoder response is unstable large erratic displayed error motor jerking oscillating try reducing Var03 00 s value proportional gain If the feedback follower encoder response is sluggish large slow changing displayed error try increasing Var03 00 s value If the Var03 00 changes don t significantly improve the feedback follower encoder response or if they get to a point of diminishing return try adjusting Var03 01 integral time constant Higher Var03 01 values will improve loop stability lower Var03 01 values will increase loop responsiveness Generally speaking it is desirable to have Var03 00 as large as possible and Var03 01 as small as possible this will result in the tightest most responsive following However if Var03 00 is set too high and or Var03 01 is set too low the follower loop will become unstable Open the Run Stop switch Repeat c several times Notes Higher Proportional Gain Var03 00 values make proportional compensation more aggressive up to a certain max value then causing loop instability above that value Lower Integral Time Constant Var03 01 values make integral compensation more aggressive down to a certain min value then causing loop instability below that value With the PID properly adjusted the displayed following error shoul
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18. 1 The DIP switches should be changed only while the MS332 is powered down 2 Pull up pull down DIP switch pairs should never be configured both ON while the MS332 is powered up If any pull up pull down switch pair is configured both ON while the MS332 is powered up the internal protective device reset able fuse may trip disconnecting all pull up switches from the internal 12Vdc supply If this happens the protective device may be reset by powering down the MS332 for a few seconds Encoder Variables Variable 01 00 Process Maximum Feedback Encoder RPM For Master mode Enter the feedback encoder RPM corresponding to Var01 01 Process Max Feedback Encoder RPM in User Units For Ratio Follower mode Enter the feedback encoder RPM corresponding to Var01 03 Process Maximum Lead Encoder RPM and Var01 04 Process Max Feedback Encoder RPM Process Max Lead Encoder RPM in User Units This is the expected feedback encoder RPM when the lead encoder is running at the process max and the set point is max For Index Follower mode Enter the feedback encoder RPM corresponding to Var01 03 Process Maximum Lead Encoder RPM This can be calculated from the formula Var01 00 value Var01 03 Var01 07 Var01 02 Var01 05 Var01 08 Var01 10 Var01 11 Variable 01 01 Process Max Feedback Encoder RPM in User Units See Reference Section Operational Variables Set points and Set point Units for details on Var01 01
19. 1 Phase setpt 2 Phase setpt 2 Phase setpt 3 Note Vars 06 13 06 14 and 06 15 are overridden have no effect when the Active Set point Select Switch Input Function s are assigned to Switch Inputs See Reference Section Switch Inputs for details on this method Ref Sect page 39 bA02 XX 101701 Operational Variables cont Set points and Set point Units The MS332 has four Master mode speed set points four Ratio Follower mode speed ratio set points four Index Follower mode phase set points and one Jog mode speed set point Set points Set points are stored in Variables 06 00 through 06 12 a k a Pr 06 00 to Pr06 12 The set point description and their Change Variable Menu Change Set point Menu level one mnemonics are given for each in the following table Set point Change Variable Menu Change Set point Menu Description mnemonic level one mnemonic ear EN one Master mode speed setpt 0 Pr 06 00 SsPO0 00 Master mode speed setpt 1 Pr 06 01 SP 01 Master mode speed setpt 2 Pr 06 02 SP 02 Ratio Follower mode speed ratio setpt 3 Pr 06 07 SP 07 Index Follower mode phase setpt 0 Pr 06 08 SP 08 Index Follower mode phase setpt 1 Pr 06 09 SP 09 Index Follower mode phase setpt 2 Pr 06 10 SP 10 Index Follower mode phase setpt 3 Pr 06 11 SP 11 Jog mode speed setpt Pr 06 12 SP 12 Note All set points can be set and changed by using either the Change Variable or the Change Set point Menus Also the activ
20. 3 8 5 33 S 6 8 8 d S 0 5X 2 8 3 d 2 s 32 m ud 5 amp amp 2 2 3 mu d 5 amp amp g E BH Mou MB e EB OE D M Od4 M x c Switch 8 8 B B B8 S amp 38888885 g Purpose poe TN E xad a Sus l E E zm es Switch e o Position zZ Z O o V V 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 v A 4 E Ss pull ups 4 4o pull downs 72 7 s 1 4 N I P d hy 1 Pd L4 N Rear Terminal Strip J end of MS332 Front Panel end of MS332 i c Apply power to the MS332 Set up Sect page 7 bA02 XX 022301 4 5 Encoder PPRs Max RPMs and Max set point value a Var01 05 Lead Encoder PPR Enter the lead encoder s pulses per revolution value into Var01 05 b Var01 03 Process Maximum Lead Encoder RPM Enter the maximum expected lead encoder RPM for the process into Var01 03 This value may be known or it may have to be converted from lead process units into lead RPM See example at end of this Ratio Follower mode set up section c Var01 04 Process Max Feedback Encoder RPM Process Max Lead Encoder RPM in User Units The output feedback follower RPM to input lead RPM relationship is given by the equation FbRPM LdRPM Set point Var01 00 Var01 03 Var01 04 This shows FbRPM LdRPM to be the Feedback Lead ratio of process max encoder RPMs Var01 00 Var01 03 scaled by the factor Set point Var
21. 4 bA02 XX 031301 Wiring cont Wiring guidelines 1 2 3 4 5 6 7 8 9 Use shielded cable for signals Connect the shield to signal common at the receiving end only See the wiring diagram on the previous page Use separate cables for separate sensors Don t run signals from multiple sensors sources through a shared multi conductor cable Each sensor source should run its signal s through a dedicated cable See the wiring diagram on the previous page Never use signal cable with unused conductors Unused conductors can induce noise onto the signal conductors Always use a shielded cable with the correct number of conductors Physically separate signal cables from power cables Do not bundle signal and power cables together or route them through the same conduit or wire trays Power wiring includes any AC or DC with current greater than 1 amp or voltage greater than 24 volts such as 115 VAC 230 VAC 460 VAC armatures fields and ignition wires Do not run signal cables near high magnetic or electrostatic generators This includes motors fans power switching devices contactors and ignitors Aluminum shielded cable does not stop magnetic noise and braided shielded cable only partially reduces magnetic noise Neither can stop all noise or eliminate the need for good signal routing Do not run signal cables encoders prox sensors analog sensor or control signals etc along a motor case or in the s
22. Addendum Accessing User Vars and Display Values function codes data types and addressing MS332 Modbus Master compatibility Significant flexibility is built into the MS332 Serial Communications for compatibility with virtually all Modbus RTU Masters One example is the MS332 s ability to communicate using various 16 bit and 32 bit data types Although the Modbus standard is oriented towards 16 bit registers and does not explicitly support any data type widely used Modbus adaptations exist for supporting 32 bit types The following explains in detail how the MS332 utilizes these adaptations for supporting both 16 bit and 32 bit data types Background 1 Although the MS332 User Variables and Display Values are stored internally using 32 bit floating point format many in most cases all of them can be represented in 16 bit integer format because a In most cases these values don t have a fractional part nonzero value to the right of the decimal point b In most cases these values fall within the range 32768 gt 32767 the range of 16 bit integers 2 To provide both data type flexibility and compatibility with various Modbus Masters the data type for accessing User Vars and Display Values using Serial Communications is selectable The available data types are 32 bit float 32 bit long int 16 bit int and 16 bit unsigned int 3 Modbus data is addressed in 16 bit increments not by the more common 8 bit byte increments For
23. Feedback encoder PPR 1 gt 4096 01 03 41030 Max process RPM Lead 1 00000 gt 99999 01 04 41040 Var01 00 Var01 03 in user units 0 0001 gt 99999 01 05 41050 Lead encoder PPR 1 gt 4096 01 06 41060 Follower mode configuration 0 Ratio 1 Index 01 07 41070 Feedback encoder PPI 0 gt 99999 01 08 41080 Lead encoder PPI 0 gt 99999 01 09 41090 PPI measure average control O off 1 32 ave last 1 32 01 10 41100 Feedback index pulse match 1 gt 21474 01 11 41110 Lead index pulse match 1 221474 02 00 42000 Accel ramp 0 0 1 gt 3600 0 s 02 01 42010 Accel ramp 1 0 1 gt 3600 0 s 02 02 42020 Decel ramp 0 0 1 gt 3600 0 s 02 03 42030 Decel ramp 1 0 1 gt 3600 0 s 02 04 42040 Fast stop decel ramp 0 1 gt 3600 0 s 02 05 42050 Active ramp pair select 0 1 03 00 43000 Proportional gain 1 gt 1024 03 01 43010 Integral time constant 0 0 off gt 100 0 s 03 02 43020 Derivative gain 1 gt 1024 03 03 43030 Derivative sample period sec 0 001 gt 1 000 03 04 43040 Zero lead speed PID control 0 gt 4 04 00 44000 NPN output 0 function assign 0 gt 17 04 01 44010 NPN output 1 function assign 0 217 04 02 44020 NPN output 2 function assign 0 217 04 03 44030 NPN output 3 function assign 0 217 04 04 44040 NPN output 0 function param 00000 gt 99999 04 05 44050 NPN output 1 function param 00000 gt 99999 04 06 44060 NPN output 2 function param 00000 gt 99999 04 07 44070 NPN output 3 function param 00000 gt 99999 04 08 44080 NPN output hysteresis 0 gt 10
24. If the default Var07 14 value causes index phase correction to take too long try decreasing Var07 14 to less than 1 0s If excessive overshoot undershoot is observed or if the follower appears to be hunting to get into phase try increasing the value of Var07 14 When properly adjusted the displayed error should shrink towards zero with minimal over under shoot and then stay zero or small and centered around zero f Open the Run Stop switch the follower will ramp down to a stop g Repeat e and f several times until acceptable performance is achieved Notes Index phase correction does not occur during follower ramps Index pulses occurring during the follower ramp are ignored Index phase correction first occurs after the follower motor has ramped up to speed at the first feedback index pulse after the first lead index pulse 11 Setting the Active Index Follower Phase Set point Index follower mode set points are entered in units of feedback follower encoder pulses This sets the relative phase of the effective feedback follower index pulses to the effective lead index pulses A positive set point causes the effective feedback index pulses to occur before the effective lead index pulses A zero set point causes the effective feedback index pulses to occur concurrently with the effective lead index pulses A negative set point causes the effective feedback index pulses to occur after the effective lead index pulses Dep
25. NPN Outputs Device Compatibility cont Driving logic inputs NPN Output Protection Diode Ground C NPN Outputs Functions The NPN Output Functions operate as described in the following table NPN Output External Device DC Logic Level Supply Ref to Ground C NPN Function Turns ON the NPN Output when Turns OFF the NPN Output when Function Input the function input is the function input is High Alarm Feedback speed gt Threshold 1 Hysteresis 100 lt Threshold 1 Hysteresis 100 or speed ratio Low Alarm Feedback speed lt Threshold 1 Hysteresis 100 gt Threshold 1 Hysteresis 100 or speed ratio Deviation Feedback speed gt Setpoint SetpointDev lt Setpoint SetpointDev Alarm or 1 Hysteresis 100 1 Hysteresis 100 speed ratio or and lt Setpoint SetpointDev gt Setpoint SetpointDev 1 Hysteresis 100 1 Hysteresis 100 Zero Speed Feedback speed lt Fraction Var01 00 gt Fraction Var01 00 1 Hysteresis 100 1 Hysteresis 100 Contactor Reverse Switch Jog or Master modes Jog or Master modes Reverse and or Reverse Switch closed Reverse Switch open or not Lead Encoder Ratio or Index Follower modes assigned direction Lead running forward and Reverse Ratio or Index Follower modes See Note 2 below Switch closed Lead r
26. Scroll is accessed or until it reaches its limit When Scroll is de accessed the display window reverts back to real time information as selected by Var05 00 Scroll Variables Variable 07 07 Master Speed Scroll Step Enter the desired scroll step for scrolling the active Master mode speed set point Var07 07 values must be entered in the same units as Var01 01 Variable 07 08 Ratio Follower Speed Ratio Scroll Step Enter the desired scroll step for scrolling the active Ratio Follower mode ratio set point Var07 08 values must be entered in the same units as Var01 04 Variable 07 09 Phase Scroll Step Enter the desired scroll step for scrolling either the current phase offset or the active Index Follower mode phase set point Var07 09 values must be entered in units of feedback encoder pulses Variable 07 10 Jog Speed Scroll Step Enter the desired scroll step for scrolling the Jog mode speed set point Var07 10 values must be entered in units of RPM Set point Scroll Set point Scroll up down changes only the active set point i e the selected set point from the current operating mode Master mode Speed Ratio Follower mode Ratio Index Follower mode Phase or Jog mode Speed There are two ways to access Set point Scroll up or Scroll down 1 From the Keypad by pressing the UP or DOWN arrow keys if not security locked when at Keypad Level Zero 2 From a remote switch by remotely closing a Switch Inp
27. Sect page 11 bA02 XX 101701 Keypad Menus Diagnostic Menu cont NPN Outputs Test Diagnostic Level Two Select NPN Output group Use this level to select which group of NPN Outputs to test This is on the second level of the Diagnostic Menu level one above RUN SET TACH PROG STOP SPD ERR eeeoo Note Enter level two by selecting nPnou in the display window while at level one of the Diagnostic Menu See LED s Display Window All of the status led s are lit except for the ERR led Display Window initially shows the group of NPN Outputs tested last with all the digits flashing Ex Showing ou 3210 for NPN outputs 3 2 1 and 0 Valid Keys To select which group of outputs to test Press A or to select ou 3210 etc Note The standard MS332 has only the one group Press to confirm and enter level three of the NPN Outputs diagnostic OR Press to exit the Diagnostic Menu and return to level zero Invalid Ke S Pressing ira Ey Ca J or Ce results in no action other than lighting the ERR error led Level Three Test NPN Output statuses Use this level to test and display the status of each NPN Output in the selected group This is used to temporarily only for the duration of this diagnostic control the state of each NPN Output for the purpose of testing This is on the third level of the Diagnostic Menu RUN SET TACH PROG STOP SPD ERR ee e
28. See Reference Section Analog Output for more information on Drive Compatibility Set up Sect page 8 bA02 XX 022301 6 7 8 Encoder Test To avoid wasted set up time it is important to verify that both the Feedback and Lead encoder channel A and B quadrature lines are not improperly ordered reversed a Feedback Encoder A B channel test Enter 2 into Var05 00 display Feedback encoder frequency in Hz With the MS332 Run Stop switch OPEN Stop rotate the Feedback Encoder shaft in the forward direction relative to the process while observing the MS332 display The display should show a positive value If the display shows a negative value swap the Feedback Encoder channel A and B wires at TB4 8 and TB4 9 b Lead Encoder A B channel test Enter 3 into Var05 00 display Lead encoder frequency in Hz With the MS332 Run Stop switch OPEN Stop rotate the Lead Encoder shaft in the forward direction relative to the process while observing the MS332 display The display should show a positive value If the display shows a negative value swap the Lead Encoder channel A and B wires at TB4 3 and TB4 4 Analog Output Calibration a Use the Analog Output Calibration Utility to set the Offset for no feedback encoder rotation 0 RPM while Pc Dac is 000 0 b Use the Analog Output Calibration Utility to set the Scale to turn the feedback encoder at Var01 00 Process Maximum Feedback Encoder RPM whil
29. Set up Section WPN Outputs for details on how to set up NPN Outputs Set up Sect page 14 bA02 XX 022301 6 7 8 See Reference Section WPN Outputs for more information on the Contactor Reverse Function See Reference Section Analog Output for more information on Drive Compatibility Encoder Test To avoid wasted set up time it is important to verify that both the Feedback and Lead encoder channel A and B quadrature lines are not improperly ordered reversed a Feedback Encoder A B channel test Enter 2 into Var05 00 display Feedback encoder frequency in Hz With the MS332 Run Stop switch OPEN Stop rotate the Feedback Encoder shaft in the forward direction relative to the process while observing the MS332 display The display should show a positive value If the display shows a negative value swap the Feedback Encoder channel A and B wires at TB4 8 and TB4 9 b Lead Encoder A B channel test Enter 3 into Var05 00 display Lead encoder frequency in Hz With the MS332 Run Stop switch OPEN Stop rotate the Lead Encoder shaft in the forward direction relative to the process while observing the MS332 display The display should show a positive value If the display shows a negative value swap the Lead Encoder channel A and B wires at TB4 3 and TB4 4 Analog Output Calibration a Usethe Analog Output Calibration Utility to set the Offset for no feedback encoder rotation 0 RPM while
30. Variable Menu Press key to enter level one of the Change Set point Menu x O See the Change Set point Menu Press key to enter level one of the Diagnostic Menu C vw See the Diagnostic Menu Note The Run Stop switch must be open and the DAC must be at zero before the Diagnostic Menu can be accessed If the DAC is ramping to zero then the Diagnostic Menu cannot be entered until the DAC reaches zero Pressing while the Run Stop switch is closed or even while the Run Stop switch is open and the DAC is still not Zero results in no action other than lighting the ERR error led Press Le key to enter level one of the Keypad Security Menu See the Keypad Security Menu Press LA and arrows to increase decrease the mode determined active set point See Reference Section Scrolling for details on the Set point Scroll feature Press gt and arrows to Advance Retard the feedback encoder See Reference Section Scrolling for details on the Advance Retard Scroll feature Invalid Keys Note Any invalid keys are shaded in the keypad diagram to the left Pressing the key results in no action other than lighting the ERR error led Note Here at Keypad Level Zero the active set point may be changed by Scrolling with the 4 and v keys and the feedback encoder may be Advance Retard Scrolled using the J and EJ keys These changes take effect immediately and without pressing t
31. Vrms Ground C referenced circuit 11 5 to 11 5 Vdc max swing From Keypad stored in non volatile memory 2 Vdc to 2 Vdc programmable 0 DAC 0 to 11 5 Vdc programmable full scale DAC 00 150 uS to 1 DAC bit 0 1uF load 12 bit plus sign 8192 steps 2500 Vrms Ground A referenced circuit Yes 300 Vdc 0 5 Vdc max 625 mW max 2500 Vrms Ground C referenced circuit 12 Vdc 300mA max unregulated Polyfuse type cycle power to reset 2500 Vrms Ground C referenced circuit 12 kQ min 0 2V max 7 Vde to 12 Vdc 1 5 Vdc differential minimum 54Q load 3 Vdc max 2500 Vrms Ground B referenced circuit Specification Section page 2 bA02 XX 101801 Electrical cont Isolation Configuration 4 circuits 2500 Vrms isolation each Ground A referenced Analog Output Ground B referenced RS485 Com Port Ground C referenced Encoder Index Aux and Switch Inputs En coder supply and NPN Outputs Digital Gnd referenced Internal digital circuitry Environmental Temperature 0 70 C Humidity 0 9096 Non Condensing Mechanical Terminal Plug screw torque 2 2 b in 0 25 N m Enclosure material ABS Plastic 94V 0 Keypad Polycarbonate tactile switch pad chemical resistant splash proof Weight 2 2 Lb 1 0 Kg Dimensions Top View of MS332 Front View of MS332 340 i Specification Section page 3 bA02 XX 101801 MS332 Appendix Section Front
32. XX 022301 3 MS332 DIP Switch settings bA02 XX Note Do not apply power to the MS332 until the DIP Switches have been set DIP Switch Diagram for Ratio Follower Mode This diagram shows the MS332 DIP switches looking down on top of the MS332 front panel on the left Do steps a and b to set all of the MS332 DIP Switches a DIP switches corresponding to unused inputs Indexes Aux 0 Aux 1 are shown in this diagram in their default ON OFF positions Set these DIP switches to their default positions b DIP switches corresponding to inputs used by Ratio Follower mode are shown in this diagram with an asterisk Each used input must have its Pull up and Pull down DIP switches configured for the type of device driving it Configure each input s DIP switches according to the following table Driving Device Pull up DIP Pull down Notes Switch DIP Switch NPN ON OFF Input provides pull up to 12C PNP OFF ON Input provides pull down to Ground C TTL CMOS Gate OFF OFF Hi Z input Daisy chained Lead OFF OFF Hi Z input doesn t load signal or provide encoder any type pull up or pull down See Reference Section Encoder Index Inputs Power Supply Outputs DIP Switches for details on the DIP switches s g 2 2 e B Pe 558 5 5 S oS oo ii 22 22 223 a R 4 m a a R E x mx amp lt m amp S sd 35 lt m 9 d sd a 7 OU d sS S F 0 UO d g g c oS 3 umm B 55 EZ 323 8 5 F 35
33. amuru Jad AA 766666 0000 I NdYA Jepooug xp eqpeeJ XEN ss9 014d 00710 on eA njea ased JnoX 3 nejoq res Joy Sjuaululo Ku Jr Sjyrun asuery uondrosoq IBA uum oo an BA MO X IY ui SINJBA Jno P1099 piooo5 ogee WPISOIg JOS TE SIN SIEA A31noog pedo SZUNI S q 3IAS qq uoneaqie dymo So eu y sre A ureJS04q ISN Sp I0293 I9S 032601 bA02 XX Appendix Section page 5 1d3os oseud c Z 1dios oseud z T Idjas eseud q joejes juTod jag oAnoy 0 Le 0 ides aseyd 0 0 IPON Io o oA Xopu S190 1djos ones poods Z d s ones poods z T 3djes onea poods jos eg yulod jag DANDY 0 Le 0 Idhas ones peeds 0 0 IPON Je o 04 OD A vT 90 1d3os paods Z dias p ds z T Idjas poods joej eg qurod jag oAnoy 0 LE 0 1djes peeds Q 0 IPON INSEW 1 90 CLI 8 anuru Jod AA 66666 00000 1dios poods Sof zr90 0 8 sos nd Japoous qq Ul 66666 66666 1dios oseud 1o o o4 xopur 11 90 0 8 sos nd Japoous qq Ul 66666 66666 Z Idias oseud 10 o o4 xopur 0190 0 8 sos nd Japoous qq Ul 66666 66666 I idjas oseud 1o o o4 xopu 60 90 0 8 sos nd Japooue qq Ul 66666 66666 0 dios oseud 1o o o4 xopur 80 90 000 T 8 Syrum po OJE A UI 66666 00000 c 1dios ont poods 1o oqo4 oney L0 90 000 T 8 Syrum
34. consists of measuring the average encoder pulses per index pulse values for both Feedback and Lead and writing these values into Var01 07 and Var01 08 respectively To execute this procedure the MS332 must first be wired for optional Jog Mode operation Connect an unused MS332 Switch Input to Ground C either through a closed switch or a wire This Switch Input will enable Jog Mode selection Example Connect TB3 pin 7 Switch Input 4 to TB3 pin 8 Ground C Modbus addresses accessed This procedure requires accessing certain MS332 Display Values and User Variables over Serial Communications The Modbus address type of access read write and description of each is listed below Address Access Description 31100 Read Average Lead PPI Display option 10 31110 Read Average Feedback PPI Display option 11 41000 Read Process max feedback encoder RPM Var01 00 41010 Write Process max feedback encoder RPM in User Units Var01 01 41070 Write Feedback PPI Var01 07 41080 Write Lead PPI Var01 08 41090 Write PPI Measurement and Averaging Control Var01 09 46120 Write Jog Mode speed set point Var06 12 470X0 Write Switch input function assignment X 0 6 depending on input Configure Jog Mode PPI measurement averaging 1 Open the MS332 Run switch 2 Set the feedback speed user units to RPM by setting Var01 01 address 41010 equal to Var01 00 address 41000 your Process Maximum Feedback Encoder RPM 3 Assign the Jog func
35. diagram in their default ON OFF positions Set these DIP switches to their default positions b DIP switches corresponding to inputs used by Master mode are shown in this diagram with an asterisk Each used input must have its Pull up and Pull down DIP switches configured for the type of device driving it Configure each input s DIP switches according to the following table Driving Device Pull up DIP Pull down Notes Switch DIP Switch NPN ON OFF Input provides pull up to 12C PNP OFF ON Input provides pull down to Ground C TTL CMOS Gate OFF OFF Hi Z input Daisy chained Lead OFF OFF Hi Z input doesn t load signal or provide encoder any type pull up or pull down See Reference Section Encoder Index Inputs Power Supply Outputs DIP Switches for details on the DIP switches Switch Purpose Lead Encoder ChA pull up Lead Encoder ChB pull up Lead Index pull up FDBK Encoder ChA pull up FDBK Encoder ChB pull up FDBK Index pull up Aux 0 pull up Aux pull up Lead Encoder ChA pull down Lead Encoder ChB pull down Lead Index pull down FDBK Encoder ChA pull down FDBK Encoder ChB pull down FDBK Index pull down Aux 0 pull down Aux 1 pull down OFF gt OFF gt Switch Position lt ON Rear Terminal Strip Front Panel end of MS332 end of MS332 c Apply power to the MS332 Set up Sect page 2 b
36. digit flashing Ex Showing SP 02 for master mode speed setpt 2 Valid Keys To select desired set point Press 4 or Cv to change the flashing selected digit Press EJ or to select which digit to change When the desired set point is displayed press to confirm and enter level two of the Change Set point Menu OR Press to exit from Change Set point Menu and return to level zero Invalid Ke s Pressing 3 Or Ce results in no action other than lighting the ERR error led Level Two Change set point value Use this level to change the value of the selected set point This is the second level of the Change Set point Menu RUN SET TACH PROG STOP SPD ERR Oooeo LED s Display Window SET SPD led remains lit Display Window shows the selected set point s value with the right most digit flashing Ex Showing 100 0 for a master mode speed setpt value of 100 0 feet min Valid Keys To change set point value Press or to change the flashing selected digit Press 3 or to select which digit to change Press to change the decimal point position When the desired new value is displayed press to save the new set point value and to return to level one OR Press to exit from Change Set point Menu and return to level zero without saving any changes Invalid Ke s Pressing or results in no action other than lighting the ERR error led Ref Sec
37. displayed press to confirm and enter level two of that particular diagnostic utility Note Levels two and three if applicable are specific to the particular diagnostic utility selected in level one This means for example that level two in the Switch Input Diagnostic is completely separated from level two in the NPN Outputs Diagnostic Jumping from level two in one diagnostic utility to level two in another diagnostic utility is not possible OR Press to exit the Diagnostic Menu and return to level zero Invalid Keys Pressing vs Er Co J or Ce results in no action other than lighting the ERR error led Ref Sect page 10 bA02 XX 101701 Keypad Menus Diagnostic Menu cont Switch Inputs Observation Diagnostic Level Two Select Switch Input group Use this level to select which group of Switch Inputs to observe This is on the second level of the Diagnostic Menu level one above RUN S TACH PROG STOP SPD ERR eeeoo SETPT ENTER Dog giajn BE Note Enter level two by selecting SInPu in the display window while at level one of the Diagnostic Menu See LED s Display Window All of the status led s are lit except for the ERR led Display Window initially shows the group of Switch Inputs observed last with all the digits flashing Ex Showing In 7654 for switch inputs 7 6 5 and 4 Valid Keys To select which group of inputs to observe Press A or
38. example address 41000 holding register 1000 and address 41001 holding register 1001 access separate 16 bit data with no overlap 4 The Modbus address of each MS332 User Var 4XXX0 or Display Value 3XXXO refers to a One 16 bit half for 32 bit data types b Theentire value for 16 bit data types The next higher address from each User Var 4XXX1 or Display Value 3X XX1 refers to c The other 16 bit half for 32 bit data types d Nothing Illegal Data Address for 16 bit data types Note Var08 04 selects the data type 32 bit long int or float 16 bit int or unsigned int and the ordering of 16 bit halves of 32 bit data types Accessing User Vars and Display Values Function codes 03 04 and 16 multiple contiguous access Since the Modbus addresses for MS332 User Vars and Display Values are non contiguous they are separated by increments of 10 not 1 function codes 03 and 16 cannot access multiple User Vars and function code 04 cannot access multiple Display Values However function codes 03 04 and 16 are supported for accessing single User Vars and Display Values when using 32 bit data types a Access 2 adjacent registers together starting at 4X XX0 or 3XXXO both 16 bit halves accessed together in one query response transaction User Vars One 16 bit half at 4AXX XO other 16 bit half at 4AXXX1 1 query response cycle Display Values One 16 bit half at 3X XXO other 16 bit half at 3XXX1 1 query response cycle Re
39. feedback encoder RPM in user units Var01 01 46120 Write Jog Mode speed set point Var06 12 470X0 Write Switch input function assignment X 0 6 depending on input 49000 Write Analog Output offset calibration Var09 00 49010 Write Analog Output scale calibration Var09 01 Configure Jog Mode 1 Open the MS332 Run switch 2 Set the feedback speed user units to RPM by setting Var01 01 address 41010 equal to Var01 00 address 41000 your Process Maximum Feedback Encoder RPM 3 Assign the Jog function to a Switch Input as mentioned above by writing 1 Jog to the corresponding Switch Input function assignment variable Example To use Switch Input 4 write 1 to Var07 03 address 47030 4 Setthe Jog Speed set point to zero Write zero 0 into Var06 12 address 46120 5 Close the MS332 Run Switch Offset adjustment 1 Slowly increase the Aout Offset by incrementing the Var09 00 address 49000 value until the motor creeps forward if not already doing so 2 Next slowly decrease the Aout Offset by decrementing the value in Var09 00 address 49000 by increments of until it stops This sets the Analog Output base voltage 0 Dac just below the voltage at which the motor creeps forward Scale adjustment 1 Setthe Jog Speed set point equal to your Process Maximum Feedback Encoder RPM by setting Var06 12 address 46120 equal to Var01 00 address 41000 The motor should turn 2 Monitor Display Value 0 address 31000 T
40. for more information on Drive Compatibility Encoder Test To avoid wasted set up time it is important to verify that the Feedback encoder channel A and B quadrature lines are not improperly ordered reversed a Feedback Encoder A B channel test Enter 2 into Var05 00 display Feedback encoder frequency in Hz With the MS332 Run Stop switch OPEN Stop rotate the Feedback Encoder shaft in the forward direction relative to the process while observing the MS332 display The display should show a positive value If the display shows a negative value swap the Feedback Encoder channel A and B wires at TB4 8 and TB4 9 Set up Sect page 3 bA02 XX 022301 7 8 Analog Output Calibration a b See Use the Analog Output Calibration Utility to set the Offset for no feedback encoder rotation 0 RPM while Pc Dac is 000 0 Use the Analog Output Calibration Utility to set the Scale to turn the feedback encoder at Var01 00 Process Maximum Feedback Encoder RPM while Pe Dac is 090 0 Reference Section Keypad Keypad Menus Diagnostic Menu Analog Output Calibration Utility for details on calibration Operational Variables a b c See d e Var03 00 PID Tuning Proportional Gain Enter the default value of 32 for an initial value Adjustments can be made later in step 9 Var03 01 PID Tuning Integral Time Constant Enter the default value of 2 0s for an initial value Adjustments can be made l
41. m 8 B 28 Y mum 5 g amp R amp Bom amp EB om amp x x M oo x x M o Switch 922 388 8 8 9288 85848 Purpose d YAH amp m e lt lt d amp t amp amp lt lt l l l l l l m m zm es Switch e o Position zZ P Z O o V V l 1 2 3 4 5 6 7 8 4 m4 j pull downs 2 4 L 1 M bj I l 8 x A i i H i H v 4 1 i i i a T o n f i i i i i i i i i H i i gt n Rear Terminal Strip J end of MS332 Front Panel end of MS332 i c Apply power to the MS332 Set up Sect page 13 bA02 XX 022301 4 5 Encoder Index Averaging and Index Matching Variables a Var01 02 Feedback follower Encoder PPR Enter the feedback encoder s pulses per revolution b Var01 05 Lead Encoder PPR Enter the lead encoder s pulses per revolution c Var01 09 Pulses per Index Measurement and Averaging Control Enter 0 d Var01 07 Feedback PPI Enter the number of feedback encoder pulses per feedback index pulse e Var01 08 Lead PPI Enter the number of lead encoder pulses per lead index pulse Note If either or both the Var01 07 or 01 08 values are unknown use the Encoder Pulses Per Index Learn utility to determine and enter the variable values See Reference Section Keypad Keypad Menus Diagnostics Menu Encoder Pulses Per Index Learn Utility for details f Var0
42. mode speed setpt 1 Change Set point Menu key on MS332 keypad Encoder with one channel used to detect only speed MS332 uses quadrature encoders Term sometimes used in place of the term follower as in slave encoder meaning the same as follower encoder A status LED Lights up to indicate when the MS332 is showing real time information selected by the Var05 00 code Terminal strip TB1 on back of MS332 analog inputs and outputs Terminal strip TB2 on back of MS332 AC line power input Terminal strip TB3 on back of MS332 switch inputs npn outputs Terminal strip TB4 on back of MS332 pulse output sensor inputs sensor power serial communications microfarad as in 0 1 uF capacitance Analog voltage signal capable of positive and zero voltage relative to its base or offset voltage microsecond as in 150 usec for Analog Output Settling Time MS332 user variables setup parameters Appendix Section page 4 bA02 XX 032601 0 r Sopo uonoe egS 10j UONII IIUAIJOY 99S v lt 0 JonUOD qid peeds peo 0197 0 0 100 r 9es 000 1 1000 porod ajdureg oAneAueq did 0 0 0 r SATIBALIOP SO QESID Q 001 lt 0 ured MPAA CId c0 0 oT cv U139jut so qesrp 0 0 998 0 001 lt 0 0 juejsuo aur e1390 Id 10 0 TE cv vool lt T ure puon1odoad Cid 00 0 eg dures so qeuo T Iv 0 1req dures so qeuo
43. of the Index Phase Error is less than the Threshold window the index pulses are said to be in sync as seen according to this formula Index Phase Error lt Threshold window See Reference Section Display Display Window Variable Variable 05 00 Codes 6 and 7 for details on the Index Phase Error and Index Phase Ref Sect page 47 bA02 XX 101701 NPN Outputs Function Variables Function Assignment Variables 04 00 gt 04 03 Each NPN Output has a Function Assignment Variable for entering the desired function code The code determines the 1 Function 2 Operating mode in which the function will be active 3 Input to the function Function Parameter Variables 04 04 gt 04 07 Each NPN Output has a Function Parameter Variable for entering a Threshold Setpoint Deviation or Fraction for threshold type functions or an option code OpCode for selecting function options The Variables 04 00 gt 04 07 correspond to the NPN Outputs as shown in this table NPN Output Function Assignment Variable Function Parameter Variable 0 Var04 00 Var04 04 1 Var04 01 Var04 05 2 Var04 02 Var04 06 3 Var04 03 Var04 07 To assign a certain NPN function to a certain NPN Output First find the desired function active operating mode and function input from the table below Enter the corresponding function code into the NPN Output s Function Assignment Variable Enter a desire
44. panel ERR led The front panel ERR status led is a general alarm alerting the user to errors and potential fault conditions The following lists the conditions under which the ERR status led is lit Invalid Keypress Invalid keypresses are those not supported at a given Keypad menu and level An invalid keypress results in no action other than lighting the front panel ERR led See Reference Section Keypad Keypad Level Zero and Keypad Menus for details on when keys are valid invalid for each menu and level Example When in keypad level one of the Change Set point Menu pressing the VAR key is invalid and results in no action other than lighting the ERR led Invalid Variable Values Each user program variable has a permitted range of values Any attempt to enter a value outside a user program variable s permitted range is rejected resulting in no action other than lighting the front panel ERR led See Appendix Section User Records User Program Vars for details on ranges of variable values Example Var05 00 Display Selection has a range of 0 to 15 If the user attempts to enter 16 the value is rejected and the ERR led lights up Previously assigned Switch Input or NPN Output Function Codes Each Switch Input function is exclusive and may be assigned to only one Switch Input at a time Attempts to assign a Switch Input function code to a second Switch Input are rejected and result in no action other than lighting the ERR led Ea
45. por OJE A Ut 66666 00000 c dios ones poods Jomojjoj oney 90 90 000 T 8 sun po OJE A Ut 66666 00000 I idjas ones poods 1o ojo4 onew 090 0001 8 Syrum pot OJE A Ut 66666 00000 0 ides ones poeds 19 o o4 oneq T0790 0001 8 sun Q7 OJE A UI 66666 00000 dios poods 1ojse 090 0001 8 Syun Q7 OE A UI 66666 00000 Z Mas poods Jase 70 90 0001 8 Syun Q7 OJE A UI 66666 00000 T idias poeds 1ojsejq 10 90 0001 8 Syun Q7 OJE A UI 66666 00000 0 1djos poods Jase 00 90 pojueuro durun our aepdy amp ejdsiq TOSO 0 v Sopop Kejdstiq 10 uonoog oouoigjoy 90S ST lt 0 uonoapas Aeydsiq 00 S0 T LY 001 0 stsarasKH MAMO NdN 80 70 0 9y 66666 lt 00000 Jojourered uonouny MAMO NdN LO vYO 0 9y 66666 lt 00000 Jojourered uonouny z MAMO NdN 90 70 0 9v 66666 00000 1ojoureaed uonouny MAMO NdN S00 0 9y 66666 00000 Jojourered uonouny 0 MAMO NdN TO YO 0 9p Sopo uonoungj 10j uonooeg eouaiojos 99S LI 0 usisse uonoung c 3jndino NdN 0 v0 0 9p sapod uonoung 10 uonooeg eouaiojos 99S LI 0 usisse uonoung z 3jdino NdN c0 v0 0 9p sapod uonoung 10 uonoeg eouaiojos 99S LI lt 0 usisse uoroung jndinQ NdN I0 v0 0 9p sapod uonoung 10 uonoeg eouaiojos 99S LI 0 usisse uoroung 0 jndino NdN 00 70 on eA njea osed mnog ynejag PPA Sjuaururo Aue Jr syrum asuey uondrbsoq IBA 032601 bA02 XX Appendix Section page 6
46. reset to their factory default values and the utility has finished executing Display mnemonic Interpretation PrOCES Reset executing writing factory default values to variables dOnE Reset done done writing factory default values to variables Tacu proc BUN SET ce LED s Display Window eo All of the status led s are lit except for the ERR led Display Window first flashes PrOCES then displays dOnE nr Valid Keys Note Any key pressed while ProCES is flashing will be ignored When dOnE is displayed these two keys are valid Press to return to level two OR Press to exit the Diagnostic Menu and return to level zero VAR SETPT ENTER Invalid Keys Pressing ver er 4 Cv 3 or Le results in no action other than lighting the ERR error led L EJHIC HOG Ref Sect page 19 bA02 XX 101701 Keypad Menus Diagnostic Menu cont Encoder Pulses Per Index Learn Utility Index Follower mode applications only This utility determines your system s encoder pulses per index pulse PPI values and writes them into Var01 07 Feedback PPI and Var01 08 Lead PPI When invoked the selected feedback or lead encoder is rotated while the PPI value is automatically measured then written into the appropriate PPI variable This utility is useful for setting up applications where these values are not initially known Notes To learn the Var01 08 Le
47. to approximately 10 higher than your process maximum speed This provides some over speed capability to the MS332 so it can close the loop at your process maximum follower speed Set the acceleration deceleration settings to the minimum time settings fastest These adjustments minimize limitations imposed on the control loop by the drive thereby allowing the MS332 more control Electrical connections Note Do not apply power to the MS332 yet Connect all necessary components for Ratio Follower Mode Operation See Description of Operating Modes Section Ratio Follower Mode for a block diagram showing basic necessary components For details about terminal connections and terminal strips see the following See Reference Section Hardware Illustrations for a general Rear View diagram showing the MS332 terminal strips and the individual pin outs See Reference Section Encoder Index Inputs Power Supply Outputs Terminal Connections for a further detailed diagram showing the Encoder connections See Reference Section Switch Inputs Terminal Connections for a further detailed diagram showing the connections available for the Run Stop switch See Reference Section Analog Output Terminal Connections for a further detailed diagram showing the Analog Output connections See Physical Installation Section Wiring for details on proper wiring shielding grounding etc Set up Sect page 6 bA02
48. value Press A or v to change the flashing selected digit Press EJ or J to select which digit to change gt Press Le to change the decimal point position LJ When the desired new value is displayed press to save the new v DIAG variable value and to return to level one OR Press to exit from Change Variable Menu and return to level zero without saving any changes Invalid aa Pressing or results in no action other than lighting the ERR error led Ref Sect page 8 bA02 XX 101701 Keypad Menus cont Change Set point Menu Follow these steps to access the Change Set point Menu Note The Change Set point Menu is used to change any set point However the active set point can also be Scrolled See both Reference Section Operational Variables Active Set point Selection and Reference Section Switch Inputs Functions for details on active set point selection See Reference Section Scrolling for details on the Scroll feature Level One Select set point Use this level to select which set point to change This is the first level of the Change Set point Menu Note Enter level one by pressing while at level zero See level zero above RUN SET TACH PROG STOP SPD ERR OOO Seo AR SETPT ENTER DIAG BAE Eb AME LED s Display Window SET SPD led lit Display Window initially shows the active set point with the right most
49. 0 05 00 45000 Display selection 0 gt 15 06 00 46000 Master mode speed setpoint 0 00000 gt 99999 06 01 46010 Master mode speed setpoint 1 00000 gt 99999 06 02 46020 Master mode speed setpoint 2 00000 gt 99999 06 03 46030 Master mode speed setpoint 3 00000 gt 99999 06 04 46040 Ratio fol mode ratio setpoint 0 00000 gt 99999 06 05 46050 Ratio fol mode ratio setpoint 1 00000 gt 99999 06 06 46060 Ratio fol mode ratio setpoint 2 00000 gt 99999 06 07 46070 Ratio fol mode ratio setpoint 3 00000 gt 99999 06 08 46080 Index fol mode phase setpoint O 99999 gt 99999 06 09 46090 Index fol mode phase setpoint 1 99999 gt 99999 06 10 46100 Index fol mode phase setpoint 2 99999 gt 99999 06 11 46110 Index fol mode phase setpoint 3 99999 gt 99999 06 12 46120 Jog mode speed setpoint 00000 gt 99999 06 13 46130 Master mode active setpoint 0 3 06 14 46140 Ratio fol mode active setpoint 03 06 15 46150 Index fol mode active setpoint 0 3 Ref Sect page 53 bA02 XX 101701 Serial Communications Modbus Implementation Address Mapping cont 2 User Var cont Modbus Holding Register 4X XXX mapping cont XX in address 31XXO is the selection code 0 gt 15 Each User Variable Holding Register address includes the Class Var code of that User Variable address 4XXXO accesses User Var 0X XX Supported Modbus Function Codes a
50. 01 04 Var01 04 configures the units in which speed ratio set points are entered and sets the max set point value To use unitless RPM ratio user units set Var01 04 equal to Var01 00 Var01 03 The set point value may range from 0 to Var01 04 Notes Var01 04 also determines the units of Ratio Follower set point scroll steps and NPN Output speed ratio alarm threshold parameters The decimal pt position entered into Var01 04 determines the decimal pt position for the Follower Ratio in User Units display option Var05 00 option code 1 Enter the Process Max Feedback Encoder RPM Process Max Lead Encoder RPM in User Units into Var01 04 d Var01 02 Feedback follower Encoder PPR Enter the feedback encoder s pulses per revolution value into Var01 02 e Var01 00 Process Maximum Feedback follower Encoder RPM Generally speaking this value must be calculated from known information The feedback encoder will turn at the Process Maximum Feedback Encoder RPM when the lead encoder is running at its Process Maximum Lead Encoder RPM Var01 03 s value and the ratio set point is set to its maximum Var01 04 s value Enter the process maximum feedback encoder RPM into Var01 00 Note See example at end of this Ratio Follower mode set up section f Var01 01 Process Max Feedback Encoder RPM in User Units For Ratio Follower applications enter the same value into Var01 01 that was entered into Var01 00 Set up for M
51. 1 10 Feedback Index Pulses per Match Enter the desired number of feedback index pulses per match g Var01 11 Lead Index Pulses per Match Enter the desired number of lead index pulses per match Note For 1 1 index matching enter 1 into Var01 10 1 into VarO1 11 For 3 2 index matching enter 3 into Var01 10 2 into Var01 11 etc See Description of Operating Modes Section Index Follower Mode Control Theory for information on Index Matching h Var01 03 Process Maximum Lead Encoder RPM Enter the maximum lead encoder RPM for your process Note If this value is unknown enter code 3 into Display Selection Var05 00 display lead encoder speed in Hz run the lead at the process maximum speed and record the lead frequency Use the following formula to calculate the Var01 03 process maximum lead RPM Var01 03 value measured max lead frequency in Hz 60 Var01 05 i Var01 00 Process Maximum Feedback follower Encoder RPM Note This is the feedback follower encoder RPM corresponding to the Process Maximum Lead Encoder RPM Var01 03 If unknown it can be calculated from the following formula Var01 00 value Var01 03 Var01 07 Var01 02 Var01 05 Var01 08 Var01 10 Var01 11 Enter this value into Var01 00 j Var01 01 Process Max Feedback Encoder RPM in User Units For Index Follower applications enter the same value into Var01 01 that was entered into Var01 00 Set up for Motor Drive Compatibility a N
52. 2 Fraction of Var01 00 ex 1 enter 0 01 Zero Speed Master amp Ratio Fol Feedback RPM 13 Fraction of Var01 00 ex 1 enter 0 01 Contactor Reverse Master Ratio Fol Reverse Switch and or 14 Uses no parameter Index Fol Jog Lead Encoder direction Drive Enable Master Run Stop Switch 15 Unitless OpCode select per NPN Output Ratio Follower and Dac turn OFF requirement Index Follower 1 OFF when Run Stop switch open Jog 2 OFF when Run Stop open and Dac 0 Index Sync Index Follower Index Phase Error 16 Threshold in Feedback Encoder Pulses Encoder Position Master Closed loop 17 Threshold in Feedback Encoder Pulses Error Alarm Ratio Follower Position Phase Error Index Follower Note Each function code except code 0 can be assigned to only one NPN Output at a time If you attempt to assign a function code that is already assigned to another NPN Output the front panel ERR led lights up and your code is not accepted To proceed with the change the desired function code must first be un assigned from the other NPN Output Ref Sect page 48 bA02 XX 101701 NPN Outputs Function Variables cont Variable 04 08 NPN Output Hysteresis Threshold type NPN Output functions have hysteresis to prevent the NPN Output from chattering ON OFF when the function input is at the threshold Hysteresis breaks a threshold into two thresholds for changing function state one for the function input going high and one for t
53. 2 XX Note Do not apply power to the MS332 until the DIP Switches have been set DIP Switch Diagram for Index Follower Mode This diagram shows the MS332 DIP switches looking down on top of the MS332 front panel on the left Do steps a and b to set all of the MS332 DIP Switches a DIP switches corresponding to unused inputs Aux 0 Aux 1 are shown in this diagram in their default ON OFF positions Set these DIP switches to their default positions b DIP switches corresponding to inputs used by Index Follower mode are shown in this diagram with an asterisk Each used input must have its Pull up and Pull down DIP switches configured for the type of device driving it Configure each input s DIP switches according to the following table Driving Device Pull up DIP Pull down Notes Switch DIP Switch NPN ON OFF Input provides pull up to 12C PNP OFF ON Input provides pull down to Ground C TTL CMOS Gate OFF OFF Hi Z input Daisy chained Lead OFF OFF Hi Z input doesn t load signal or provide encoder any type pull up or pull down See Reference Section Encoder Index Inputs Power Supply Outputs DIP Switches for details on the DIP switches s g 2 2 e B BF a4 5 5 S oS oo ii 22 22 223 a R 4 m a a R E x mx amp lt m amp d sS 94 lt m S d sS F a 7 OU d sS S F 0 UO d g g 2 2 2585 amp so 2 Boh mBSOROR 5 5 amp 23 559 5 5 272 43 8 5 8 8 8 Bg F S 8 8 8 8 pes e 8 9 m
54. 3 Select a switch input from Switch Inputs 1 gt 7 located on TB3 See Reference Section Hardware Illustrations Rear View for the MS332 pin out Wire your switch or compatible device between the selected Switch Input pin and Ground C on TB3 See Reference Section Switch Inputs Terminal Connections for a further detailed diagram showing the connection s available for the Switch Inputs See Reference Section Switch Inputs Device Compatibility for what devices can be connected to the Switch Inputs Enter the desired switch input Function Code into the selected switch input s Function Assignment Variable Var07 00 gt Var07 06 See Reference Section Switch Inputs Functions for a description of the Switch Input Functions See Reference Section Switch Inputs Function Assignment Variables for the table showing which Function Code corresponds to which Switch Input Function See Reference Section Switch Inputs Function Assignment Variables for the table showing which Function Assignment Variable Var07 00 through Var07 06 corresponds to which Switch Input NPN Outputs Set up Procedure For applications employing one or more MS332 NPN Output Functions do the following for each 1 2 3 4 Select an NPN Output from NPN Outputs 0 gt 3 located on TB3 See Reference Section Hardware Illustrations Rear View for the MS332 pin out Wire your device between the
55. 9 mdu yms S0 L0 0 gz Sopo uonounj 10g uonoog eouo1ojow 3S TI lt 0 usIsse uonoung mdu yms 0 L0 0 gz Sopo uonounj 10g uonoog eouo19Jow oos TI lt 0 usIsse uonoung p Mdu YIMS 0 L0 0 Sc Sopo uonounj 10g uonoog eouo1oJow 39S TI lt 0 usisse uonoung c mdu yomg c0 LO 0 gz S9po uonounj 10g uonoog eouo19jow 3S TI lt 0 usIsse uonoung c mdu yomg 10 L0 0 gz SapoD uonounj 10g uonoog oouo19Jow 3S TI lt 0 usisse uonoung mdu yomg 00 L0 njea onyea ased mog yned PEPA Sjuaululo Ku Jr sjrum asuey uondrposoq IBA 032601 bA02 XX Appendix Section page 7 User Records cont Analog Output Calibration Record Record your Calibrated Analog Output Voltage when the Pc dAC is 000 0 Vdc Record your Calibrated Analog Output Voltage when the Pc dAC is 090 0 Vdc DIP Switch Settings Record Record both your left bank and right bank DIP Switch Settings by writing ON or OFF in the switch locations in the diagram below S z E a a S E Z 3 3 T og d d 7 Y d 4 a 2 z z 3 g a TEIE lt m s a lt m S sS amp 7 x ESI 7 S Q z EI X D O O c c oO O md pe 3 oO O ad EI ES 2 n 8 S S A d amp 2 n B 9 9S A 5 9 98 a 3 BS x 5 S 9 9 A g BS x 9 d 3 9 sn 38 2 BBE 9 9 5s 3 9 3 2 89 BH 8 BH E E 2 9 85 8 23 3 amp e m m a a a amp g m m a A BD E d M M Mo ns m ee MM 4o Y To R ea ae ea x lt x g 3 7 ea ea ea x x Switch o D o a a a 3 3 o o D a a a 3 3 iue pu u S
56. A or v to select LdLrn FbLrn or FbSPd When the desired selection is displayed press to confirm and enter level three of the Encoder Pulse Per Index Learn utility Note Pressing while LdLrn or FbLrn is displayed automatically begins the PPI learn process in level three VAR ENTER La ib B1210 OR Press to exit the Diagnostic Menu and return to level zero Invalid Ke s Pressing os e Ca J or Ce results in no action other than lighting the ERR error led Ref Sect page 20 bA02 XX 101701 Keypad Menus Diagnostic Menu cont Encoder Pulses Per Index Learn Utility cont Level Three Learn PPI value or set temporary speed Use this level to execute the PPI learn operation selected in level two The feedback encoder RPM is displayed when the FbSPd operation is selected Two mnemonics are displayed when either the LdLrn or FbLrn operations are selected First PrOCES displays flashing while the MS332 measures the PPI Then dOnE displays indicating the Feedback PPI or Lead PPI value has been measured and stored in Var01 07 or Var01 08 respectively Display mnemonic value Interpretation PrOCES LdLrn or FbLrn selected LdLrn or FbLrn executing dOnE LdLrn or FbLrn selected LdLrn or FbLrn done Numeric value FbSPd selected Display shows the real time feedback encoder speed in RPM Tach peog RUN SET LED s Display Window 420 All of the status
57. A02 XX 022301 4 5 6 Encoder PPR Max set point value Max RPM a Var01 02 Feedback Encoder PPR Enter the feedback encoder s pulses per revolution value into Var01 02 b Var01 01 Process Max Feedback Encoder RPM in User Units Enter the maximum process output RPM in user units into Var01 01 This sets the units and maximum value for the Master Mode set point To use RPM units enter your process maximum feedback encoder rpm Note Var01 01 sets the units for speed set points speed scroll step certain NPN Output alarm thresholds as well as the decimal point position of the Feedback Encoder Speed In User Units display option Var05 00 option code 0 c Var01 00 Process Maximum Feedback Encoder RPM This variable must hold the encoder RPM corresponding to Var01 01 the maximum process output Enter this value into Var01 00 Note Var01 01 must be set to the maximum process output RPM in user units for the application Applications using RPM user units have Var01 00 set to the same value as Var01 01 the user units are RPM Applications using non RPM user units require entering Var01 01 s value converted to RPM units into Var01 00 This value will be numerically different from Var01 01 s value but will represent the same maximum process output See the Example in Setting up Var01 00 and Var01 01 for non RPM User Units at the end of this Master mode set up section Set up for Motor Drive Compatibility a Non Co
58. Electro Sensors Inc 952 930 0100 MGN gt 6111 Blue Circle Dr 800 328 6170 ELECTRO SENSORS Minnetonka MN 55343 9108 USA fax 952 930 0130 NY http www electro sensors com MS332 Motion Controller Users Manual bA02 XX RUN SET TACH PROG STOP SPD ERR MS332 MOTION CONTROLER p n 990 000201 rev F 091102 MS332 Introduction The MS332 is a powerful and versatile speed mode motor drive controller for building closed loop processes Capabilities include speed and phase control electronic line shaft and gearing event synchronization and bidirectional motion The MS332 receives a feedback quadrature pulse signal from an incremental shaft encoder while outputting an analog control voltage signal to a variable speed motor drive For follower operating modes the MS332 also receives a lead master quadrature pulse signal from a second incremental shaft encoder Depending on the follower mode the MS332 may also receive index event pulse signals from sensors at both a lead and the follower processes Powerful user variables and numerous user assignable switch input and transistor output functions are provided to tailor the MS332 to both the motor drive and application requirements The internal 32 bit processor and 1024 per second PID loop update rate make the controller precise and responsive How to use this manual This user s manual is organized to be used as follows 1 Description of Operating Modes Section complete descri
59. I I Er I I I I REMOVING STANDARD amp t MOUNTING BRACKETS ALLOW A MINIMUM 1 5 INCHES CLEARANCE ON ALL SIDES Phys Install Sect page 3 bA02 XX 031301 Wiring This diagram shows typical signal wiring shielding and connections MS332 TYPICAL ENCODER AND INDEX DEVICE WIRING LEAD ENCODER CABLE INDEX DEVICE MASTER gt CONTROLLED PROCESS FEEDBACK d ENCODER N Ole ale CABLE Quadrature 7 Encoder 12 Vdc C E p A HH Fdbk Ch B Fs LL redis ete INDEX FOLLOWER Fdbk index eee eae hore mmm md m CONTROLLED PROCESS FEEDBACK INDEX CABLE INDEX DEVICE HA q 4L BOS Oe Sade oe ee el v TYPICAL DRIVE WIRING mm Variable Speed Drive Speed Reference Input Output to Motor Switch Input drive enable etc Common TYPICAL NPN OUTPUT WIRING Current limit Resistor NPN Output HA A A DC Power Supply N 300 Volts or Less Ground C w U vA Ref to Ground C TYPICAL SWITCH INPUT WIRING Switch Input B der asic Switch Notes This diagram shows proper wiring of signals devices d c power commons and cable shields for all types of MS332 signal inputs and outputs No specific MS332 Operating Mode or external device configuration is intentionally suggested For a given application the actual devices utilized depend on both the selected MS332 Operating Mode and the specific needs of the application Phys Install Sect page
60. N 6 11006 Switch Input 6 0 OFF 1 ON 7 11007 Switch Input 7 0 OFF 1 ON Keypad Key 11024 Variable Menu Key 0 OFF 1 ON A 11025 Up Key 0 OFF 1 ON 11026 Setpoint Menu Key 0 OFF 1 ON La 11027 Left Key 0 OFF 1 ON ENTER 11028 Enter Key 0 OFF 1 ON gt J 11029 Right Key 0 OFF 1 ON Le 11030 Decimal Point Key 0 OFF 1 ON v 11031 Down Key 0 OFF 1 ON DIAG 11032 Diagnostics Menu Key 0 OFF 1 ON Display Values Modbus Input Register 3X XXX mapping Display Value Modbus Address Description 0 31000 Feedback speed in user units 1 31010 Fol speed ratio in user units 2 31020 Feedback pulse freq in Hz 3 31030 Lead pulse freq in Hz 4 31040 Current DAC value 2 31050 Feedback encoder position error 6 31060 Index phase error 7 31070 Index phase 8 31080 Lead index pulse freq in Hz 9 31090 Feedback index pulse freq in Hz 10 31100 Ave Lead encoder PPI 11 31110 Ave Feedback encoder PPI 15 31150 PID Integral term Ref Sect page 52 bA02 XX 101701 Serial Communications Modbus Implementation Address Mapping cont User Var Modbus Holding Register 4XXXX mapping User Var Modbus Address Description Range 01 00 41000 Max process RPM Feedback 1 00000 gt 99999 01 01 41010 Var01 00 in user units 0 0001 gt 99999 01 02 41020
61. Outputs Each of the four NPN Outputs may have one of seventeen different NPN Output Functions assigned to them by the user or they may be left with no functions assigned to them The NPN Output Functions are ON OFF type alarm indicator functions An alarm indicator function is true when the MS332 turns its assigned NPN Output ON driving the output voltage down near Ground C An alarm indicator function is false when the MS332 turns its NPN Output OFF MS332 NPN Output compatibility includes relay coils diodes DC lamps and logic inputs See Device Compatibility diagrams below Terminal Connections D NPN Output NPN NPN NPN NPN Ground Protection Cathode Output 0 Output 1 Output 2 Output 3 C TB3 Bottom Edge MS332 Rear View See Reference Section Hardware Illustrations Rear View for a complete diagram showing the details of terminal strip TB3 containing the NPN Outputs on the back of the MS332 package Device Compatibility Driving relays and other inductive loads MS332 NBN Output Protection DC Power Supply Diode Ic max 2 250 mA O 300 Volts or less 4 A Ref to Ground C NPN Output Current limit resistor Ground C Driving lamps LED s and other non inductive loads NPN Output Protection Diode DC Power Supply 300 Volts or less Ref to Ground C Ic max 250 mA Current limit resistor NPN Output Ground C Ref Sect page 46 bA02 XX 101701
62. Pulses per Match Note See Description of Operating Modes Section Index Follower Mode for a more complete description of the usage and effect of PPI measurement and averaging and of index matching Ref Sect page 35 bA02 XX 101701 Analog Output Terminal Connections Calibration Vars OFFSET SCALE Drive Compatibility The standard MS332 provides one Analog Output signal This is the analog speed reference voltage signal sent to the motor drive The Analog Output voltage swings positive or negative as needed Functionally the Analog Output behaves like a 12 bit plus sign DAC with adjustable offset and scale voltage The Analog Output voltage obeys the following relationship Analog Output voltage OFFSET volts SCALE volts DAC code 4095 OFFSET volts range 2 1Vdc to 2 1Vdc SCALE volts range 0 to 11Vdc DAC code range 4095 to 4095 Note The Analog Output voltage is limited to a maximum possible range of 11 0 to 11 0 Vdc Terminal Connections Analog Output Unused Unused Unused Unused Analog Ground Unused Unused Unused Output 1 A Bottom Edge MS332 Rear View See Reference Section Hardware Illustrations Rear View for a complete diagram showing the details of terminal strip TB1 containing the Analog Output on the back of the MS332 package Calibration Variables The OFFSET and SCALE volts are adjusted with the OFFSET and SCALE calibration variables The MS332 h
63. VAI SETPT ENTER DIAG BI Jb oija while at level zero See level zero above LED s Display Window PROG and SET SPD led s are lit Display Window shows the selected security variable with all the digits flashing Ex Showing PASIn for the Password code Input variable Valid Keys To select which security variable to access or CZ to select PASIn PASdEF or SECdEF When the desired variable is displayed press to confirm and enter level two of the Keypad Security Menu OR Press Ce to exit the Keypad Security Menu and return to level zero Invalid Keys Pressing ver ery Ca J or results in no action other than lighting the ERR error led Press Level Two Change security variable value Use this level to observe and or change the value of the selected security variable This is on the second level of the Keypad Security Menu RUN SET TACH PROG STOP SPD ERR oeoeo rrr 3234 HHH EI SETPT ENTER DIAG Jai gjan 8 v B LED s Display Window PROG and SET SPD led s remain lit Display Window shows the value of the selected security variable with the right most digit flashing Ex Showing 000332 for the factory default value of PASIn Exception When PASdEF is selected while keypad is locked the mnemonic HlddEn is displayed concealing PASdEF s value Valid Keys To change the value of the selected security var
64. _y UP VAr Displayed with the right most character flashing when first entering the Factory Default Reset utility Diagnostic Menu SUrE_n is the mnemonic for not sure Displayed with the right most character flashing when selecting to reset all the variables in the Factory Default Reset utility Diagnostic Menu SUrE_y is the mnemonic for yes sure Flashes when testing the Up arrow key in the Keypad diagnostic Diagnostic Menu Flashes when testing the VAR Variable key in the Keypad diagnostic Diagnostic Menu Acronyms abbreviations Accel Advance Algorithm Aux Bipolar Cathode ChA Chan A Chan ChB Chan B Closed loop Config DAC De accesses Decel DIAG DIP Switches Encoder pulses ENTER ERR Fast Stop Fb Fdbk FbPPI FbRPM Feedback FOL MOD Follower Ratio Follower Index Follower Funct Gnd T O Index pulses Ld Lead LdPPI LdRPM LED Acceleration as in acceleration ramps Increase add to the feedback encoder phase offset by a certain number of pulses using the Advance Retard feature A mathematical routine Auxiliary as in optional Aux 0 and Aux 1 inputs Analog voltage signal capable of positive and negative voltage relative to its base or offset voltage Cathode end of the NPN Output protection diode Quadrature encoder Channel A Encoder channel Quadrature encoder Channel B Method of control where process output measurements feedback are u
65. ad PPI value the lead encoder must first be turning Turning the lead motor and encoder is accomplished at the lead drive control apart from the MS332 To learn the Var01 07 Feedback PPI value the feedback follower encoder must first be turning This is accomplished with the FbSpd Feedback Speed selection from inside this utility explained below Level Two Select PPI learn operation Use this level to select one of three PPI learn operations The operations and their mnemonics are described below This is on the second level of the Diagnostic Menu PPI learn operations 1 LdLrn Lead Learn This operation measures the Lead PPI value and writes it into Var01 08 2 FbLrn Feedback Learn This operation measures the Feedback PPI value and writes it into Var01 07 3 FbSPd Feedback Speed This operation allows scrolling the DAC up or down setting the feedback encoder speed for FbLrn Note Enter level two by selecting PPlILrn in the display window while at level one of the Diagnostic Menu See Keypad Menus Diagnostics Menu Level One for a discussion of level one RUN SET LED s Display Window TACH PROG STOP SPD ERR play H E 00 All of the status led s are lit except for the ERR led Display Window initially shows the PPI Learn Operation last selected with all the digits flashing Ex Showing FbLrn for the Feedback Learn operation Valid Keys To select Index Learn Operation SETPT Press
66. alue into the active set point the allowed range is from 0 to Var01 04 Notes The active set point may be changed via the Change Set point Menu or by Scrolling The factory default configuration selects SP04 the first of the four Ratio Follower mode set points as the active set point and sets its default value to 1 000 See example at end of this Ratio Follower mode set up section See Reference Section Keypad Keypad Menus for details on the Change Set point Menu See Reference Section Scrolling for details on Scrolling Set up Sect page 9 bA02 XX 022301 h See Reference Section Operational Variables Active Set point Selection for details on using Var06 14 to select the active set point See Reference Section Switch Inputs for details on using Switch Inputs to select the active set point Acceleration Deceleration Ramp Times Vars02 00 to 02 03 Notes Ramp times set the ramp rate and are entered in units of seconds The time entered is the time to ramp from 0 to Var01 00 MAX RPM acceleration or from Var01 00 MAX RPM to 0 deceleration Var02 00 Var02 01 are acceleration time variables Var02 02 Var02 03 are deceleration time variables Var02 00 Var02 02 form a pair and Var02 01 Var02 03 form a pair The factory default active pair is Var02 00 Var02 02 Enter your desired acceleration and deceleration ramp times See Reference Section Operational Variables Accelera
67. ame conduit as motor power Properly connect the input power earth ground Use a proper earth ground Earth ground is used by internal noise rejection circuitry Use a series resistor capacitor type noise supressor across the coils of contactors solenoids and relays sharing AC power with or in the same enclosure panel as the controller These devices greatly reduce conducted noise on the power line They are available in two terminal packages When stepping power down from a higher AC voltage use a line filter at the transformer secondary Tighten the terminal plug screws to 2 2 Ib in 0 25 N m torque for all wired terminals Phys Install Sect page 5 bA02 XX 031301 MS332 Set up Section DA02 XX Master Mode Set up Procedure Description See Description of Operating Modes Section Master Mode for a block diagram and discussion of Master Mode Operation Set up Procedure 1 Motor Drive adjustment settings Adjust the drive settings to match the motor according to the drive instructions Set the maximum motor drive speed to approximately 10 higher than your process maximum speed This provides some over speed capability to the MS332 so it can close the loop at your process maximum speed Set the acceleration deceleration settings to the minimum time settings fastest These adjustments minimize limitations imposed on the control loop by the drive thereby allowing the MS332 more control 2 Electrical con
68. ar01 11 i e the Index Match Ratio MS332 Zero Lead Speed PID Operation The MS332 is factory configured to control follower position or phase under all lead speed conditions from a dead stop up to the maximum lead RPM When used with a bidirectional motor drive a factory default MS332 will maintain the follower at the correct stopped position even against attempts to manually move it in either direction lead encoder stopped However some follower applications have special requirements or restrictions for a stopped lead situation Some systems may require that the follower never correct its position when the lead is stopped Some may additionally require that the follower position error be cleared to zero and not measured accumulated until the lead starts up again Others may not tolerate follower reversing for any reason under any circumstances Variable 03 04 is included for these special cases Variable 03 04 Zero Lead Speed PID Control Ratio Follower and Index Follower modes only Enter the code to select desired zero lead speed PID operation Var03 04 Measure Correct Forward only Notes EU poon brror Postomino NN m 38 S e Same as 1 except forward only Same as 1 except zero out error Se AME EE eed Same as 3 except forward only Ref Sect page 45 bA02 XX 101701 NPN Outputs Terminal Connections Device Compatibility Functions NPN Output Vars 04 00 to 04 08 The MS332 has four NPN Transistor
69. as no pots all calibration is done from the keypad OFFSET The OFFSET variable adjusts the OFFSET volts This sets the Analog Output voltage component that is insensitive to the DAC code The OFFSET volts are the Analog Output volts when DAC code is zero Offset adjustment is sometimes called Zero adjustment SCALE The SCALE variable adjusts the SCALE volts This sets the Analog Output voltage sensitivity to nonzero DAC codes Scale adjustment is sometimes called Span adjustment Drive Compatibility Non Contactor Reversing Drive This type of drive uses an analog speed reference where voltage controls both speed and direction Vdc Fwd Vdc Rev By default the MS332 is programmed for this type of drive In this case the MS332 Analog Output has a possible bipolar range from the OFFSET voltage to 11 0 and 11 0 Vdc Contactor Reversing Drive This type of drive uses an analog speed reference where a positive voltage controls the speed and a contactor input determines direction of rotation The MS332 may be programmed for this type of drive by assigning the Contactor Reverse Function to one of the NPN Outputs The state of the Contactor Reverse function assigned NPN Output sets the encoder motor direction NPN Output OFF Fwd ON Rev In this case the MS332 Analog Output is restricted to a possible unipolar range from the OFFSET voltage to 11 0 Vdc See Ref Section Keypad Keypad Menus Diagnostic Menu for details on
70. ater if needed Var03 02 PID Tuning Derivative Gain Enter the default value of 0 to disable derivative compensation Reference Section Operational Variables PID Compensation for details on PID Vars Var07 13 Master Follower Mode Select Enter 1 for Master mode operation Setting the Active Master Mode Speed Set point Note Master mode set points must be entered in the same units as Var01 01 Master mode set points set the speed according to this formula desired Feedback RPM Set point Var01 00 Var01 01 Enter your desired value into the active set point the allowed range is from 0 to Var01 01 Notes The active set point may be changed via the Change Set point Menu or by Scrolling The factory default configuration selects SPOO the first of the four Master mode set points as the active set point and sets its default value to 1000 See Reference Section Keypad Keypad Menus for details on the Change Set point Menu See Reference Section Scrolling for details on Scrolling See Reference Section Operational Variables Active Set point Selection for details on using Var06 13 to select the active set point See Reference Section Switch Inputs for details on using Switch Inputs to select the active set point Acceleration Deceleration Ramp Times Vars02 00 to 02 03 Notes Ramp times set the ramp rate and are entered in units of seconds The time entered is the time to ramp fr
71. ation on Drive Compatibility See Reference Section NPN Outputs for related information on the Contactor Reverse NPN Output Function Ref Sect page 13 bA02 XX 101701 Keypad Menus Diagnostic Menu cont Analog Output Calibration Utility continued Level Three Change Analog Output calibration setting Use this level to change settings RUN TACH PROG STOP SPD ERR eee eo aon LL LLL SETPT ENTER B Eb Hue LED s Display Window All of the status led s are lit except for the ERR led Display Window shows the numerical Pc dAC setting if Pc dAC is selected Note Pc dAC is initially 000 0 upon entering this utility Display Window shows the present feedback encoder RPM if oFESET or SCALE are selected Note that numeric OFFSET and SCALE settings are not displayed Instead the feedback encoder RPM is displayed to show the immediate effect of OFFSET and SCALE settings and adjustments Valid Keys To change the selected Analog Output calibration setting Press la or to scroll the selected setting up or down Note that Pc dAC is the only selection whose numerical setting is displayed The OFFSET and SCALE selections display real time feedback encoder RPM measurements so the immediate effect of calibration settings and adjustments may be observed When the desired adjustment is achieved press to save the new setting and return to level two OR Press to exit the D
72. ave four set points The Jog mode has only one set point For the Master Ratio Follower and Index Follower modes the active set point is selected by remote switch or from the keypad Active Set point Selection by remote switch See Reference Section Switch Inputs for details on assigning and using the Active Set point Select Switch Input Function s Active Set point Selection from the keypad If the Active Set point Select Switch Input Function s are not assigned to any Switch Inputs then Var06 13 selects the Master mode speed set point Similarly Var06 14 selects the Ratio Follower mode ratio set point and Var06 15 selects the Index Follower mode phase set point Variable 06 13 Master Mode Active Set point Select Enter the corresponding code to select the active Master mode speed set point Var06 13 CODE Master Mode Active Set point 0 Speed setpt 0 1 Speed setpt 1 2 3 Variable 06 14 Ratio Follower Mode Active Set point Select Enter the corresponding code to select the active Ratio Follower mode speed ratio set point Var06 14 CODE Ratio Follower Mode Active Set point MEME COMUNE Speed Ratio setpt 0 is ous a Speed Ratio setpt 1 2 Speed Ratio setpt 2 Speed Ratio setpt 3 Variable 06 15 Index Follower Mode Active Set point Select Enter the corresponding code to select the active Index Follower mode phase set point Var06 15 CODE Index Follower Mode Active Set point 0 Phase setpt 0
73. ay flashes LEAd 0 when the lead encoder stops or fails Appendix Section page 1 bA02 XX 032601 Mnemonics Glossary Display Window messages Anov dISP dn dOnE dP dSPSEL En FACdEF FbLrn FbSPd HEYPAd HiddEn LdLrn LEAd 0 LEF In XXXX noFbAC nonE nPnou oFFSE ou XXXX PASdEP PASIn Pc dAC PPlILrn Pr XX XX PrOCES 19h SCALE SECdEF SInPu SP XX SP Flashes when selecting the Analog Output Calibration utility Diagnostic Menu Flashes when selecting Display Window diagnostic Diagnostic Menu Flashes when testing the Down arrow key in the Keypad diagnostic Diagnostic Menu 1 Displayed when done resetting the variables in the Factory Default Reset utility Diagnostic Menu 2 Displayed when done learning teaching a Pulses per Index value in the Encoder Pulses per Index Learn utility Diagnostic Menu Flashes when testing the Decimal Point key in the Keypad diagnostic Diagnostic Menu Flashes when choosing an erroneous Var05 00 display selection code the ERR status led also lights up Indicates the selected Var05 00 code doesn t apply to present operating mode Flashes when testing the Enter key in the Keypad diagnostic Diagnostic Menu Flashes when selecting the Factory Default Reset utility Diagn
74. ch NPN Output function is exclusive and may be assigned to only one NPN Output at a time Attempts to assign an NPN Output function code to a second NPN Output are rejected and result in no action other than lighting the ERR led See both Reference Section Switch Inputs Function Assignment Variables and Reference Section NPN Outputs Function Variables for details Keypad Security Protection Keypad operations may be selectively disabled by Keypad Security Attempts to change a user program variable or set point using a disabled keypad menu or execute a disabled keypad scroll will result in no action other than lighting the ERR led See Reference Section Keypad Keypad Menus Keypad Security Menu for details on Keypad Security Example When the front panel Set point Scroll is disabled by Keypad Security pressing the scroll UP DOWN keys result in no action other than lighting the ERR led Loss of Feedback Encoder Signal no feedback condition When the feedback encoder signal fails or stops while the MS332 attempts to run closed loop the ERR led lights and the display flashes noFbAC no feedback Restoring the feedback encoder signal stopping the lead if follower mode or opening the Run switch will clear the noFbAC message and turn off the ERR led Stopped Lead Follower mode Display option 1 When in follower mode and displaying the follower speed ratio code 1 in Var05 00 the ERR led lights and the displ
75. croll step certain NPN Output alarm thresholds as well as the decimal point position of the Feedback Encoder Speed In User Units display option Var05 00 option code 0 Ref Sect page 40 bA02 XX 101701 Operational Variables Set points and Set point Units cont Variable 01 04 Process Max Feedback Encoder RPM Process Max Lead Encoder RPM in User Units This variable configures the user units of the feedback lead encoder RPM ratio for Ratio Follower set points feedback lead encoder velocity ratio display and npn output velocity ratio threshold parameters To configure for set points given in user units set Var01 04 to Var01 00 Var01 03 converted to user units See Set up Section Ratio Follower Mode Step 10 for an example that includes setting up Var01 04 for user defined user units To use unitless RPM ratio user units set Var01 04 equal to Var01 00 Var01 03 Note Var01 04 also sets the decimal point position of the Follower Ratio In User Units display option Var05 00 option code 1 Index Follower Phase Set point Units Index Follower mode phase set points set the position phase relationship between each effective feedback index pulse and each effective lead index pulse Index Follower mode phase set points must be entered in units of Feedback follower Encoder Pulses Note See Description of Operating Modes Section Index Follower Mode for a more complete description of index phase set points
76. ction forward or reverse Normally the feedback encoder follows in the same direction as the lead When using the Reverse Switch Input Function the feedback may be switched to follow in the opposite direction Ratio Follower mode utilizes one lead encoder and one feedback encoder connected to the MS332 lead and feedback encoder channel inputs as shown in the following diagram RATIO FOLLOWER CONTROLLED APPLICATION LEAD IENCODER SIGNAL i MASTER CONTROLLED i PROCESS MS332 IN RATIO FOLLOWER i QUADRATURE MODE i ENCODER RUN STOP SWITCH 60056 i QUADRATURE i i ENCODER VARIABLE i RATIO i a SPEED FOLLOWER i GROUND C C ANALOG DRIVE i CONTROLLED i OAA output i PROCESS OWE Z i i ere rerrrrrr reer rere rrrere FOLLOWER FEEDBACK ENCODER SIGNAL Control Theory Closed loop pulse meshing algorithm The feedback follower encoder speed is controlled by forcing the number of feedback encoder pulses received in time T equal to the expected number determined by the lead encoder pulses received in time T the ratio set point and certain other variables With this pulse meshing algorithm the feedback encoder follows the lead encoder as though mechanically geared with zero slippage over time RPM ratio and active set point The output feedback follower RPM to input lead RPM relationship is given by the equation FbRPM
77. ction a Hardware Ist all OBS desee odo t Verdad ei FAR VOR DAR E vias Ref Sect p 1 Rear View Top View Block View oM C aR a Ref Sect p 4 Status LED s Display Window Display Var 05 00 AW RCV DACs cuss var EE PEE Ref Sect p 6 Keys Keypad Level Zero Keypad Menus Menu Access d Switch inei Ref Sect p 27 Terminal Connections Device Compatibility Functions Switch Input Vars 07 00 to 07 06 ceci vadens aun ce E EE TEER E EAEE Scroll Vars 07 07 to 07 10 Set point Scroll Advance Retard Scroll Ref Sect p 31 Table of Contents page 1 bA02 XX 091102 f Encoder Index Inputs Power Supply Outputs Terminal Connections DIP Switches Encoder Vars 01 00 01 02 01 03 01 05 to 01 08 01 12 Index Averaging Matching Vars 01 09 to 01 11 pj Anlon Output acs sr rh ads tene ERIT ERI xU EPA Eas Terminal Connections Calibration Vars OFFSET SCALE Drive Compatibility h Operational Variables eere rtr Rr PRO Y ERR AVE PETS Jog Mode Ramp Configuration Var07 11 Open Loop Configuration Var07 12 Master Follower Mode Selection Var07 13 Phase Change Release Time Var07 14 Active Set point Selection Vars 06 13 06 14 06 15 Set points and Set point Units Vars 06 00 to 06 12 Vars 01 01 01 04 Acceleration and Deceleration Ramps Vars 02 00 to 02 05 PID Compensation Vars 03 00 to 03 04 1 NPN OUIDUS S 9
78. ctions Run Stop Function The Run Stop function is permanently assigned to Switch Input 0 When Switch Input 0 is closed the MS332 will drive its Analog Output to the set point calibration lead speed if follower determined voltage and then begin decoding encoder inputs When Switch Input 0 is opened the MS332 will cease decoding encoder inputs and drive the Analog Output to the zero DAC offset voltage If the Run Stop switch is Then the command is Open STOP RUN Note In Master or Follower modes the Analog Output will ramp In Jog mode the Analog Output will ramp or step depending on the Jog Mode Configuration Var07 11 Jog Mode Function Selects Jog mode when the assigned Switch Input is closed The feedback encoder then runs at the Jog mode set point when the Run Stop switch is closed Var06 12 sets the Jog mode speed See Reference Section Operational Variables Set points and Set point Units for details on Var06 12 Note Selecting Jog mode by closing the Jog mode function assigned Switch Input overrides the Master Follower operating mode selection Set point Scroll down Function Accesses the Set point Scroll down feature when the assigned Switch Input is closed and de accesses this feature when the Switch is opened See Reference Section Scrolling for details on Set point Scroll Set point Scroll up Function Accesses the Set point Scroll up feature when the assigned Switch Input is closed and de acc
79. ctions feedback encoder speed is controlled by forcing the number of feedback encoder pulses received in time T equal to the expected number determined by the lead encoder pulses received in time T and certain user variables see formula below No pulses are gained or lost between index phase corrections the cumulative error is zero Therefore if either index pulse source were to fail index phase corrections would cease but the follower to lead phase relationship would not change This closed loop pulse meshing algorithm is similar to that of Ratio Follower mode However unlike Ratio Follower mode the RPM ratio derives from a feedback to lead index pulse matching ratio Var01 10 Var01 11 and not from the set point The Index Follower mode feedback lead RPM ratio formula is shown here FbRPM LdRPM FbPPI LdPPI Var01 05 Var01 02 Var01 10 Var01 11 Desc Oper Mode Sect page 3 bA02 XX 101801 Where FbPPI and LdPPI are the feedback and lead encoder pulses per index pulse Var01 02 and Var01 05 are the feedback and lead encoder pulses per revolution Var01 10 and Var01 11 are the desired feedback and lead index pulses per match Index Follower Mode cont PPI Measurement and Averaging Although it is necessary for an application to exhibit constant or near constant feedback and lead encoder pulse per index pulse counts some variation is tolerable to the MS332 Possible causes of variation may include slippage o
80. d drive towards zero at an acceptable rate determined by Var03 01 after the ramp After that the following error should stay zero or small and centered around zero Set up Sect page 16 bA02 XX 022301 10 Enabling and adjusting index phase correction a Var05 00 Display Selection Enter code 6 to display Index Phase Error b Var07 12 Open loop Configuration Enter code 0 to disable the Closed loop Open loop Switch Input Function from opening either the index or encoder feedback loops c Var07 14 Phase Change Release Time This variable sets the time over which index phase errors are introduced into the PID loop for correction Longer time values cause slower and smoother corrections shorter values cause faster more abrupt corrections If not already set to the factory default value of 1 0s enter 1 0 into Var07 14 If necessary this value may be changed later in step e d Run the lead encoder at the process maximum value Var01 03 RPM e Close the Run Stop switch with the lead running observing the initial index phase correction that occurs after the follower ramp Index phase correction can be observed at the display The display shows zero during and immediately after the follower ramp then the display changes from zero to some nonzero value This value is the index phase error and it should immediately begin shrinking towards zero as the follower motor under speeds or over speeds to correct the phase
81. d value in the indicated units into the NPN Output s Function Parameter Variable To un assign an NPN function from a certain NPN Output Enter code 0 into the NPN Output s Function Assignment Variable The NPN Output Functions and their corresponding Codes are shown in this table NPN Function Active Operating Function Function Function Parameter Type and Units Mode Input Code None unused Q High Alarm Master Feedback RPM 1 Threshold in Var01 01 Feedback Units High Alarm Ratio Follower Feedback RPM 2 Threshold in Var01 01 Feedback Units High Alarm Ratio Follower Follower ratio 3 Threshold in Var01 04 Follower Units High Alarm Master amp Ratio Fol Feedback RPM 4 Threshold in Var01 01 Feedback Units Low Alarm Master Feedback RPM 5 Threshold in Var01 01 Feedback Units Low Alarm Ratio Follower Feedback RPM 6 Threshold in Var01 01 Feedback Units Low Alarm Ratio Follower Follower ratio 7 Threshold in Var01 04 Follower Units Low Alarm Master amp Ratio Fol Feedback RPM 8 Threshold in Var01 01 Feedback Units Deviation Alarm Master Feedback RPM 9 SetpointDev in Var01 01 Feedback Units Deviation Alarm Ratio Follower Follower ratio 10 SetpointDev in Var01 04 Follower Units Zero Speed Master Feedback RPM 11 Fraction of Var01 00 ex 1 enter 0 01 Zero Speed Ratio Follower Feedback RPM 1
82. de It is the Vout present when Pc dAC is 000 0 DAC code 0 oFFSET is typically adjusted to produce no feedback encoder rotation when Pc dAC is 000 0 Once changed this calibration setting will remain until explicitly changed again SCALE sets the sensitivity of the DAC code dependent Vout component SCALE should be adjusted to turn the feedback encoder at Var01 00 Process Max Feedback Encoder RPM when Pc dAC is 090 0 DAC code 3686 Once changed this calibration setting will remain until explicitly changed again Notes Usually the Analog Output is calibrated in the feedback encoder s forward direction the direction produced by a positive Pc dAC However it can be calibrated in the reverse direction the direction produced by a negative Pc dAC Although the MS332 can run the feedback encoder motor in both directions regardless of the direction in which it was calibrated it is recommended that the Analog Output be calibrated in the direction produced in your application In order to run your motor in the reverse direction the MS332 must first be properly configured and wired to your drive according to your drive s reversing method negative voltage input or contact closure See the Set up for Motor Drive Compatibility step in your selected operating mode s set up procedure for details Set up Section your mode Set up for Motor Drive Compatibility The variables Var01 00 Process Max Feedback Encoder RPM a
83. e Switch is opened See Reference Section Scrolling for details on Retard Scroll Ref Sect page 28 bA02 XX 101701 Switch Inputs Functions cont Closed loop Open loop Select Function Selects operating mode to run closed loop or open loop when the assigned Switch Input is open closed If the assigned Switch Input is Then the Master Follower operating mode runs in Closed loop Open loop per Var07 12 Note See Reference Section Operational Variables Open loop Configuration for details on Var07 12 Master Follower Mode Select Function Selects Follower or Master operating mode when the assigned Switch Input is open closed If the assigned Switch Input is Then the selected operating mode is Open Follower mode Notes 1 Assigning this function to a Switch Input overrides the Master Follower Mode Select Var07 13 Var07 13 then has no effect 2 When using this function to select Follower mode you must further configure which Follower mode is actually desired Ratio Follower or Index Follower See Reference Section Encoder Index Inputs Power Supply Outputs VEncoder Variables Variable 01 06 for details on Follower Mode Configuration 3 This Master Follower Mode Select Function is overridden if Jog mode is selected by closing a Jog mode function assigned Switch Input Active Ramp Pair Select Function Selects the active ramp pair when the assigned Switch Input is open closed If t
84. e Pc Dac is 090 0 See Reference Section Keypad Keypad Menus Diagnostic Menu Analog Output Calibration Utility for details on calibration Operational Variables a Var03 00 PID Tuning Proportional Gain Enter the default value of 32 for an initial value Adjustments will be made later in step 9 b Var03 01 PID Tuning Integral Time Constant Enter the default value of 2 0s for an initial value Adjustments will be made later in step 9 c Var03 02 PID Tuning Derivative Gain Enter the default value of 0 to disable derivative compensation d Var03 04 Zero Lead Speed PID Control Enter the code to select desired zero lead speed PID operation The factory default is code 0 See Reference Section Operational Variables PID Compensation for details on PID Vars e Var07 13 Master Follower Mode Select Enter 0 for follower mode operation f Var01 06 Follower Mode Configuration Enter 0 for Ratio Follower mode g Setting the Active Ratio Follower Speed Ratio Set point Note Ratio Follower mode set points must be entered using the user units determined by Var01 04 Ratio Follower mode set points set the Feedback Lead speed ratio according to this formula Feedback RPM Lead RPM Process Max Feedback RPM Process Max Lead RPM Ratio Set point Var01 04 Therefore Ratio Set point desired Feedback RPM Lead RPM Process Max Lead RPM Process Max Feedback RPM Var01 04 Enter your desired v
85. e Rx 2 l NPN Output 2 L2 Neutral A NPN Output 3 L1 Line 9 Ground B 2 22 222222222 Ground C Bottom Edge of MS332 Ref Sect page 1 bA02 XX 101701 Hardware Illustrations cont Top View Showing location of both DIP Switch banks on the MS332 package The eight DIP Switches in each bank are also identified in this diagram s E g g a a B Eg 2 E 3 3S 5 5 us a an man ECT 3 y od 3 3 g 5 z a a 2 3 c a a Q e lt a amp Q E lt c 2 lt m amp E T lt m S9 d sS F S gt O E ae wq Q D n c ce O U Hu Hu 5 O O H 2 z 5 5 E 9 4 amp a amp S 5 E 9g 8 amp 9 6 T x 3 S 39 dt 9 uk 8 8 B 3 E oO amp amp Bo 5 amp amp d a 2 8 3 mJ ud 5 B 2 2 3 5H d 5 amp amp g m A A M M Mc m oH Fs M x x o a T a 3 T Switch S s s D Wm OB wx x S 8 m m m x x 2 Q o A A A 5 i D 5 QA fA Qa 3 3 Purpose a F 2 no u u lt lt n 4 E E kt lt l l l l l l l l l l E om Es a Switch e c Position Z Z o v v Switch Number 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 v A 4 Y nip Rear Terminal Strip Front Panel end of MS332 end of MS332 Encoder Index Aux Pull up and Pull down DIP Switches Ref Sect page 2 bA02 X X 101701 Hardware Illustrations cont Block View Diagram showing MS332 I O blocks terminals and signal commons TB4 14 TB4 16 C
86. e display Press enter Scale adjustment 9 Observe the display it will show the RPM at which the follower encoder is presently rotating Press or until the displayed RPM is equal to your follower process maximum RPM of the value in Var01 00 If the displayed RPM is too high press v to reduce it If the displayed RPM is too low press 4 to increase it When the displayed RPM is equal to your follower process maximum RPM press save the scale Exit the Analog Output calibration utility 10 Press exit the Diagnostics menu The follower motor will stop Calibration is complete Ref Sect page 15 bA02 XX 101701 Keypad Menus Diagnostic Menu cont Keypad Diagnostic Level Two Test keypad keys Use this level to individually test each key on the keypad This is on the second level of the Diagnostic Menu Note Enter level two by selecting KEYPAd in the display window while at level one of the Diagnostic Menu See level one above tach prog BUN SET LED s Display Window STOP SPD ERR oO All of the status led s are lit except for the ERR led Display Window initially shows the mnemonic nonE with all the digits The mnemonic nonE is displayed when no keys are pressed Valid Keys Press the desired key to test it If the key is working properly then the respective mnemonic is displayed in the Display Window SETPT ENTER Press var the mnemonic VAr is dis
87. e set point can be changed directly without entering a menu by using the Set point Scroll feature See Reference Section Scrolling for details on the Scroll feature See Reference Section Keypad Keypad Menus for details on the Change Variable and Change Set point Menus See Reference Section Operational Variables Active Set point Selection for details on the active set point Set point Units Master mode speed set points are in units set by Var01 01 Ratio Follower mode speed ratio set points are in units set by Var01 04 Index Follower mode phase set points are in units of Feedback Encoder Pulses Jog speed set point is in units of RPM Variable 01 01 Process Max Feedback Encoder RPM in User Units This variable configures the units in which speed set points are entered and sets the max speed set point value Set points may be entered in your user units or entered as RPM user units In either case the set point value may range from 0 to the Var01 01 value To configure for set points given in non RPM user units set Var01 01 to the maximum process output value in your user units See Set up Section Master Mode Setting up Var01 00 Var01 01 for non RPM User Units for an example To configure for set points given in RPM user units set Var01 01 equal to the Process Max Feedback Encoder RPM same numerical value as Var01 00 Note Var01 01 sets the units for Master mode speed set points Master mode speed s
88. ed in the other sections see Table of Contents Note The material in this manual is subject to change without notice Introduction and How to use bA02 XX 031301 MS332 Manual Table of Contents 1 Description of Operating Modes Section aj Master Modes 202 rere ra ER Tu eon Description Control Theory b Ratio Follower Mode ccc cece ence ene eeeeeneeee eens Desc Oper Mode Sect p 2 Description Control Theory c Index Follower Mode erc eerte toan ax Res nune Desc Oper Mode Sect p 3 Description Control Theory d Jog Mode meneen poe TOR db eh tc PER theese take Desc Oper Mode Sect p 5 Description Control Theory Desc Oper Mode Sect p 1 2 Physical Installation Section Phys Install Sect a Standard Panel Mount Installation eese p 1 b Optional Side Mount Bracket Installation Phys Install Sect p 2 E MITIS eode nc HERE dpt std E Ded EE Phys Install Sect p 4 3 Set up Section a Master Mode Set up Procedure cece ccc eeeeeeeeeeeeeeeeeenaes Set up Sect p 1 b Ratio Follower Mode Set up Procedure cc ce ece cence ence ners Set up Sect p 6 c Index Follower Mode Set up Procedure cc eceeeee cence eeee Set up Sect p 12 d Switch Inputs Set up Procedure 2 e ceo ree e een ene Set up Sect p 18 e NPN Outputs Set up Procedure sees Set up Sect p 18 4 Reference Se
89. ee ee ee E E Switch o o Position Z Z O Oo V V Switch o P ako lee dedu PI eb s p qp A Number 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 pull ups w pull downs Keypad Security Variable Record Record your values in the Your value column Var Description Range Comments Ref Sect Default Your page value value PASIn Keypad password 000000 Enter code to lock unlock 22 000332 code input gt 999999 view change at any time PASdEF Keypad password 000000 Define unlock code 22 000332 code define gt 999999 view change only when unlocked SECdEF Keypad security 000000 Define lock disabled 22 000000 define 2011111 keypad features view at any time change only when unlocked Appendix Section page 8 bA02 XX 032601 Rear View Showing all four terminal strips TB1 TB2 TB3 and TB4 Top Edge of MS332 rear view optional Analog Input 0 Ground C e Switch Input 0 Run Stop optional Analog Input O N 12 Vdc C Encoder Index Pwr 1 e 2 Pee ay ee cer E ce Ground C optional Analog Input 1 3 s 3 e Lead Chan A Switch Input 1 optional Analog Input 1 e 4 4 e Lead Chan B See ee ee ee ee Switch Input 2 Analog Output 0 5 5 Lead Index ia naaien Teaia Aa Ground C Ground A e 6 i 6 e Ground C Switch Input 3
90. encoders must be incremental quadrature output type Outputs from encoder and index devices may be NPN PNP TTL logic gate or CMOS logic gate types The MS332 also provides an unregulated 12 Vdc power supply for powering encoder and index devices Terminal Connections Lead Lead Feedback Feedback Encoder Index Encoder Index Encoder Index Encoder Index Power Supply Signal Power Supply Signal Ground 12 C Lead Lead Lead Ground 12 C Fdbk Fdbk Fdbk C volt ChA ChB Index C volt ChA ChB Index Top Edge MS332 Rear View See Reference Section Hardware Illustrations Rear View for a diagram showing the details of terminal strip TB4 containing the encoder index signal and power terminals on the back of the MS332 package DIP Switches This diagram shows the Pull up and Pull down DIP Switches for the Encoders and Indexes View looking down on top of the MS332 package with the front panel on left There are two banks of switches See Reference Section Hardware Illustrations Top View for a diagram showing the location of the DIP Switches on the MS332 package S g a a E a a 7 9 7 To m sa od S UM i g d d 3 3 3 a amp 3 3 s amp amp El a Q lt ea e s Qa z lt ta o lt 1 m amp sS ms 8 X RS 3 d do C x E ee RE c u B Qm WV mw A Lom Ye ae 95 dE iB 2 9 9 9 V 9g x 5 5 9 9 ao SB Bx d S 7 x 9 9 8 X AL 3 8S x 9 9 9 Xi L 9 9 amp 8 2 Z 9 9 85 8 2 3 8 Ss g m mu a amp
91. ending on your process and the physical position of your index pulse sources a nonzero set point may be needed If known enter the desired set point value If unknown try different values by active Set point up down scroll or Change Set point Menu until the desired process phase relationship is found Notes In 1 1 index pulse matching every feedback index pulse and every lead index pulse is effective In 3 2 index pulse matching every third feedback index pulse and every second lead index pulse are effective See Description of Operating Modes Section Index Follower Mode Control Theory for information on Index Matching The active set point is changed via the Change Set point Menu or by Scrolling The factory default configuration selects SP08 the first of the four phase set points as the active set point and sets its default value to zero See Reference Section Keypad Keypad Menus for details on the Change Set point Menu See Reference Section Scrolling for details on Scrolling See Reference Section Operational Variables VActive Set point Selection for details on using Var06 15 to select the active set point See Reference Section Switch Inputs for details on using Switch Inputs to select the active set point Set up Sect page 17 bA02 XX 022301 Switch Inputs Set up Procedure For applications employing one or more MS332 Switch Input Functions do the following for each 1 2
92. er Vars All 16 bits at 4XXXO 1 query response cycle Display Values All 16 bits at 3XXXO 1 query response cycle Function code 06 Function code 06 Preset Single Register is supported for writing User Variables using 32 bit data types as follows Two function code 06 write transactions One each to the addresses 4XXXO0 and 4XXX1 First write one 16 bit half to one address first query response cycle Then write the other 16 bit half to the other address second query response cycle Notes Coherency of the two 16 bit halves is ensured if the two 16 bit transactions occur together with no other transactions to that MS332 between them 32 bit User Variable writes do not take effect until the second half is written The order in which the 16 bit halves are written does not matter If the second 16 bit query contains a different function code address the same 16 bit half or addresses a different User Var than the first a new access is begun and the previous write begun by the first 16 bit query is discontinued Function code 06 Preset Single Register is also supported for writing User Variables using 16 bit data types as follows One function code 06 write to address 4XXXO one query response cycle Ref Sect page 61 bA02 XX 101701 MS332 Specification Section bA02 XX Functional Encoder Index Inputs 2 ports Lead and Feedback Follower each receiving 2 quadrature incremental encoder signals A B and one index pu
93. er loop will become unstable Open the Run Stop switch Repeat c several times Notes Higher Proportional Gain Var03 00 values make proportional compensation more aggressive up to a certain max value then causing loop instability above that value Lower Integral Time Constant Var03 01 values make integral compensation more aggressive down to a certain min value then causing loop instability below that value With the PID properly adjusted the displayed following error should drive towards zero at an acceptable rate determined by Var03 01 after the ramp After that the following error should stay zero or small and centered around zero 10 Display selection Var05 00 Enter the selection code for the desired real time display Note Most Ratio Follower mode applications use code 1 Follower Ratio in User Units or code 5 Closed loop Error in feedback encoder pulses See Reference Section Display Display Window Variables for details on Var05 00 selection codes Set up Sect page 10 bA02 XX 022301 11 Example Ratio Follower mode A continuous duty wastewater treatment system requires that neutralizer solution be precisely dispensed in proportion to incoming wastewater flow The maximum dispensing ratio will be 12 0 mL per L of wastewater The incoming wastewater flow is controlled by a motor driven pump with an encoder on the motor shaft The neutralizer flow is also controlled by a motor driven pump
94. es Table of Contents page 2 bA02 XX Appendix Sect 091102 SUP PT WwWnew US N p 9 MS332 Description of Operating Modes Section bA02 XX Master Mode Description Input hardware Master mode uses a single quadrature output incremental feedback encoder on the controlled shaft Operation Master mode controls motor speed causing the feedback encoder to rotate at the precise set point speed When using a bidirectional drive and motor forward and reverse Master mode operation may be achieved by utilizing the Reverse Switch Input Function Master mode utilizes only one encoder connected to the MS332 feedback encoder channel inputs as shown in the following diagram MASTER MODE CONTROLLED APPLICATION MS332 IN eee modu deities Moor i QUADRATURE RUN STOP ENCODER SWITCH VARIABLE i MASTER MODE p SPEED CONTROLLED ANALOG __ DRIVE PROCESS OUTPUT ms Qo GROUND C FEEDBACK ENCODER SIGNAL fl 1 Control Theory Closed loop pulse counting algorithm The feedback encoder speed is controlled by forcing the number of feedback encoder pulses received in time T equal to the expected number determined by the master set point and certain other variables Since the MS332 time base is controlled by an accurate precise crystal based clock the speed does not significantly drift over time or vary with environmental conditions Feedback speed and active set point
95. ese keys are also used in a few places of the Diagnostic Menu When running closed loop without index correction and not in one of the four menus these keys are used to Advance Retard the feedback encoder RIGHT arrow advances LEFT arrow retards The UP and DOWN ARROW keys are used to increase or decrease the value of the flashing selected display digit while in the Change Variable Change Set point and Keypad Security Menus These keys are also used in many places of the Diagnostic Menu When not in one of the four menus these keys are used to increase decrease the mode determined active set point the Master mode speed the Ratio Follower mode speed ratio the Index Follower mode phase or the Jog mode speed Ref Sect page 6 bA02 XX 101701 Keypad Level Zero Real time Display This is the base keypad level not in a menu where the display window shows real time information according to Var05 00 and real time status Status LED s Real time display select menu scroll active set point scroll advance retard Use this level to display real time measurements and status enter keypad menus scroll the active set point and scroll the phase advance retard 1 1 rach proc RUN SET er LED s Display Window eoooo TACH led lit Display Window shows information according to Var05 00 Ex A feedback speed of 1500 RPM Valid Keys Press key to enter level one of the Change Variable Menu See the Change
96. esponse to a failed or otherwise unresponsive feedback encoder Var01 12 CODE Response to No Feedback condition 0 Let Position Error grow to max remain closed loop 1 Clear Position Error run open loop Index Averaging and Matching Variables Index Follower mode only Variable 01 09 Pulses per Index Measurement and Averaging Control In Index Follower mode the Feedback Lead RPM ratio between index phase corrections is given by the following relationship FbRPM LdRPM FbPPI LdPPI Var01 05 Var01 02 Var01 10 Var01 11 Where FbPPI and LdPPI are the effective Feedback and Lead Pulses Per Index values used in determining the RPM ratio Var01 09 determines the values used for FbPPI and LdPPI as shown in the following table Var01 09 PPI PPI FbPPI LdPPI values used for RPM ratio CODE Measurement Averaging 0 disabled disabled Var01 07 Var01 08 1 enabled disabled Most recent measured Feedback Pulses Per Feedback Index and Lead Pulses Per Lead Index 25 32 enabled enabled Average of last 2 32 measured Feedback Pulses Per Feedback Index and Lead Pulses Per Lead Index Variable 01 10 Feedback Index Pulses per Match Enter the number of feedback index pulses to be matched with Var01 11 the number of Lead Index Pulses per Match Variable 01 11 Lead Index Pulses per Match Enter the number of lead index pulses to be matched with Var01 10 the number of Feedback Index
97. esses this feature when the Switch is opened See Reference Section Scrolling for details on Set point Scroll Active Set point Select Function s Selects different set points when assigned Switch Input s are open closed If only one of the set point select functions is assigned to a Switch Input then that function selects from only two mode determined set points as shown in the top half of the table If both set point select functions are assigned to Switch Inputs then both functions work together to select from all four mode determined set points as shown in the bottom half of the table Note Code 4 and 5 refer to Switch Input function codes If the code 4 a And if the code 5 assigned Then the selected mode Opens not moassigne sept OES 0 Note Assigning codes 4 and or 5 to Switch Inputs overrides the Master mode set point select Var06 13 the Ratio Follower mode set point select Var06 14 and the Index Follower mode set point select Var06 15 Vars 06 13 06 14 and 06 15 have no effect when codes 4 and or 5 are assigned to Switch Inputs Advance Scroll Function Accesses the Advance Scroll feature when the assigned Switch Input is closed and de accesses this feature when the Switch is opened See Reference Section Scrolling for details on Advance Scroll Retard Scroll Function Accesses the Retard Scroll feature when the assigned Switch Input is closed and de accesses this feature when th
98. f Sect page 60 bA02 XX 101701 Serial Communications Addendum Access User Vars and Display Values cont b Access 2 adjacent registers separately at 4XXX0 and 4XXX1 or 3XXX0 and 3XXX1 16 bit halves are accessed separately each in a separate query response transaction User Vars First access one 16 bit half at one address first query response cycle Then access the other 16 bit half at the adjacent address second query response cycle Display Values First read one 16 bit half at one address first query response cycle Then read the other 16 bit half at the adjacent address second query response cycle Notes Coherency of the two 16 bit halves is ensured if the two 16 bit transactions occur together with no other transactions to that MS332 between them User Variable writes do not take effect until the second half is written Second 16 bit halves of User Variable or Display Value reads come from the same 32 bit values as the first The order in which the 16 bit halves are accessed does not matter If the second 16 bit query contains a different function code address the same 16 bit half or addresses a different User Var or Display Value than the first a new access is begun and the previous access begun by the first 16 bit query is discontinued Function codes 03 04 and 16 are also supported for accessing single User Vars and Display Values using 16 bit data types as follows Access 1 register at 4XXX0 or 3XXX0 Us
99. ge Variable Menu editing Menu may be entered variables may be observed but not changed Change Set point Menu editing Menu may be entered variables may be observed but not changed Diagnostic Menu Menu may not be entered Set point Scroll Attempts to scroll the active set point from the keypad have no effect Advance Retard Scroll Attempts to Advance or Retard scroll from the keypad have no effect Keypad Security Variables Security is controlled by three Keypad Security Variables found in the Keypad Security Menu 1 PASIn PASsword code Input This 6 digit variable is where a code is entered to lock or unlock the keypad To unlock the keypad enter the password code value into PASIn Any other code locks the keypad This variable may be thought of as a keyhole for which only one key or code the password code will unlock the keypad PASdEF PASsword dEFinition This 6 digit variable defines the password code for unlocking To unlock the keypad the numerical value of PASdEF the password code must be entered into PASIn This variable may be thought of as defining the key to the keypad Therefore changing this variable may be thought of as changing the lock Note When PASIn s value is different from PASdEF s value the keypad is locked Conversely when PASIn s value is identical to PASdEF s value the keypad is unlocked SECdEF keypad SECurity dEFinition This 6 digit variable defines the effect of keypad lock This is where the previ
100. he assigned Switch Input is Then the selected Active Ramp Pair is Accel 0 and Decel 0 Accel and Decel 1 Note Assigning this function to a Switch Input overrides the Active Ramp Pair Select Var02 05 Var02 05 then has no effect Fast Stop Function Fast Stops the feedback motor encoder when the assigned Switch Input is closed The Fast Stop Decel Ramp Var02 04 determines how quickly to ramp down the Analog Output under this condition Note The Fast Stop function when enabled overrides and disables the Run Stop Switch Input function If the feedback motor encoder is running or jogging closing the Fast Stop switch overrides the Run Stop switch and ramps the encoder to a stop using the Var02 04 ramp The Run Stop Switch Input will remain disabled as long as the Fast Stop switch is closed To re enable the Run Stop Switch Input open up the Fast Stop switch Reverse Function Selects the feedback encoder s reverse or opposite direction when the assigned Switch Input is closed The feedback encoder then runs in the reverse or opposite direction when the Run Stop switch is closed If the assigned Then the Jog or Master mode Then the Follower mode Ratio or Index Switch Input is direction is direction is Open Forward Chan A leads Chan B Same as lead encoder direction Reverse Chan A lags Chan B Opposite of lead encoder direction Notes 1 The Reverse function requires using a bidirectional motor drive See Refe
101. he function input going low Low to High effective threshold Threshold 1 Hysteresis 100 High to Low effective threshold Threshold 1 Hysteresis 100 Hysteresis is entered in units of so the allowed range of Var04 08 is 0 gt 100 The Hysteresis is always applied to the threshold The Hysteresis applies to all active threshold type NPN Output functions all NPN Output functions except for the Contactor Reverse Function and the Drive Enable Function See the table in the NPN Outputs Functions discussion for a mathematical description of each function with hysteresis Note The statuses of the NPN Outputs 0 through 3 can be displayed on the Display Window See Reference Section Display Display Window Variable for details Ref Sect page 49 bA02 XX 101701 Serial Communications Interface Port Serial Protocol Serial Communications Vars 08 00 to 08 04 Modbus Implementation Data Types Remote Analog Output Calibration Procedure Remote Encoder PPI Variable Determination Procedure Addendum MS332 Serial Communications provide an alternative to the Front Panel Keypad Display whereby User Variables including Setpoints real time Display Values Switch Inputs Keypad buttons and NPN Outputs may be remotely accessed Interface Port The Interface Port consists of one balanced EIA 485 tri state driver one balanced EIA 485 receiver and their reference common Ground B The Interface P
102. he key Ref Sect page 7 bA02 XX 101701 Keypad Menus Change Variable Menu Follow these steps to access the Change Variable Menu Level One Select variable Use this level to select which user program variable to change This is the first level of the Change Variable Menu Note Enter level one by pressing while at level zero See level zero above TACH PROG Shs Spy ERR LED s Display Window O dooo PROG led lit Display Window initially shows the last variable changed with the right Qo t i A n most digit flashing Ex Showing Pr 01 00 for Var01 00 Valid Keys To select desired variable Press 4 or v to change the flashing selected digit Mau A Press EO or BJ to select which digit to change gt When the desired variable is displayed press to confirm and enter level two of the Change Variable Menu OR Press to exit from Change Variable Menu and return to level zero Invalid Keys Pressing ern or Ce results in no action other than lighting the ERR error led Level Two Change variable value Use this level to change the value of the selected variable This is the second level of the Change Variable Menu LED s Display Window PROG led remains lit Display Window shows the selected variable s value with the right most digit flashing Ex Showing 1000 for a Var01 00 value of 1000 RPM Valid Keys To change variable
103. his is the real time feedback encoder RPM 3 Slowly adjust the Aout Scale Var09 01 address 49010 until the real time feedback encoder RPM is equal or as close as possible to the Jog Speed set point If the displayed RPM is higher than setpoint reduce Aout Scale Var09 01 address 49010 If the displayed RPM is lower than setpoint increase Aout Scale Var09 01 address 49010 This sets the Analog Output s voltage output DAC input sensitivity Ref Sect page 56 bA02 XX 101701 Serial Communications Remote Analog Output Calibration Procedure cont Exit Jog Mode 1 Open the MS332 Run Switch 2 Un assign the Jog Switch Input function from the Switch Input by writing 0 to the corresponding Switch Input function assignment variable Example If you previously wrote 1 Jog to Var07 03 address 47030 assigning Jog to Switch Input 4 write 0 to it now to un assign Jog from it Ref Sect page 57 bA02 XX 101701 Procedure Remote Encoder PPI Variable Determination and Initialization Index Follower mode Notes Index Follower Mode setup requires determining values for and writing Var01 07 Feedback PPI Feedback Encoder pulses per Feedback Index pulse and Var01 08 Lead PPI Lead Encoder pulses per Lead Index pulse This procedure provides a Serial Communications alternative to the Keypad method given in the Reference Section Keypad Menus Diagnostic Menu Encoder Pulses Per Index Learn Utility This procedure
104. iable Note When the keypad is locked i e PASIn s value does match PASdEE s value PASdEF or SECdEF can t be changed Trying to do so results in no action other than lighting up the ERR led Press 4 or v to change the flashing selected digit Press EJ or J to select which digit to change When the desired value is reached press to save the new value and return to level one OR Press Ce to exit the Keypad Security Menu without saving and return to level zero Invalid Keys Pressing Ca or results in no action other than lighting the ERR led Ref Sect page 25 bA02 XX 101701 Keypad Menus Keypad Security Menu cont Using Keypad Security Note The state of the keypad locked or unlocked may be observed by viewing the PASdEF variable If unlocked then the numerical password value is displayed If locked then the HlddEn mnemonic is displayed Unlocking 1 Enter the password code into PASIn An unlocked keypad can be verified by observing PASdEF s value Defining the effect of keypad lock 1 Unlock the keypad by entering the password code into PASIn 2 Enter the SECdEF settings digit values for desired disables during keypad lock Locking 1 Enter a number other than the password code into PASIn A locked keypad can be verified by attempting to observe PASdEF s value Changing the password code 1 Unlock the keypad by entering the current password code into PASIn 2 En
105. iagnostic Menu and return to level zero Note Level three changes to Pc dAC oFFSET and SCALE settings take immediate effect at the Analog Output but remain temporary for the duration of this utility until is pressed to store the new setting The effect of pressing for any one of the three selections is described below Pc dAC is stored remaining in effect for the duration of the Analog Output Calibration utility This gives the user control over the DAC for the purpose of setting SCALE OFFSET is stored in non volatile memory and remains in permanent effect at the Analog Output until it is deliberately changed again SCALE is stored in non volatile memory and remains in permanent effect at the Analog Output until it is deliberately changed again The oFFSET and SCALE values together comprise the Analog Output calibration Invalid Keys Pressing vs e Ca or Ce results in no action other than lighting the ERR led Ref Sect page 14 bA02 XX 101701 Keypad Menus Diagnostic Menu cont Analog Output Calibration Utility continued Step By Step Analog Output Calibration Procedure Note Before calibrating the analog output your system s Process Maximum Feedback Encoder RPM must be entered into Var01 00 and Feedback Encoder PPR must be entered into Var01 02 Enter the Analog Output Calibration Utility 1 Open the MS332 RUN switch open the contact across TB3 pins and 2 2 From keypad
106. isplay The real time display selection codes are summarized in this table and described below 0 Feedback encoder velocity in user units Index phase error in feedback encoder pulses rn pine dink eode pke Lead index frequency in Hz Feedback index frequency in Hz Average number of Lead Pulses per Index o no O Average number of Feedback Pulses per Index Switch Input 3 2 1 0 status Switch Input 7 6 5 4 status NPN Output 3 2 L 0 status PID Integral Term Ref Sect page 4 bA02 X X 101701 Display Display Window Variable cont Code 0 Code 1 Code 2 Code 3 Code 4 Code 5 Code 6 Code 7 Code 8 Code 9 Code 10 Code 11 Code 12 Code 13 Code 14 Code 15 Displays the feedback encoder velocity in user units Display value Fdbk RPM Var01 00 Var01 01 Var01 00 is the Process Max Feedback Encoder RPM Var01 01 is the Process Max Feedback Encoder RPM in User Units Note A negative display value indicates reverse direction Fdbk encoder B pulses leading A pulses Displays the feedback lead encoder velocity ratio in user units Display value Fdbk RPM Lead RPM Var01 00 Var01 03 Var01 04 Var01 00 is the Process Max Feedback Encoder RPM Var01 03 is the Process Max Lead Encoder RPM Var01 04 is the process maximum encoder RPM ratio Process Max Feedback Encoder RPM Process Max Lead Encoder RPM in User Units Note A negative display
107. ition relative to lead encoder position expressed in units of follower encoder pulses Ratio Follower mode Phase offset is controlled by the Advanced Retard feature The desired position difference of the Feedback Index pulse relative to the Lead Index pulse expressed in units of feedback encoder pulses Index Follower mode only Proportional Integral Derivative The MS332 uses PID compensation to achieve and maintain accurate speed and position control Pulses per revolution as in encoder pulses per revolution A status LED Lights up to indicate when the MS332 is in the Change Variable Menu i e program variable A resistor or other device that pulls an undriven signal line down to signal common A resistor or other device that pulls an undriven signal line up to a positive DC voltage Power as in 12 Vdc encoder Pwr supply at terminals TB4 2 Encoder with two output squarewave signal lines A and B Frequency signals speed A to B phase relationship signals direction Not delayed as in real time display of encoder RPM during a controlled process Decrease subrtact from the feedback encoder phase offset by a certain number of pulses using the Advance Retard feature Revolutions per minute as in encoder RPM second A status LED Lights up to indicate when the MS332 is in the Change Set point Menu i e set the speed Set point Deviation threshold as in NPN Output Deviation Alarm function Set point as in master
108. lculated from known information The feedback encoder will rotate at its process maximum RPM when the lead encoder rotates at its process maximum lead RPM and the set point is at its maximum Process Max Feedback Encoder RPM 800 L wastewater min 12 0 mL neutralizer L wastewater 1 follower rev 10 mL neutralizer 960 follower rev min Enter 960 into Var01 00 Note that this value is less than the follower motor s rated max of 1800 RPM Var01 01 Maximum Master Mode Set point Value in User Units Enter the same value into Var01 01 that was entered into Var01 00 Now any setpoint value between 0 0 and 12 0 may be entered to set the follower pump s mL neutralizer per L wastewater dispensing ratio Set up Sect page 11 bA02 XX 022301 Index Follower Mode Set up Procedure Description See Description of Operating Modes Section Index Follower Mode for a block diagram and discussion of Index Follower Mode Operation Set up Procedure 1 2 Follower Motor Drive adjustment settings Adjust the drive settings to match the motor according to the drive instructions Set the follower motor drive s maximum motor speed to approximately 10 higher than your process maximum speed This provides some over speed capability to the MS332 so it can close the loop at your process maximum follower speed Set the acceleration deceleration settings to the minimum time settings fastest These adjustments mini
109. lection code Function Code Use 01 Read Coil Status Read NPN Outputs 02 Read Input Status Read Switch Inputs 03 Read Holding Registers Read User Variable 04 Read Input Registers Read Display Value 05 Force Single Coil 06 Preset Single Register 15 Force Multiple Coils 16 Preset Multiple Registers Write single NPN Write User Variable Write multiple NPNs Write User Variable Note on function codes 05 and 15 These function codes allow forcing NPN outputs ON or OFF regardless of assigned NPN Output Functions Outputs without an assigned NPN Output Function remain in their forced state until forced to the opposite state Outputs with an assigned NPN Output Function remain in their forced state only until the next function execution 19 2 mS or less after which each follows its function Ref Sect page 54 bA02 XX 101701 Serial Communications Modbus Implementation cont 3 Supported Modbus Exception Responses Code Name Meaning 01 ILLEGAL FUNCTION Function code received not supported by slave 02 ILLEGAL DATA ADDRESS Data address received not supported by slave 03 ILLEGAL DATA VALUE Data value received is not valid 4 Response Message Delay A maximum 30mS delay occurs from the end of Query Message reception to the start of Response Message transmission This time interval is independent of Baud Rate and is required for Query Message error checking and validation task processing synchroni
110. led s are lit except for the ERR led e eeo P i Display Window shows feedback speed in RPM if FbSPd is selected flashes PrOCES then displays dOnE if LdLrn or FbLrn are selected Valid Keys SETPT If FbSPd is selected Press 4 Or v to scroll the feedback motor and encoder speed When the desired RPM is reached press to temporarily save the DAC code for the duration of this utility and return to level two OR Press to exit the Diagnostic Menu and return to level zero VAR ENTER BIAIS ib Be If LdLrn or FbLrn are selected Press to return to level two OR Press to exit the Diagnostic Menu and return to level zero Note Only these two keys are valid while ProCES is flashing or while dOnE is displayed However pressing either key while ProCES is flashing interrupts the Learn operation and no new value is stored into Var01 07 or Var01 08 Invalid Keys Pressing vs e C J or Ce results in no action other than lighting the ERR error led Ref Sect page 21 bA02 XX 101701 Keypad Menus Diagnostic Menu cont Encoder Pulses Per Index Learn Utility cont Step By Step PPI Learn Procedure Note The feedback encoder Pulses Per Revolution value should be entered into Var01 02 before executing this utility Enter the Pulse Per Index learn utility l Open the MS332 RUN switch open the contact across TB3 pins 1 and 2 2 F
111. level 0 not in a menu press enter the Diagnostics menu 3 Press A Or v several times until Anou appears on the display Press enter Analog Output calibration Adjust Analog Output Offset 4 Press A or v until oFFSE appears on the display Press enter Offset voltage adjustment 5 Observe the follower system and listen to its motor If itis completely still not even slightly rotating press 4 until the follower creeps forward then press until it stops then press save the adjusted offset voltage and proceed to step 6 If it is rotating forward even slightly creeping press v until it stops then press save the adjusted offset voltage and proceed to step 6 If it is rotating reverse even slightly creeping press 4 until it the follower creeps forward then press until it stops then press save the adjusted offset voltage and proceed to step 6 Adjust Analog Output Scale 6 Press La or v until Pc dAC appears on the display Press enter DAC adjustment 7 The display will initially show 000 0 Press and hold 4 until the display shows 090 0 DAC at 90 0 of full scale This will take about 70 seconds The follower motor should start rotating steadily increasing in speed If you scroll past 90 0 just press CV and J to get exactly 090 0 When the display shows exactly 090 0 press temporarily keep the DAC at 90 0 of full scale 8 Press 4 or v until SCALE appears on th
112. ll is enabled for Master Ratio Follower or Index Follower modes if both of the following requirements are met Advance Retard Scroll is never enabled for Jog mode 1 The feedback encoder loop is closed applies to all three modes 2 The feedback index loop is open applies to Index Follower mode only The conditions for meeting these requirements are listed in the rows of this table Operating Var01 06 Code Any Var07 00 gt 06 Open loop switch Var07 12 Code Mode Fol Mod Config Code 8 Open loop Open loop Config Master No Master Yes Open Master Yes Closed 0 or 2 enable encoder loop Follower 0 NoIndex No Follower 0 NoIndex Yes Open Follower 0 NoIndex Yes Closed 0 or 2 enable encoder loop Follower 1 Index Yes Closed 2 enable encoder loop disable index loop Note The term phase offset is not to be confused with the term Phase Set point Phase Set point In Index Follower mode with index loop closed the absolute position of the feedback encoder relative to the lead encoder is measured and corrected per the active Phase Set point each time the selected pair lead and feedback of index pulses is received In between such index pulse pairs the phase from the previous correction is maintained In Index Follower mode with index loop closed there is no phase offset or Advance Retard Scroll feature phase changes in this m
113. ll other User Variables are accessible with serial communications Do not change these variables in a networked MS332 while the Master is transmitting queries The Master should be disabled or MS332 disconnected before any of these variables are changed User Var Values Usage Notes Var08 00 1 247 Slave Address Sets the MS332 s Modbus slave address Var08 01 0 4 Baud Rate Selects Baud Rate Var08 02 0 2 Parity Selects or Disables Parity Var08 03 1 Mode Modbus mode RTU only Var08 04 0 5 Data Type Select Data Type 16 bit word ordering Var08 00 Value Slave Address Slave Address Var08 00 value 1 1 2 2 247 247 Var08 01 Value Baud Rate Baud rate selected by Var08 01 value 0 1200 1 2400 2 4800 3 9600 4 19200 Var08 02 Value Parity Parity enabled disabled selected by Var08 02 value 0 Disabled 2 stop bits when parity is disabled 1 Enabled Odd 1 stop bit when parity is enabled 2 Enabled Even 1 stop bit when parity is enabled Var08 03 Value Mode Message framing selected by Var08 03 value 0 ASCII Not implemented 1 RTU Var08 04 Value Data Type Address XXXX0 Access Address XXXX1 Access 0 float 32 bit High 2 bytes 32 of 3210 Low 2 bytes 10 of 3210 1 float 32 bit Low 2 bytes 10 of 3210 High 2 bytes 32 of 3210 2 long int 32 bit High 2 bytes 32 of 3210 Low 2 bytes 10 of 3210 3 long int 32 bit Low 2 bytes 10 of 3210 High 2 bytes 32
114. lse signal Switch Inputs 8 switch inputs 1 dedicated Run Stop 7 user programmable 12 user assignable switch input functions Keypad 9 button tactile 6 user selectable lockout options Analog Output 1 dedicated motor drive control analog configurable for Bipolar input volts and Contactor Reversing volts with contactor reverse input type motor drives NPN Transistor Outputs 4 user programmable open collector NPN outputs 8 user assignable NPN output functions Alarm Annunciator and Control functions Display 6 character 7 segment alphanumeric LED display for real time menu and error information 16 user selectable real time display options 5 discrete annunciator LEDs Encoder Index Power Supply 12Vdc 300mA for powering incremental encoders and event index sensors Serial Communications Interface Port Modbus RTU protocol 1 Balanced EIA 485 tri state driver 1 Balanced EIA 485 receiver Operational Accuracy Master mode maximum speed set point error 0 004 0 C 0 002 25 C 0 010 70 C Follower mode cumulative error Zero 0 70 C Processor 16MHz 32 bit PID loop update rate 1024 per second 977 uS NPN Output update rate 51 2 per second 19 5 mS Switch Input read rate 51 2 per second 19 5 mS Keypad read rate 51 2 per second 19 5 mS Display update rate 2 56 updates per second 391 mS Specification Section page 1 bA02 XX 101801 Electrical Line Voltage Line Power Fuse in
115. mize limitations imposed on the control loop by the drive thereby allowing the MS332 more control Electrical connections Note Do not apply power to the MS332 yet Connect all necessary components for Index Follower Mode Operation Connect a small wire from the rear panel TB3 3 Switch Input 1 to TB3 5 Ground C This will serve as a closed switch to the Closed loop Open loop Switch Input Function more on this in step 7 See Description of Operating Modes Section Index Follower Mode for a block diagram showing basic necessary components For details about terminal connections and terminal strips see the following See Reference Section Hardware Illustrations for a general Rear View diagram showing the MS332 terminal strips and the individual pin outs See Reference Section Encoder Index Inputs Power Supply Outputs Terminal Connections for a further detailed diagram showing the Encoder Index connections See Reference Section Switch Inputs Terminal Connections for a further detailed diagram showing the connections available for the Run Stop switch and the Closed loop Open loop switch See Reference Section Analog Output Terminal Connections for a further detailed diagram showing the Analog Output connections See Physical Installation Section Wiring for details on proper wiring shielding grounding etc Set up Sect page 12 bA02 XX 022301 3 MS332 DIP Switch settings bA0
116. mp Pair po Accel O and Decel 0 Accel 1 and Decel 1 Note Var02 05 is overridden has no effect when the Active Ramp Pair Select Switch Input Function is assigned to a Switch Input See Reference Section Switch Inputs for details on this method Switch Input selected Accel Decel Ramp pair See Reference Section Switch Inputs for details on assigning and using the Active Ramp Pair Select Switch Input Function Causes and Criterion for Ramping In a given operating mode certain events enable ramping in the MS332 When one such enabling event occurs the MS332 checks the ramp criterion to decide whether or not to ramp If the ramp criterion is true the MS332 ramps to the Target Feedback RPM otherwise the MS332 achieves the Target Feedback RPM by normal means In most cases the ramp criterion is whether the Current Feedback RPM to Target Feedback RPM difference is greater than 10 of the process maximum Feedback RPM Current Enabling Event Ramp Criterion Operating Mode All Run Stop Switch Input Current RPM Target RPMI gt 0 1 Var01 00 Change open or close All Fast Stop Switch Input Current RPM Target RPMI gt 0 1 Var01 00 Change open or close Jog Master Setpoint value or selection Current RPM Target RPMI gt 0 1 Var01 00 Ratio Follower Change All Operating Mode Change Current RPM Target RPMI gt 0 1 Var01 00 All Fwd Rev Switch Input Always ramp Change open o
117. mp rates are Var01 00 Var02 0X Acceleration Ramp Variables Enter the desired time in seconds to ramp the feedback encoder RPM from 0 to Var01 00 The value may range from 0 1 to 3600 0 seconds Variable 02 00 Accel Ramp 0 Variable 02 01 Accel Ramp 1 Deceleration Ramp Variables Enter the desired time in seconds to ramp the feedback encoder RPM from Var01 00 to 0 The value may range from 0 1 to 3600 0 seconds Variable 02 02 Decel Ramp 0 Variable 02 03 Decel Ramp 1 Variable 02 04 Fast Stop Decel Ramp See Reference Section Switch Inputs Functions for details on the Fast Stop Switch Input Function Note The time values entered into Var02 00 Var02 04 define ramp rates of RPM change per second slopes The time the feedback encoder speed spends ramping depends on the initial pre ramp RPM the ramp rate and the final post ramp RPM Speed changes less than the maximum 0 RPM to Var01 00 ramp up or Var01 00 to 0 RPM ramp down spend less time ramping but still ramp at the same rate as these maximum speed changes Ref Sect page 42 bA02 XX 101701 Operational Variables Acceleration and Deceleration Ramps cont Ramp selection Accel Decel ramps are selected together Ramp pairs may be selected by either Var02 05 Active Ramp Pair Select or by a Switch Input Variable 02 05 selected Accel Decel Ramp pair Enter the code to select the desired active ramp pair Var02 05 CODE Selected Active Ra
118. nal and Integral Compensation Variable 03 02 Derivative Gain Var03 02 controls how hard any instantaneous phase difference errors are driven to zero This is done by controlling the amount or strength of the Derivative Compensation The allowed range is 1 gt 100 Generally speaking larger values result in tighter stiffer phase control If the Derivative Gain is set too high for the drive motor load encoder subsystem phase control will worsen resulting in phase oscillations Generally a higher resolution encoder will require less Derivative Gain than a lower resolution encoder A zero value disables turns off Derivative Compensation Variable 03 03 Derivative Sample Period This is the time between re calculations of the Follower phase difference error deviation for Derivative Compensation The allowed range is 0 001 gt 1 000 seconds Generally speaking setting this variable to smaller values makes the Derivative more effective but for any system that benefits from Derivative Compensation there will be a point of diminishing or even counterproductive returns below which no more or even less phase difference accuracy is achieved Note ratio scaled lead encoder is a lead encoder speed or count value multiplied by a ratio factor This ratio factor is determined by the Follower mode used In Ratio Follower mode ratio the selected Follower Speed Ratio Set point In Index Follower mode ratio var01 10 v
119. nd Var01 02 Feedback Encoder PPR must both be written with correct values before running this Analog Output Calibration Utility Level Two Select Analog Output calibration characteristic Use this level to select from among Pc dAC OFFSET and SCALE This is on the second level of the Diagnostic Menu L gigg BE Note Enter level two by selecting Anou in the display window from level one of the Diagnostic Menu See Keypad Menus Diagnostics Menu Level One for a discussion of level one Tach prog BUN SET oo LED s Display Window oO All of the status led s are lit except for the ERR led Display Window initially shows the last changed Analog Output De d a d characteristic with all the display characters flashing Ex Showing Pc dAC for temporary Percent of DAC code Valid Keys To select which Analog Output characteristic to adjust e EN Press LA or UY to select Pc dAC oFFSET or SCALE When the desired selection is displayed press to confirm and enter level three of the Analog Output Calibration Utility OR Press to exit the Diagnostic Menu and return to level zero ENTER Invalid Keys Pressing vs Ey Ca J or CJ results in no action other than lighting the ERR error led Notes on Feedback Encoder Reverse Operation Operating in the Reverse or opposite direction requires using a bidirectional motor drive See Reference Section Analog Output for related inform
120. nd their use User Var Modbus Address Description Range 07 00 47000 Switch input function assign 0 gt 12 07 01 47010 Switch input 2 function assign 0 gt 12 07 02 47020 Switch input 3 function assign 0 gt 12 07 03 47030 Switch input 4 function assign 0 gt 12 07 04 47040 Switch input 5 function assign 0 gt 12 07 05 47050 Switch input 6 function assign 0 gt 12 07 06 47060 Switch input 7 function assign 0 gt 12 07 07 47070 Master speed scroll step 000001 gt 100 000 07 08 47080 Ratio fol speed ratio scroll step 000001 gt 100 000 07 09 47090 Phase scroll step 0 gt 100 07 10 47100 Jog speed scroll step 000001 gt 100 000 07 11 47110 Jog mode ramp configuration 0 gt 3 07 12 47120 Open loop configuration 0 gt 3 07 13 47130 Master Follower mode select 0 Follower 1 Master 07 14 47140 Phase change release time sec 0 01 gt 100 0 08 00 Not serially accessible Modbus Slave Address 08 01 Not serially accessible Baud Rate select 08 02 Not serially accessible Parity select 0 08 03 Not serially accessible Modbus mode RTU ASCID 08 04 Not serially accessible Datatype select 09 00 49000 Aout calibrate OFFSET 734 734 09 01 49010 Aout calibrate SCALE 0 gt 1150 Notes Each Display Value Input Register address includes the corresponding User Var 05 00 Display Se
121. nections Note Do not apply power to the MS332 yet Connect all necessary components for Master Mode Operation See Description of Operating Modes Section Master Mode for a block diagram showing basic necessary components For details about terminal connections and terminal strips see the following See Reference Section Hardware Illustrations for a general Rear View diagram showing the MS332 terminal strips and the individual pin outs See Reference Section Encoder Index Inputs Power Supply Outputs Terminal Connections for a further detailed diagram showing the Encoder connections See Reference Section Switch Inputs Terminal Connections for a further detailed diagram showing the connections available for the Run Stop switch See Reference Section Analog Output Terminal Connections for a further detailed diagram showing the Analog Output connections See Physical Installation Section Wiring for details on proper wiring shielding grounding etc Set up Sect page 1 bA02 XX 022301 MS332 DIP Switch settings bA02 XX Note Do not apply power to the MS332 until the DIP Switches have been set DIP Switch Diagram for Master Mode This diagram shows the MS332 DIP switches looking down on top of the MS332 front panel on the left Do steps a and b to set all of the MS332 DIP Switches a DIP switches corresponding to unused inputs Leads Indexes Aux 0 Aux 1 are shown in this
122. ng MS332 data using the various Data Types Ref Sect page 55 bA02 XX 101701 Serial Communications cont Procedure Remote Analog Output Calibration Notes The MS332 Analog Output must be calibrated to the motor drive and the process This procedure provides a Serial Communications alternative to the Keypad method given in the Reference Section Keypad Menus Diagnostic Menu Analog Output Calibration Utility To execute this procedure the MS332 must first be wired for optional Jog Mode operation Jog Mode is an open loop speed control mode the actual encoder speed has no effect on the Analog Output DAC only the Jog speed set point determines the DAC value When the Analog Output is calibrated open loop to your process closed loop performance is improved because less compensation is required Connect an unused MS332 Switch Input to Ground C either through a closed switch or a wire This Switch Input will enable Jog Mode selection for calibrating the Analog Output Example Connect TB3 pin 7 Switch Input 4 to TB3 pin 8 Ground C Modbus addresses accessed This procedure requires accessing certain MS332 Display Values and User Variables over Serial Communications The Modbus address type of access read write and description of each is listed below Address Access Description 31000 Read Feedback encoder speed Display option 0 41000 Read Process max feedback encoder RPM Var01 00 41010 Write Process max
123. ntactor Reversing Drives input voltage alone controls both speed and direction of rotation Do not assign the Contactor Reverse NPN Output function code 14 should not be entered into any of the function assignment variables Vars04 00 to 04 03 This configures the MS332 analog output voltage to swing bipolar positive or negative voltage swing from the offset voltage b Contactor Reversing Drives a positive voltage controls speed a contactor input determines direction of rotation Assign the Contactor Reverse NPN Output function to an NPN Output enter code 14 into one of the NPN Output function assignment variables Vars04 00 to 04 03 This configures the MS332 analog output voltage to swing unipolar positive voltage swing from the offset voltage for speed control and enables the selected NPN Output to control rotation direction NPN Output OFF Fwd ON Rev Note There are various contactor input configurations and polarities among the various contactor reversing type drives so direct MS332 NPN Output to drive contact input control may or may not be possible For drives incompatible with direct MS332 NPN Output control a relay can be used between the MS332 NPN Output and the drive contact input s to achieve compatibility See Set up Section WPN Outputs for details on how to set up NPN Outputs See Reference Section NPN Outputs for more information on the Contactor Reverse Function See Reference Section Analog Output
124. o LED s Display Window All of the status led s are lit except for the ERR led Display Window initially shows all the NPN Outputs in the selected group are OFF with the right most digit flashing When an Output is OFF then the status is a 0 When an Output is ON then the status is a 1 Valid Keys To test an NPN Output Press EJ or to select which individual output to test from the group Press 2 or BI to toggle ON OFF the selected flashing output Press to save only for the duration of the diagnostic the status of each NPN Output in the group and return to level two OR Press to exit the Diagnostic Menu and return to level zero without saving the temporary statuses of the NPN Outputs Invalid Keys Pressing var or Ce results in no action other than lighting the ERR error led Ref Sect page 12 bA02 XX 101701 Keypad Menus Diagnostic Menu cont Analog Output Calibration Utility This utility facilitates changing the Analog Output s offset voltage and DAC code voltage sensitivity When invoked the analog output voltage Vout obeys the following formula Vout oFFSET volts SCALE volts Pc dAC 100 Pc dAC sets a temporary DAC code for the duration of this utility The units of Pc dAC are of full scale DAC 4095 for the 12 bit DAC Pc dAC may range from 100 0 to 100 096 OFFSET sets the Vout component that is independent of DAC co
125. ode are accomplished by changing the active phase set point Advance Retard Scroll has no effect on Phase Set points and is not enabled in Index Follower mode unless the feedback index loop is open Phase offset In Master and Ratio Follower modes i e closed loop modes without index phase correction the position of the feedback encoder is dictated solely by its starting position phase offset Master speed set point or Follower ratio set point lead speed and time The phase offset may be changed only through the Advance Retard mechanism Unlike Phase Set points the phase offset defaults to zero at power up and mode changes See Reference Section Keypad Keypad Level Zero for details on keypad level zero See Reference Section Switch Inputs for details on assigning and using any of the Scroll Switch Input Functions See Reference Section VOperational Variables Active Set point Selection for details on the active set point See Reference Section Operational Variables Set points and Set point Units for information on changing any active or non active set point Ref Sect page 32 bA02 XX 101701 Encoder Index Inputs Power Supply Outputs Terminal Connections DIP Switches Encoder Vars 01 00 01 02 01 03 01 05 to 01 08 01 12 Index Averaging Matching Vars 01 09 to 01 11 The MS3322 takes input signals from a lead encoder a feedback encoder a lead index device and a feedback index device The
126. ode controls follower motor speed causing the feedback encoder to follow the lead encoder according to the rpm ratio while simultaneously positioning feedback index pulses relative to lead index pulses according to the index phase set point When using a bidirectional drive and motor the feedback encoder follows the lead encoder in either direction forward or reverse The connections to the MS332 lead and feedback encoder inputs and lead and feedback index inputs are as shown in the following diagram INDEX FOLLOWER CONTROLLED APPLICATION LEAD ENCODER SIGNAL LEAD INDEX PULSE SIGNAL ERI RU INDEX DEVICE i MASTER MS332 IN CONTROLLED i QUADRATURE INDEX FOLLOWER Braise prin E i ENCODER i i QUADRATURE GROUND C E EJ anatoc DRIVE CONTROLLED 9 OHA output PROCESS CLOSED LOOP OPEN FEEDBACK INDEX PULSE SIGNAL LOOP SWITCH FOLLOWER FEEDBACK ENCODER SIGNAL 1 FF L Control Theory Index Phasing Index phase corrections position the effective feedback index pulses relative to the effective lead index pulses according to the Index Phase set point In this way a periodic feedback process event may be precisely phased to precede coincide with or follow a periodic lead process event by a desired number of feedback encoder pulses Index phase corrections occur immediately after each effective feedback index pulse RPM Ratio Between index phase corre
127. of 3210 4 int 16 bit 2 bytes entire value Illegal exception code 02 5 unsigned int 2 bytes entire value Illegal exception code 02 16 bit Note The RTU mode character frame format is always 11 bits total Start Bit 8 Data Bits Parity Bit and 1 Stop Bit parity enabled or 2 Stop Bits parity disabled Ref Sect page 51 bA02 XX 101701 Serial Communications cont Modbus Implementation 1 MS332 Modbus Address Mapping Modbus defines separate address spaces for Coils OX XXX Discrete Inputs 1XXXX Input Registers 3XXXX and Holding Registers 4XXXX MS332 outputs inputs Display Values and User Variables are mapped into these spaces as indicated in the following tables NPN Outputs Modbus Coil OXXXX mapping NPN Output Modbus Address Description Range 0 01000 NPN output 0 0 OFF 1 ON 1 01001 NPN output 1 0 OFF 1 ON 2 01002 NPN output 2 0 OFF 1 ON 3 01003 NPN output 3 0 OFF 1 ON Switch Inputs Front Panel Keypad Modbus Discrete Input 1LXXXX mapping Switch Input Modbus Address Description Range 0 11000 Switch Input 0 Run Stop 0 OFF 1 ON 1 11001 Switch Input 1 0 OFF 1 ON 2 11002 Switch Input 2 0 OFF 1 ON 3 11003 Switch Input 3 0 OFF 1 ON 4 11004 Switch Input 4 0 OFF 1 ON 5 11005 Switch Input 5 0 OFF 1 O
128. om 0 to Var01 00 MAX RPM acceleration or from Var01 00 MAX RPM to 0 deceleration Var02 00 Var02 01 are acceleration time variables Var02 02 Var02 03 are deceleration time variables Var02 00 Var02 02 form a pair and Var02 01 Var02 03 form a pair The factory default active pair is Var02 00 Var02 02 Enter your desired acceleration and deceleration ramp times See Reference Section Operational Variables Acceleration and Deceleration Ramps for details on using Var02 05 to select the active Acceleration Deceleration Ramp Pair using the keypad See Reference Section Switch Inputs for details on selecting the active Acceleration Deceleration Ramp Pair using a Switch Input Set up Sect page 4 bA02 XX 022301 9 PID Proportional Gain and Integral Time adjustments a Var05 00 Display Selection Enter code 5 to choose closed loop feedback error b Close the Run Stop switch Observe the feedback behavior at the top of the acceleration ramp and while it runs steady state Notes If the feedback encoder response is unstable large erratic displayed error motor jerking oscillating try reducing Var03 00 s value proportional gain If the feedback encoder response is sluggish large slow changing displayed error try increasing Var03 00 s value If the Var03 00 changes don t significantly improve the feedback encoder response or if they get toa point of diminishing return try adjusting Var03 01 integ
129. om Port TX TB4 17 Modbus RS485 TX TB4 15 TB4 18 Ground B Ground B TB4 18 z Analog Input 1 E TBI nalog Input 1 g 3 z 4 a TBI 2 Analog Input 1 H Li FE 10 Vdc Ref 4 TB1 8 28 TBI 3 Analog Input 2 2 bj t 29 E 10 Vdc Ref gnd TBI 9 TB1 4 Analog Input 2 m 4 S Analog Output 1 TB1 5 TB4 1 Aux Input 0 TB4 12 Ground C Ground A TB1 6 z Analog Output 2 TB1 7 TB4 13 Aux Input 1 See Note 3 T m pis Ground C E NPN Output Protection Cathode TB3 13 Ha ga B4 2 12Vdc C Encoder Index Pwr 3 E NPN Output 0 TB3 14 TB4 3 Lead Ch lA S DOES s NPN Output 1 TB3 15 TB4 4 E Lead Channel B Ps z NPN Output 2 TB3 16 TB4 5 Lead Index a NPN Output 3 TB3 17 TB4 6 Ground C 5 7 Ground C TB3 18 amp TB4 7 12Vdc C Encoder Index Pwr E RS TB4 8 Feedback Channel A Ra T 73 B4 9 Feedback Channel B El S Display I S s TB4 10 Feedback Index Window and z TB3 1 Switch Input 0 Run Stop Status LED s TB3 2 Ground C TB3 3 Switch Input 1 TB3 4 Switch Input 2 TB3 5 Ground C TB3 6 Switch Input 3 synduy yms TB3 7 Switch Input 4 TB3 8 Ground C TB3 9 Switch Input 5 TB3 10 Switch Input 6 TB3 11 Ground C TB3 12 Switch Input 7 Note 1 The Analog Input circuitry is referenced to Ground A Note 2 The 10 Vdc Ref gnd is internally tied to Ground A Note 3 Not all I O shown here in this Block View diagram are available on the standard MS332 Certain I O are opti
130. on Contactor Reversing Drives control voltage determines both speed and direction of motor rotation For these drives a positive control voltage rotates the motor in one direction while a negative control voltage rotates the motor in the opposite direction Do not assign the Contactor Reverse NPN Output function code 14 should not be entered into any of the function assignment variables Vars04 00 to 04 03 Leaving this function unassigned configures the MS332 analog output voltage to swing bipolar positive or negative voltage swing from the offset voltage b Contactor Reversing Drives positive control voltage determines speed contactor input determines direction of motor rotation Assign the Contactor Reverse NPN Output function to an NPN Output enter code 14 into one of the NPN Output function assignment variables Vars04 00 to 04 03 This configures the MS332 analog output voltage to swing unipolar positive voltage swing from the offset voltage for speed control and enables the selected NPN Output to control rotation direction NPN Output OFF Fwd ON Rev Note There are various contactor input configurations and polarities among the various contactor reversing type drives so direct MS332 NPN Output to drive contact input control may or may not be possible For drives incompatible with direct MS332 NPN Output control a relay can be used between the MS332 NPN Output and the drive contact input s to achieve compatibility See
131. onal Ref Sect page 3 bA02 XX 101701 Display Status LED s Display Window Display Var 05 00 The MS332 front panel has five status LED s and a 6 digit Display Window as shown here Status LED s show T pros PH SED El Display Menu and O j Operation Status 4 Display Window MS332 MOTION CONTROLLER Status LED s The meanings of the Status LED s and their various combinations are indicated in the following table TACH PROG RUN SET ERR Meaning STOP SPD ON OFF X OFF X Display shows real time display information according to Var05 00 OFF ON X OFF X Display shows Change Variable Menu information X X ON X X Selected operating mode is running Run Stop switch closed Fast Stop switch if assigned open OFF O FF X ON X Display shows Change Set Point Menu Set Point scroll or Advance Retard scroll info X X X X ON Indicates an error condition See Appendix Sect ERR led Errors ON ON ON ON OFF Display shows Diagnostics Menu information OFF ON OFF ON X Display shows Keypad Security Menu information Note X indicates don t care the LED can be ON or OFF Display Window The Display Window shows real time information as selected by Var05 00 when at Keypad Level Zero See Reference Section Keypad for details on Keypad Level Zero Display Window Variable Variable 05 00 Display Selection Enter the selection code for the desired real time d
132. ort is electrically isolated from all other MS332 circuits and terminals If desired reference common Ground B may be tied to an external reference potential Separate terminals are provided for the driver receiver and reference common Ground B The driver tri state outputs TX TX are transmitter controlled remaining in Hi Z state when not transmitting The interface port is compatable with both 4 wire TX TX RX RX all separate and 2 wire TX RX connected TX RX connected network configurations The interface port is multi slave compatible in both 2 wire and 4 wire network configurations Interface Port Terminal Connections TB4 Bottom Edge MS332 Rear View See Reference Section Hardware Illustrations Rear View for a complete diagram showing the details of terminal strip TB4 containing the Serial Communication Ports on the back of the MS332 package Interface Port Electrical Diagram 5 Vdc internal Ground B Ref Sect page 50 bA02 XX 101701 Serial Communications cont Serial Protocol MS332 Serial Communications use the Modbus RTU protocol configured as a Slave Modbus is a trademark of Modicon Inc Serial Communications User Variables MS332 class 8 Var08 0X User Variables configure serial communications These variables are accessible from the Front Panel Keypad Display only serial communications User Variables are not accessible with serial communications A
133. ostic Menu Flashes when selecting the Feedback Learn operation in the Encoder Pulses per Index Learn utility Diagnostic Menu Flashes when selecting the set temporary Feedback Speed operation in the Encoder Pulses per Index Learn utility Diagnostic Menu Flashes when selecting the Keypad diagnostic Diagnostic Menu Displayed when trying to see the value of the PASdEF variable while the keypad is locked PASdEP s value is hidden during keypad lock Keypad Security Menu Flashes when selecting the Lead Learn operation in the Encoder Pulses per Index Learn utility Diagnostic Menu Flashes when the Display Window is set via Var05 00 to display the follower speed ratio and there are no lead encoder pulse received at terminals TB4 3 and TB4 4 can t calculate speed ratio if lead speed is zero Flashes when testing the Left arrow key in the Keypad diagnostic Diagnostic Menu Flashes when selecting the Switch Input group in the Switch Inputs Observation diagnostic Diagnostic Menu Flashes when feedback encoder pulses are not received when they should be indicating a no feedback condition Flashes when testing none of the keys in the Keypad diagnostic Diagnostic Menu Flashes when selecting the NPN Outputs diagnostic Diagnostic Menu Flashes when selecting the OFFSET variable in the Analog Output Calibration utility Diagnostic Menu Flashes when selecting the NPN Output group in the NPN Output test diagnostic
134. otor Drive Compatibility a Non Contactor Reversing Drives input voltage alone controls both speed and direction of rotation Do not assign the Contactor Reverse NPN Output function code 14 should not be entered into any of the function assignment variables Vars04 00 to 04 03 This configures the MS332 analog output voltage to swing bipolar positive or negative voltage swing from the offset voltage b Contactor Reversing Drives a positive voltage controls speed a contactor input determines direction of rotation Assign the Contactor Reverse NPN Output function to an NPN Output enter code 14 into one of the NPN Output function assignment variables Vars04 00 to 04 03 This configures the MS332 analog output voltage to swing unipolar positive voltage swing from the offset voltage for speed control and enables the selected NPN Output to control rotation direction NPN Output OFF Fwd ON Rev Note There are various contactor input configurations and polarities among the various contactor reversing type drives so direct MS332 NPN Output to drive contact input control may or may not be possible For drives incompatible with direct MS332 NPN Output control a relay can be used between the MS332 NPN Output and the drive contact input s to achieve compatibility See Set up Section WPN Outputs for details on how to set up NPN Outputs See Reference Section NPN Outputs for more information on the Contactor Reverse Function
135. ously mentioned selective disabling is defined When the keypad is locked SECdEF s five right most digits define which if any keypad features are lock disabled SECdEP s digit to keypad lock effect correspondence is as follows SECdEF digits O0XXXXX 2 3 Change Variable Menu editing Change Set point Menu editing Diagnostic Menu Set point Scroll Advance Retard Scroll Unused must be zero i The allowed SECdEF digit values and their effects are as follows Digit value Effect on corresponding keypad feature when keypad is locked 1 Disabled 0 Enabled Note Each SECdEF digit will accept a 1 ora 0 only The left most digit is unused and must be 0 Note When the keypad is unlocked each of the three keypad security variables may be observed and changed in the Keypad Security Menu The effects of keypad lock on the security variables are as follows Keypad security variable Effect of keypad lock PASIn None always observable and changeable PASdEF May not be observed or changed SECdEF May be observed but not changed Ref Sect page 24 bA02 XX 101701 Keypad Menus Keypad Security Menu cont Follow these steps to access the Keypad Security Menu Level One Select security variable Use this level to select from among PASIn PASdEF and SECdEF This is the first level of the Keypad Security Menu Note Enter level one by pressing RUN SET TACH PROG STOP SPD ERR oOoeo
136. played Press A the mnemonic UP is displayed ABE age alala Press Cy the mnemonic dn is displayed Press eren the mnemonic SP is displayed Press EJ the mnemonic LEF is displayed Press gt the mnemonic rI9h is displayed Press enten the mnemonic En is displayed Press Ce the mnemonic dP is displayed Press to exit the Diagnostic Menu and return to level zero Invalid Keys NONE Ref Sect page 16 bA02 XX 101701 Keypad Menus Diagnostic Menu cont Display Window Diagnostic Level Two Test the Display Window Use this level to test if the Display Window is working properly by correctly displaying the numbers 0 through 9 This is on the second level of the Diagnostic Menu Note Enter level two by selecting dISP in the display window while at level one of the Diagnostic Menu See level one above LED s Display Window All of the status led s are lit except for the ERR led Display Window initially shows the last number tested with all the digits flashing Ex Flashing 777777 in all the digits Valid Keys To test the Display Window for the digits 0 through 9 Press to increment the Display Window digits 111111 222222 333333 etc is displayed when the key is repeatedly pressed Press to decrement the Display Window digits 999999 888888 777777 etc i
137. ptions of each operating mode Use this section to understand the operating modes or to look up basic information on a particular operating mode The descriptions in this section describe the external hardware operation and control theory for each MS332 operating mode 2 Physical Installation Section mounting wiring Use this section to look up mounting and wiring instructions options and guidelines 3 Set up Section complete step by step set up procedures for setting up each operating mode Use the corresponding step by step procedure in this section to set up the MS332 for a given operating mode The intent of this section is to provide clear set up procedures that avoid all nonessential information Each procedure guides the user through all necessary steps to set up for that operating mode Note Facility in using the keypad menus and changing user variables is required For details see the Reference Section Keypad subsection 4 Reference Section a complete and detailed product reference Use this section to look up specific information describing the function use and operation of user variables and hardware Many details relating to the internal operation are also included in the subsections of this section 5 Specifications Section Use this section to look up functional operational electrical environmental and mechanical specifications 6 Appendix Section Use this section to access various information not includ
138. r close change direction by ramping through zero RPM Note In Jog mode acceleration or deceleration ramps are further qualified by Var07 11 Jog Mode Ramp Configuration If Var07 11 disables acceleration ramps the Analog Output voltage will step up to the new voltage Similarly if Var07 11 disables deceleration ramps the Analog Output voltage will step down to the new voltage Ref Sect page 43 bA02 XX 101701 Operational Variables cont PID Compensation Each of the MS332 s closed loop control modes utilize PID compensation to help achieve and maintain precise accurate speed and phase control The MS332 control loop reads the encoders recalculates the PID terms and writes the Analog Output DAC 1024 times per second Four user programmable PID variables are provided for tuning the closed loop system When adjusting these variables it is best to test the dynamic performance start stop load changes set point changes in addition to the steady state performance running at set point constant load of the system MS332 PID compensation and the four PID variables are described in the following MS332 Proportional Compensation The MS332 proportional compensation maintains accurate speed control In Master mode the proportional compensation drives the difference between the active speed set point and the feedback encoder speed to zero In the Follower modes the proportional compensation drives the difference between the
139. r pulses per feedback index pulse When finished the display shows dOnE the measured feedback PPI value has been written into variable 1 07 Exit the Pulse Per Index learn utility 13 Press exit the Diagnostics menu The follower system will stop PPI Learn is complete Ref Sect page 22 bA02 XX 101701 Keypad Menus Diagnostic Menu cont Product Version Revision Diagnostic Level Two Observe Product Version Revision code Use this level to observe the MS332 product version revision code Note Enter level two by selecting UErrEU in the display window while at level one of the Diagnostic Menu See level one above rach pros BUN SET er LED s Display Window o o 00 All of the status led s are lit except for the ERR led Display Window shows the Product Version Revision code 5 n 9 dE D Ex Showing bA00 00 Basic MS332 Version 00 Revision 00 Valid ae Press to exit the Diagnostic Menu and return to level zero SETPT Invalid Keys Pressing vs e A v E lt or Ce results in no action other than lighting the ERR error led ENTER 38 Y owe Ref Sect page 23 bA02 XX 101701 Keypad Menus cont Keypad Security Menu Keypad Security allows selective disabling of keypad menu editing and level zero scrolling when the keypad is locked The effect of each selected disable is as follows Keypad feature disabled Effect when disabled Chan
140. r stretching in the medium coupling the encoder shaft and index pulse trigger multiple somewhat unevenly spaced index pulse triggers per mechanical cycle and multiple irregularly shaped oriented index pulse triggers In such cases this PPI variation alone causes periodic index phase corrections as the MS332 maintains the set point mandated feedback to lead index pulse phase relationship To mitigate the size of such index phase corrections MS332 provides user configurable feedback and lead encoder PPI measurement and averaging functionality controlled by Var01 09 When enabled averages of measured FbPPI and LdPPI values are used in determining the FBRPM LdRPM ratio see the formula given above in the RPM Ratio discussion When the RPM ratio runs on averages of measured PPI values instead of constant values that differ from the actual PPI values the magnitue of index phase corrections is reduced resulting in smoother operation When not enabled the constant PPI values of Var01 07 and Var01 08 are used Index Matching and effective Index Pulses The ratio Var01 10 Var01 11 defines an index match pattern Var01 10 feedback index pulses get matched with Var01 11 lead index pulses For most applications these two variables are each set to 1 feedback and lead index pulses occur 1 1 In these cases each lead pulse is effective and each feedback pulse is effective That is to say each feedback pulse causes index phase measurement and if nece
141. ral time constant Higher Var03 01 values will improve loop stability lower Var03 01 values will increase loop responsiveness Generally speaking it is desirable to have Var03 00 as large as possible and Var03 01 as small as possible this will result in the tightest most responsive control However if Var03 00 is set too high and or Var03 01 is set too low the feedback loop will become unstable Open the Run Stop switch Repeat b several times Higher Proportional Gain Var03 00 values make proportional compensation more aggressive up to a certain max value then causing loop instability above that value Lower Integral Time Constant Var03 01 values make integral compensation more aggressive down to a certain min value then causing loop instability below that value With the PID properly adjusted the displayed feedback error should drive towards zero at an acceptable rate determined by Var03 01 after the ramp After that the feedback error should stay zero or small and centered around zero 10 Display Selection Var05 00 Enter the selection code for the desired real time display Note Most Master mode applications use code 0 Feedback Encoder Speed in User Units See Reference Section Display Display Window Variables for details on Var05 00 selection codes 11 Setting up Var01 00 and Var01 01 for non RPM User Units Applications using non RPM user units such as threads min gallons hr require entering Var01 01
142. ratio scaled lead encoder and feedback encoder speeds to zero Variable 03 00 Proportional Gain Var03 00 controls how hard speed difference errors are driven to zero This is done by controlling the amount or strength of the proportional compensation The allowed range is 1 21024 Generally speaking larger values result in tighter stiffer speed control over the motor s range of loads If the Proportional Gain is set too high for the drive motor load encoder subsystem instability will result ranging from small speed oscillations after a set point or load change to continuous violent jerking Generally speaking a higher resolution encoder will require less Proportional Gain than a lower resolution encoder MS332 Integral Compensation The MS332 Integral Compensation maintains an accurate average feedback encoder phase or position This is particularly important in Follower mode applications such as electronic gearing and event synchronizing where a particular phase difference from the ratio scaled lead encoder must be maintained The phase or position difference is the cumulative difference in feedback encoder quadrature counts between the ratio scaled lead encoder and the feedback encoder Proportional Compensation achieves and maintains speed accuracy by maintaining a stable unchanging phase or position difference between the feedback encoder and the ratio scaled lead encoder under steady state conditions However a s
143. rence Section Analog Output and Reference Section NPN Outputs Contactor Reverse Function for related information 2 If the Reverse function is not assigned to a Switch Input then the direction is always Forward in Jog or Master modes and Same as lead encoder direction in the Follower modes 3 If the Reverse function assigned Switch Input changes state while the feedback encoder is running then the feedback encoder speed ramps through zero to the same speed in the opposite direction Ref Sect page 29 bA02 XX 101701 Switch Inputs Function Assignment Variables Function Assignment Variables 07 00 gt 07 06 Each Switch Input has a Function Assignment Variable for selecting the desired function These variables correspond to the Switch Inputs as shown in this table None Reserved for Run Stop To assign a certain Switch Input function to a certain Switch Input First find the desired Switch Input function from the table below Then enter the corresponding function code into the Switch Input s Function Assignment Variable To un assign a Switch Input function from a certain Switch Input Enter code 0 into the Switch Input s Function Assignment Variable The Switch Input Functions and their corresponding Codes are shown in this table Switch Input Function Function Code Run Stop None permanently assigned to Switch Input 0 Unused Switch Input 0 Advance Active Ramp Pair select 0 or 1 Fast Stop
144. rom keypad level 0 not in a menu press res enter the Diagnostics menu 3 Press A or Cy several times until the display flashes PPILrn Press E Ee enter PPI learn Determine Lead PPI 4 Run the lead system to generate lead encoder and index pulses The exact speed is not important 5 Press L amp or Ly until the display flashes LdLrn Press E Ee begin Lead PPI learn The display will flash PrOCES process while the MS332 counts the lead encoder pulses per lead index pulse When finished the display shows dOnE the measured lead PPI value has been written into variable 1 08 6 Stop the lead system 7 Press E Ey The display will flash LdLrn again Determine Feedback PPI 8 Press 4 Or v until the display flashes FbSPd Press enter feedback speed adjustment 9 The display will initially show 000000 feedback encoder stopped Press and hold A The follower system should start moving steadily increasing in speed The display shows the feedback encoder rpm 10 When the follower system is moving at a moderate speed the exact speed is not important remove your finger from 11 Press Ey The display will flash FbSPd again The follower system will continue moving allowing the MS332 to receive feedback encoder and index pulses 12 Press 4 or v until the display flashes FbLrn feedback learn Press ves The display will flash PrOCES process while the MS332 counts the feedback encode
145. s violent jerking A zero value disables turns off Integral Compensation Ref Sect page 44 bA02 XX 101701 Operational Variables PID Compensation cont MS332 Derivative Compensation The MS332 Derivative Compensation together with Integral Compensation attempts to maintain an accurate instantaneous feedback encoder phase or position It was previously explained how Integral Compensation drives the average phase difference error to zero This means that with Proportional and Integral Compensation only the Follower phase or position difference at any given instant may not be the exact desired value but on average the Follower phase difference will be the desired value Viewed over time the phase difference error may be described as a sum of the average value plus an instantaneous deviation or from the average value It is this instantaneous error component that Derivative Compensation attempts to drive to zero If Integral Compensation is viewed as reducing slow cumulative errors Derivative Compensation may be viewed as reducing fast non cumulative errors In many systems Proportional and Integral Compensation alone are fully adequate to achieve the desired system performance and in many systems Derivative Compensation produces little or no noticeable effect due to the response time limitations of the drive motor load encoder subsystem For these reasons Derivative Compensation is used less often than Proportio
146. s displayed when the key is repeatedly pressed Note The decimal point position of each digit is tested when the number 0 is tested The digits all flash with zeros but the decimal points are displayed without flashing Press to exit the Diagnostic Menu and return to level zero Invalid Keys Pressing vs er Ca gt or C results in no action other than lighting the ERR error led Ref Sect page 17 bA02 XX 101701 Keypad Menus Diagnostic Menu cont Factory Default Reset Utility Use this utility to reset all the variables the user program variables the Analog Output calibration values and the security variables to their factory default values Level Two Confirm intent to reset To avoid inadvertent execution of this utility level two prompts for confirmation of intent by offering two options 1 When entering level two the initial option is Do Not Proceed indicated by the SUrE n display mnemonic Pressing while SUrE n is displayed je no action other than lighting the ERR led 2 To confirm and proceed with reset press Or to select SUrE y Then press to proceed to level three and reset Option Display mnemonic Response to pressing Eey Do Not Proceed SUrE_n No action other than lighting ERR led Proceed SUrE_y Proceed to level three and reset Note Enter level two by selecting FACdEF in the display window while at level one of the Diagnostic Menu See level one above
147. s the feedback encoder position when the lead index pulse arrives minus the feedback encoder position when the feedback index pulse arrives Display value Fdbk encoder pulse count at Lead index Fdbk encoder pulse count at Fdbk index Note A positive value indicates the feedback index pulse leads arrives before the lead index pulse A negative value indicates the feedback index pulse lags arrives after the lead index pulse Displays the lead index pulse frequency in Hz Displays the feedback index pulse frequency in Hz Displays the average number of Lead Encoder Pulses received per Lead Index Pulse received Displays the average number of Feedback Encoder Pulses received per Feedback Index Pulse received Displays the status of Switch Inputs 3 2 land O ordered left to right across the display digits one digit per input 0 indicates an open input 1 indicates an closed input Displays the status of Switch Inputs 7 6 5 and 4 ordered left to right across the display digits one digit per input 0 indicates an open input 1 indicates an closed input Displays the status of NPN Outputs 3 2 1 and 0 ordered left to right across the display digits one digit per output 0 indicates the NPN is off 1 indicates the NPN is on Displays PID Integral term Ref Sect page 5 bA02 XX 101701 Keypad Keys Keypad Level Zero Keypad Menus Menu Access The MS332 front panel has a 9 key keypad as shown here Keys VAR
148. s value converted to RPM units into Var01 00 This value will be numerically different from Var01 01 s value but will represent the same maximum process output Example Master mode An MS332 is to control a water pump We want to use gallons per hour GPH for both the set point and display units Known The required process maximum flow is 90 0 GPH In The pump is rated to deliver 100 GPH when its shaft is rotating 1500 RPM Therefore our conversion factor is 1500 RPM 100 GPH this example our user units are GPH and our application s maximum process output in user units is 90 GPH Steps 1 2 The process output is flow measured in GPH The maximum process output is 90 0 GPH so enter 90 0 into Var01 01 Determine the process maximum feedback encoder RPM Var01 00 from the maximum process output Var01 00 value 90 GPH 1500 RPM 100 GPH 1350 RPM Enter 1350 into Var01 00 Now set points between 0 and 90 0 GPH may be used and the display will read in units of GPH Set up Sect page 5 bA02 XX 022301 Ratio Follower Mode Set up Procedure Description See Description of Operating Modes Section Ratio Follower Mode for a block diagram and discussion of Ratio Follower Mode Operation Set up Procedure 1 2 Follower Motor Drive adjustment settings Adjust the drive settings to match the motor according to the drive instructions Set the follower motor drive s maximum motor speed
149. sed to control the process output Configuration as in Open loop Configuration Digital to Analog Converter used in Analog Output circuitry To no longer access as in de accessing a Switch Input function Deceleration as in deceleration ramps Diagnostic mode or Diagnostic key on MS332 keypad Dual inline package switches as in Encoder Index Pull up and Pull down DIP Switches Pulses received from an encoder or ring kit Enter key on MS332 keypad Error as in the front panel ERR led A Switch Input function for quickly stopping the feedback encoder motor not an emergency stop Feedback as in feedback encoder or feedback signal pulses Feedback encoder Pulses Per Index pulse Index Follower mode Feedback encoder RPM 1 Pulses from the encoder or index sensor at the MS332 controlled process 2 Term sometimes used in place of the term follower as in feedback encoder meaning the same as follower encoder Follower mode as in Follower Mode Configuration variable An MS332 controlled process that tracks or follows an independent lead or Master process An MS332 follower mode where the follower encoder rotates at a setpoint ratio of lead encoder rpm i e electronic gearing An MS332 follower mode where follower index pulses are positioned or phased relative to lead index pulses according to a phase setpoint Function as in NPN Output or Switch Input functions Circuit common as in
150. selected NPN Output pin collector and the positive side of an isolated DC power supply referenced to Ground C on TB3 Note The internal 12C supply located on TB4 can be used See Reference Section NPN Outputs Terminal Connections for a further detailed diagram showing the connection s available for the NPN Outputs See Reference Section NPN Outputs Device Compatibility for what devices can be connected to the NPN Outputs Enter the desired NPN Output Function Code into the selected NPN Output s Function Assignment Variable Var04 00 Var04 03 See Reference Section WPN Outputs Functions for the table describing the NPN Output Functions See Reference Section WPN Outputs Function Variables for the table showing which Function Code corresponds to which NPN Output Function See Reference Section NPN Outputs Function Variables for the table showing which Function Assignment Variable Var04 00 through Var04 03 corresponds to which NPN Output If the selected NPN Output function requires a parameter value enter it into the selected NPN Output s Function Parameter Variable Var04 04 gt Var04 07 See Reference Section NPN Outputs Function Variables for the table showing which Function Parameter Variable Var04 04 through Var04 07 corresponds to which NPN Output See Reference Section NPN Outputs Function Variables for the table showing the type and units of the Func
151. ssary correction and each lead index pulse gets corrected to In some applications it is necessary to match index pulses in a non 1 1 pattern Var01 10 Feedback index pulses per match and Var01 11 Lead index pulse per match accomidate these applications by accepting integer values from 1 to 21474 Generally speaking n Var01 10 feedback index pulses get matched to m Var01 11 lead index pulses in a n m pattern with every nth feedback index pulse and every mth lead index pulse effective Desc Oper Mode Sect page 4 bA02 XX 101801 Jog Mode Description Input hardware Jog mode may use a single quadrature output incremental encoder on the driven shaft Operation Jog mode is a simple open loop mode similar to a speed pot where the output voltage is proportional to the Jog speed set point Although an encoder is generally connected for display purposes Jog mode does not use encoder pulses to drive the encoder RPM to the set point determined RPM but instead outputs a set point determined voltage independent of actual encoder RPM When using a bidirectional drive and motor forward and reverse Jog mode operation may be achieved by utilizing the Reverse Switch Input Function The basic connections necessary for Jog mode including an optional feedback encoder are as shown in the following diagram OG MODE CONTROL MS332 IN RUNISTOP JOG penne SWITCH MODE i i QUADRATURE T i ENCODER 099000 VARIABLE i
152. suu deo sueta aoa on ate A E EE AA eas pedo Terminal Connections Device Compatibility Functions NPN Output Vars 04 00 to 04 08 j Serial Communications eee cuta tes ere ed au Cs eve EE IR EN ER rV ER Interface Port Serial Protocol Serial Communication Vars 08 00 to 08 04 Modbus Implementation Data Types Remote Analog Output Calibration Procedure Remote Encoder PPI Variable Determination and Initialization Procedure Addendum 5 Specifications Section a HUNCH ONAL es o ore eI Deb MEN RE NO POE i Rare reu uei OE b Operational ss cores pev ARP EET SEEN RR E Perte e ru E e Blectrical soi a eie tro Ime UR URL dace ed luis d Environmental eseeeeeeeee e eene e Mechanical recu uA REDE VIDENDI PET 6 Appendix Section sodes Ref Sect p 33 TM Ref Sect p 36 Ref Sect p 37 sates Ref Sect p 46 e Ref Sect p 50 ER Spec Sect jog Spec Sect dens Spec Sect Wess Spec Sect sete Spec Sect a vEront panel PRR oer oot teo qam x tection EEE Appendix Sect b NInenmonics GIOSSA yos es ve eat a RR RR NT VE SARANNO NR ARN RS Appendix Sect Display Window Messages Acronyms and Abbreviations User Records sese vesci erai eex o Re TA SENTI E Oen ee EE VACUA Appendix Sect User Program Variable Record Analog Output Calibration Record DIP Switch Settings Record Keypad Security Variable Record d MS332 Rear View repeated here for easy reference ecceee eee e
153. t Assuming the selective keypad security is disabled the Diagnostic Menu can be entered only if the Run Stop Switch is open and the DAC is at zero Therefore no real time control operations occur while in the Diagnostic Menu Ref Sect page 26 bA02 XX 101701 Switch Inputs Terminal Connections Device Compatibility Functions Switch Input Vars 07 00 to 07 06 The MS332 has eight Switch Inputs One Switch Input 0 is dedicated to the Run Stop Function Each of the other seven Switch Inputs may have one of twelve different Switch Input Functions assigned to them by the user or they may be left with no functions assigned to them For ON OFF type functions the function is turned ON or active by connecting the Switch Input to Ground C and turned OFF or inactive by disconnecting the Switch Input from Ground C MS332 Switch Inputs are compatible with mechanical ON OFF switches relays and open collector NPN transistors See Device Compatibility diagram below Terminal Connections TB 3 Top Edge MS332 Rear View See Reference Section Hardware Illustrations Rear View for a complete diagram showing the details of terminal strip TB3 containing the Switch Inputs on the back of the MS332 package Device Compatibility MS332 Switch Input Compatible Devices 12 Vdc C Q NPN relay switch open collector x Switch Input Ground C Ref Sect page 27 bA02 XX 101701 Switch Inputs Fun
154. t page 9 bA02 XX 101701 Keypad Menus cont Diagnostic Menu Follow these steps to access the Diagnostic Menu Level One Select diagnostic utility Use this level to select which diagnostic utility to perform This is the first level of the Diagnostic Menu Note Enter level one by pressing while at level zero See level zero above Tach proc BUN SET us LED s Display Window o 000o All of the status led s are lit except for the ERR led Display Window initially shows the diagnostic utility last performed with all the digits flashing Ex Showing Anov for the Analog Output Calibration utility Valid Keys To select diagnostic Press or to select which diagnostic utility to perform Choose from SInPu nPnou Anou KEYPAd dISP FACdEF PPlLrn or UErrEU lt gt Note The eight diagnostics utilities are abbreviated in the Display Window in this manner E v SInPu for Switch Inputs diagnostic nPnou for NPN Outputs diagnostic Anov for Analog Output Calibration utility KEYPAd for Keypad diagnostic dISP for Display Window diagnostic FACdEF for Factory Defaults Reset utility PPILrn for Encoder Pulses Per Index Learn utility UErrEU for Product Version Revision diagnostic See the remaining pages here in Diagnostic Menu for the descriptions of each individual diagnostic utility When the desired diagnostic utility is
155. table phase difference cannot be maintained under dynamic conditions with Proportional Compensation alone if the set point or load changes a new phase difference will be established to maintain speed accuracy Integral Compensation maintains an accurate average phase difference by driving the average difference between the desired and actual phase difference to zero So while Proportional Compensation maintains accurate speed at the expense of creating a certain phase difference to fit the set point drive motor load encoder conditions Integral Compensation drives the average phase difference to the desired value by driving the average phase difference error to zero Variable 03 01 Integral Time Constant Var03 01 controls how quickly any average phase difference errors are driven to zero Var03 01is the phase or position correction rate time constant The allowed range is 0 0 to 100 0 seconds A nonzero value is the time to reduce phase difference error to approximately 37 of its previous value exponential response Phase difference error is reduced to less than 0 25 after six Var03 01 time spans have passed Generally speaking smaller nonzero values result in faster phase correction over the motor s range of loads If the Integral Time Constant is set too low i e too fast for a system s drive motor load encoder combination instability will result ranging from small phase speed oscillations after a set point or load change to continuou
156. ter the new password code into PASdEF Important note regarding Keypad Security In any environment where tampering is a concern it is strongly suggested that the keypad be kept locked with knowledge of the password code limited to the intended individuals This is suggested even if no keypad features are set for lock disable in SECdEF i e when SECdEF is set to 000000 This is because anyone who changes the lock also changes the key When the keypad is unlocked i e PASIn and PASdEF hold the same values anyone can change PASdEF thereby changing the lock with a new and unknown to you password code Leaving the keypad unlocked is simlar to removing the lock from a door Anyone can put on a new lock change PASdEB and unless the individual is thoughtful enough to leave the new key in the new lock enter PASdEF s new value into PASIn you are locked out Keypad Menu Access The Keypad Security Change Variable and Change Set point Menus can be entered at any time even when the MS332 is running i e when the Run Stop Switch is closed and the Fast Stop Switch is open if assigned However the selective keypad security determines if variables or set points are changeable or not once inside the respective menus The MS332 continues all real time control operations when in the Keypad Security Change Variable and Change Set point Menus Changed security variables changed program variables and changed set points take immediate effec
157. ternal 115 Vac 230 Vac Encoder Index Aux Inputs Compatibility Encoder Type Encoder Signaling Index Sensor Type Index Signaling Frequency range Input resistance Signal logic Levels Isolation Switch Inputs Polarity Compatibility Source current ON state Isolation Analog Output Signal Range Calibration method Offset Adjust Scale Adjust Output Resistance Settling Time Resolution Isolation Short circuit Protection NPN Outputs each output Vce max Vce Ic 20 mA Pd power dissipation Isolation Encoder Index Power Supply Power Output Short circuit Protection Isolation RS485 Communications Port RX input resistance RX differential threshold RX common mode range TX differential voltage TX common mode volts Isolation 115 Vac 230 Vac optional 10 50 60 Hz 15 W max 200 mA 5x20mm slo blo 100 mA 5x20mm slo blo NPN PNP TTL CMOS single ended outputs Incremental Quadrature squarewaves A amp B channels Proximity sensor encoder index line Pulse 1 per cycle event rising edge triggered 1Hz to 70KHz 2 2 kQ pull up or pull down switched in 2 100 kQ pull up down switched out Low OtolVdc High 4 to 28 Vdc 2500 Vrms Ground C referenced circuit Closed switch to Ground C ON Open switch OFF Mechanical ON OFF switches Relays NPN open collector transistors 3 5 mAdc switching device must sink a maximum 3 5 mA when ON 2500
158. the Analog Output Calibration Utility See Reference Section NPN Outputs for details on assigning using the Contactor Reverse NPN Output Function See Reference Section Switch Inputs for related information about the Reverse Switch Input Function Ref Sect page 36 bA02 XX 101701 Operational Variables Vars 07 11 to 07 14 06 13 to 06 15 06 00 to 06 12 and 01 01 01 04 02 00 to 02 05 03 00 to 03 04 Jog Mode Ramp Configuration Variable 07 11 enables disables the acceleration and deceleration ramps in any combination for Jog mode Enter the code to select desired configuration Var07 11 CODE Jog Deceleration Jog Acceleration OFF OFF Note In Jog mode acceleration means ramping to the Jog mode set point Dac value deceleration means ramping to the 0 Dac value Open loop Configuration Variable 07 12 defines the effect of open loop when a Closed loop Open loop function assigned Switch Input is closed Enter the code to select desired configuration Open loop Effect Yes Yes Note See Reference Section Switch Inputs Functions for details on the Closed loop Open loop Switch Input Function Master Follower Mode Selection The Master or Follower operating mode is selected by remote switch or from the keypad Master Follower Mode Selection by remote switch See Reference Section Switch Inputs for details on assigning and using the Master Follower Mode Select Switch Input F
159. the encoder index switch input npn output circuit common GndC Input Output as in the I O Connection Block View Diagram Pulses received from an encoder Z output proximity sensor etc in Index Follower mode Pulses from the encoder or index sensor at the independent process Follower mode Lead encoder Pulses Per Index pulse Index Follower mode Lead encoder RPM Light emitting diode as in status indicator LED s Appendix Section page 3 bA02 XX 032601 Mnemonics Glossary Acronyms abbreviations cont Master MaxFbRpm Max Lead RPM m ms msec NPN Output NPN PNP Logic gate OpCode Open loop Phase offset Phase set point PID PPR PROG Pull down Pull up Pwr Quadrature Real time Retard RPM Sec SET SPD SetpointDev Setpt SETPT Single Channel Slave TACH TBI TB2 TB3 TB4 uF Unipolar usec Var s 1 An MS332 control mode where the feedback encoder rotates at a setpoint rpm 2 The independent encoder in a follower mode process Same as Lead Maximum Feedback encoder RPM for a given process Var01 03 Process Maximum Lead Encoder RPM millisecond The NPN Outputs of the MS332 are open collectors of NPN transistors Encoder or Index device output types Function option code as in NPN Output function option code A control method where process feedback e g encoder pulse index sensor pulses is either nonexistent or ignored The difference of follower encoder pos
160. tion Parameter used by the corresponding NPN Output Function Set up Sect page 18 bA02 XX 022301 MS332 Reference Section DA02 XX Hardware Illustrations Rear View Top View Block View Rear View Showing all four terminal strips TB1 TB2 TB3 and TB4 Top Edge of MS332 rear view B optional Analog Input 1 4 Ground C Switch Input 0 Run Stop optional Analog Input 1 N 12 Vdc C Encoder Index Pwr B 1 e 2 pee earn Coie mea maa Ground C optional Analog Input 2 3 3 e Lead Chan A asia tara aati bale baad Switch Input 1 optional Analog Input 2 4 4 e Lead Chan B a aaa aaa me eR Switch Input 2 Analog Output 1 e 5 E 5 Lead Index MEGS 7 osUaas eee seo af ee Ground C Ground A e 6 6 9 Ground C WereccUsceuseu meu cvm Switch Input 3 optional Analog Output 2 e T 7 e 12 Vde C Encoder Index Pwr Switch Input 4 10 Vdc Ref 8 E 8 e Feedback Chan A aa aaa ARa APE T Ground C 10 Vdc Ref gnd 9 Feedback Chan B Switch Input 5 M Feedback Index rieri eea te e ae Switch Input 6 Aux Input 0 optional Ground C karan ontana Ta pan R Switch Input 7 Aux Input 1 optional NPN Out Protect Cathode DDADD DDD DDH ADHD ODODOO No T TX 2 d 4 NPN Output 0 e a 1 l d NPN Output 1 L3 Earth Ground a
161. tion and Deceleration Ramps for details on using Var02 05 to select the active Acceleration Deceleration Ramp Pair using the keypad See Reference Section Switch Inputs for details on selecting the active Acceleration Deceleration Ramp Pair using a Switch Input 9 PID Proportional Gain and Integral Time adjustments a Var05 00 Display Selection Enter code 5 to choose closed loop follower error b Run the lead encoder at the process maximum value Var01 03 RPM c Close the Run Stop switch with the lead running Observe the follower behavior at the top of the acceleration ramp and while it runs steady state If the feedback follower encoder response is unstable large erratic displayed error motor jerking oscillating try reducing Var03 00 s value proportional gain If the feedback follower encoder response is sluggish large slow changing displayed error try increasing Var03 00 If the Var03 00 changes don t significantly improve the feedback follower encoder response or if they get to a point of diminishing return try adjusting Var03 01 integral time constant Higher Var03 01 values will improve loop stability lower Var03 01 values increase loop responsiveness Generally speaking it is desirable to have Var03 00 as large as possible and Var03 01 as small as possible this will result in the tightest most responsive following However if Var03 00 is set too high and or Var03 01 is set too low the follow
162. tion to a Switch Input as mentioned above by writing 1 Jog to the corresponding Switch Input function assignment variable Example To use Switch Input 4 write 1 to Var07 03 address 47030 4 Set the Jog Speed set point to zero Write zero 0 into Var06 12 address 46120 5 Write 32 into Var01 09 address 41090 This causes Display Options 10 address 31100 and 11 address 31110 to display real time averages of the last 32 measured Lead PPI and Feedback PPI values respectively 6 Close the MS332 Run Switch Measure Average Lead PPI write Var01 08 address 41080 1 Rotate the Lead Encoder by starting the Lead process Leave the Lead process running 2 View the Average Lead PPI address 31100 This is the average of the last 32 measured Lead PPI values The displayed Average Lead PPI will initially change as more measured Lead PPI values are included in the running average if the measured values are not equal to Var01 08 Wait for at least 33 Lead Index pulses to occur This ensures the Lead PPI averaging buffer contains only measured Lead PPI values At this point the displayed Lead PPI value should have settled down to a stable value 3 Wirite the displayed Average Lead PPI value address 31100 into Var01 08 address 41080 4 Stop the Lead process Ref Sect page 58 bA02 XX 101701 Serial Communications Remote Encoder PPI Var Procedure cont Measure Average Feedback PPI write Var01 07 address 41070
163. uch as attaching the MS332 to the back or inside wall of a control cabinet With the Side Mount Bracket the MS332 may be installed in any orientation One common usage is mounting the entire MS332 inside a control cabinet away from view Side Mount Bracket Dimensions in inches Dimensions of End Mounting Flange end view 0 500 Holes are 0 190 dia 0 900 1 End flange on near side of End flange bracket protrudes up and out of page d 0 089 Side flange protrudes up and MS332 is out of page NS inserted Holes are through d 0 190 dia 5 400 this cutout in bracket terminal strip end Phe first Side flange on far side of bracket 3400 Dimensions of Outer Perimeter front view Phys Install Sect page 2 Dimensions of Side Mounting Flange side view bA02 XX 031301 Optional Side Mount Bracket Installation cont Installation The MS332 attaches to the Side Mount Bracket using the Standard Mounting Brackets in the same way it attaches into a panel cut out The Side Mount Bracket attaches to a mounting surface using the mounting screw holes in either the end or side flanges SIDE MOUNT BRACKET SHOWN WITH MOUNTING FLANGES PROTRUDING TO THE z ds Toa TOP AND TO THE INSERTING STANDARD 4 V TRIGHTOBREYPAB MOUNTING BRACKETS N i I l aa I I I I incre CAE LEFT SIDE VIEW OF MS332 i OF MS332 l FRONT PANEL END i OF MS332 I
164. unction Master Follower Mode Selection from the keypad Variable 07 13 Master Follower Mode Select Enter the code to select between Master and Follower operating modes Var07 13 CODE Selected operating mode ane Sees Follower mode Notes 1 Var07 13 is overridden has no effect when the Master Follower Mode Select Switch Input Function is assigned to a Switch Input See Reference Section Switch Inputs for details on this method 2 Var07 13 is also overridden if a Jog mode function assigned Switch Input is closed Jog mode over rides Master or Follower modes See Reference Section Switch Inputs Functions for details on the Jog mode function 3 When Var07 13 is set to select Follower mode it is necessary to further configure which of the two Follower modes is actually desired Ratio Follower or Index Follower See Reference Section Encoder Index Inputs Power Supply Outputs Encoder Variables Variable 01 06 for details on configuring for Ratio Follower or Index Follower mode Ref Sect page 37 bA02 XX 101701 Operational Variables cont Phase Change Release Time The MS332 accomplishes phase changes by introducing externally determined phase difference errors into the closed loop PID algorithm To ensure smooth phase difference error correction the error is not introduced to the PID all at once but is instead time released spread out over time This is accomplished by dividing the error into
165. unning forward and Reverse Lead running backward and Reverse Switch open or not assigned Switch open or not assigned Lead running backward and Reverse Switch closed Drive Run Stop Switch Run Stop Switch closed OpCode 1 Run Stop Switch open Enable and OpCode 2 Run Stop Switch open Analog Output Dac and Dac 0 Index Sync Index Phase Error Threshold 1 Hysteresis 100 gt Threshold 1 Hysteresis 100 See Note 3 below Encoder Closed loop gt Threshold 1 Hysteresis 100 lt Threshold 1 Hysteresis 100 Position Position Phase Error Or and Error Alarm Threshold 1 Hysteresis 100 gt Threshold 1 Hysteresis 100 Note 1 Active NPN functions are recalculated 51 2 times per second Therefore the maximum delay from an event to an NPN Output change will be less than 19 6 mS Note 2 Assigning the Contactor Reverse Function to an NPN Output also changes the Analog Output signal from a bipolar to a unipolar swing See Reference Section VAnalog Output for details on Drive Compatibility See Reference Section Switch Inputs for details on assigning using the Reverse Switch Input Function Note 3 Index Sync exists when the Index Phase Error between the appropriate lead and feedback indexes is within Threshold feedback encoder pulses Index Sync ceases to exist when the Index Phase Error falls outside the Threshold window As long as the magnitude
166. ut that has the Set point Scroll up or Set point Scroll down Switch Input function assigned to it Advance Retard Scroll Use Advance to speed up and Retard to slow down the feedback encoder when running closed loop without index phase correction There are two ways to access Advance Scroll or Retard Scroll 1 From the Keypad by pressing the RIGHT Advance or LEFT Retard arrow keys if not security locked when at Keypad Level Zero 2 From a remote switch by remotely closing a Switch Input that has the Advance Scroll or Retard Scroll Switch Input function assigned to it When either Advance Retard Scroll is accessed the current phase offset is displayed expressed in feedback pulses and is then scrolled up or down in Phase Scroll Step Var07 09 increments As the phase offset changes the feedback motor speed increases or decreases accordingly effecting the displayed phase offset Ref Sect page 31 bA02 XX 101701 Scrolling Advance Retard Scroll cont When Advance Retard Scroll is de accessed scrolling terminates and the motor speed returns to the mode determined active speed or ratio set point as the case may be At this point everything is as it would otherwise have been except that the feedback encoder has advanced a certain number current phase offset previous phase offset of feedback pulses more or less than would have been the case if the advance or retard had not occurred Advance Retard Scro
167. v to select between In 3210 In 7654 etc Note The standard MS332 has only the two groups When the desired group of inputs is displayed press to confirm and enter level three of the Switch Inputs diagnostic OR Press to exit the Diagnostic Menu and return to level zero Invalid Keys Pressing vs e Ca or Ce results in no action other than lighting the ERR error led Level Three Observe Switch Input statuses Use this level to display the status of each Switch Input in the selected group This is used to observe whether the Switch Inputs are OFF or ON open or closed This is on the third level of the Diagnostic Menu LED s Display Window All of the status led s are lit except for the ERR led Display Window shows the status of each Switch Input in the selected group A switch input is ON if the status is a 1 The switch is closed connecting the input to Ground C A switch input is OFF if the status is a 0 The switch is open disconnecting the input from Ground C Ex Showing 1010 for the statuses of switch inputs 7 6 5 and 4 This shows that input 7 is ON input 6 is OFF input 5 is ON and input 4 is OFF Valid Keys Press to return to level two OR Press to exit the Diagnostic Menu and return to level zero Invalid Keys Pressing vs e A Cy C J or Ce results in no action other than lighting the ERR error led Ref
168. value indicates the feedback and lead encoders running in opposite directions Displays feedback encoder pulse frequency in Hz Note A negative display value indicates reverse direction Fdbk encoder B pulses leading A pulses Displays the lead encoder pulse frequency in Hz Note A negative display value indicates reverse direction Lead encoder B pulses leading A pulses Displays the current value of the output DAC The DAC ranges from 0 up to 4095 Displays the closed loop feedback encoder error in feedback encoder pulse units Feedback encoder error is the difference between the expected correct feedback encoder position and the actual feedback encoder position Feedback encoder error is calculated every time the PID loop executes 1024 times per second Display value Expected feedback encoder pulse count Actual feedback encoder pulse count Displays the feedback index phase error in feedback encoder pulse units Index follower mode only Index phase is the feedback encoder position when the lead index pulse arrives minus the feedback encoder position when the feedback index pulse arrives Index phase error is the difference between the actual index phase and the index phase set point Index phase error is calculated upon receipt of a feedback index pulse Display value Index phase set point Index phase Displays the feedback index phase in feedback encoder pulse units Index follower mode only Index phase i
169. witch wire installed back in step 2 disables index correction g Var07 13 Master Follower Mode Select Enter 0 for follower mode operation h Var01 06 Follower Mode Configuration Enter 1 for Index Follower mode Set up Sect page 15 bA02 XX 022301 8 Operational Variables cont i Acceleration Deceleration Ramp Times Vars02 00 to 02 03 Notes Ramp times set the ramp rate and are entered in units of seconds The time entered is the time to ramp from 0 to Var01 00 MAX RPM acceleration or from Var01 00 MAX RPM to 0 deceleration Var02 00 Var02 01 are acceleration time variables Var02 02 Var02 03 are deceleration time variables Var02 00 Var02 02 form a pair and Var02 01 Var02 03 form a pair The factory default active pair is Var02 00 Var02 02 Enter your desired acceleration and deceleration ramp times See Reference Section Operational Variables Acceleration and Deceleration Ramps for details on using Var02 05 to select the active Acceleration Deceleration Ramp Pair using the keypad See Reference Section Switch Inputs for details on selecting the active Acceleration Deceleration Ramp Pair using a Switch Input 9 PID Proportional Gain and Integral Time adjustments index phase correction disabled a Var05 00 Display Selection Enter code 5 to choose closed loop follower error b Run the lead encoder at the process maximum value Var01 03 RPM c Close the Run Stop switch
170. with an encoder on its motor shaft The MS332 will control the neutralizer pump with a set point value entered in units of mL neutralizer per L wastewater Known Lead wastewater motor encoder pump Motor rated max speed 1800 RPM Encoder 60 PPR Pump characteristic 0 5 L per shaft revolution The lead pump will run at a maximum flow of 800 L min Follower neutralizer motor encoder pump Motor rated max speed 1800 RPM Encoder 60 PPR Pump characteristic 10 mL per shaft revolution The follower pump motor runs at an RPM determined by both the lead RPM and the selected mL neutralizer L wastewater set point The Encoder PPRs Max set point value and Max RPMs are set as follows for this example Var01 05 Lead Encoder PPR Enter 60 lead encoder PPR into Var01 05 Var01 03 Process Maximum Lead Encoder RPM We must convert the wastewater maximum flow of 800 L min into lead RPM 800 L min 1 shaft revolution 0 5 L 1600 RPM Enter 1600 into Var01 03 Note that this value is less than the lead motor s rated max of 1800 RPM Var01 04 Max Ratio Set point Value in User Units We want to program the flow ratio in units of mL neutralizer per L wastewater so we enter the required maximum of 12 0 mL neutralizer per L wastewater Enter 12 0 into Var01 04 Var01 02 Feedback follower Encoder PPR Enter 60 feedback encoder PPR into Var01 02 Var01 00 Process Maximum Feedback Encoder RPM This value must be ca
171. zation function execution and Response Message construction This delay time should be used in determining the Master s Receiver Timeout Period It is necessary that the Master s Receiver Timeout Period be set sufficiently long to ensure the Master does not time out and re transmit a Query Message to an MS332 or query any other device before the MS332 has had sufficient time to transmit the Response Message Data Types User Variables and Display Values The Data Type for accessing User Variables and Display Values is selectable 16 bit signed integer 16 bit unsigned integer 32 bit signed integer and 32 bit IEEE floating point data types are supported Integer types allow writing whole numbers numbers with no fractional part only When real numbers numbers with a fractional part are read using an integer type only the whole number part is returned the fractional part is truncated IEEE floating point allows reading and writing both whole numbers and real numbers Although IEEE floating point is the most versatile data type for MS332 serial communications it is usually unecessary because most applications don t require User Variable and Set Point values with fractional resolution Since the Master and Slave data types must match only those data types supported by both Master and Slave may be used See Addendum Accessing User Vars and Display Values at the end of this section for a complete discussion of issues related to accessi

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