E
Technical Assistance If you have comments or questions concerning the operation of the ML-Drive, please call. A member of our Technical Support Staff will be happy to assist you.
DANGER Improper installation can cause severe injury, death or damage to your system. Integrate this motion control unit into your system with caution. Operate this motion control unit only under the conditions prescribed in this manual. Any other use shall be deemed inappropriate. Comply with the National Electrical Code and all applicable local and national codes.
iv
Table of Contents Introduction...................................................................... 1-1 Introducing the ML-Drive ............................................................................ 1-3 Examples of ML-Drive Applications .............................................................. 1-4 Installation / Setup ......................................................... 2-1 Mounting .......................................................................................................
Monitor Parameters ................................................................................... 3-39 Input Monitoring ................................................................................. 3-40 Output Monitoring ............................................................................... 3-42 Performance Monitoring ..................................................................... 3-43 Status Monitoring ...............................................................................
List of Illustrations Figure 1-1 Figure 1-2 Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 2-6 Figure 2-7 Figure 2-8 Figure 2-9 Figure 2-10 Figure 2-11 Figure 2-12 Figure 2-13 Figure 2-14 Figure 2-15 Figure 2-16 Figure 2-17 Figure 3-1 Figure 3-2 Figure 4-1 Figure 4-2 Figure 4-3 Figure 4-4 Figure 4-5 Figure G-1 Figure G-2 Figure G-3 Figure G-4 ML-Drive Master Mode ............................................................ 1-4 ML-Drive Follower Mode ..........................................
List of Tables Table 3-1 Table 3-2 Table 3-3 Table 3-4 Table 3-5 Table 3-6 Table 3-7 Table 3-8 Table 3-9 Table 3-10 Table 3-11 Table 3-12 Table 3-13 Table 3-14 Table 3-15 Table 3-16 Table 3-17 Table 3-18 Table 3-19 Table 3-20 Table 3-21 Table 3-22 Table 3-23 Table 3-24 Table 3-25 Table 3-26 Table 3-27 Table 3-28 Table 3-29 Table 3-30 Table 3-31 Table 3-32 Table 3-34 Table 3-35 Table 3-36 Table 3-36 viii Basic Keypad Entry .................................................................
Introduction Introducing the ML-Drive Examples of ML-Drive Applications 1-1
1-2
INTRODUCING THE ML-DRIVE The ML-Drive is a highly accurate, digital, motor drive which can drive 1/4 to 2 horsepower PM DC motors. It has advanced embedded software that is capable of solving a great variety of speed control tasks. It operates as either a stand-alone control of a single motor (Master mode) or as a part of a complex multi-drive system (Follower mode).
EXAMPLES OF ML-DRIVE APPLICATIONS Figure 1-1 is an example of a Master mode of operation for a pump application. The scaling format allows the operator to enter a setpoint in Engineering Units of gallons per minute. The ML-Drive compares the sensor shaft feedback to the scaled setpoint and calculates any speed error. When the ML-Drive finds speed error, the control algorithm adjusts the drive output and reduces the error to zero.
Figure 1-2 is an example of the Follower mode of operation in a pump application. The scaling format allows the operator to enter the setpoint as a ratio of ingredient B to ingredient A. The ML-Drive compares the setpoint ratio to the Follower sensor shaft (feedback) and Lead sensor shaft to calculate any speed error. When the ML-Drive finds speed error, the control algorithm adjusts the drive output and reduces the error to zero.
—NOTES— 1-6
Installation / Setup Mounting Wiring Inputs Outputs Serial Communications Calibration Current Limit 2-1
, , , Contrex TOUT .03" 3.60" ( 3C.6U5" ( CUTOUT 3.60" (3.65" .03") DOOR PANEL Contrex CODE SELECT 7 SET POINT 4 TACH 4.00" 6 5 3 2 1 . 0 – *6.00" 9 8 CLEAR ENTER 4.
MOUNTING This section contains instructions for mounting the ML-Drive in the door panel of a NEMA Industrial Electrical enclosure. The ML-Drive is packaged in a compact 1/4 DIN Vertical Instrument Enclosure that mounts easily in the door of your Industrial Electrical Enclosure. The Electrical Enclosure must have an IP54 rating or higher to comply with CE installations.
J2 5 AC POWER 9 10 11 12 13 14 15 16 17 18 1 2 1 2 3 4 5 6 7 8 J4 J3 COM ALARM DRV_EN V_DO COM SETPT MST / FOL COM F–STOP R–STOP COM JOG RUN COM FDBK_FQ LEAD_FQ COM 5V_DI COM_AUX 5V Figure 2-2 ML-Drive General Wiring Use 230 VAC with ML-Drive model # 3200-1934 * Use 115 VAC with ML-Drive model # 3200-1933 GND PE NEUT * Neut or L2 GND/PE 3 L1 MOTOR ARM 4 2 A2— Fuses 15A 250V L1 A2 1 – MOTOR ARM 1 HP 90 VDC 10.0 FLA 3 2 1 A1+ Motor DC PM AC POWER 115 VAC 15.
WIRING This section contains the power supply, input, and output wiring for the ML-Drive. Please read this section prior to wiring the ML-Drive to ensure that you make the appropriate wiring decisions. NOTE: The installation of this motor control must conform to area and local electrical codes. For information, refer to the National Electrical Code (NEC) Article 430 published by the National Fire Protection Association, or the Canadian Electrical Code (CEC). Refer to local codes as applicable.
—NOTES— 2-6
INPUTS NOTE: The installation of this motor control must conform to area and local electrical codes. See The National Electrical Code (NEC,) Article 430 published by the National Fire Protection Association, or The Canadian Electrical Code (CEC). Use local codes as applicable. I/O Power (J4 pins 1, 2) +5VDC MAXIMUM For isolated operations, the Frequency Inputs (J4 pins 3, 4, 5), the Digital Inputs (J4 pins 6-14 ) and the Digital Outputs (J4 pins 15-18) require an external source of +5VDC power.
AC Power (J2 pins 3, 4, 5) The ML–Drive model #3200-1933 operates on 115 VAC + 15%, 0.1 Amp., 50/60 Hz. The ML–Drive model #3200-1934 operates on 230 VAC + 15%, 0.1 Amp., 50/60 Hz. * Fuse L1 for 115VAC applications. Fuse L1 and L2 for 230VAC applications. Use 15 AMP 250V normal blow fuses. L1 Neutral or L2 GND/PE * * 1 2 3 J3 Figure 2-5 Input Power Lead Frequency (J4 pins 3, 5) The Lead Frequency is a pulse train input that the ML-Drive uses to determine the speed of the lead motor.
Feedback Frequency (J4 pins 4, 5) The Feedback Frequency is a pulse train input that the ML-Drive uses to determine the speed of the follower motor. For signal level specifications refer to References: Appendix A, ML-Drive Specifications, page A-1. 4 Signal 5 Common J4 Figure 2-7 Feedback Frequency DANGER ! If the Feedback Frequency is lost, the ML-Drive will command a 100% speed out and the motor will run at 100% capacity. This can damage your equipment or cause severe injury or death.
Jog (J4 pins 7, 8) Jog is a maintained input. When Jog is closed, the ML-Drive commands the motor to move at the selected jog speed. As a maintained input, Jog is only active when the operator device is closed. NOTE: Close the R–Stop and F–Stop inputs and open the Run input, prior to entering Jog. If you are only using one of the Stop inputs, wire short the other Stop input to common or the ML-Drive will not enter Jog. JOG 7 8 J4 Figure 2-9 Jog R–Stop (J4 pins 9, 11) R–Stop is a momentary input.
F–Stop (J4 pins 10, 11) F–Stop is a momentary input. When it is open, the ML-Drive stops immediately (zero RPM) and ignores the specified deceleration rate. As a momentary input, F-Stop is internally latched and does not need to be maintained by an operator device. F-STOP 10 11 J4 Figure 2-11 F–Stop Master / Follower (J4 pins 12, 14) This input determines the ML–Drive's mode of operation and resulting scaling formula that the control algorithm uses.
Setpoint Select (J4 pins 13, 14) The Master and Follower setpoints are determined by the Setpoint Select input combined with the Master, Follower Input. For access to Master Control Parameters 1 and 2 and Follower Control Parameters 3 and 4, refer to the chart below.
OUTPUTS NOTE: The installation of this motor control must conform to area and local electrical codes. See The National Electrical Code (NEC,) Article 430 published by the National Fire Protection Association, or The Canadian Electrical Code (CEC). Use local codes as applicable. Drive Output (J2 pins 1, 2) + Connect the Drive Output (J2 pins 1, 2) to the armature leads (A1 and A2) of your permanent magnet, DC motor. If you reverse the armature leads, then the direction of the motor rotation also reverses.
Alarm (J4 pin 17) By entering alarm Control Parameters, you can establish circumstances under which the ML-Drive will alert you to potential operating problems. The alarm can be wired to activate a warning light, a warning sound, or to shut down the system under specified conditions. Alarm Format (CP-10) determines which alarm conditions will activate the Alarm output, using the values that are entered in Low Alarm (CP-12), High Alarm (CP-13), Ramped Error (CP-14) and Scaled Error (CP-15). See Figure 2-15.
SERIAL COMMUNICATIONS NOTE: The installation of this motor control must conform to area and local electrical codes. See The National Electrical Code (NEC,) Article 430 published by the National Fire Protection Association, or The Canadian Electrical Code (CEC). Use local codes as applicable. The Serial Communications interface on the ML-Drive complies with EIA Standard RS–485-A for balanced line transmissions.
Isolated RS232 to RS485 Converter TXD/ COM RXD — TXD/ RXD + J1 1 T/R+ 2 T/R– 3 COM J1 2 ML-Drive #1 ML-Drive #2 1 T/R+ 2 T/R– 3 COM 1 1. Shield only at one end of the cable. 2. If you need to terminate the communication line, then terminate it at the unit which is the furthest away from the converter. A 100 ohm, 1/2 Watt resistor will usually terminate successfully. Refer to EIA Standard RS485A, for more information.
CALIBRATION Calibration sets the ML-Drive's current limit. The ML-Drive must be properly installed prior to calibration. Refer to Installation/Setup; Mounting, page 2-3, and Installation/ Setup; Wiring, page 2-5. DANGER Hazardous voltages. Can cause severe injury, death or damage to the equipment. Make adjustments with caution.
CURRENT LIMIT The ML-Drive provides current limiting for both RMS continuous duty and RMS peak intermittent duty. The RMS current limit level is controlled by RMS Current Limit (CP-80). The RMS peak current level is controlled by Peak Current Limit (CP-81). The ML-Drive allows the RMS continuous duty load current to exceed the RMS Current Limit (CP-80) level for an accumulated total of one minute out of ten minutes.
Use Motor Current (MP-82) to display the value, in amps, of the motor armature's current: Press “Code Select” Enter “82” (Motor Current) Press “Enter” The motor armature's present RMS current is displayed, in amps Use Current Limit Status (MP-83) to display the present status of the current limit: Press “Code Select” Enter “83” (Current Limit Status) Press “Enter” The present status of the current limit is displayed “0” = The ML-Drive is not in current limit “1” = The ML-Drive is current limiting 2 - 19
—NOTES— 2 - 20
Operation Keypad Operation Keypad Lockout Control Parameters (CP) Direct Mode Master Mode Follower Mode Inverse Master Mode Inverse Follower Mode Acceleration/Deceleration Tuning Alarms Jog Logic Control Logic Inputs Logic Outputs Monitor Parameters (MP) Input Monitoring Output Monitoring Performance Monitoring Status Monitoring Serial Communications Using Serial Communications Communications Software Design 3-1
3-2
KEYPAD OPERATION The front panel of the ML-Drive is an easy to use keypad that gives you direct access to the Parameters (Control Parameters and Monitor Parameters) by entering the Parameter Code. You can also use the keypad to change the value of a Control Parameter. The keypad has keys for Code Select, Enter, Clear, and Scroll Up/Down. It also has numeric keys and two dedicated keys: Setpoint and Tach. The LED display is above the keys.
Table 3-1 Basic Keypad Entry To Enter a Parameter Code: Press “Code Select”. Enter a Parameter Code (For a Control Parameter or Monitor Parameter). Press “Enter” (within 15 seconds). The Parameter Code and it's current value are displayed on the LED display. The Parameter Code decimal point is illuminated. To Enter a Parameter Value: Follow the steps to enter a Parameter Code. Enter a new value (Use the numeric keys) . Press “Enter” (within 15 seconds). The Parameter Code decimal point turns “Off”.
KEYPAD LOCKOUT Keypad Lockout (CP-98) displays the present status of the keypad lockout. When the keypad is locked, then “LOC” is displayed: Code Locked When the Keypad is unlocked, then “ULOC” is displayed: Code Unlocked To lock out the keypad, enter a numerical “password” between “1” and “9999” in Keypad Lockout (CP-98), then press the “enter” key. This numerical password will flash briefly on the screen, then the screen will display “LOC”.
Record your numeric Keypad Lockout password here: Please read the “CAUTION” statement on Page 3-5 3-6
CONTROL PARAMETERS Parameters are divided into two classifications; Control Parameters (CP) and Monitor Parameters (MP). The numbered code that represents the Parameter is the Parameter Code. The operational data is the Parameter's value. Control Parameter 05 = 50 (default) Monitor Parameter 40 = 200 (arbitrary) Parameters = Parameter Code Parameter Value This section is about Control Parameters. Monitor Parameters are explained in Operation: Monitor Parameters, page 3-39.
Direct Mode In the Direct mode of operation, the drive output from the ML-Drive to the motor can be set directly. Direct mode is an open-loop mode of operation. Scaling, Acceleration/ Deceleration, and closed loop compensation (PID) software are not involved in the Direct mode. The Direct mode is used in conjunction with the Run and Stop controls. The Direct Setpoint (CP-06) is entered as a percentage of the ML-Drive's drive output. To enable or disable Direct mode, use the Direct Enable (CP-61).
Master Mode The Master, or stand-alone mode of operation, is a single motor operation. In this simple mode of operation, the entire process is controlled by a single motor and one ML-Drive. The ML-Drive allows you to control your system in Master Engineering Units (e.g., RPMs, gallons per hour, feet per minute). The Master Engineering Units at which you want the system to operate, are entered into the two available Master Setpoints (CP-01 and CP-02).
Table 3-4 Default Master Scaling Control Parameters CP Parameter Name CP-34 Max RPM Feedback CP-31 PPR Feedback CP-20 Master Engineering Units Parameter Value 2000 60 2000 Table 3-5 Entering Master Scaling Control Parameters CP Parameter Name Parameter Value CP-34 Max RPM Feedback Enter the maximum desired RPMs, measured at the sensor shaft. CP-31 PPR Feedback Enter the number of gear teeth or encoder lines on the sensor per one revolution (pulses per revolution).
Table 3-6 Entering Master Setpoint Control Parameters CP Parameter Name Parameter Value CP-01 Master Setpoint 1 Enter the Master Engineering Units value that you want your system to operate at when Setpoint 1 is active. CP-02 Master Setpoint 2 Enter the Master Engineering Units value that you want your system to operate at when Setpoint 2 is active. An example of the Master mode of operation is demonstrated on the following page.
Master Mode Example The following example demonstrates how scaling and setpoint Control Parameters are entered for a typical Master mode of operation: A pump delivers 15 gallons/minute when the motor runs at a maximum RPM of 1725. The motor shaft is equipped with a 30 tooth ring kit. The Master Engineering Units are gallons per minute. Master Setpoint 1 will be setup to pump 10 gallons per minute when it is the active setpoint.
Follower Mode The Follower mode of operation is the most frequently used mode of operation. It is a multi-motor operation in which the entire process can be controlled by any number of motors and ML-Drives. The ML-Drive allows you to control your system in Follower Engineering Units (e.g., Follower to Lead ratio or percentage of RPMs, gallons per minute, feet per minute).
Table 3-8 Default Follower Scaling Control Parameters CP Parameter Name Parameter Value CP-33 Max RPM Lead 2000 CP-34 Max RPM Feedback 2000 CP-30 PPR Lead 60 CP-31 PPR Feedback 60 CP-21 Follower Engineering Units 1.000 Table 3-9 Entering Follower Scaling Control Parameters 3 - 14 CP Parameter Name Parameter Value CP-33 Max RPM Lead Enter the maximum operating RPM of the Lead motor, measured at the Lead sensor shaft (pulses per revolution).
With your scaling established, you can enter values for Follower Setpoints 1 and 2 (CP-03, CP-04). The value that you enter for a setpoint is the ratio of the Follower E.U.s at which you want to operate the system, divided by the E.U.s that the Lead is operating at. Follower E.U. desired Setpoint = ________________________________ Lead E.U. operation You can toggle between the two setpoints, if you have wired the Setpoint Select accordingly.
Follower Mode Examples A and B Example A demonstrates how scaling and setpoint Control Parameters are entered for a typical Follower mode of operation that uses a ratio setpoint: The Lead pump delivers 10 gallons/minute when the motor is running at a maximum RPM of 1725. The Lead sensor shaft is equipped with a 60 tooth Ring kit. The Follower pump delivers 30 gallons/minute when the motor is running at a maximum RPM of 1800. The Follower sensor shaft is equipped with a 30 tooth ring kit.
To find Follower Setpoint 1 (CP-03) for Example A: Follower E.U. desired Setpoint 1 ________________________________ = 15 = Lead E.U. operation 15 gal/min ___ = 3 5 The Follower Engineering Units (gallon per minute) at which you want the Follower to operate. Divided by 5 gal/min The Lead Engineering Units that the Lead is operating at. Equals 3.00 Follower Setpoint 1 (CP-03) value. To find Follower Setpoint 2 (CP-04) for Example A: Follower E.U.
Table 3-11 Follower Mode Control Parameters Example A CP Parameter Name Parameter Value CP-33 Max RPM Lead 1725 CP-34 Max RPM Feedback 1800 CP-30 PPR Lead 60 CP-31 PPR Feedback 30 CP-21 Follower E.U. 3.00 CP-03 Follower Setpoint 1 3.00 CP-04 Follower Setpoint 2 4.50 The ML-Drive will adjust and monitor the speed of the Follower motor to achieve the desired gallons/minute. This completes the scaling and setpoint information for Example A.
Example B demonstrates how scaling and setpoint Control Parameters are entered for a typical Follower mode of operation that uses a percentage setpoint: The Lead pump delivers 20 gallons/minute of ingredient A. The Lead motor's is running at a maximum RPM of 1800 and the Lead sensor shaft is equipped with a 60 tooth ring kit. The Follower pump delivers 10 gallons/minute of ingredient B.
To find Follower Setpoint 1 (CP-03) for Example B: Follower E.U. desired Setpoint 1 ________________________________ = x 100 (%) Lead E.U. operation 10 gal/min The Follower Engineering Units (gallons/minute of ingredient B) at which you want the Follower to operate. Divided by 20 gal/min The Lead Engineering Units (gallons/minute of ingredient A) that the Lead is operating at. Multiplied by 100 (%) Equals 50 Follower Setpoint 1 (CP-03) value.
Table 3-12 Follower Mode Control Parameters Example B CP Parameter Name Parameter Value CP-33 Max RPM Lead 1800 CP-34 Max RPM Feedback 1800 CP-30 PPR Lead 60 CP-31 PPR Feedback 30 CP-21 Follower E.U. 50 CP-03 Follower Setpoint 1 50 CP-04 Follower Setpoint 2 70 The ML-Drive will adjust and monitor the speed of the motors to achieve the desired gallons/minute. That completes the scaling and setpoint information for Example B.
Inverse Master Mode The Inverse Master Mode is a variation of the Master Mode. The Inverse Master Mode has an inverted setpoint. If you increase the value of the setpoint (CP-01 or CP-02), then the motor speed will decrease. Inverse Mode setpoints generally use engineering units of time. With the Inverse Scaling (CP-62) set to “2”, enter values in the Master Setpoints (CP-01 and CP-02) that represent the E.U. at which you want the system to operate. The higher the setpoint value; the slower the motor speed.
Inverse Master Mode Example The Inverse Master Mode Example demonstrates how scaling and setpoint Control Parameters are entered for a typical Inverse Master mode of operation: It takes 10 seconds to move a product through a heat treat oven when the conveyor motor is running at 1500 RPM. The conveyor motor shaft is equipped with a 60 tooth ring kit. Set Master Setpoint 1 (CP-01) so that the product is in the oven for 20 seconds.
Inverse Follower Mode The Inverse Follower Mode is a variation of the Follower Mode. The Inverse Follower Mode has an inverted setpoint. If you increase the value of the setpoint (CP-03 or CP-04), then the ratio of Follower speed to Lead speed will decrease. With the Inverse Scaling (CP-62) set to “2”, enter values in the Follower Setpoints (CP-03 and CP-04) that represent the E.U. at which you want the system to operate. The higher the setpoint value; the lower the Follower to Lead ratio speed.
Inverse Follower Mode Example The Inverse Follower Mode Example demonstrates how the scaling and setpoint Control Parameters are entered for a typical Inverse Follower mode of operation: In a wire machine twisiting application, the Follower twists the wire as the Lead pulls the wire. When the Follower is at the maximum revolutions per minute of 1800 RPM and the Lead is at the maximum revolutions per minute of 2000 RPM, then the twist length (lay) is at its minimum of 2.0 inches.
Acceleration/Deceleration Acceleration/Deceleration (CP-16 and CP-17) control the rate of speed change in response to setpoint changes. These parameters apply to both the Master and Follower modes of operation. The ML-Drive comes factory pre-loaded with default Control Parameters for Acceleration/Deceleration. Generally, these default settings are suitable for most applications and do not require modification. The factory default Control Parameters for Timing are found in Table 3-19.
Tuning If your system is unstable, or the speed error is unacceptable, tuning stabilizes speed error differences between the setpoint and feedback. You can achieve a stable system using conservative tuning Control Parameter values, however the speed error may be unacceptable. On the other hand, aggressive tuning Control Parameter values may cause the system to become unstable. The goal is to reduce the speed error to the level that you want, yet maintain the system's stability.
Table 3-22 Entering Master / Follower Tuning Control Parameters CP Parameter Name Parameter Value CP-65 Gain (Proportional) With Integral (CP-66) set to “0” , reduce the Gain (CP-65) until the system becomes unstable, then increase it slightly until the system stabilizes. Reduced values will increase Gain. To verify the stability of the speed changes, you can access Tach through either the Tach key or the Monitor Parameter for Tach (MP-40).
Alarms The Control Parameters for Alarms are identical for both the Master and the Follower modes of operations. By entering values in the Control Parameters for the Alarms, you can establish circumstances under which the ML-Drive will alert you to potential operating problems. Use Alarm Format (CP-10) to establish the circumstances under which the ML-Drive will alert you to potential operating problems.
Table 3-23 Default Alarms Control Parameters 3 - 30 CP Parameter Name Parameter Value CP-10 Alarm Format 15 CP-12 Low Alarm 0 CP-13 High Alarm 2000 CP-14 Ramped Error Alarm 2000 CP-15 Scaled Error Alarm 2000
Table 3-24 Entering Alarms Control Parameters CP Parameter Name Parameter Value CP-10 Alarm Format This Control Parameter determines the circumstances under which the ML–Drive will alert you to potential operating problems. The alarm can be wired to activate a warning light, a warning sound, or to shut down the system under specified conditions.
Jog Jog increases the RPMs at the acceleration rate that you specified in Acceleration Time (CP-16) until the Jog Setpoint (CP-05) is achieved. When Jog is terminated, there is no Deceleration Time (CP-17); the drive comes to an immediate stop. The factory default Control Parameter for Jog is found in Table 3-25. To modify this default parameter, refer to Table 3-26. If you are uncertain how to enter a Control Parameter, review the Operations: Keypad section, page 3-3.
LOGIC CONTROL This section addresses the four digital inputs that control the ML-Drive's operating state. Logic Control also addresses one digital output. The four digital inputs are F–Stop, R–Stop, Run and Jog. When the ML-Drive is powered up, it defaults to R–Stop. If either Run or Jog have been hardwired, the ML-Drive will operate in either Run or Jog instead of R–Stop. Run is hardwired by shorting Run, R–Stop and F–Stop to common. Jog is hardwired by shorting Jog, R–Stop, and F–Stop to common.
Logic Inputs F–Stop has priority over the other operating states. F–Stop brings the ML-Drive's drive output to an immediate Zero. To activate F–Stop: • Open the F–Stop Input. (F–Stop is latched and does not need to be maintained to remain active.) F-STOP 10 F-STOP 11 COMMON J4 Open Momentarily R–Stop has the second highest operating priority. R–Stop decelerates the drive output to Zero, using the Deceleration Time (CP-17). To activate R–Stop: • Short the F–Stop input to common.
Run has the third highest operating priority. Run ramps to the scaled setpoint speed, using the Acceleration Time (CP-16). Run can be activated when the ML-Drive is in R–Stop or F–Stop, however Run cannot be activated when the ML-Drive is in Jog. To activate Run: • Short the F–Stop and R–Stop inputs to common. • Open the Jog input. • Short the Run input to common. (Run is latched and does not need to be maintained to remain active.
Jog has the least operating priority. Jog ramps to the Jog Setpoint (CP-05), using the Acceleration Time (CP-16). When Jog is terminated, the ML-Drive brings the drive output to an immediate Zero. Unlike the other inputs, Jog is not latched and must be sustained to remain active. To activate Jog: • Short the F–Stop and R–Stop inputs to common. • Open the Run input. • Short the Jog input to common. (Jog must be sustained to remain active).
Logic Output The Drive Enable output is controlled by the Ramped Reference (MP-46) and the feedback. Drive Enable Logic (CP-74) determines which conditions of the Ramped Reference (MP-46) and feedback will control the Drive Enable output. The Ramped Reference (MP-46) is the calculated setpoint that is output from the Acceleration/ Deceleration routine. The factory default for Drive Enable Logic (CP-74) is found in Table 3-27. To modify this default parameter, refer to Table 3-28.
—NOTES— 3 - 38
MONITOR PARAMETERS Parameters are divided into two classifications; Control Parameters (CP) and Monitor Parameters (MP). The numbered code that represents the Parameter is the Parameter Code. The operational data is the Parameter's value. Control Parameter 05 = 50 (default) Monitor Parameter 40 = 200 (arbitrary) Parameters = Parameter Code Parameter Value This section is about Monitor Parameters. Control Parameters are explained in Operation: Control Parameters, page 3-7.
Input Monitoring These MPs monitor the ML-Drive's inputs. MP-41 LEAD FREQUENCY The Lead Frequency (MP-41) displays the frequency of the Lead Frequency Input (J4 pin 3) in units of hertz (pulses per second). The Lead Frequency (MP-41) is not averaged or filtered; it is the ten millisecond frequency calculation prior to the display update. Because the Lead Frequency (MP-41) is not averaged or filtered and because of sensor irregularities, it may appear less stable than Tach (MP-40).
MP-54 LOGIC INPUTS - GROUP A The Logic Inputs - Group A (MP-54) displays the status of the Run, Jog, R–Stop and F– Stop digital inputs. The number “1” indicates an open, or logic high level. The number “0” indicates a closed, or logic low level (shorted to common). In the example below, “Jog” is the open or logic high level.
Output Monitoring These MPs monitor the ML-Drive's outputs. MP-47 DRIVE OUTPUT The Drive Output (MP-47) displays the drive output to the motor (J2 pin 1, 2). Drive Output is displayed as a percentage; 100 represents 100% of the drive output. MP-56 LOGIC OUTPUTS The Logic Outputs (MP-56) displays the status of the Drive Enable and the Alarm digital outputs. The number “1” indicates an inactive or de-energized (logic high) level. The number “0” indicates an active or energized (logic low) level.
Performance Monitoring Performance Monitor Parameters monitor the performance of the ML-Drive and your system. Figure 3-2 is a block diagram of the internal control structure of the ML-Drive and the Performance Monitor Parameters.
MP-45 SCALED REFERENCE The Scaled Reference (MP-45) is the scaled setpoint number converted to hertz. It is the calculated value that is input to the Acceleration/Deceleration routine. This parameter may display numbers that are larger than 9999. These larger values are displayed with two decimal places. For example, 10,000 hertz is displayed as “10.00.”. MP-46 RAMPED REFERENCE The Ramped Reference (MP-46) is the calculated output of the Acceleration/ Deceleration routine in hertz.
Status Monitoring These MPs monitor the status of the ML-Drive's modes of operation and operating states. MP-50 ACTIVE SCALING MODE The digit that displays a number “1” is the active Scaling mode. In the example below, “Master Mode” is the active Scaling mode. Code MP-51 Direct Mode Master Mode Follower Mode Inverse KEYPAD ERROR If a Control Parameter entry has been rejected, Keypad Errors (MP-51) will ascertain the reason that it was rejected. The digit that displays a number “1” is the error.
MP-52 ALARM STATUS The digit that displays a number “1” is the active Alarm. In the example below, “High Speed Alarm ” is the active alarm. Code MP-53 Low Speed Alarm High Speed Alarm Ramped Error Scaled Error CONTROL STATE The digit that displays a number “1” is the active control state of the ML-Drive. In the example below, “Run” is the active control state. Code Jog Run R-Stop F-Stop MP-57 EEPROM STATUS The Control Parameters are stored in the EEPROM memory chip.
MP-59 FREQUENCY OVERFLOW COUNTER The Frequency Overflow Counter (MP-59) is a counter that increments each time the frequency input to the ML-Drive causes an overflow. To reset the counter to “0”, press the Clear key. MP-82 MOTOR CURRENT Motor Current (MP-82) displays the value, in amps, of the motor armature's RMS current. MP-83 CURRENT LIMIT STATUS Current Limit Status (MP-83) displays the present status of the current limit . When the ML-Drive is current limiting, then the number “1” is displayed.
—NOTES— 3 - 48
SERIAL COMMUNICATIONS The ML-Drive can interface with a host computer through a RS485 Serial Communications Interface. This interface allows the host computer to perform remote Control Parameter entry, status or performance monitoring, and remote control of the ML-Drive. Refer to Using Serial Communications, page 3-50, in this section. If you are using the M-Host software, your communications network is user ready and does not require any software programming.
Using Serial Communications This section describes how to use the Serial Communications. Before you can apply this section, The ML-Drive must be interfaced with a host computer through a RS485 Serial Communications Interface. The host computer must have the M-Host software or its equivalent installed. The ML-Drive comes factory pre-loaded with default Control Parameters for Serial Communications Setup.
CP-72 CHARACTER FORMAT The ML-Drive uses three different character formats. Enter the number for the required format, as listed below. 1 = 8 Data Bits, No Parity, One Stop Bit 2 = 7 Data Bits, Even Parity, One Stop Bit 3 = 8 Data Bits, No Parity, Two Stop Bits CP-73 CONTROL MASK The Serial Communications can control some of the digital input functions. Enter the number for the required functions, as listed below.
Communications Software Design The ML-Drive Serial Communications Interface uses a polling technique to establish a link with the host computer. With the exception of Keypad Lockout (CP-98), all of the Control Parameters and Monitor Parameters that are accessible through the ML-Drive's front panel keypad are also accessible through the Serial Communications Interface.
Parameter Send Use the Parameter Send to change any of the ML-Drive's Control Parameters. Table 3-29 Parameter Send - Host Transmission Character # 1 DESC STX ASCII STX 2 3 4 DEV # DEV # MSG 10s 1s TYPE 0-9 0-9 3 5 6 7 8 PAR # PAR # DATA DATA 10s 1s 1000s 100s 0-9 0-9 0-9 0-9 9 10 11 12 DATA 10s DATA 1s DATA FORM ETX 0-9 0-9 0-8 ETX The following is a description of the Parameter Send-Host Transmission Characters.
Character 4 - Message Type: This character should always be “3”. Character 5, 6 - Parameter Number: These characters identify the Control Parameter that you want to change (i.e., “16” = CP-16). Characters 7 through 10 - DATA: These characters transmit the new value for a Control Parameter that you want to change. The Data must be within the range specified in Appendix D.
Character 12 - ETX: Always use the ASCII “ETX” character to terminate the character string. Example of Parameter Send: A new Acceleration Time of 52.3 seconds is sent to the ML-Drive at address 4. ASCII character string: “STX0431605230ETX” Note: The character string has no spaces between the integers.
Table 3-30 Parameter Send - ML-Drive Response Character # 1 DESC STX ASCII STX 2 3 4 5 6 7 8 DEV # DEV # ERROR PAR # PAR # DATA DATA 10s 1s CODE 10s 1s 1000s 100s 0-9 0-9 @-DEL 0-9 0-9 0-9 0-9 9 10 11 12 DATA 10s DATA 1s DATA FORM ETX 0-9 0-9 0-8 ETX The following is a description of the Parameter Send-ML-Drive Response Characters. Character 1 - STX: This is the first character in the character string.
Characters 5,6 - Parameter Number: The Control Parameter code is sent back to the host computer from the ML-Drive. Characters 7 through 10 - DATA: The Control Parameter data is sent back to the host computer from the ML-Drive. Character 11 - Data Format: The Data Format character is sent back to the host computer from the ML-Drive. Character 12 - ETX: The return message is always terminated with the ASCII “ETX” character.
Control Command Send The Control Command Send allows the host computer to control the operating functions of the ML-Drive that are associated with the digital inputs (Run, Stop, Setpoint Select and Master/Follower).
Characters 5,6 - Parameter Number: These characters should always be “0”. Characters 7 through 8 - DATA: These characters should always be “0”. Characters 9,10- DATA: 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 F–Stop R–Stop Run Enable Master Mode Enable Follower Mode Not in Use Not in Use Not in Use Not in Use Enable Setpoint 1/3 Enable Setpoint 2/4 Not in Use Not in Use Not in Use Not in Use Character 11 - Data Format: This character should always be “0”.
Table 3-32 Control Command Send - ML-Drive Response Character # 1 DESC STX ASCII STX 2 3 4 5 6 7 8 DEV # DEV # ERROR PAR # PAR # DATA DATA 10s 1s CODE 10s 1s 1000s 100s 0-9 0-9 @-DEL 0 0 0 0 9 10 11 12 DATA 10s DATA 1s DATA FORM ETX 0-9 0-9 0 ETX The following is a description of the Control Command Send-ML-Drive Response Characters. Character 1 - STX: This is the first character in the character string.
Characters 5,6 - Parameter Number: These characters will always be “0”. Characters 7 through 10 - DATA: These characters will always be “0”. Character 11 - Data Format: This character will always be “0”. Character 12 - ETX: The return message is always terminated with the ASCII “ETX” character.
Data Inquiry Use the Data Inquiry to request the current value for Parameters (i.e., Control Parameters or Monitor Parameters). Table 3-33 Data Inquiry - Host Transmission Character # 1 DESC STX ASCII STX 2 3 4 DEV # DEV # MSG 10s 1s TYPE 0-9 0-9 5 6 7 8 PAR # PAR # DATA DATA 10s 1s 1000s 100s 2 0-9 0-9 0 0 9 10 11 12 DATA 10s DATA 1s DATA FORM ETX 0 0 0 ETX The following is a description of the Data Inquiry - Host Transmission Characters.
Characters 5,6 - Parameter Number: This is the Control Parameter code (i.e., enter “16” for CP–16). Characters 7 through 10 - DATA: These characters should always be “0”. Character 11 - Data Format: This character should always be “0”. Character 12 - ETX: Always use the ASCII “ETX” character to terminate the character string.
Table 3-34 Data Inquiry - ML-Drive Response Character # 1 DESC STX ASCII STX 2 3 4 5 6 7 8 DEV # DEV # ERROR PAR # PAR # DATA DATA 10s 1s CODE 10s 1s 1000s 100s 0-9 0-9 @-DEL 0-9 0-9 0-9 0-9 9 10 11 12 DATA 10s DATA 1s DATA FORM ETX 0-9 0-9 0-; ETX The following is a description of the Data Inquiry-ML-Drive Response Characters. Character 1 - STX: This is the first character in the character string.
Characters 5,6 - Parameter Number: The Control Parameter code is sent back to the host computer from the ML-Drive. Characters 7 through 10 - DATA: The Control Parameter data that was requested is sent back to the host computer from the ML-Drive. For an interpretation of the MP-50 through MP-56, and CP-73 data, refer to Table 3-36 (page 3-67). For the ASCII to binary conversion, refer to Table 3-35 (page 3-66).
Table 3-35 ASCII to Binary ASCII NUL SOH STX EXT EOT ENQ ACK BEL BS HT LF VT FF CR SO SI DLE DC1 DC2 DC3 DC4 NAK SYN ETB CAN EM SUB ESC FS GS RS US 3 - 66 ASCII Binary ASCII Binary Binary ASCII Binary Bit 7 Bit 1 Bit 7 Bit 1 Bit 7 Bit 1 Bit 7 Bit 1 0000000 0000001 0000010 0000011 0000100 0000101 0000110 0000111 0001000 0001001 0001010 0001011 0001100 0001101 0001110 0001111 0010000 0010001 0010010 0010011 0010100 0010101 0010110 0010111 0011000 0011001 0011010 0011011 0011100 0011101 0011110 0011111 SP
3 - 67 Always “0” Always “0” Always “0” Always “0” Always “0” Always “0” 6 7 Always “0” Always “0” Always “1” Always “1” Always “1” 5 Always “1” Always “1” Always “1” Always “1” Always “1” Always “0” Always “0” Always “1” Always “1” Always “0” Always “0” Always “1” Always “1” No F-Stop No R-Stop No Run 1 Always “0” Always “0” Always “1” Always “1” F-Stop R-Stop Run Jog MP-53 No Jog 0 Always “0” Always “0” Always “1” Always “1” F-Stop Low R-Stop Low Jog Low 1
—NOTES— 3 - 68
Troubleshooting Diagnostics Troubleshooting PROM Chip Replacement 4-1
4-2
DIAGNOSTICS This section describes how to use the diagnostic routines to verify that the ML-Drive is operating properly as well as to identify any ML-Drive problems. The diagnostic routines are run independently, with the ML-Drive temporarily disconnected from your system. Begin diagnostics with the Clear/4 procedure, then run tests 1-5. Each of the tests can be performed without repeating the Clear/4 procedure, unless you exit diagnostics.
RAM Test #1 - To Test Random Access Memory Clear/4 will automatically default to RAM Test #1. The diagnostic indicator and the number “1” will be visible on the left side of the LED display. To enter this test from another diagnostic test, press the UP or DOWN scroll keys until the number “1” is visible in the left side of the LED display. Press “Enter” to start the test. If RAM fails, “---5” is displayed. The test will stop if a failure is detected. Press “Clear ” to exit the test.
Display Test #2 - To Test the LED Display Panel Segments Press the “UP” or “DOWN” scroll keys until the diagnostic indicator and the number “2” are visible on the left side of the LED display. Press “Enter” to start the test. The ML-Drive will quickly run through all of the display variations. Watch each of the display variations carefully for missing segments. For example, a nine with missing segments could look like a seven.
Keypad Test #3 - To Test the Keypad Press the “UP” or “DOWN” scroll keys until the diagnostic indicator and the number “3” are visible on the left side of the LED display. Press “Enter” to start the test. The ML-Drive displays the number “15” for the “Enter” key.
Input Test #4 - To Test the Logic Inputs Press the “UP” or “DOWN” scroll keys until the diagnostic indicator and the number “4” are visible on the left side of the LED display. Press “Enter” to start the test. The LED display will be blank unless an input has been shorted. If an input has been shorted, it's number will display. For example, if the number three appears in the display, then R–Stop has been shorted. To test an input, short that input and open all of the other inputs.
Output Test #5 - To Test the Logic Outputs Press the “UP” or “DOWN” scroll keys until the diagnostic indicator and the number “5” are visible on the left side of the LED display. Only the diagnostic indicator and the number “5” will be visible on the LED display during this test. To run this test, connect the outputs to a pull up resistor and either a meter or LED, or connect the outputs to a relay and either lights or sound. Press “Enter” to start the test. Press keys 1 - 2 to activate the outputs.
In addition to diagnostic tests 1-5, the ML-Drive automatically performs two power up diagnostic routines during every Power Up. RAM TEST - Random Access Memory The ML-Drive performs a pattern read/write test on RAM. If RAM fails, “---5” Is displayed. The test will stop if a failure is detected. Press “Clear ” to exit the test. IF the RAM is good, the ML-Drive will begin the PROM test. PROM TEST The ML-Drive performs a checksum comparison on the PROM. If the test fails, “---3” is displayed.
—NOTES— 4 - 10
TROUBLESHOOTING This section contains four troubleshooting flowcharts to help you resolve four possible system operating problems. The four scenarios that are addressed by the flowcharts are: Motor Does Not Stop Motor Does Not Run Motor Runs at Wrong Speed Motor Runs Unstable If you need to verify the integrity of the ML–Drive independently, refer to the Troubleshooting: Diagnostics section, page 4-3.
Motor Does Not Stop No No No MP-53 = 0100 (R–Stop) MP-53 = 1000 (F–Stop) No Wiring to Motor is correct? No No Yes Yes Yes MP-53 = 0001 (Jog) MP-53 = 0010 (Run) Yes No No Yes J4, Pin 7 is shorted to common J4, Pin 6 is shorted to common Yes Yes Open J4, pin 6 and J4, pin 9 Open J4, Pin 7 Correct Wiring Problem Corrected No Consult Tech Support 1-800-342-4411 No Problem Corrected Figure 4-1 Motor Does Not Stop Flowchart 4 - 12 No
Motor Does Not Run No No MP-53 = 0001 (Jog) MP-53 = 0100 (R–Stop) MP-53 = 1000 (F–Stop) No Yes No No MP-53 = 0010 (Run) No No Yes J4, Pin 10 is shorted to common No J4, Pin 9 is shorted to common Yes Yes Yes No CP-05 is correct ? Yes Yes Short J4, Pin 10 to common MP-50 = 0010(Master) No MP-50 = 0100(Follower) No No No Yes Yes Short J4, Pin 9 to common MP-50 = 0001(Direct) Yes Enter Correct Jog Setpoint Setpoint is correct ? Yes No No CP-06 is correct ? Yes Yes Problem C
Motor Runs at Wrong Speed No MP-50 = 0100(Follower) MP-50 = 0010(Master) No MP-50 = 0001(Direct) No No Yes Yes Yes Setpoint is correct ? Yes No No CP-06 is correct ? Yes Yes MP-46 is correct ? MP-45 is correct ? No No Enter Correct Setpoint Enter Correct Scaling Yes Problem Corrected No Consult Tech Support 1-800-342-4411 Figure 4-3 Motor Runs at Wrong Speed Flowchart 4 - 14
Motor Runs Unstable Change CP-61 to “1” and Run in Direct Mode Motor Still Unstable ? No Yes Change CP-61 to “0”and run in Master Mode Repeat Tuning Procedure Problem Corrected No Consult Tech Support 1-800-342-4411 Figure 4-4 Motor Runs Unstable Flowchart 4 - 15
PROM CHIP REPLACEMENT The PROM (Programmable Read Only Memory) chip is the software for the ML-Drive. See Figure 4-5 for the PROM's location on the CPU Board. To replace the PROM chip: • Make a record of your current Control Parameter values; the replacement chip contains default values that will replace your current values when you perform the Clear/7 step. • Turn off the power to the ML-Drive. • Remove the back panel. • Pull out the CPU board. • Ground yourself - Static electricity can damage the PROM.
Insert Tool Here Insert Tool Here Beveled Corner Figure 4-5 PROM Location 4 - 17
—NOTES— 4 - 18
Glossary Glossary - 1
Glossary - 2
GLOSSARY Acceleration/Deceleration Acceleration Time (CP-16) and Deceleration Time (CP-17) control the rate of speed change in response to setpoint changes. These parameters apply to both the Master and Follower modes of operation. Acceleration Time See Appendix C; CP-16. Alarms See Appendix C; CP-10, 12, 13, 14, or 15. Calibration Calibration sets the current limit of the ML-Drive and monitors the current limit.
the Follower mode, Acceleration/Deceleration, Tuning, Alarms, and Jog. The ML-Drive comes factory pre-loaded with a complete set of default Control Parameters. Data Inquiry Use the Data Inquiry to request the current value for Parameters (i.e., Control Parameters or Monitor Parameters) in serial communications. Deceleration Time See Appendix C;CP-17. Dedicated Keys The Setpoint key and the Tach key are shortcut keys.
Drive Enable The Drive Enable output is activated based on the Ramped Reference (MP-46) and the feedback. The Ramped Reference is the calculated setpoint that is output from the Acceleration/Deceleration routine. See Appendix C; CP-74. Engineering Units (E.U.) Master Engineering Units are the units of measure that your system operates at, such as, RPMs, gallons per hour, feet per minute.
Input Monitoring Lead Frequency (MP-41) Feedback Frequency (MP-43) Logic Inputs, Group A (MP-54) Logic Inputs, Group B (MP-55) Input Test Tests the Logic Inputs. Inputs AC Power (J2 pins 3, 4, 5) I/O Power (J4 pins 1,2) Lead Frequency (J4 pins 3, 5) Feedback Frequency (J4 pins 4,5) Run (J4 pins 6, 8) Jog (J4 pins 7, 8) R–Stop (J4 pins 9, 11) F-Stop (J4 pins 10, 11) Master or Follower (J4 pins 12, 14) Setpoint Select (J4 pins 13, 14) Integral See Appendix C;CP-66. Jog One of four operating states.
Master Mode A stand-alone control of a single motor. The scaling format allows the operator to enter a setpoint in Engineering Units. The ML-Drive compares the sensor shaft feedback to the scaled setpoint and calculates any speed error. When the ML-Drive finds speed error, the control algorithm adjusts the drive output and reduces the error to zero. Master Setpoints See Appendix C; CP-01 and CP-02. Max RPM Feedback See Appendix C; CP-34. Max RPM Lead See Appendix C; CP-33.
Glossary - 8
Output Test Tests the Logic Outputs. Outputs Drive Out (J2 pins 1, 2) Drive Enable (J4 pin 16, 18) Alarm (J4 pin 17, 18) Parameters Parameters are divided into two classifications; Control Parameters (CP) and Monitor Parameters (MP). Parameter Code The numbered code that represents a Parameter. Parameter Send Use the Parameter Send to change any of the ML-Drive's Control Parameters in Serial Communications.
Tuning Tuning stabilizes speed error differences between the setpoint and feedback. Ring Kits Ring Kits are flange motor mounted sensors that measure the pulses per revolution (PPR) of the motor shaft. R–Stop One of four operating states. R–Stop uses Deceleration Rate (CP-17) to decelerate the drive output to zero. R–Stop has the second highest operating state priority. RAM Test Tests Random Access Memory. This test can be run as part of the diagnostic tests.
Appendices Appendix A - ML-Drive Specifications Appendix B - Formulas Appendix C - Parameter Summary Numeric Quick Reference Appendix D - Control Parameter Reference Appendix E - Monitor Parameter Reference Appendix F - Fax Cover Sheet Appendix G - Wiring Diagram Examples Appendix H - Revision Log
APPENDIX A: ML-DRIVE SPECIFICATIONS Accuracy: .
A-2 Digital Outputs: Open-Collector Driver (ULN2003) (50 VDC max, 200 mA continuous, 500 mA peak) Optically Isolated Drive Enable Alarm Drive Output: Phase Fired - Single Quadrant 0 - 90 VDC, 10.0 FLA, 1/4 to 1 HP (115V version) 0 - 180 VDC, 10.0 FLA, 1/2 to 2 HP (230V version) PM Motors Current Limit: 4.0 to 10.0 Amps RMS 4.0 to 15.
HZ RPM General HZ RPM General (CP-1,2) X X = = X SetpointFollower (CP-21) E.U.Follower (CP-3,4) X X SetpointFollower (CP-21) E.U.Follower (CP-3,4) SetpointFollower (CP-21) E.U.
—NOTES— B-2
APPENDIX C: PARAMETER SUMMARY NUMERIC QUICK REFERENCE CP-01 MASTER SETPOINT 1 The Engineering Units value that you want your system to operate at when Master Setpoint 1 (CP-01) is active. If the Master Setpoint is equal to the Master Engineering Units (CP-20) then the system will run at its maximum RPMs, or Max RPM Feedback (CP-34). The factory default Master Setpoint Control Parameters are set at “0”.
CP-06 DIRECT SETPOINT Use the Direct Setpoint (CP-06) to set the drive output that is used when the ML-Drive is in the Direct Mode of operation. Direct mode is an open-loop mode of operation. Scaling, Acceleration/Deceleration, and closed loop compensation (PID) software are not involved in the Direct mode. The Direct mode is used in conjunction with the Run and Stop controls.
CP-15 SCALED ERROR ALARM The Scaled Error Alarm (CP-15) is the RPM deviation between the scaled reference and the feedback that will activate the Alarm output (at or above). CP-16 ACCELERATION TIME Acceleration Time (CP-16) controls the rate of speed change in response to setpoint changes. This Control Parameter applies to both the Master and Follower modes of operation. Enter the desired number of seconds to increase the motor speed from 0 to 2000 RPMs.
CP-31 PPR FEEDBACK PPR Feedback (CP-31) is the number of gear teeth or number of encoder lines on the Follower feedback sensor per revolution (pulses per revolution). CP-33 MAX RPM LEAD Measured at the Lead sensor shaft, Max RPM Lead (CP-33) is the maximum RPMs at which the Lead will operate your system. This number is not to be confused with the full capacity at which the Lead is capable of running. A system is not generally run at full capacity.
MP-43 FEEDBACK FREQUENCY The Feedback Frequency (MP-43) displays the frequency of the Feedback Frequency Input (J4 pin 4) in units of hertz (pulses per second). Feedback Frequency (MP-43) is not averaged or filtered; it is the ten millisecond frequency calculation prior to the display update. Because Feedback Frequency (MP-43) is not averaged or filtered and because of sensor irregularities, it may appear less stable than Tach (MP-40).
MP-47 DRIVE OUTPUT The Drive Output (MP-47) displays the drive output level to the motor (J2 pin 1, 2). Drive Output is displayed as a percentage; 100 represents 100% of the drive output. MP-48 TRIM OUTPUT The Trim Output (MP-48) is the calculated output of the PID Compensation routine. The Trim Output added to the feedforward equals the Drive Output (MP-47). The Trim Output (MP-48) is represented in DAC (Digital-to-Analog Converter) bits, for example 4095 equals 100% output, 2048 equals 50% output.
MP-51 KEYPAD ERROR If a Control Parameter entry has been rejected, Keypad Error (MP-51) will ascertain the reason that it was rejected. Keypad Error (MP-51) displays a number “1” to indicate the error. In the example below, “Above Maximum Allowed Value” is the error. Code Invalid Code Parameter Above Maximum Allowed Value Below Minimum Allowed Value Entry Timeout MP-52 ALARM STATUS Alarm Status (MP-52 ) displays a number “1” to indicate the active Alarm.
MP-53 CONTROL STATE Control State (MP-53 ) displays a number “1” to indicate the active control state of the ML–Drive. In the example below, “Run” is the active control state. Code Jog Run R-Stop F-Stop MP-54 LOGIC INPUTS - GROUP A The Logic Inputs - Group A (MP-54) displays the status of the Run, Jog, R–Stop and F–Stop logic inputs. The number “1” indicates an open, or logic high level. The number “0” indicates a closed, or logic low level (shorted to common).
MP-55 LOGIC INPUTS - GROUP B The Logic Inputs - Group B (MP-55) displays the status of the Master/Follower and Setpoint Select logic inputs. The number “1” indicates an open, or logic high level. The number “0” indicates a closed, or logic low level (shorted to common). In the example below, “Setpoint Select” is the open or logic high level.
MP-58 SERIAL COMMUNICATIONS ERROR Serial Communications Error (MP-58) identifies errors in the last transmitted message that was sent to the ML-Drive by the host computer. The mode that displays a number “1” indicates the error. In the example below, “Invalid Parameter Code” is the error.
CP-62 INVERSE SCALING Use Inverse Scaling (CP-61) to select either the Standard or the Inverse setpoint scaling format. Enter “2” for Inverse Scaling. Enter "1" for Standard Scaling. Code Inverse Scaling CP-64 DISPLAY MODE FOLLOWER In the Follower mode of operation, Display Mode Follower (CP-64) determines how the data will display in Tach (MP-40). Enter "2" to display the ratio of feedback to lead, in E.U.(Follower) Enter "1" to display the feedback in E.U.
CP-67 DERIVATIVE In systems with a very large inertia, use Derivative (CP-67) to reduce the overshoot from the integral term. Decrease the value of Derivative (CP-67) until the overshoot is acceptable. The system may operate erratically or become unstable if the value of Derivative (CP-67) is too small. CP-68 FEEDFORWARD To adjust the Feedforward (CP-68), run the ML-Drive in the Master mode of operation, using the default PID parameters and a setpoint value of 1000 RPM.
CP-73 CONTROL MASK The Serial Communications can control some of the logic input functions. Enter the number for the required functions in Control Mask (CP-74), as listed below. 0 = F-Stop only 1 = F-Stop, Run, R-Stop 2 = F-Stop, Master/Follower, Setpoint Select 3 = All of the above CP-74 DRIVE ENABLE LOGIC Drive Enable Logic (CP-74) determines which conditions of the Ramped Reference (MP-46) and the feedback will control the Drive Enable digital output.
MP-83 CURRENT LIMIT STATUS Current Limit Status (MP-83) displays the present status of the current limit. When the ML-Drive is current limiting, then the number “1” is displayed. When the ML-Drive is not in current limit, then the number “0” is displayed. CP-98 KEYPAD LOCKOUT Keypad Lockout (CP-98) displays the present status of the keypad lockout. When the keypad is locked, then “LOC” is displayed. When the Keypad is unlocked, then “ULOC” is displayed.
APPENDIX D: CONTROL PARAMETER REFERENCE CODE DESCRIPTION CP-01 CP-02 CP-03 CP-04 CP-05 CP-06 CP-10 CP-12 CP-13 CP-14 CP-15 CP-16 CP-17 CP-20 CP-21 CP-30 CP-31 CP-33 CP-34 CP-61 CP-62 CP-64 CP-65 CP-66 CP-67 CP-68 CP-70 CP-71 CP-72 CP-73 CP-74 CP-80 CP-81 CP-98 Master Setpoint 1 Master Setpoint 2 Follower Setpoint 1 Follower Setpoint 2 Jog Setpoint Direct Setpoint Alarm Format Low Alarm High Alarm Ramped Error Alarm Scaled Error Alarm Acceleration Time Deceleration Time Master Eng. Units Follower Eng.
—NOTES— D-2
APPENDIX E: MONITOR PARAMETER REFERENCE CODE DESCRIPTION MIN MAX UNITS MP-40 MP-41 MP-43 MP-44 MP-45 MP-46 MP-47 MP-48 MP-49 MP-50 MP-51 MP-52 MP-53 MP-54 MP-55 MP-56 MP-57 MP-58 MP-59 MP-82 MP-83 MP-99 Tach 0 Lead Frequency 0 Feedback Frequency 0 Deviation (Error) 0 Scaled Reference 0 Ramped Reference 0 Drive Output 0 Trim Output -4095 PIDF Output 0 Active Scaling Mode 0 Keypad Error 0 Alarm Status 0 Control State 0 Logic Inputs - Group A 0 Logic Inputs - Group B 0 Logic Outputs 0 EEPROM Status 0 Ser
—NOTES— E- 2
APPENDIX F: ML-DRIVE FAX COVER SHEET Date: ______________________ Atten: Contrex Technical Support Fax Number: 1-763-424-8734 From: Name ______________________________________________ Ext___________________ Company _______________ Telephone #________________ Fax # _________________ We have ______ ML-Drive(s) that are used for: ____________________________________ __________________________________________________________________________ _____________________________________________________________________
Please record the Control Parameters that you have changed from the default value: Code# Description CP-01 CP-02 CP-03 CP-04 CP-05 CP-06 CP-10 CP-12 CP-13 CP-14 CP-15 CP-16 CP-17 CP-20 CP-21 CP-30 CP-31 Master Setpoint 1 Master Setpoint 2 Follower Setpoint 1 Follower Setpoint 2 Jog Setpoint Direct Setpoint Alarm Format Low Alarm High Alarm Ramped Error Alarm Scaled Error Alarm Acceleration Time Deceleration Time Master Eng. Units Follower Eng.
APPENDIX G: WIRING DIAGRAM EXAMPLES DANGER This diagram is for conceptual purposes only! Use safety equipment. Make wiring connections carefully. Incorrect use of equipment or connections can cause injury or death. + A1 AC POWER 115 VAC 0.1 AMPS 50 / 60 HZ MOTOR ARM 1 HP 90 VDC 12.2 FLA DC PM Motor A2 MOTOR ARM – A1+ A2— AC POWER L1 NEUT GND PE AUX PWR 5V I/O PWR 5V_DI FREQ INPUTS LEAD_FQ COM_AUX COM + – 5V Ext Pwr Supply COM Feedback Freq.
DANGER This diagram is for conceptual purposes only! Use safety equipment. Make wiring connections carefully. Incorrect use of equipment or connections can cause injury or death. Neut Line R-Stop F-Stop Start K-R K-R Run K-R Jog K-FS + A1 AC POWER 115 VAC 0.1 AMPS 50 / 60 HZ MOTOR ARM 1 HP 90 VDC 12.
DANGER This diagram is for conceptual purposes only! Use safety equipment. Make wiring connections carefully. Incorrect use of equipment or connections can cause injury or death. + AC POWER 115 VAC 0.1 AMPS 50 / 60 HZ A1 MOTOR ARM 1 HP 90 VDC 12.2 FLA DC PM M1 Motor MOTOR ARM – A1+ A2 A2— M1 AC POWER L1 NEUT GND PE AUX PWR 5V I/O PWR 5V_DI COM_AUX + – COM 5V Ext Pwr Supply FREQ INPUTS LEAD_FQ FDBK_FQ COM Feedback Freq.
DANGER This diagram is for conceptual purposes only! Use safety equipment. Make wiring connections carefully. Incorrect use of equipment or connections can cause injury or death. DC PM Motor A1+ A2— AC POWER L1 NEUT GND PE AUX PWR I/O PWR FREQ INPUTS R–STOP R-Stop F–STOP F-Stop COM MST / FOL Setpoint Select SETPT COM V_DO DRV_EN ALARM MOTOR ARM 1 HP 90 VDC 12.2 FLA MOTOR ARM A1+ A2— AC POWER L1 NEUT GND PE AUX PWR 5V I/O PWR RS485 COMM AC POWER 115 VAC 0.
E --04/13 --- Update Page 2-5 for Motor Over-temp protection
—NOTES— H-2
Warranty Service Policy Warranty Warranty - 1
Warranty - 2
SERVICE POLICY Contrex, Inc., recognizes that with each sale of its product there are certain product obligations. This document defines the limits of such obligations and provides guidelines for the performance of related services. Applicability This Service Policy shall apply to all product sales of Contrex, Inc. However, it may be modified by mutual consent.
WARRANTY Contrex, Inc., guarantees this device against defects in workmanship and materials for a period of one (1) year from the date of purchase. Any parts or components that fail during the warranty period will be replaced or repaired without charge. This guarantee is void if the device has been damaged by improper installation or operation, tampering, careless handling or accident.
Index Index - 1
Index - 2
Index A AC Power (J2 pins 3, 4, 5)..page 2-8 Acceleration Time..page 3-26, 3-32, C-3, D-1 Acceleration/Deceleration..page 3-26, Glossary-3 Active Scaling Mode..page 3-45, C-6, E-1 Alarm Format..page 3-29, C-2, D-1 Output (J4 pin 17)..page 2-14 Status..page 3-46, C-7, E-1 Alarms, grouped..page 3-29 Appendix A..page A-1 Appendix B..page B-1 Appendix C..page C-1 Appendix D..page D-1 Appendix E..page E-1 Appendix F..page F-1 Appendix G..page G-1 Appendix H..page H-1 ASCII, Serial Communications Messages..
Control Parameters..page 3-7, Glossary-3 CP-01..page 3-9, 3-10, 3-11, 3-23, C-1, D-1 CP-02..page 3-9, 3-10, 3-11, 3-23, C-1, D-1 CP-03..page 3-13, 3-15, 3-21, 3-25, C-1, D-1 CP-04..page 3-13, 3-15, 3-21, 3-25, C-1, D-1 CP-05..page 3-32, C-1, D-1 CP-06..page 3-8, C-2, D-1 CP-10..page 3-29, C-2, D-1 CP-12..page 3-29, C-2, D-1 CP-13..page 3-29, C-2, D-1 CP-14..page 3-29, C-2, D-1 CP-15..page 3-29, C-3, D-1 CP-16..page 3-26, 3-32, C-3, D-1 CP-17..page 3-26, 3-32, C-3, D-1 CP-20..page 3-9, C-3, D-1 CP-21..
Dedicated Keys. See Keys: Dedicated Derivative..page 3-27, C-12, D-1 Deviation..page 3-29, 3-43, C-2, C-5, E-1 Device Address..page 3-50, C-12, D-1 Diagnostics..page 4-3 Automatic Test Routines..page 4-9 Digital Motor Controller..page Glossary-4 Direct Enable..page 3-8, C-10, D-1 Direct Mode..page 3-8, Glossary-4 Direct Setpoint..page 3-8, C-2, D-1 Display Mode Follower..page 3-43, C-11, D-1 Display Test..page 4-5, Glossary-4 Drive Enable..page 3-37, Glossary-5 Logic..page C-13, D-1 Output (J4 pin 16)..
H Hardwired..page Glossary-5 High Alarm..page 3-29, 3-46, C-2, D-1 Host Computer, Interface..page 3-49, 3-52 Housing the ML-Drive..page 2-3 How to Enter a Parameter Code..page 3-4 Enter a Parameter Value (Control Parameters)..page 3-4 Replace the PROM Chip..page 4-16 Use Serial Communications..page 3-50 Use the Setpoint Key..page 3-4 Use the Tach Key..page 3-4 Use the Up/Down Scroll Keys..page 3-4 I I/O Power (J4 pins 1, 2)..page 2-7 Input Monitoring..page 3-40, Glossary-6 Test..
J4 pins 9, 11 (R–Stop)..page 2-10 Jog..page 3-32, 3-36, Glossary-6 Jog input (J4 pins 7, 8)..page 2-10 Jog Setpoint..page 3-32, C-1, D-1 K Keypad Basic Entry..page 3-4 Error..page 3-45, C-7, E-1 Lockout..page 3-5, C-14, D-1, F-2 Record your Password..page 3-6 Operation..page 3-3 Test..page 4-6, Glossary-6 Keys Code Select..page 3-3, Glossary-3 Dedicated..page 3-3, Glossary-4 Numeric..page 3-3, Glossary-7 Setpoint..page 3-3 Tach..page 3-3 Up/Down Scroll..page 3-3, Glossary-10 L Lead Frequency..
Master Setpoint 2..page 3-9, C-1, D-1 Max RPM Feedback..page 3-9, 3-13, C-4, D-1 Max RPM Lead..page 3-13, C-4, D-1 ML-Drive Example of Application..page 1-4 Internal Structure..page 3-43 Introducing the..page 1-3 Mounting. See Mounting the ML-Drive Operation. See Operation Mode of Operation..page Glossary-7 Monitor Parameter Reference List..page E-1 Monitor Parameters..page 3-7, 3-39, Glossary-7 MP-00..page C-14 MP-40..page 3-43, C-4, E-1 MP-41..page 3-40, C-4, E-1 MP-43..page 3-40, C-5, E-1 MP-44..
O Open Loop..page 1-3, Glossary-7 Operating State..page Glossary-7 Operating States F–Stop..page 3-34 Jog..page 3-36 R–Stop..page 3-34 Run..page 3-35 Operation Acceleration/Deceleration..page 3-26 Alarms..page 3-29 Control Parameters..page 3-7 Direct Mode..page 3-8 Follower Mode..page 3-13 Example..page 3-16 Input Monitoring..page 3-40 Inverse Follower Mode..page 3-24 Example..page 3-25 Inverse Master Mode..page 3-22 Example..page 3-23 Jog..page 3-32 Keypad Operation..page 3-3 Logic Control..
Send..page 3-53, Glossary-9 Summary Reference List..page C-1 Value..page 3-7, 3-39, Glossary-9 Peak Current Limit. See Current Limit: Peak Performance Monitoring..page 3-43, Glossary-9 PIDF Output..page 3-27, 3-44, C-6, E-1 PPR Feedback..page 3-9, 3-13, C-4, D-1 Lead..page 3-13, C-3, D-1 PROM Chip..page Glossary-9 Chip Replacement..page 4-16 Test..page 4-9, Glossary-9 R R–Stop..page 3-34, Glossary-10 Input (J4, pins 9, 10)..page 2-10 RAM Test..page 4-4, 4-9, Glossary-10 Ramped Error Alarm..
Setpoint Select Input (J4 pins 13, 14)..page 2-12 Setup Calibration..page 2-17 Mounting the ML-Drive..page 2-3 Wiring..page 2-5 Software Code Revision..page C-14, E-1 Design/Communications..page 3-52 Part Number..page C-14 Specifications, ML-Drive..page A-1 Status Monitoring..page 3-45 Support, Technical. See Technical Support T Tach..page 3-43, C-4, E-1 Technical Support..page ii, 4-3, 4-11 Test Random Access Memory..page 4-4 The Keypad..page 4-6 The LED Display Panel Segments..page 4-5 The Logic Inputs..
—NOTES— Index - 12
