MDC-COV.
MDC-COV.QXD 10/21/04 10:51 AM Page 2 INTRODUCTION The Motor Drive Controller (MDC) is another unit in our multi-purpose series of industrial control products that is field-programmable for solving various applications. This series of products is built around the concept that the end user has the capability to program different indication and control requirements.
TABLE OF CONTENTS GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 A) Safety Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 B) Quick Start - Setting Up The MDC . . . . . . . . . . . . .
TABLE OF CONTENTS (Cont’d) IV. PROGRAMMING MODULE (Cont’d) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-30 C) Program User Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-21 1. No Mode . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (Cont’d) IV. PROGRAMMING MODULE (Cont’d) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-30 G) Program Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-30 1. Test Inputs . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL DESCRIPTION Application flexibility is provided through the two-line by eight-character alphanumeric display. The display features English language menus for easy viewing and simplified programming. The four scroll-through Indication Displays can be programmed to show various parameters and to automatically scroll, if desired. A program disable DIP switch used with an external User Input can be utilized to protect the settings and guarantee that no unwanted changes occur during operation.
QUICK START - SETTING UP THE MDC RPM LD, which are part of setting the Unity Ratio. Understanding the Unity Ratio is crucial to scaling in Follower Mode. While it is generally recommended that you read this instruction manual thoroughly before attempting to set up and operate the model MDC Motor Drive Controller, the following quick set-up procedure provides the basic steps to get the MDC up and running. 7.
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THEORY OF OPERATION In Master Mode, the MDC uses actual motor speed (Feedback Input) and an analog control voltage (Drive Output) to precisely control the motor’s speed. The MDC operates on a 10 msec control cycle. Actual motor speed is read and drive output is corrected every 10 msec. The Drive Output voltage is generated by a 12 bit DAC (digital to analog converter). Motor speed is controlled by adjusting the Output Value (in bits) to the DAC.
NORMAL OPERATING MODE When the MDC is powered up, it is in the Normal Operating Mode with the Indication Display Module viewed. The up and down arrow keys are used to scroll through the Indication Displays. The Indication Displays are referenced as 1 to 4 with the factory default settings of 1 (SPEED), 2 (OPERATING STATUS), 3 (ALARM STATUS), and 4 (TRIM). The Indication Displays can be programmed to show other parameters and automatically scroll if desired (See Program Displays Menu for details).
KEYPAD DESCRIPTION Shown here is a diagram of the keypad and a description of each key. Some keys have a dual function. KEYPAD FUNCTIONS (Cont’d) KEYPAD FUNCTIONS - The Down arrow key scrolls through the Indication Displays. When v in the User Setpoints Module, it is used to decrement the current speed setpoint (Setpoint Scroll Menu), or to scroll through the setpoint values. In the Programming Module, it scrolls through the programming menus and sub menus.
DEDICATED CONTROL INPUT FUNCTIONS FRONT PANEL ACCESSIBLE PROGRAMMING The Motor Drive has inputs dedicated to certain primary operations. These functions are as follows: The MDC has several ways to limit the programming of parameters in the User Setpoints Module and the Programming Module. The Operator Access Menu, in the Programming Module, can be used with the Program Disable (PGM. DIS) DIP switch or an external User Input to limit programming of parameters in the User Setpoints Module.
OVERFLOW INDICATION An input frequency overflow occurs in the normal operating mode when the input frequency specifications are exceeded. The MDC continuously displays “FB FREQ OVERFLOW”, or “LD FREQ OVERFLOW” when the respective input frequency exceeds specifications. A second type of overflow is an Indication Display overflow. The MDC flashes the word “OVERFLOW” in the appropriate display when the overflow condition occurs. A display overflow occurs if the capacity of the display is exceeded.
PROGRAMMING GENERAL DESCRIPTION Programming is done through the front panel keypad, which allows the user to enter into Main Menus, Sub-Menus, and Edit Menus. English language prompts, flashing parameter values, and the front panel keypad aid the operator during programming. Although the unit has been programmed at the factory, the parameters generally have to be changed to suit the desired application.
USER SETPOINTS MODULE The User Setpoints Module is accessed from any of the Indication Displays, or from any of the main menus in the Programming Module (except Operating Mode Menu), by pressing the SET key. Pressing “SET” once enters the Setpoint Scroll Menu. In this menu, the current speed or ratio setpoint may be incremented or decremented using the Up and Down arrow keys. The top line of the display shows the current setpoint value and the bottom line shows actual speed in display units.
USER SETPOINTS IN MASTER MODE Speed Setpoint 1 (S1) Jog Speed (JOG SPD) The Jog Speed setpoint is used in JOG mode (See JOG under Dedicated Control Input Functions for details). The value entered is in display units with the same range and limitations as Speed Setpoint 1. Speed Setpoint 1 is one of two user selectable speeds used in “RUN” mode. The speed value is entered in display units (user units) as defined in the Program Scaling Menu.
USER SETPOINTS IN FOLLOWER MODE Ramp Rate 2 (RAMP 2) The setpoints listed below are independent FOLLOWER mode setpoints. They are retained separately from the MASTER mode setpoints in non-volatile memory. Jog, Alarm, and Gain values are shared parameters used by both MASTER and FOLLOWER modes. Ramp Rate 2 is the second user selectable ramp rate. A User Input must be configured to allow selection of RAMP 1 or 2 for use as the current ramp rate.
PROGRAMMING MODULE OPERATING MODE SELECTION MENU The Programming Module is used to access all parameters for configuring the unit. To enter the Programming Module, the user must first press PGM/ENT from the Indication Display Module. This causes “PROGRAM MODE” to be displayed. The user must then press SEL to enter the Programming Module. Depending upon the program disable state, access to the Programming Module may be denied or require a security code entry. (See Front Panel Accessible Programming.
PROGRAM SCALING MENU PPR FB (Pulses Per Revolution- Feedback) Enter the number of pulses per revolution generated by the feedback transducer. The value for PPR FB ranges from 1 to 59999. The Program Scaling Menu is used to scale the MDC to the specific motor (or shaft) feedback transducer output. This Menu also scales the speed in RPM to the Display units which are seen on the display and used for speed setpoint entry.
PROGRAM SCALING MENU (Cont’d) For example, in a Master/Follower application where two motors are driving conveyors which are feeding product into a hopper, conveyor A must run 2X faster than conveyor B to get a product mix of 1:1. The maximum speed for both motors is 1750 RPM. We will use motor B for the Follower since it runs slower than motor A. The max RPM feedback is set to 1750 (the max motor speed for conveyor B). Set the unity ratio so that a ratio setpoint of 1.
PROGRAM USER MENU There are four external User Inputs and two front panel Function keys, which have a variety of programmable capabilities. An external User Input is active when tied to common. A front panel function key is active when pressed. The options for each User input are the same, except as noted below: 1. The two Function keys (F1/RUN & F2/STP) have some additional functions: RUN (F1 only), R-STOP, F-STOP and JOG. 2. The two Function keys DO NOT have the Program Disable (PGM.DIS.) option.
PROGRAM USER MENU (Cont’d) SETPOINT SELECT/TOGGLE (SPT SEL/TOG) ONLY ONE USER INPUT SHOULD BE PROGRAMMED FOR SPT SEL/TOG. If more than one is programmed, the highest priority input is recognized and all of the others are ignored. The priority order from highest to lowest is USR INP4, USR INP3, USR INP2, USR INP1, F1/F2. NO MODE If a User Input terminal or a Function key is activated, it will be ignored.
SETPOINT INCREMENT (INC SPT) Only an external User Input can be used for this option. The currently active speed or ratio setpoint is incremented when the User Input is made active. If the input remains active for more than 5 display unit increments, the scroll rate will progressively increase. Additional Options Available For F1 & F2 Keys SETPOINT DECREMENT (DEC SPT) Only an external User Input can be used for this option.
PROGRAM ALARMS MENU Alarm parameters 1 and 2 activate solid state Alarm Outputs 1 and 2 respectively. A manual reset, which requires the use of a User Input, will reset an Alarm Output (see Program User Menu). Both alarms may be programmed for any of the five alarm functions: High Alarm, Low Alarm, Deviation Alarm, Zero Speed Alarm, and Disabled.
Stop Enabled or Disabled This is an option that pertains only to the Low alarm and Deviation alarm. It refers to the alarm function when the MDC is in STOP mode or ramping to or from STOP mode. When the alarm is Stop Enabled, the alarm functions normally in stop mode. A low alarm would always be on since zero speed is always less than or equal to the speed setpoint. When the alarm is programmed to be Stop Disabled, the alarm is always inactive in stop mode and when ramping to or from stop mode.
PROGRAM DISPLAYS MENU Each line of each Indication Display can be programmed individually to show mnemonics or a numeric value for: Speed/Ratio Setpoint 1 or 2, Speed, Ratio, % Deviation, % Output, Feedback Frequency, Lead Frequency, Alarm 1 or 2 setpoint and Trim. Or, each line may be programmed to one of the two status displays: Operating Status or Alarm Output status.
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PROGRAM OPTIONS MENU The Program Options Menu is used to enable or disable the operator accessible functions, load the Factory Settings, or enable/disable No Feedback Detection. The following flowchart shows only the Options portion: OPERATOR ACCESS The Operator Access menu is used with the program disable DIP switch or an external User Input that is selected for the program disable function.
USER SETTINGS This Menu should only be entered if the operator wants to reset ALL parameters in either Master or Follower mode to the factory settings. If the MDC is in Master Mode when the word “FACTORY” is flashing in the display and the ENT key is pressed, all parameters for that mode are reset to the factory settings upon exiting the Programming Module. The same is true for Follower Mode. Parameters common to both Master and Follower modes are reset regardless of the operating mode.
FACTORY SETTINGS COMMON TO MASTER AND FOLLOWER MODES: USER SETTINGS MASTER MODE: USER SETPOINTS: S1 S2 R1 R2 FOLLOWER MODE: USER SETPOINTS: S1 S2 R1 R2 USER SETPOINTS: JOG SPD JOG RAMP AL-1 AL-2 GAIN DISPLAY 1 LINE 1 LINE 2 DISPLAY 1 LINE 1 LINE 2 DISPLAY 2 LINE 1 LINE 2 DISPLAY 2 LINE 1 LINE 2 SCALING: PPR FB MAX RPM FB DSP DP DSP UNIT DISPLAY 3 LINE 1 LINE 2 DISPLAY 3 LINE 1 LINE 2 DISPLAY 4 LINE 1 LINE 2 DISPLAY 4 LINE 1 LINE 2 ALARM OUTPUTS: ALARM 1: Alarm Type Phase Latched/Boundary Update
PROGRAM DIAGNOSTICS MENU TEST INPUTS The MDC displays an alphanumeric character to indicate a Dedicated Function Input or a User Input is active. This allows the user to check switch operation and wiring connections to the Inputs. It is made up of two sections. READ INP (read inputs) shows the state of the dedicated control inputs. READ USR (read user) shows the state of the programmable User Inputs.
PROGRAM DIAGNOSTICS MENU (Cont’d) PROGRAM SECURITY MENU TEST ALARMS The up and down arrow keys are used to select an alarm output and set it to the active or inactive state. This allows the user to check the operation of devices wired to the alarm outputs and the wiring connections. Please note that the active state is defined by the PHASE programming in the Program Alarms Menu. This is used to select the PRO.CODE used for Program Mode access when either the PGM.DIS.
INSTALLATION & CONNECTIONS unauthorized programming changes. The MDC should be installed in a location that does NOT exceed the maximum operating temperature and provides good air circulation. Placing the unit near devices that generate excessive heat should be avoided. The bezel should be cleaned only with a soft cloth and neutral soap product. Do NOT use solvents. Continuous exposure to direct sunlight may accelerate the aging process of the bezel.
EMC INSTALLATION GUIDELINES point of the enclosure. The following EMI suppression devices (or equivalent) are recommended: Ferrite Suppression Cores for signal and control cables: Fair-Rite#0443167251 (RLC#FCOR0000) TDK # ZCAT3035-1330A Steward #28B2029-0A0 Line Filters for input power cables: Schaffner#FN610-1/07 (RLC#LFIL0000) Schaffner # FN670-1.8/07 Corcom #1VB3 Corcom #1VR3 Note: Reference manufacturers instructions when installing a line filter. 5.
WIRING CONNECTIONS AC POWER WIRING The AC power is connected to the bottom terminals, TBA 1 & 2, marked AC PWR. The voltage selector switch, located at the side of the unit, is used to select the proper voltage. The switch is a slide movement type and can be set using a small screwdriver. If the switch is towards the front of the unit, it is set for 115 VAC input. If the switch is towards the rear of the unit, it is set for 230 VAC input. The switch is in the 230 VAC position when shipped from the factory.
SIGNAL WIRING LEAD AND FEEDBACK FREQUENCY INPUTS The Lead and Feedback Inputs have identical input circuitry. The Lead and Feedback inputs each have separate DIP switches for setting the type of signal input. A Magnetic Pickup or Logic Input signal can be sent to either input. When a MAGNETIC PICKUP is used, the Sink/Source DIP switch, for the appropriate input, must be in the “SRC” position for the frequency to be detected. The Input schematic shows the details of the Lead and Feedback input circuitry.
DEDICATED FUNCTION AND USER INPUTS Refer to the Terminal Connections drawing. TBA is the bottom terminal block and TBB is the top terminal block. JOG (TBB11): The jog function is only available from the STOP mode. A sustained closure from the JOG input to common causes the MDC to accelerate the motor to the jog speed setpoint using the jog ramp rate. The motor will remain at the jog speed until the closure is removed, at which point the MDC will execute an F-STOP. - Operative from STOP mode only.
DIP SWITCH SET-UP ISOLATED DRIVE OUTPUT Before connecting the MDC to the motor drive, refer to the Isolated Drive Output Calibration section to determine if the MDC’s analog drive output needs calibration. Most applications require calibration of the motor drive only. The MDC can be operated with an internal or external voltage reference. The jumper above the bottom rear terminal block selects the internal reference when in the position closest to the board edge. The unit is shipped in this configuration.
VARIOUS SENSOR OUTPUT CONNECTIONS (See Note 1) FREQUENCY SOURCE W/ISOLATED TRANSISTOR OUTPUTS CURRENT SOURCE CONNECTED CURRENT SINK CONNECTED RLC SENSOR MODELS: PR & RR PHOTO-ELECTRICS 2-WIRE PROXIMITY SENSORS MAGNETIC PICKUPS CURRENT SOURCE CONNECTED OLDER STYLE SENSORS WITH -EF OUTPUT-CURRENT SRC CONN. SENSORS WITH CURRENT SINK OPEN COLLECTOR (NPN O.C.) SENSORS WITH CURRENT SOURCE OUTPUT (PNP O.C.) RLC SENSOR MODELS: LMP-EC RLC SENSOR MODELS: ASTC, LMPC, LSC, PSAC, RPGB, RPGC, RPGH A.C.
NOTES: 1. SENSOR VOLTAGE AND CURRENT The +12 VDC (out) terminal can supply voltage to a sensor within a ±25% variation, due to line and internal load variations. All RLC sensors will accommodate this variation. 2. When shielded cable is used, the shield should be connected to “COMM.” at the unit and left disconnected at the sensor end. 3. The Lead and Feedback frequency inputs can accept source pulses from other circuits up to +28 V in amplitude.
ISOLATED DRIVE OUTPUT CALIBRATION VERIFYING SYSTEM OPERATION Note: There is no need to calibrate the Drive Output Span if an EXTERNAL reference is used or if the INTERNAL reference is used with the factory calibrated 0 to 10 V span. If this is the case, skip Drive Output Span Calibration and go to Motor Drive Setup. 1) With the MDC connected to the Drive as noted in Installation and Connections, power up the MDC and enter the Programming Module.
SPECIFICATIONS & DIMENSIONS 1. DISPLAY: 2x8, 0.3" (7 mm) high characters, negative image transmissive LCD, with red LED backlighting. 2. POWER: Switch selectable for: 115 VAC ±10%, 50/60 Hz, 10 VA or 230 VAC ±10%, 50/60 Hz, 10 VA. 3. MEMORY: Non-volatile E2Prom retains all programming information and values when power is removed or interrupted. Power Cycles (ON/OFF): 100,000 minimum. Data Retention: 10 years minimum. 4. SENSOR POWER: +12 VDC ± 25% @ 100 mA. 5.
14. CERTIFICATIONS AND COMPLIANCES: ELECTROMAGNETIC COMPATIBILITY 11. CONTROL INPUTS: Internal 10 KW pull-up to +5 VDC. VIL = 1.0 VMAX, VIH = 4.0 VMIN. Response time = 10 msec nominal, 30 msec maximum. INPUTS RUN FAST STOP RAMP STOP JOG OPEN LOOP USER INPUTS (4) SWITCH CONNECTIONS Momentary N.O. Momentary N.C. Momentary N.C. Sustained N.O. Maintained Function Specific 12. OUTPUTS: DRIVE ENABLE, ALARM 1, and ALARM 2: Solid state, current sinking NPN Open collector transistor. VCE = 1.
TROUBLESHOOTING GUIDE Use the Program Diagnostics Menu in the MDC to functionally test the system hardware. Each input and output can be tested independently. The following list may also help localize the problem. For further technical assistance, contact technical support at the numbers listed on the back cover of the instruction manual. PROBLEMS POSSIBLE CAUSE REMEDIES NO DISPLAY 1. Power off 2. Improperly wired 3. Voltage selector switch in the wrong position. 4. Power in a Brown out condition. 1.
TROUBLESHOOTING GUIDE (Cont’d) PROBLEMS UNIT WILL NOT ENTER JOG MODE POSSIBLE CAUSE REMEDIES 1. R-STOP, F-STOP inputs wired incorrectly. 1. R-STOP and F-STOP inputs must be held low or tied to comm. to enter JOG mode. 2. JOG is disabled. Exit the programming module. 3. Place unit in STOP mode. 2. Unit in Program mode. 3. Unit is in RUN mode. UNIT INDICATES ZERO SPEED (MOTOR RUNNING) 1. No feedback signal. 2. Type of input signal incorrectly selected. 3. Scaling parameters programmed incorrectly.
TROUBLESHOOTING GUIDE (Cont’d) PROBLEMS POSSIBLE CAUSE REMEDIES UNIT DOES NOT INDICATE SPEED CORRECTLY 1. Type of input signal incorrectly selected. 2. Feedback input improperly connected. 3. Electrical noise interference. 1. Check DIP switch set-up on side of unit. 2. Check sensor connection. 3. Check power source for noise. Check signal wire routing. 4.Check parameters in Program Scaling Menu. Verify correct FB freq. in Program Diagnostics Menu TEST DRV OUT. 4.
APPENDIX “A” APPLICATIONS MASTER MODE APPLICATION A pump delivers 30.0 gallons per minute with a shaft speed of 1750 RPM. A shaft pulse encoder generates 60 pulses/revolution. Set the MDC scaling to control and display pumping speed in tenths of a gallon/minute. 1) Set the pulses per revolution feedback to 60. 2) Set the maximum RPM feedback to 1750. This is the pump shaft’s maximum operating speed. 3) Set display decimal point to 0.0. Display units are in 0.1 gpm. 4) Set max display units to 30.0.
FOLLOWER MODE APPLICATION A fertilizer production facility is mixing pellets containing Nitrogen with pellets that contain Phosphorus. A chemical ratio of 1:1 is determined by the speed of two different conveyors. Because of differences in the gearing of the conveyor and concentration of the pellets, the Nitrogen conveyor motor must run at 3 times the speed of the Phosphorus conveyor motor in order to produce a 1:1 mix. The maximum speed of both motors is 2000 RPM.
APPENDIX “B” - ORDERING INFORMATION PART NUMBER 115/230 VAC MDC Motor Drive Controller MDC00100 For information on Pricing, refer to the RLC catalog or contact your local RLC distributor. MODEL NO.
MDC-COV.QXD 10/21/04 10:51 AM Page 3 LIMITED WARRANTY The Company warrants the products it manufactures against defects in materials and workmanship for a period limited to one year from the date of shipment, provided the products have been stored, handled, installed, and used under proper conditions. The Company’s liability under this limited warranty shall extend only to the repair or replacement of a defective product, at The Company’s option.
MDC-COV.QXD 10/21/04 10:51 AM Page 4 MDC/IM - F 10/00 DRAWING NO.
