CONTREX ML-Drive User Manual

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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. Ask for Technical Support: (763) 424-7800 or 1-800-342-4411

Contrex

8900 Zachary Lane North

Maple Grove, Minnesota 55369

Page 3

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.

iii

Page 4

Page 5

Introduction ...................................................................... 1-1

Introducing the ML-Drive ............................................................................ 1-3

Examples of ML-Drive Applications.............................................................. 1-4

Installation / Setup ......................................................... 2-1

Mounting ....................................................................................................... 2-3

Wiring ............................................................................................................ 2-5

Inputs.................................................................................................... 2-7

Outputs............................................................................................... 2-13

Serial Communications ...................................................................... 2-15

Calibration .................................................................................................. 2-17

Current Limit....................................................................................... 2-18

Operation.......................................................................... 3-1

Keypad Operation ........................................................................................ 3-3

Keypad Lockout ........................................................................................... 3-5

Control Parameters ..................................................................................... 3-7

Direct Mode.......................................................................................... 3-8

Master Mode ........................................................................................ 3-9

Follower Mode.................................................................................... 3-13

Inverse Master Mode ......................................................................... 3-22

Inverse Follower Mode....................................................................... 3-24

Acceleration/Deceleration .................................................................. 3-26

Tuning ................................................................................................. 3-27

Alarms ................................................................................................ 3-29

Jog...................................................................................................... 3-32

Logic Control.............................................................................................. 3-33

Logic Inputs........................................................................................ 3-34

Logic Output....................................................................................... 3-37

Page 6

Monitor Parameters ................................................................................... 3-39

Input Monitoring ................................................................................. 3-40

Output Monitoring............................................................................... 3-42

Performance Monitoring..................................................................... 3-43

Status Monitoring ............................................................................... 3-45

Serial Communications............................................................................. 3-49

Using Serial Communications............................................................ 3-50

Communications Software Design..................................................... 3-52

Troubleshooting.............................................................. 4-1

Diagnostics................................................................................................... 4-3

Troubleshooting......................................................................................... 4-11

PROM chip Replacement ............................................................................ 4-16

Glossary..............................................................Glossary-1

Glossary.............................................................................................Glossary-3

Appendices ......................................................................A-1

Appendix A: ML-Drive Specifications............................................................ A-1

Appendix B: Formulas ..................................................................................B-1

Appendix C: Parameter summary - numeric quick reference ......................C-1

Appendix D: Control Parameter Reference..................................................D-1

Appendix E: Monitor Parameter Reference..................................................E-1

Appendix F: ML-Drive Fax Cover Sheet....................................................... F-1

Appendix G: Wiring Diagram Examples ...................................................... G-1

Appendix H: Revision Log ............................................................................H-1

Warranty ........................................................... W arranty - 1

Service Policy ..................................................................................Warranty - 3

Warranty...........................................................................................Warranty - 4

Index .......................................................................... Index-1

Page 7

List of Illustrations

Figure 1-1 ML-Drive Master Mode ............................................................ 1-4

Figure 1-2 ML-Drive Follower Mode........................................................... 1-5

Figure 2-1 ML-Drive Cutout Dimensions and Mounting Guide .................2-2

Figure 2-2 ML-Drive General Wiring Guide .............................................. 2-4

Figure 2-3 I/O Power (Isolated).................................................................. 2-7

Figure 2-4 I/O Power (Non-Isolated) .......................................................... 2-7

Figure 2-5 AC Power.................................................................................. 2-8

Figure 2-6 Lead Frequency ....................................................................... 2-8

Figure 2-7 Feedback Frequency ............................................................... 2-9

Figure 2-8 Run ........................................................................................... 2-9

Figure 2-9 Jog .......................................................................................... 2-10

Figure 2-10 R–Stop .................................................................................... 2-10

Figure 2-11 F–Stop .................................................................................... 2-11

Figure 2-12 Master / Follower .................................................................... 2-11

Figure 2-13 Setpoint Select........................................................................ 2-12

Figure 2-14 Drive Output............................................................................ 2-13

Figure 2-15 Drive Enable and Alarms Output ............................................ 2-14

Figure 2-16 ML-Drive Multidrop Installation ............................................... 2-15

Figure 2-17 ML-Drive Serial Communications Connections .................... 2-16

Figure 3-1 ML-Drive Front Panel ............................................................... 3-4

Figure 3-2 ML-Drive Internal Structure .................................................... 3-43

Figure 4-1 Motor Does Not Stop Flowchart ............................................ 4-12

Figure 4-2 Motor Does Not Run Flowchart ............................................. 4-13

Figure 4-3 Motor Runs at Wrong Speed Flowchart ................................ 4-14

Figure 4-4 Motor Runs Unstable Flowchart ............................................ 4-15

Figure 4-5 PROM Location ...................................................................... 4-17

Figure G-1 ML-Drive Wiring Connections without Relays ....................... G-1

Figure G-2 Relay Start/Stop Wiring Connections .................................... G-2

Figure G-3 Start/Stop with Armature Contactor ....................................... G-3

Figure G-4 Two Channel Start/Stop - Lead/Follower Logic ..................... G-4

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Page 8

List of Tables

Table 3-1 Basic Keypad Entry ................................................................. 3-4

Table 3-2 Default Direct Mode Control Parameters ................................. 3-8

Table 3-3 Entering Direct Mode Control Parameters ............................... 3-8

Table 3-4 Default Master Scaling Control Parameters .......................... 3-10

Table 3-5 Entering Master Scaling Control Parameters ........................ 3-10

Table 3-6 Entering Master Setpoint Control Parameters ....................... 3-11

Table 3-7 Master Control Parameters Example .................................... 3-12

Table 3-8 Default Follower Scaling Control Parameters ....................... 3-14

Table 3-9 Entering Follower Scaling Control Parameters ..................... 3-14

Table 3-10 Entering Follower Setpoint Control Parameters .................... 3-15

Table 3-11 Follower Scaling Control Parameters Example A .................. 3-18

Table 3-12 Follower Scaling Control Parameters Example B ................. 3-21

Table 3-13 Default Inverse Master Control Parameters .......................... 3-22

Table 3-14 Entering Inverse Master Control Parameters ........................ 3-22

Table 3-15 Inverse Master Mode Control Parameters Example ............ 3-23

Table 3-16 Default Inverse Follower Control Parameters ....................... 3-24

Table 3-17 Entering Inverse Follower Control Parameters ..................... 3-24

Table 3-18 Inverse Follower Mode Control Parameters Example .......... 3-25

Table 3-19 Default Master or Follower Accel/Decel Control Parameters 3-26 Table 3-20 Entering Master or Follower Accel/Decel Control Parameters3-26

Table 3-21 Default Master or Follower Tuning Control Parameters ........ 3-27

Table 3-22 Entering Master or Follower Tuning Control Parameters ...... 3-28

Table 3-23 Default Alarm Control Parameters ......................................... 3-30

Table 3-24 Entering Alarm Control Parameters ....................................... 3-31

Table 3-25 Default Jog Control Parameters ............................................ 3-32

Table 3-26 Entering Jog Control Parameters .......................................... 3-32

Table 3-27 Default Drive Enable Logic Control Parameters .................... 3-37

Table 3-28 Entering Drive Enable Logic Control Parameters .................. 3-37

Table 3-29 Parameter Send - Host Transmission..................................... 3-53

Table 3-30 Parameter Send - ML-Drive Response ................................. 3-56

Table 3-31 Control Command Send - Host Transmission ....................... 3-58

Table 3-32 Control Command Send - ML-Drive Response...................... 3-60

Table 3-34 Data Inquiry - Host Transmission ........................................... 3-62

Table 3-35 Data Inquiry - ML-Drive Response ........................................ 3-64

Table 3-36 ASCII to Binary ...................................................................... 3-66

Table 3-36 Binary to Monitor Parameters ................................................ 3-67

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Introduction

Introducing the ML-Drive Examples of ML-Drive Applications

1 - 1

Page 10

1 - 2

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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).

The ML-Drive is ideal for motor control applications where your present open loop or rudimentary closed loop operations are inaccurate or where there is inadequate load regulation. The ML-Drive is also at the forefront in digitally accurate Follower applications. See Figure 1-1 and Figure 1-2 for examples of Master and Follower applications.

The ML-Drive is unique among its competition because the ML-Drive has preprogramed software that integrates with your system with little effort from you. The ML-Drive will also allow you to enter data that is unique to your system's specific needs (e.g., maximum RPMs, setpoints, acceleration/deceleration ramp rates). Using Control Parameters (CPs), this data is entered through either the ML-Drive's integrated keypad or though a host computer via the RS485 Serial Communications port. In addition to the Control Parameters that allow you to customize for your systems specific needs, the ML-Drive's Monitor Parameters (MPs) allow you to monitor your system's performance.

The ML-Drive's multiple scaling formats allow you to enter the setpoints and monitor speed in the Engineering Units (e.g., RPMs, gallons per hour, feet per minute) that are unique to your system. Among the ML-Drive's advanced capabilities is the flexibility to preset up to four setpoint entries.

Integrating the ML-Drive's applied intelligence with your system puts precise speeds at your fingertips, quickly, easily and cost effectively.

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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.

Drive Output

Contrex

CODE SELECT

456

SET

POINT

TACH

–

ENTER

CLEAR

ML-Drive

1 - 4

Motor

Sensor

Pump

Feedback Frequency

Figure 1-1 ML-Drive Master Mode

Page 13

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.

Lead

Drive Output

Lead Motor

Sensor

Feedback Frequency

Pump

Contrex

CODE SELECT

4 5 6

SET POINT

TACH

CLEAR

ML-Drive

8 9

2 3

–

ENTER

Ingredient A

Final Product

Follower

Follower Motor

Lead Frequency

Drive Output

Contrex

8 9

CODE SELECT

4 5 6

SET POINT

2 3

TACH

–

ENTER

CLEAR

ML-Drive

Feedback Frequency

Sensor

Pump

Ingredient B

Figure 1-2 ML-Drive Follower Mode

1 - 5

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—NOTES—

1 - 6

Page 15

Installation / Setup

Mounting Wiring

Inputs Outputs Serial Communications

Calibration

Current Limit

2 - 1

Page 16



Contrex

CUTOUT

(

3.65" .03"

6.00"

(

DOOR PANEL

Contrex

8 9

CODE

SELECT

4 5 6

SET

POINT

TACH

–

CLEAR

2 3

ENTER

)

3.60"

CUTOUT

(

3.65" .03"

3.60"

4.00"

From the rear of the door panel to the back of the connectors

4.00"

2 - 2

Figure 2-1 ML-Drive Cutout Dimensions and Mounting Guide

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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.

To mount the ML-Drive:

1) The NEMA Industrial Electrical Enclosure that will house the ML-Drive must conform to the following environmental conditions:

Temperature: 0 - 55 degrees C

(Internal NEMA enclosure temperature) Humidity: 0 - 95% RH non-condensing Environment: Pollution degree 2 macro - environment Altitude: To 3300 feet (1000 meters)

NOTE: Allow adequate spacing between the ML-Drive and other equipment to provide for proper heat convection. Placing the ML-Drive too close to adjacent equipment could cause the interior ambient temperature to exceed 55 degrees C. Spacing requirements depend on air flow, enclosure construction and applied horsepower.

2) The dimensions for the door panel cutout are 3.65"+ .03" x 3.65 + .03" (see Figure 2-1). Allow two inches of clearance on all sides of the cutout for mounting clamp attachments, wire routing and heat convection.

3) Insert the ML-Drive through the door panel cutout until the gasket and bezel are flush with the door panel (see Figure 2-1).

4) Slide the mounting clamps into the slots that are located on the top and bottom of the ML-Drive. Tighten the mounting screws until the ML-Drive is mounted securely in the NEMA Electrical Enclosure. Do not overtighten.

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5V_DI

COM

LEAD_FQ

FDBK_FQ

COM

RUN

JOG

COM

R–STOP

F–STOP

COM

MST / FOL

SETPT

COM

V_DO

DRV_EN

ALARM

COM

USE COPPER WIRE ONLY. SELECT WIRE SIZE ACCORDING TO AMPACITY FOR 60/75 C WIRE ONLY. TIGHTEN J2 TERMINALS TO 5 LB-INS.

J1 J3

AUX

PWR

A1+

A2—

NEUT

GND

POWER

MOTOR

ARM

AC POWER

115 VAC

15.0 AMPS

50 / 60 HZ

I / O

PWR

FREQ

INPUTS

DIGITAL

INPUTS

DIGITAL

OUTPUTS

COM_AUX

Run

Jog

R-Stop

F-Stop

Master/

Follower

Setpoint

Select

Lead

Frequency

Sensor

Feedback

Frequency

Sensor

+5VDC External

DC Power

Supply

+5V COM

+5V

SIG

COM

+5V

SIG

COM

50V

MAX

COM

External

DC Power

Supply

Use 115 VAC with ML-Drive model # 3200-1933

Use 230 VAC with ML-Drive model # 3200-1934

RS485 Serial

Communications

TD/RD+

TD/RD–

COM

MOTOR ARM

1 HP

90 VDC

10.0 FLA

–

DC PM

Motor

T / R +

T / R –

COM_AUX

RS485 COMM

12345

678

10111213141516

Neut or L2

GND/PE

Fuses

15A

250V

2 - 4

Figure 2-2 ML-Drive General Wiring

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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.

The installation of this motor control must conform to area and local electrical

NOTE:

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.

Branch Circuit Protection: “Suitable For Use On A Circuit Capable Of Delivering Not More Than 5,000 rms Symmetrical Amperes, 250 Volt Maximum.”

Class G branch circuit fuses rated 250V, 15A shall be provided in the end application.

Motor overload protection shall be provided in the end installation in accordance with the NEC.

This drive does not provide over-temperature sensing.

Use a minimum wire gauge of 18 AWG.

Use shielded cable to minimize equipment malfunctions from electrical noise.

Keep the AC power wiring (J2) physically separated from all other wiring on the ML-Drive. Failure to do so could result in additional electrical noise and cause the ML-Drive to malfunction.

A hand operated supply disconnect device must be installed in the final application. The primary disconnect device must meet EN requirements.

Inductive coils on relays, contactors, solenoids that are on the same AC power line or housed in the same enclosure should be suppressed with an RC network across the coil. For best results, use resistance (r) values of 50 ohms and capacitance (c) values of 0.1 microfarads.

Install an AC line filter or isolation transformer to reduce excessive EMI noise, such as line notches or spikes, on the AC power line.

WARNING

Hazardous voltages! Can cause severe injury, death, or damage

to equipment. The ML-Drive should only be installed by a

qualified electrician.

2 - 5

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—NOTES—

2 - 6

Page 21

INPUTS

COM_AUX

+5V

NOTE: The installation of this motor control must conform to area and local electrical

codes. See National Fire Protection Association, or Use local codes as applicable.

I/O Power (J4 pins 1, 2)

The National Electrical Code

The Canadian Electrical Code

(NEC,) Article 430 published by the

(CEC).

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.

CAUTION: The ML-Drive is shipped from the factory with J3 and J4 jumpers. You must remove the J3 and J4 jumpers before you connect the external power supply or you can damage the equipment. Do not exceed +5VDC on the I/O Power input.

Use the Auxiliary Power Output (J3 pins 1, 2) to supply power for non-isolated operations. The ML-Drive is shipped from the factory with the wiring defaulted to nonisolated operation.

+5VDC MAXIMUM

Do not connect the External Power Supply

Common to Earth Ground.

+5V

COM

Figure 2-3 I/O Power / Isolated

+5VDC External Power Supply

Figure 2-4 I/O Power / Non-Isolated

2 - 7

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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.

Neutral or L2

* *

* Fuse L1 for 115VAC applications.

Fuse L1 and L2 for 230VAC applications. Use 15 AMP 250V normal blow fuses.

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. For signal level specifications, refer to

ML-Drive Specifications,

References: Appendix A

page A-1

GND/PE

Figure 2-5 Input Power

Signal

Common

2 - 8

Figure 2-6 Lead Frequency

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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

ML-Drive Specifications,

References: Appendix A

page A-1.

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.

Figure 2-7 Feedback Frequency

DANGER !

Signal

Common

Run (J4 pins 6, 8)

When the Run input (J4 pin 6) is momentarily shorted to common, the ML-Drive enters Run. As a momentary input, Run is internally latched and does not need to be maintained by an operator device.

NOTE: Close the R–Stop and F–Stop

inputs prior to entering Run. If you are only using one of the Stop inputs, wire short the other Stop input to common or the ML-Drive will not enter “Run”.

RUN

Figure 2-8 Run

2 - 9

Page 24

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.

JOG

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.

R–Stop (J4 pins 9, 11)

R–Stop is a momentary input. When it is opened, the ML-Drive ramps to zero speed at the specified deceleration rate. As a momentary input, R–Stop is internally latched and does not need to be maintained by an operator device.

Figure 2-9 Jog

R-STOP

2 - 10

Figure 2-10 R–Stop

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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

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. The ML-Drive is in Master mode when the circuit is open, and Follower mode if the circuit is shorted to the common.

MASTER

FOLLOWER

Figure 2-12 Master / Follower

2 - 11

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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.

CONTROL

PARAMETER 1 OR 3

CONTROL PARAMETER 2 OR 4

Figure 2-13 Setpoint Select

Setpoint Select / Closed Setpoint Select / Open

Master, Follower Input Open

Master, Follower Input Closed

Master Control Parameter 1 Master Control Parameter 2

Follower Control Parameter 3

Follower Control Parameter 4

2 - 12

Page 27

OUTPUTS

NOTE: The installation of this motor control must conform to area and local electrical

codes. See National Fire Protection Association, or Use local codes as applicable.

Drive Output (J2 pins 1, 2)

The National Electrical Code

The Canadian Electrical Code

(NEC,) Article 430 published by the

(CEC).

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.

DC PM Motor

–

Figure 2-14 Drive Output

Drive Enable (J4 pin 16)

The Drive Enable output is activated (driven low) when the ML-Drive is signaling a nonzero speed to the motor, as defined by Drive Enable Logic (CP-74) The Drive Enable output is driven high (relay deactivated) after Power Up and during R–Stop and F–Stop. See Figure 2-15. Refer to page 3-37 for details.

Operations: Logic Control, Logic Output,

NOTE: This is an open-collector relay driver. For specification details, see

Appendix A

supply to power the relays. Free-wheeling diodes are incorporated internally in the ML-Drive and do not need to be added externally.

ML-Drive Specifications,

page A-1. Use an external DC power

References:

2 - 13

Page 28

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. Refer to

Operations: Logic Control, Logic Output,

NOTE: This is an open-collector relay driver. Use an external DC power supply to

power the relays. Free-wheeling diodes are incorporated internally in the ML-Drive and do not need to be added externally.

page 3-37 for details.

+V_DO

Drive Enable

Alarm

Common

EXTERNAL DC POWER SUPPLY

(50V Max)

–

Figure 2-15 Drive Enable and Alarm Outputs

Auxiliary DC Power (J3 pin 1, 2)

The 5 volt output (J3 pin 1) is a DC regulated output that can be used to power encoders or other auxiliary equipment that is used in conjunction with the ML-Drive. If this output is used, it will nullify optical isolation.

WARNING

Do not exceed the maximum current output of 150 mA for +5 VDC.

2 - 14

Exceeding the maximum current output can damage the ML-Drive.

Page 29

SERIAL COMMUNICATIONS

NOTE: The installation of this motor control must conform to area and local electrical

codes. See National Fire Protection Association, or Use local codes as applicable.

The Serial Communications interface on the ML-Drive complies with EIA Standard RS–485-A for balanced line transmissions. This interface allows the host computer to perform remote computer parameter entry, status or performance monitoring, and remote control of the ML-Drive. See information on using Serial Communications. The ML-Drive is designed to use with an isolated RS232 to RS485 converter.

Figure 2-16 illustrates a multidrop installation of the Serial Communications link and Figure 2-17 illustrates the Serial Communications connections.

The National Electrical Code

The Canadian Electrical Code

Operations: Serial Communications,

(NEC,) Article 430 published by the

(CEC).

page 3-49 for

Contrex

8 9

CODE

SELECT

4 5 6

SET POINT

2 3

TACH

–

ENTER

CLEAR

Isolated

RS232 to RS485

Converter

Contrex

8 9

CODE

SELECT

4 5 6

SET POINT

2 3

TACH

–

ENTER

CLEAR

Figure 2-16 ML-Drive Multidrop Installation

Contrex

8 9

CODE

SELECT

4 5 6

SET POINT

2 3

TACH

–

ENTER

CLEAR

8 9

CODE SELECT

4 5 6

SET POINT

2 3

TACH

–

ENTER

CLEAR

Contrex

8 9

CODE SELECT

4 5 6

SET

POINT

2 3

TACH

–

ENTER

CLEAR

8 9

CODE

SELECT

4 5 6

SET

POINT

2 3

TACH

–

ENTER

CLEAR

2 - 15

Page 30

Isolated

RS232 to RS485

Converter

TXD/ TXD/ COM RXD RXD — +

ML-Drive #1

T/R+ T/R– COM

ML-Drive #2

T/R+ T/R– COM

2 - 16

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.

Figure 2-17 ML-Drive Serial Communications Connections

Page 31

CALIBRATION

Calibration sets the ML-Drive's current limit. The ML-Drive must be properly installed prior to calibration. Refer to

Setup; Wiring

, page 2-5.

Hazardous voltages. Can cause severe

injury, death or damage to the equipment.

Installation/Setup; Mounting,

DANGER

page 2-3, and

Installation/

Make adjustments with caution.

2 - 17

Page 32

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. If the load current attempts to exceed the RMS Current Limit (CP-80) level for more than one minute, then the ML-Drive will restrict the motor current to the RMS Current Limit (CP-

80) level for the remainder of the ten minute period. The RMS peak intermittent duty load current is restricted to a level that is below the value that is entered in Peak Current Limit (CP-81). See below for instructions on entering the RMS Current Limit (CP-80) and the Peak Current Limit (CP-81).

The level of the ML-Drive's RMS Current Limit (CP-80) can be set in the range of

4.0 amps to 10.0 amps. Enter the value (in amps) at which you want to set the RMS Current Limit (CP-80), as follows:

Press “Code Select” Enter “80” (RMS Current Limit) Press “Enter” Enter the value at which you want to set the current limit

(range = 4.0 - 10.0 amps)

Press “Enter”

The level of the ML-Drive's Peak Current Limit (CP-81) can be set in a range of

4.0 amps to 15.0 amps. Enter the value (in amps) at which you want to set the Peak Current Limit (CP-81), as follows:

Press “Code Select” Enter “81” (Peak Current Level) Press “Enter” Enter the value at which you want to set the peak current limit

(range = 4.0 - 15.0 amps)

Press “Enter”

2 - 18

Page 33

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

Page 34

—NOTES—

2 - 20

Page 35

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

Page 36

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Page 37

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. Figure 3-1 displays the location of the keys and LED display on the keypad. Table 3-1 demonstrates basic keypad entry.

The keypad functions as follows:

Code Select Key Press this key prior to entering a Parameter Code (either a

Control Parameter or a Monitor Parameter).

Numeric Keys Use the numeric keys to enter a Parameter Code for either a

Control Parameter (CP) or a Monitor Parameter (MP) or to enter a value for a Control Parameter. Use the Enter key after each entry. Use the Clear key to delete your entry.

Dedicated Keys The Setpoint key and the Tach key are shortcut keys. The

Setpoint key accesses the active setpoint variable directly and the Tach key accesses the tach variable directly (rather than manually entering the Code Parameter).

Scroll Up/Down Keys These keys will change the active setpoint value, even if that

setpoint is not displayed in the LED Display. Each time you press the scroll up key, the active setpoint will increase by one increment. Each time you press the scroll down key, the active setpoint value will decrease by one increment. It will also automatically scroll through the increments or decrements if you hold the key down.

LED Display The two digit Parameter Code is displayed on the left LED

Display. The Parameter Code's value is displayed on the right LED display. This value can be up to four digits.

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Page 38

Table 3-1 Basic Keypad Entry

To Enter a Parameter Code:

To Enter a Parameter Value:

(For Control Parameters only - Monitor Parameters can not be changed manually)

To Use the Tach Key:

To Use the Setpoint Key: To Use the Up/Down

Scroll Keys:

Parameter Code

(2 digits)

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.

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”.

Press “Tach’. The scaled Engineering Unit Feedback is displayed.

Press “Setpoint”. The active setpoint and its value are displayed.

Press the “Up” scroll key to increase the active setpoint value. Press the “Down” scroll key to decrease the active setpoint value.

Parameter Value

(up to 4 digits)

Led Display

Code Select Key

Dedicated Keys

Up/Down Scroll Keys

3 - 4

Numeric Keys

Enter Key

Clear Key

Figure 3-1 The ML-Drive Front Panel

Page 39

KEYPAD LOCKOUT

Keypad Lockout (CP-98) displays the present status of the keypad lockout. When the keypad is locked, then “LOC” is displayed:

Code

When the Keypad is unlocked, then “ULOC” is displayed:

Code

To lock out the keypad, enter a numerical “password” between “1” and “9999” in Keypad Lockout (CP-98), then press the “enter” key. This numerical password will flash briefly on the screen, then the screen will display “LOC”. To unlock the keypad, enter the same numerical password in Keypad Lockout (CP-98). The number will flash briefly on the screen and then the screen will display “ULOC”. Control Parameters and Monitor Parameters may be monitored during lockout, however, Control Parameters can not be changed during lockout. The Clear/7 procedure will default Keypad Lockout (CP-98) to “ULOC” (unlocked).

Locked

Unlocked

CAUTION:

Make certain that you record your password in the space provided on page 3-6, as your password becomes transparent once you have entered it. If you forget your password, you can use the Clear/7 procedure to revert back to the default “ULOC” (unlocked). Please note, however, that the Clear/7 procedure will revert all of the Control Parameters back to their original default values and you will lose any changes that you have made to the Control Parameters. Therefore, make certain that you have recorded all Control Parameter changes in the space provided in Appendix D before you use the Clear/7 procedure. Refer to instructions on the Clear/7 procedure. If you are uncertain how to enter a Control Parameter, review the

Troubleshooting:Troubleshooting

Operations: Keypad

section, page 3-3.

, page 4-11 for

3 - 5

Page 40

Record your numeric Keypad Lockout password here:

Please read the “CAUTION” statement on Page 3-5

3 - 6

Page 41

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)

Parameters =

Monitor Parameter 40 = 200

(arbitrary)

Parameter Code Parameter Value

This section is about Control Parameters. Monitor Parameters are explained in

Operation: Monitor Parameters,

The ML-Drive comes factory pre-loaded with a complete set of default Control Parameters values. The majority of these default settings are suitable for most applications and do not require modification.

Control Parameters allow you to enter data that is unique to your system (e.g., encoder resolution, Lead to Follower ratios) and modify the ML-Drive for your specific needs (e.g., maximum RPMs, setpoints, acceleration/deceleration ramp rates) by entering a parameter value.

The ML-Drive is designed to execute either the Direct mode of operation, the Master (stand-alone) mode of operation or the Follower mode of operation. The values that you enter in the relevant Control Parameters, as well as the manner in which you wire your ML-Drive, determine which of the modes of operation your ML-Drive is set up for. The mode of operation that you use is determined by your systems operational requirements.

page 3-39.

The following subsections demonstrate how to enter Control Parameters for the Direct mode, Master (stand-alone) mode or the Follower mode of operation. In addition, Control Parameters for speed change, stability, warning methods and fast forward are addressed in the subsections on Acceleration/Deceleration, Tuning, Alarms, and Jog.

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Page 42

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).

The factory default Control Parameters for the Direct mode are found in Table 3-2. To modify the default parameters, refer to Table 3-3. If you are uncertain how to enter a Control Parameter, review the

Table 3-2 Default Direct Mode Control Parameters

CP Parameter Name Parameter Value

CP-06 Direct Setpoint 0 CP-61 Direct Enable 0

Operations: Keypad

section, page 3-3.

Table 3-3 Entering Direct Mode Control Parameters

CP Parameter Name Parameter Value

CP-06 Direct Setpoint

Enter the percentage of the calibrated full scale drive output at which you want your system to operate.

CP-61 Direct Enable

Enter “1” to enable the Direct Mode. Enter “0” to disable the Direct Mode.

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Page 43

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). However, before the ML-Drive can determine how to operate at those setpoints, you must enter Scaling Control Parameters into the ML-Drive. Scaling is a convenient method for translating the relationship of the motor RPMs into Master Engineering Units. The Scaling Control Parameters give the ML-Drive the following information:

Max RPM Feedback (CP-34)

Measured at the sensor shaft, this number is the maximum RPMs at which you want your system to operate.

PPR Feedback (CP-31)

The number of gear teeth or number of encoder lines on the feedback sensor per one revolution (pulses per revolution).

Master Engineering Units (CP-20)

The actual value of the Master Engineering Units if the system were to operate at the maximum RPMs that you entered in Max RPM Feedback (CP-34).

The factory default Control Parameters for Scaling are found in Table 3-4. To modify the default parameters, refer to Table 3-5. If you are uncertain how to enter a Control Parameter, review the entry follows Table 3-5.

Operations: Keypad

section, page 3-3. Information on setpoint

3 - 9

Page 44

Table 3-4 Default Master Scaling Control Parameters

CP Parameter Name Parameter Value

CP-34 Max RPM Feedback 2000

CP-31 PPR Feedback 60

CP-20 Master Engineering Units 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).

CP-20 Master Engineering Units

Enter the Master Engineering Units value if the system were to operate at the maximum desired RPMs entered in CP-34.

Now that your scaling has been established, you can enter a value for Master Setpoints 1 and 2. The value that you enter for a setpoint is the Engineering Units (E.U.s) that you want to operate your system at.

The factory default Control Parameters for Master Setpoint 1 and 2 are set at “0”. To modify these default parameters, refer to Table 3-6. You can toggle between the two setpoints, if you have wired the Setpoint Select accordingly. Setpoint Select (located at J4 pins 13, 14) determines which of the two setpoints is active (refer to

Select

the

on page 2-12). If you are uncertain how to enter a Control Parameter, review

Operations: Keypad

section, page 3-3.

Setpoint

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Page 45

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.

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Page 46

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. Master Setpoint 2 will be setup to pump 5 gallons per minute when it is the active setpoint.

Table 3-7 shows the scaling Control Parameters that would be entered in the ML-Drive for this example.

Table 3-7 Master Mode Control Parameters Example

CP Parameter Name Parameter Value

CP-34 Max RPM Feedback 1725 CP-31 PPR Feedback 30 CP-20 Master Engineering Units 15 CP-01 Master Setpoint 1 10 CP-02 Master Setpoint 2 5

After the Scaling and the Master Setpoints for your system have been entered, you can enter the Acceleration/Deceleration Control Parameters for the Master mode. The Acceleration/Deceleration Control Parameters are identical for both the Master and the Follower modes of operations. Acceleration/Deceleration is discussed in

Control Parameters, Acceleration/Deceleration,

The following section demonstrates how to enter Control Parameters for the Follower mode of operation.

3 - 12

page 3-26.

Operation:

Page 47

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). The Follower Engineering Units that you want the system to operate at are entered into the two available Follower Setpoints (CP-03 and CP-04). However, before the ML-Drive can determine how to operate at these setpoints, you must enter Scaling Control Parameters into the ML-Drive. Scaling is a convenient method for translating the relationship of the Lead and Follower motor RPMs into Follower Engineering Units. Scaling Control Parameters give the ML-Drive the following information:

Max RPM Lead (CP-33)

Measured at the Lead sensor shaft, this number is the maximum RPMs at which the Lead will operate in your system.

Max RPM Feedback (CP-34)

Measured at the sensor shaft, this number is the maximum RPMs at which you want the follower to operate when the Lead is operating at its maximum RPMs.

PPR Lead (CP-30)

The number of gear teeth or number of encoder lines on the Lead sensor per revolution (pulses per revolution).

PPR Feedback (CP-31)

The number of gear teeth or number of encoder lines on the Follower feedback sensor per revolution.

Follower Engineering Units (CP-21)

Enter a number that will represent the setpoint Engineering Units when the Lead and Follower are operating at their maximum RPMs. This number is usually either the ratio of Max RPM Feedback (CP-34) to Max RPM Lead (CP-33) or the ratio of Follower to Lead Engineering Units at maximum desired RPM. When this number is also entered as a setpoint (CP-03 or CP-04), the Follower will operate at maximum desired RPM when the Lead is at maximum desired RPM.

The factory default Control Parameters for Scaling are found on Table 3-8. To modify these default parameters, refer to Table 3-9. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

section, page 3-3.

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Page 48

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

CP Parameter Name Parameter Value

3 - 14

CP-33 Max RPM Lead

CP-34 Max RPM Feedback

CP-33 PPR Lead

CP-31 PPR Feedback

CP-21 Follower Engineering Units

Enter the maximum operating RPM of the Lead motor, measured at the Lead sensor shaft (pulses per revolution).

Enter the maximum desired RPM of the Follower motor, measured at the Follower feedback sensor shaft.

Enter the number of gear teeth or encoder lines on the Lead sensor.

Enter the number of gear teeth or encoder lines on the Follower feedback sensor.

Enter the Engineering Units value if the Lead (CP-33) is operating at maximum RPM and the Follower (CP-34) is operating at maximum RPM.

Page 49

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. Setpoint Select (located at J4 pins 13, 14), determines which of the two setpoints is active (refer to

Setpoint Select

on page 2-12). The factory preset, default Follower Setpoints 1 and 2 (CP-03 and CP-04) are set at “0”. To modify these default parameters, refer to Table 3-10.

Table 3-10 Entering Follower Setpoint Control Parameters

CP Parameter Name Parameter Value

CP-03 Follower Setpoint 1

Divide the Follower E.U. that you want, by the Lead E.U. that the Lead is operating at, and enter that value.

CP-04 Follower Setpoint 2

Divide the Follower E.U. that you want, by the Lead E.U. that the Lead is operating at, and enter that value.

Examples of the Follower mode of operation are demonstrated on the following pages.

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Page 50

Follower Mode Examples A and B

Example A demonstrates how scaling and setpoint Control Parameters are entered for

a typical Follower mode of operation that uses a ratio setpoint:

The Lead pump delivers 10 gallons/minute when the motor is running at a maximum RPM of 1725. The Lead sensor shaft is equipped with a 60 tooth Ring kit. The Follower pump delivers 30 gallons/minute when the motor is running at a maximum RPM of 1800. The Follower sensor shaft is equipped with a 30 tooth ring kit. Follower Setpoint 1 will be set so that when the Lead pump delivers 5 gallons/minute, the Follower pump will deliver 15 gallons/minute. Follower Setpoint 2 will be set so that when the Lead pump delivers 5 gallons/minute, the Follower pump will deliver 22.5 gallons/minute.

Table 3-11 shows the Control Parameters that would be entered in the ML-Drive for Example A.

To find the ratio for the Follower Engineering Units (CP-21) for Example A:

Follower E.U. (CP-21) =

30 gal / min The Follower Engineering Units when the Follower is operating

10 gal / min The Lead Engineering Units when the Lead is

3.00 Follower Engineering Units (CP-21) as a ratio of Follower to

3 - 16

at the maximum RPM.

Divided by

operating at maximum RPM.

Equals

Lead.

Follower E.U. at Max Follower RPM 30

_____________________________________________________

Lead E.U. at Max Lead RPM 10

___

Page 51

To find Follower Setpoint 1 (CP-03) for Example A:

Follower E.U. desired 15

Setpoint 1 =

________________________________

Lead E.U. operation 5

15 gal/min 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:

___

Setpoint 2 =

22.5 gal/min The Follower Engineering Units (gallon per minute) at which

5 gal/min The Lead Engineering Units (gallon per minute) that the Lead is

4.50 Follower Setpoint 2 (CP-04) value.

Follower E.U. desired 22.5

________________________________

Lead E.U. operation 5

you want the Follower to operate.

Divided by

operating at.

Equals

___

= 4.50

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Page 52

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 is discussed in the following section.

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Page 53

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. The Follower motor is running at a maximum RPM of 1800 and the Follower sensor shaft is equipped with a 60 tooth Ring kit. Follower Setpoint 1 will be set so that when the Lead pump delivers 20 gallons/minute of ingredient A, the Follower will deliver 10 gallons/minute of ingredient B. Setpoint 2 will be set so when the Lead pump delivers 10 gallons/minute of ingredient A, the Follower pump will delivers 7 gallons/minute of ingredient B.

Table 3-12 shows the Control Parameters that would be entered in the ML-Drive for Example B.

To find the ratio for the Follower Engineering Units (CP-21) for Example B:

Follower E.U. (CP-21) =

10 gal/min The Follower Engineering Units when the Follower is operating

Divided by

20 gal/min The Lead Engineering Units when the Lead is operating at

Multiplied by 100 (%) equals

50 Follower Engineering Units (CP-21) as a percent of Follower to

Follower E.U. at Max Follower RPM 10

__________________________________________________ = ___

Lead E.U. at Max Lead RPM 20

at maximum RPM

maximum RPM

Lead.

X 100(%) = 50

3 - 19

Page 54

To find Follower Setpoint 1 (CP-03) for Example B:

Follower E.U. desired

Setpoint 1 =

________________________________

Lead E.U. operation

x 100 (%)

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.

To find Follower Setpoint 2 (CP-04) for Example B:

Setpoint 2 =

3 - 20

Follower E.U. desired

________________________________

Lead E.U. operation

x 100 (%)

7 gal/min The Follower Engineering Units (gallons/minute of ingredient B)

at which you want the Follower to operate.

Divided by

10 gal/min The Lead Engineering Units (gallons/minute of ingredient A)

that the Lead is operating at.

Multiplied by 100(%) Equals

70 Follower Setpoint 2 (CP-04) value.

Page 55

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.

After the Control Parameters for the Scaling and for the Follower setpoint have been entered, you can enter the Control Parameters for the Acceleration/Deceleration of the Follower mode. The Control Parameters for Acceleration/Deceleration are identical for both the Master and the Follower modes of operations. Acceleration/Deceleration is discussed in

Operation: Control Parameters, Acceleration/Deceleration,

page 3-26.

3 - 21

Page 56

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. Inversely, the lower the setpoint value; the higher the motor speed.

The ML–Drive comes factory pre-loaded with the default Control Parameters for the standard Master Mode. These default settings are not suitable for Inverse applications and require modification. The factory default Control Parameters for the standard Master Mode are found in Table 3-13. To modify these default parameters, refer to Table 3-14. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

CP Parameter Name Parameter Value

section, page 3-3.

Table 3-13 Default Inverse Master Control Parameters

3 - 22

CP-62 Inverse Scaling 1 (Standard Scaling)

CP-20 Master E.U. 2000

Table 3-14 Entering Inverse Master Control Parameters

CP Parameter Name Parameter Value

CP-62 Inverse Scaling Enter “2” for Inverse Scaling.

CP-20 Master E.U.

Enter the minimum Master Engineering Units value if the system were to operate at the maximum RPMs entered in (CP-34).

Page 57

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. Set Master Setpoint 2 (CP-02) so that the product is in the oven for 15 seconds.

Table 3-15 shows the scaling Control Parameters that would be entered in the ML–Drive for this example.

Table 3-15 Inverse Master Mode Control Parameters Example

CP Parameter Name Parameter Value

CP-62 Inverse Scaling 2

CP-31 PPR Feedback 60

CP-34 Max RPM Feedback 1500

CP-20 Master E.U. 10.0

CP-01 Master Setpoint 1 20.0

CP-02 Master Setpoint 2 15.0

After the Scaling and the Master Setpoints for your system have been entered, you can enter the Acceleration/Deceleration Control Parameters for the Inverse Master mode. The Acceleration/Deceleration Control Parameters are identical for both the Inverse Master and the Inverse Follower modes of operations. Acceleration/Deceleration is discussed in

The following section demonstrates how to enter Control Parameters for the Inverse Follower mode of operation.

Operation: Control Parameters, Acceleration/Deceleration,

page 3-26.

3 - 23

Page 58

Inverse Follower Mode

The Inverse Follower Mode is a variation of the Follower Mode. The Inverse Follower Mode has an inverted setpoint. If you increase the value of the setpoint (CP-03 or CP-04), then the ratio of Follower speed to Lead speed will decrease.

With the Inverse Scaling (CP-62) set to “2”, enter values in the Follower Setpoints (CP-03 and CP-04) that represent the E.U. at which you want the system to operate. The higher the setpoint value; the lower the Follower to Lead ratio speed.

The ML–Drive comes factory pre-loaded with the default Control Parameters for the standard Follower Mode. These default settings are not suitable for Inverse applications and require modification. The factory default Control Parameters for the standard Follower Mode are found in Table 3-16. To modify these default parameters, refer to Table 3-17. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

Table 3-16 Default Inverse Follower Control Parameters

CP Parameter Name Parameter Value

CP-62 Inverse Scaling 1 (Standard Scaling)

section, page 3-3.

3 - 24

CP-21 Follower E.U. 1.000

Table 3-17 Entering Inverse Follower Control Parameters

CP Parameter Name Parameter Value

CP-62 Inverse Scaling Enter “2” for Inverse Scaling. CP-21 Follower E.U.

Enter the minimum Engineering Units if the system were to operate at the Max RPM Lead (CP-33) and the Max RPM Feedback (CP-34).

Page 59

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. The Follower motor uses a 1200 PPR encoder and the Lead motor shaft is equipped with a 60 tooth ring kit. Follower Setpoint 1 is setup for the minimum twist lay of 2.0 inches. Follower Setpoint 2 is setup for a twist lay of 5.0 inches.

Table 3-18 shows the scaling Control Parameters that would be entered in the ML–Drive for this example.

Table 3-18 Inverse Follower Mode Control Parameters Example

CP Parameter Name Parameter Value

CP-62 Inverse Scaling 2 CP-30 PPR Lead 60 CP-31 PPR Feedback 1200 CP-33 Max RPM Lead 2000 CP-34 Max RPM Feedback 1800 CP-21 Follower E.U. 2.0 CP-03 Follower Setpoint 1 2.0 CP-04 Follower Setpoint 2 5.0

After the Scaling and the Follower Setpoints for your system have been entered, you can enter the Acceleration/Deceleration Control Parameters for the Inverse Follower mode. The Acceleration/Deceleration Control Parameters are identical for both the Inverse Master and the Inverse Follower modes of operations. Acceleration/ Deceleration is discussed in the following section.

3 - 25

Page 60

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. To modify these default parameters, refer to Table 3-20. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

Table 3-19 Default Master or Follower Acceleration/Deceleration Control

Parameters

CP Parameter Name Parameter Value

CP-16 Acceleration Time 5.0

CP-17 Deceleration Time 5.0

section, page 3-3.

Table 3-20 Entering Master or Follower Acceleration/Deceleration Control

Parameters

CP Parameter Name Parameter Value

CP-16 Acceleration Time

Enter the desired number of seconds to increase the motor speed from 0 to 2000

RPMs.

CP-17 Deceleration Time

Enter the desired number of seconds to decrease the motor speed from 2000 to 0 RPMs.

After the Control Parameters for Acceleration/Deceleration have been entered, you can enter the Control Parameters for Tuning either the Master or the Follower mode. The tuning Control Parameters are identical for both the Master and the Follower modes of operations. Tuning is discussed in the following section.

3 - 26

Page 61

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.

Before you adjust the PID parameters (CP-65,66,67), you will need to set the Feedforward (CP-68). To accomplish this, run the ML-Drive in the Master mode of operation, using the default PID parameters and a setpoint value of 1000 RPM. When the ML-Drive has reached stability at 1000 RPM, enter the value of the PIDF Output (MP-49) into Feedforward (CP-68).

To achieve an acceptable level of speed error, adjust the Gain (CP-65) until the system stabilizes. In systems that require greater accuracy, it may be necessary to adjust the Integral (CP-66) to reduce any remaining speed error. In systems with low inertia, the speed error will be reduced more quickly if you enter low values in Integral (CP-66). An entry that is too low, however, can create instability or overshoot the setpoint before reaching the correct value. Generally, use larger entries for Integral (CP-66) on systems with a large inertia. Sometimes performance can be improved in systems with a large inertia by lowering the Derivative (CP-67). Refer to Table 3-22 to modify the Control Parameters for Tuning.

The ML-Drive comes factory pre-loaded with default Control Parameters for Tuning. These default settings are suitable for most applications and do not require modification. The factory preset, default tuning Control Parameters are found in Table 3-21. If you are uncertain how to enter a Control Parameter, review the

Keypad

section, page 3-3.

Table 3-21 Default Master or Follower Tuning Control Parameters

Operations:

CP Parameter Name Parameter Value

CP-65 Gain (Proportional) 5000

CP-66 Integral 2000

CP-67 Derivative 9000

CP-68 Feedforward 1000

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Table 3-22 Entering Master / Follower Tuning Control Parameters

CP Parameter Name Parameter Value

CP-65 Gain (Proportional)

CP-66 Integral

CP-67 Derivative

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).

While switching between the high and low setpoints, decrease the Integral's default value of “2000” until the speed error is reduced within an acceptable time frame. To verify the stability of the speed changes, you can access Tach through either the tach key or the Monitor Parameter for Tach (MP-40).

The Derivative should not be adjusted in most systems. However, sometimes in the larger inertia systems you can improve performance by lowering the Derivative term to the point of instability and then increasing it incrementally until the system stabilizes.

CP-68 Feedforward

When the ML -Drive has reached stability at 1000 RPM, enter the value of PIDF Output (MP-49) into Feedforward (CP-68).

After the Control Parameters for Tuning have been entered, you can enter the Control Parameters for the Alarms for either the Master or the Follower mode. Alarms are discussed in the following section.

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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. The alarm can be wired to activate a warning light, a warning sound, or to shut down the system under specified conditions, as listed below:

0 = No Alarm 8 = Scaled Error 1 = Low Alarm 9 = Low Alarm or Scaled Error 2 = High Alarm 10 = High Alarm or Scaled Error 3 = Low Alarm or High Alarm 11 = Low Alarm or High Alarm or Scaled Error 4 = Ramped Error 12 = Ramped Error or Scaled Error 5 = Low Alarm or Ramped Error 13 = Low Alarm or Ramped Error or Scaled Error 6 = High Alarm or Ramped Error 14 = High Alarm or Ramped Error or Scaled Error 7 = Low Alarm or High Alarm 15 = Low Alarm or High Alarm or Ramped Error or

or Ramped Error Scaled Error

Alarm Format (CP-10) determines which alarm conditions will activate the Alarm output, using the values that you enter in Low Alarm (CP-12), High Alarm (CP-13), Ramped Error Alarm (CP-14) and Scaled Error Alarm (CP-15). In Low Alarm (CP-12), enter the RPMs at or below which you want the Alarm Output to activate. In High Alarm (CP-13), enter the RPMs at or above which you want Alarm output to activate. In Ramped Error Alarm (CP-14) enter the RPM deviation between the ramped setpoint and the feedback that will activate the Alarm output (at or above). In Scaled Error Alarm (CP-15) enter the RPM deviation between the scaled setpoint and the feedback that will activate the Alarm output (at or above).

The ML-Drive comes factory pre-loaded with default Control Parameters for Alarms. These default parameter values are set for widely generic conditions that generally will not activate the alarm. This allows you to either operate your system unfettered by the alarm or design your own alarm conditions that are unique to your system. The factory default Control Parameters for the Alarms are found in Table 3-23 To modify these default parameters, refer to Table 3-24. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

section, page 3-3.

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Table 3-23 Default Alarms Control Parameters

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

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Table 3-24 Entering Alarms Control Parameters

CP Parameter Name Parameter Value

CP-10 Alarm Format

CP-12 Low Alarm

CP-13 High Alarm

CP-14 Ramped Error Alarm

CP-15 Scaled Error Alarm

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. 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 Alarm (CP-14) and Scaled Error Alarm (CP-15).

Enter the RPMs at or below which you want the Alarm output to activate.

Enter the RPMs at or above which you want the Alarm output to activate.

Enter the RPM Deviation between the Ramped Reference and the feedback that will activate the Alarm output.

Enter the RPM Deviation between the Scaled Reference and the feedback that will activate the Alarm output.

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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

CP Parameter Name Parameter Value

CP-05 Jog Setpoint 50

CP Parameter Name Parameter Value

section, page 3-3.

Table 3-25 Default Jog Control Parameters

Table 3-26 Entering Jog Control Parameters

CP-05 Jog Setpoint

For information on the Jog Logic Input, refer to page 3-36.

3 - 32

Enter the RPM at which you want your system to operate when it is in Jog.

Logic Control: Logic Inputs, Jog,

Page 67

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.

The one digital output is Drive Enable. The Drive Enable output indicates the state of the drive output.

The sections that follow demonstrate how to use the digital inputs and the Drive Enable output.

Caution

Do not use the AC line power to start or stop the system. Use the Digital Inputs to start or stop the system.

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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

Open Momentarily

F-STOP

COMMON

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.

• Open the R–Stop input. (R–Stop is latched and does not need to be

maintained to remain active.)

R-STOP

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F-STOP

Open Momentarily

F-STOP

COMMON

Page 69

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.)

RUN

JOG

R-STOP

F-STOP

Close Momentarily

RUN

JOG

COMMON

R-STOP

F-STOP

COMMON

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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).

RUN

JOG

R-STOP

F-STOP

Maintain Closed

RUN

JOG

COMMON

R-STOP

F-STOP

COMMON

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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. If you are uncertain how to enter a Control Parameter, review the

Table 3-27 Default Drive Enable Logic Control Parameter

CP Parameter Name Parameter V alue

CP-74 Drive Enable Logic 0

Operations: Keypad

section, page 3-3.

Table 3-28 Entering Drive Enable Logic Control Parameter

CP Parameter Name Parameter Value

CP-74 Drive Enable Logic Enter “0” in CP-74 to deactivate the Drive Enable

output (output high) when the Ramped Reference is zero, and activate the Drive Enable output (output low) when the Ramped Reference is not zero.

Enter “1” in CP-74 to deactivate the Drive Enable output when both the Ramped Reference and the feedback are zero, and activate the Drive Enable output when the Ramped Reference is not zero.

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—NOTES—

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MONITOR PARAMETERS

Control Parameter 05 = 50 (default)

Parameters =

Monitor Parameter 40 = 200

(arbitrary)

Parameter Code Parameter Value

This section is about Monitor Parameters. Control Parameters are explained in

Operation: Control Parameters,

The ML-Drive has a number of Monitor Parameters (MPs) that monitor the performance of the ML-Drive and your system, troubleshoot for problems, and confirm the wiring and tuning. MPs can be accessed at any time during the ML-Drive's operation, including during Run, Jog, R–Stop and F–Stop.

Note: Monitor Parameters are status indicators only - you can not directly affect a MP. There are four categories of Monitor Parameters:

Input Monitoring. Output Monitoring. Performance Monitoring. Status Monitoring.

In the subsections that follow, the Monitor Parameters are listed according to these categories.

page 3-7.

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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).

Numbers that are larger than 9999 are displayed with two decimal places. For example, 10,000 hertz is displayed like the figure below in MP-43.

MP-43 FEEDBACK FREQUENCY

The Feedback Frequency (MP-43) displays the frequency of the Feedback Frequency input (J4 pin 4) in units of hertz (pulses per second). The Feedback Frequency (MP-43) is not averaged or filtered; it is the ten millisecond frequency calculation prior to the display update. Because the Feedback Frequency (MP-43) is not averaged or filtered and because of sensor irregularities, it may appear less stable than Tach (MP-40).

Numbers that are larger than 9999 are displayed with two decimal places. For example, 10,000 hertz is displayed as follows:

Two Decimal Places

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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.

Code

R–Stop (J4 Pin 9)

F–Stop (J4 Pin 10)

Run (J4 Pin 6)

Jog (J4 Pin 7)

MP-55 LOGIC INPUTS - GROUP B

The Logic Inputs - Group B (MP-55) displays the status of the Master/Follower and Setpoint Select digital inputs. The number “1” indicates an open, or logic high level. The number “0” indicates a closed, or logic low level (shorted to common). In the example below, “Setpoint Select” is the open or logic high level.

Code

Not Used

Master / Follower (J4 Pin 12)

Setpoint Select (J4 Pin 13)

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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. In the example below, “Alarm” is the inactive or de-energized (logic high) level.

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Code

Drive Enable (J4 Pin 16)

Alarm (J4 Pin 17)

Not Used

Page 77

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.

Feedforward

PID Compensation Routine

Trim Output (MP-48)

Drive Output

(MP-47) PIDF Output

(MP-49)

Lead Frequency (MP-41)

Feedback Frequency (MP-43)

Active Scaling (MP-50)

Master Follower

Scaled Reference (MP-45)

Accel / Decel

Feedback Scaling

Ramped Reference (MP-46)

Deviation (MP-44)

–

Tach (MP-40)

Figure 3-2 ML-Drive Internal Structure

MP-40 TACH

Tach (MP-40) is the feedback displayed in scaled Engineering Units or RPM. In the Master mode, Tach (MP-40) will display the feedback in Master Engineering Units (CP-20). In the Follower mode, Tach (MP-40) will display either Master Engineering Units or the feedback to Lead ratio in Follower Engineering Units (CP-21), depending on the value in Display Mode Follower (CP-64). In Jog or the Direct mode, Tach (MP-

40) will display the feedback in RPMs. The feedback is read by the ML-Drive every ten milliseconds. The readings are summed, then averaged for one second before the Tach is displayed.

MP-44 DEVIATION (ERROR)

Deviation (MP-44) displays the difference between the Ramped Reference (MP-46) and the Feedback Frequency (MP-43) measured in units of hertz (pulses per second). Deviation (MP-44) is not averaged or filtered; it is the ten millisecond frequency calculation prior to the display update.

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MP-45 SCALED REFERENCE

The Scaled Reference (MP-45) is the scaled setpoint number converted to hertz. It is the calculated value that is input to the Acceleration/Deceleration routine. This parameter may display numbers that are larger than 9999. These larger values are displayed with two decimal places. For example, 10,000 hertz is displayed as “10.00.”.

MP-46 RAMPED REFERENCE

The Ramped Reference (MP-46) is the calculated output of the Acceleration/ Deceleration routine in hertz. It is the setpoint input to the PID compensation routine. This parameter may display numbers that are larger than 9999. These larger values are displayed with two decimal places. For example, 10,000 hertz is displayed as “10.00.”.

MP-47 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 (MP-48) added to the feedforward equals the Drive Output (MP-47). The Trim Output is represented in DAC (Digital-to-Analog Converter) bits where 4096 equals 100% output, 2048 equals 50% output, etc.

MP-49 PIDF OUTPUT

The PIDF Output (MP-49) is the total calculated output of the PID Compensation routine added to the feedforward. The PIDF Output is represented in DAC (Digital-toAnalog Converter) bits where 4096 equals 100% output, 2048 equals 50% output, etc.

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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

Follower Mode

Inverse

Direct Mode

Master Mode

MP-51 KEYPAD ERROR

If a Control Parameter entry has been rejected, Keypad Errors (MP-51) will ascertain the reason that it was rejected. The digit that displays a number “1” is the error. In the example below, “Above Maximum Allowed Value” is the error.

Code

Below Minimum Allowed Value

Entry Timeout or Keypad Lockout

Invalid Code Parameter

Above Maximum Allowed Value

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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

Ramped Error

Scaled Error

Low Speed Alarm

High Speed Alarm

MP-53 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. EEPROM Status (MP-57) displays the status of the EEPROM memory chip. The number “0” indicates no failure. The number “1” indicates a write verify error. In the event of an error, call Technical Support at (612) 424-7800 or 1-800-342-4411.

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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. When the ML-Drive is not in current limit, then the number “0” is displayed.

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—NOTES—

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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

If you are using the M-Host software, your communications network is user ready and does not require any software programming. M–Host software is available through your distributor. If you are designing your own software, refer to

Design,

establish a link through the Serial Communications Interface.

page 3-52, in this section. Once the software is installed, you are ready to

Using Serial Communications,

page 3-50, in this section.

Communications Software

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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. These Control Parameters physically set up the ML-Drive to accommodate the RS485 Serial Communications Interface. Generally, the default settings are suitable for most applications and do not require modification. The factory default Control Parameters for Serial Communications Setup are found in Appendix D. These default parameters can be modified, using the Serial Communications Interface.

CP-70 DEVICE ADDRESS

The ML-Drive has a physical address which can be set from 1 to 32. Each individual ML-Drive on a multidrop RS485 communications link needs a unique Device Address. The address “00” will be globally accepted by all of the ML-Drives on a communications link, however, they will not send a response message back to the host computer when this global address is used.

CP-71 BAUD RATE

There are six different baud rates (data rates) for the ML-Drive. Enter the number, for the required function, as listed below.

1 = 300 Baud 2 = 600 Baud 3 = 1200 Baud 4 = 2400 Baud 5 = 4800 Baud 6 = 9600 Baud

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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.

0 = F–Stop only 1 = F–Stop, Run, R–Stop 2 = F–Stop, Master/Follower, Setpoint Select 3 = All of the Above

MP-58 SERIAL COMMUNICATIONS ERROR

Serial Communications Error identifies errors in the last transmitted message that was sent to the 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.

Code

Structure Error (Parity,Framing,No ETX, No STX)

Invalid Parameter Code

Invalid Parameter Data or Out of Data Min-Max Range

Control Mask Error

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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. The host computer sends a twelve character record to the ML-Drive to establish the link and the ML-Drive responds with either a conformation or an error message. Once the ML-Drive responds, the host computer can send additional transmissions.

All of the ML-Drive's messages use the USA Standard Code for Information Interchange (ASCII). The host computer sends three types of messages;

Parameter Send - To change CPs. Control Command Send - To control operating states. Data Inquiry - To monitor CPs and MPs.

These three message types, their character level descriptions in binary and ASCII, as well as the ML-Drive's response record, are outlined in the sections that follow.

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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 2 3 4 5 6 7 8 9 10 11 12

DESC STX 10s 1s TYPE 10s 1s 1000s 100s 10s 1s FORM ETX

ASCII STX 0-9 0-9 3 0-9 0-9 0-9 0-9 0-9 0-9 0-8 ETX

DEV # DEV # MSG PAR # PAR # DATA DAT A DATA DATA DATA

The following is a description of the Parameter Send-Host Transmission Characters.

Character 1 - STX:

This is the first character in the character string. None of the other characters will be recognized without this character prefix. Always use the ASCII “STX” character; it enables the ML-Drive's receive buffer.

Characters 2, 3 - Device #:

These characters are the access address of the ML-Drive. This number identifies individual ML-Drives on a mutltidrop system. The ML-Drive will accept data only if this number matches the ML-Drive's address (CP-70), with the exception of a “00” address. The “00” address is universally accepted by all of the ML-Drives that are on the RS485 Serial Communications Interface.

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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 11 - Data Format:

Character 11 indicates the decimal location and polarity of the data that was transmitted in characters 7 through 10. Use the following codes to indicate decimal location and polarity:

3 - 54

Code Format 0 +XXXX 1 +XXX.X 2 +XX.XX 3 +X.XXX 4 -XXXX 5 -XXX.X 6-XX.XX 7 -X.XXX 8 +XX.XX.

Codes “0 ” through “7” are valid for CP-20 and CP-21. All other Code Parameters have either fixed or derived decimal locations and must use Code “0”. Code “8” does not apply to the parameter send.

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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.

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Table 3-30 Parameter Send - ML-Drive Response

Character # 1 2 3 4 5 6 7 8 9 10 11 12

DESC STX 10s 1s CODE 10s 1s 1000s 100s 10s 1s FORM ETX

ASCII STX 0-9 0-9 @-DEL 0-9 0-9 0-9 0-9 0-9 0-9 0-8 ETX

DEV # DEV # ERROR PAR # PAR # DATA DAT A DA TA DATA DATA

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 2, 3 - Device #:

This is the two character access address for the ML-Drive.

Character 4 - Error Code:

If there are errors in the transmission that the ML-Drive receives from the host computer, the Error Code will display them. Use Table 3-35 (page 3-66) to convert the ASCII code to binary. The binary code can be decoded as follows:

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Bit 7 Always “0”. Bit 6 Always “1”. Bit 5 1 = Data was out of minimum/maximum range. Bit 4 1 = Checksum or Decimal Point Error, Invalid Parameter Code. Bit 3 1 = Receive buffer filled before “ETX” received or Message Format Error. Bit 2 1 = Invalid Parameter Data. Bit 1 1 = Parity Error. Bit 0 1 = Always “0”

Note: The ML-Drive will only accept data if there are no errors. The ASCII error code “@” (Binary code “1000000”) indicates that the Host Transmission contains no errors.

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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.

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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).

Table 3-31 Control Command Send - Host Transmission

Character # 1 2 3 4 5 6 7 8 9 10 11 12

DESC STX 10s 1s TYPE 10s 1s 1000s 100s 10s 1s FORM ETX

ASCII STX 0-9 0-9 1 0 0 0 0 0-1 0-9 0 ETX

DEV # DEV # MSG PAR # PAR # DATA DAT A DATA DATA DATA

The following is a description of the Control Command Send - Host Transmission.

Character 1 - STX:

Characters 2, 3 - Device #:

These characters are the access address of the ML-Drive. This number identifies individual ML-Drives on a mutltidrop system. The ML-Drive will accept data only if this number matches the ML-Drive's address (CP-70), with the exception of a “00” address. The “00” address is universally accepted by all ML-Drives that are on the RS485 Serial Communications Interface.

Character 4 - Message Type:

This character should always be “1”.

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Characters 5,6 - Parameter Number:

These characters should always be “0”.

Characters 7 through 8 - DATA:

These characters should always be “0”.

Characters 9,10- DATA:

01 F–Stop 02 R–Stop 03 Run 04 Enable Master Mode 05 Enable Follower Mode 06 Not in Use 07 Not in Use 08 Not in Use 09 Not in Use 10 Enable Setpoint 1/3 11 Enable Setpoint 2/4 12 Not in Use 13 Not in Use 14 Not in Use 15 Not in Use

Character 11 - Data Format:

This character should always be “0”.

Character 12 - ETX:

Always use the ASCII “ETX” character to terminate the character string.

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Table 3-32 Control Command Send - ML-Drive Response

Character # 1 2 3 4 5 6 7 8 9 10 11 12

DESC STX 10s 1s CODE 10s 1s 1000s 100s 10s 1s FORM ETX

ASCII STX 0-9 0-9 @-DEL 0 0 0 0 0-9 0-9 0 ETX

DEV # DEV # ERROR PAR # PAR # DATA DAT A DA TA DATA DATA

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 2, 3 - Device #:

This is the two character access address for the ML-Drive.

Character 4 - Error Code:

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Note: The ML-Drive will only accept data if there are no errors. The ASCII error code “@” (Binary code “1000000”) indicates that the Host Transmission contains no errors.

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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.

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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 2 3 4 5 6 7 8 9 10 11 12

DESC STX 10s 1s TYPE 10s 1s 1000s 100s 10s 1s FORM ETX

ASCII STX 0-9 0-9 2 0-9 0-9 0 0 0 0 0 ETX

DEV # DEV # MSG PAR # PAR # DATA DAT A DATA DATA DATA

The following is a description of the Data Inquiry - Host Transmission Characters.

Character 1 - STX:

Characters 2, 3 - Device #:

These characters are the access address of the ML-Drive. This number identifies individual ML-Drives on a mutltidrop system. The ML-Drive will accept data only if this number matches the ML-Drive's address (CP-70), with the exception of a “00” address. The “00” address is universally accepted by all ML-Drives that are on the RS485 Serial Communications Interface.

Character 4 - Message Type:

This character should always be “2”.

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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.

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Page 98

Table 3-34 Data Inquiry - ML-Drive Response

Character # 1 2 3 4 5 6 7 8 9 10 11 12

DESC STX 10s 1s CODE 10s 1s 1000s 100s 10s 1s FORM ETX

ASCII STX 0-9 0-9 @-DEL 0-9 0-9 0-9 0-9 0-9 0-9 0-; ETX

DEV # DEV # ERROR PAR # PAR # DATA DAT A DA TA DATA DATA

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 2, 3 Device #:

This is the two character access address for the ML-Drive.

Character 4 -Error Code:

3 - 64

Note: The ML-Drive will only accept data if there are no errors. The ASCII error code “@” (Binary code “1000000”) indicates that the Host Transmission contains no errors.

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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).

Character 11 - Data Format:

Character 11 indicates the decimal location and polarity of the data that was transmitted in characters 7 through 10. Use the following codes to indicate decimal location and polarity:

Code Format Code Format 0 +XXXX 9 +XXX.X. 1 +XXX.X : +XX.XX. 2 +XX.XX ; +X.XXX. 3 +X.XXX 4 -XXXX 5 -XXX.X

6 -XX.XX

7 -X.XXX 8 +XX.XX.

Codes “0” through “7” are valid for CP-20 and CP-21. All other Code Parameters have either fixed or derived decimal locations and must use Code “0”. Code 8 is valid for MP-41 amd MP-43. For codes 9, :, and ; multiply characters 7 through 10 by ten.

Character 12 - ETX:

The return message is always terminated with the ASCII “ETX” character.

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Page 100

Table 3-35 ASCII to Binary

ASCII Binary ASCII Binary

Bit 7 Bit 1 Bit 7 Bit 1

NUL 0000000 SP 0100000 SOH 0000001 ! 0100001 STX 0000010 " 0100010 EXT 0000011 # 0100011 EOT 0000100 $ 0100100 ENQ 0000101 % 0100101 ACK 0000110 & 0100110 BEL 0000111 ' 0100111 BS 0001000 ( 0101000 HT 0001001 ) 0101001 LF 0001010 * 0101010 VT 0001011 + 0101011 FF 0001100 , 0101100 CR 0001101 - 0101101 SO 0001110 . 0101110 SI 0001111 / 0101111 DLE 0010000 0 0110000 DC1 0010001 1 0110001 DC2 0010010 2 0110010 DC3 0010011 3 0110011 DC4 0010100 4 0110100 NAK 0010101 5 0110101 SYN 0010110 6 0110110 ETB 0010111 7 0110111 CAN 0011000 8 0111000 EM 0011001 9 0111001 SUB 0011010 : 0111010 ESC 0011011 ; 0111011 FS 0011100 < 0111100 GS 0011101 = 0111101 RS 0011110 > 0111110 US 0011111 ? 0111111

Bit 7 Bit 1 Bit 7 Bit 1

@ 1000000 ' 1100000

A 1000001 a 1100001 B 1000010 b 1100010 C 1000011 c 1100011 D 1000100 d 1100100 E 1000101 e 1100101

F 1000110 f 1100110 G 1000111 g 1100111 H 1001000 h 1101000

I 1001001 i 1101001

J 1001010 j 1101010 K 1001011 k 1101011

L 1001100 l 1101100 M 1001101 m 1101101 N 1001110 n 1101110 O 1001111 o 1101111 P 1010000 p 1110000 Q 1010001 q 1110001 R 1010010 r 1110010 S 1010011 s 1110011

T 1010100 t 1110100 U 1010101 u 1110101 V 1010110 v 1110110

W 1010111 w 1110111

X 1011000 x 1111000 Y 1011001 y 1111001

Z 1011010 z 1111010

[ 1011011 { 1111011 \ 1011100 | 1111100 ] 1011101 } 1111101

^ 1011110 ~ 1111110

– 1011111 DEL 1111111

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CONTREX ML-Drive User Manual

Table of Contents

Introduction

INTRODUCING THE ML-DRIVE

Installation / Setup

MOUNTING

WIRING

INPUTS

OUTPUTS

SERIAL COMMUNICATIONS

CALIBRATION

CURRENT LIMIT

Operation

KEYPAD OPERATION

KEYPAD LOCKOUT

CONTROL PARAMETERS

Direct Mode

Master Mode

Follower Mode

Inverse Master Mode

Inverse Follower Mode

Acceleration/Deceleration

Tuning

Alarms

LOGIC CONTROL

Logic Inputs

Logic Output

MONITOR PARAMETERS

Input Monitoring

Output Monitoring

Performance Monitoring

Status Monitoring

SERIAL COMMUNICATIONS

Using Serial Communications

Communications Software Design