CONTREX MLP-Drive User Manual

C

Technical Assistance

If you have comments or questions concerning the operation of the MLP-Drive, please call.
A member of our Technical Support Staff will be happy to assist you. Ask for Technical
Support: [phone] or 1-800-342-4411

Copyright © 1999 Contrex

ii

Contrex

®

8900 Zachary Lane North

Maple Grove, Minnesota 55369

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

iv

Table of Contents

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

Introducing the MLP-Drive ............................................................................. 1-3

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

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

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

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

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

Outputs............................................................................................... 2-15

Serial Communications ...................................................................... 2-17

Calibration.................................................................................................... 2-19

Current Limit....................................................................................... 2-20

Analog Input Calibration..................................................................... 2-22

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.................................................................................... 3-19

Offset Mode........................................................................................ 3-38

Inverse Master Mode ......................................................................... 3-43

Inverse Follower Mode....................................................................... 3-45

Acceleration/Deceleration .................................................................. 3-47

Tuning ................................................................................................. 3-48

Alarms ................................................................................................ 3-52

Limits .................................................................................................. 3-54

Jog...................................................................................................... 3-55

Logic Control................................................................................................ 3-57

Logic Inputs........................................................................................ 3-58

Logic Outputs ..................................................................................... 3-61

v

Monitor Parameters ..................................................................................... 3-63

Input Monitoring ................................................................................. 3-64

Output Monitoring............................................................................... 3-67

Performance Monitoring..................................................................... 3-68

Status Monitoring ............................................................................... 3-70

Serial Communications................................................................................ 3-73

Using Serial Communications............................................................ 3-74

Communications Software Design..................................................... 3-76

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: MLP-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: MLP–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

Index ....................................................................................................... Index-3

vi

List of Illustrations

Figure 1-1 MLP–Drive Master Mode ......................................................... 1-4

Figure 1-2 MLP–Drive Follower Mode ....................................................... 1-5

Figure 2-1 MLP–Drive Cutout Dimensions and Mounting Guide .............. 2-2

Figure 2-2 MLP–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 Scroll Up ................................................................................. 2-13

Figure 2-15 Scroll Down............................................................................. 2-13

Figure 2-16 Analog Input............................................................................ 2-14

Figure 2-17 Drive Output............................................................................ 2-15

Figure 2-18 Digital Output 1 and Digital Output 2...................................... 2-16

Figure 2-19 MLP–Drive Multidrop Installation............................................ 2-17

Figure 2-20 MLP–Drive Serial Communications Connections ................. 2-18

Figure 3-1 MLP–Drive Front Panel ........................................................... 3-4

Figure 3-2 MLP–Drive Internal Structure ................................................ 3-68

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 MLP–Drive Wiring Connections without Relays .................... G-1

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

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

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

vii

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 Mode Control Parameters Example .......................... 3-12

Table 3-8 Default Scaling Control Parameters ....................................... 3-13

Table 3-9 Entering Master Scaling Analog Feedback Parameters ......... 3-14

Table 3-10 Master Mode Feedback Allocation Example .......................... 3-15

Table 3-11 Default Scaling Control Parameters ....................................... 3-16

Table 3-12 Entering Master Scaling Analog Setpoint Parameters ........... 3-17

Table 3-13 Master Mode Setpoint Allocation Example............................. 3-18

Table 3-14 Default Follower Scaling Control Parameters ....................... 3-20

Table 3-15 Entering Follower Scaling Control Parameters ..................... 3-20

Table 3-16 Entering Follower Setpoint Control Parameters .................... 3-21

Table 3-17 Follower Mode Control Parameters Example A .................... 3-24

Table 3-18 Follower Mode Control Parameters Example B .................... 3-27

Table 3-19 Default Scaling Control Parameters ....................................... 3-28

Table 3-20 Entering Follower Scaling Analog Lead Parameters.............. 3-29

Table 3-21 Follower Mode Lead Allocation Example ............................... 3-30

Table 3-22 Default Scaling Control Parameters ....................................... 3-31

Table 3-23 Entering Follower Scaling Analog Feedback Parameters...... 3-32

Table 3-24 Follower Mode Feedback Allocation Example ........................ 3-33

Table 3-25 Default Scaling Control Parameters ....................................... 3-35

Table 3-26 Entering Follower Scaling Analog Setpoint Parameters......... 3-36

Table 3-27 Follower Mode Setpoint Allocation ......................................... 3-37

Table 3-28 Default Scaling Control Parameters ....................................... 3-39

Table 3-29 Entering Offset Scaling Analog Setpoint Parameters............. 3-40

Table 3-30 Offset Mode Example ............................................................. 3-42

Table 3-31 Default Inverse Master Control Parameters ........................... 3-43

Table 3-32 Entering Inverse Master Control Parameters ......................... 3-43

Table 3-33 Inverse Master Mode Control Parameters Example .............. 3-44

Table 3-34 Default Inverse Follower Control Parameters ........................ 3-45

Table 3-35 Entering Inverse Follower Control Parameters ...................... 3-45

viii

Table 3-36 Inverse Follower Mode Control Parameters Example............ 3-46

Table 3-37 Default Master or Follower Accel/Decel Control Parameters 3-47
Table 3-38 Entering Master or Follower Accel/Decel Control Parameters 3-47

Table 3-39 Default Master or Follower Tuning Control Parameters ........ 3-48

Table 3-40 Entering Master or Follower Tuning Control Parameters ...... 3-49

Table 3-41 Default Zero Error Loop Control Parameters ......................... 3-50

Table 3-42 Entering Zero Error Loop Control Parameters ....................... 3-51

Table 3-43 Default Alarm Control Parameters ......................................... 3-52

Table 3-44 Entering Alarm Control Parameters ....................................... 3-53

Table 3-45 Default Limit Control Parameters ........................................... 3-54

Table 3-46 Entering Limit Control Parameters ......................................... 3-54

Table 3-47 Default Jog Control Parameters ............................................ 3-55

Table 3-48 Entering Jog Control Parameters .......................................... 3-55

Table 3-49 Default Drive Enable Logic Control Parameters .................... 3-61

Table 3-50 Entering Drive Enable Logic Control Parameters .................. 3-62

Table 3-51 Parameter Send - Host Transmission..................................... 3-77

Table 3-52 Parameter Send - MLP–Drive Response .............................. 3-80

Table 3-53 Control Command Send - Host Transmission ....................... 3-82

Table 3-54 Control Command Send - MLP–Drive Response................... 3-84

Table 3-55 Data Inquiry - Host Transmission ........................................... 3-86

Table 3-56 Data Inquiry - MLP–Drive Response ..................................... 3-88

Table 3-57 ASCII to Binary ...................................................................... 3-90

Table 3-58 Binary to Monitor Parameters ................................................ 3-91

ix

–NOTES–

x

Introduction

Introducing the MLP-Drive
Examples of MLP-Drive Applications

1 - 1

1 - 2

INTRODUCING THE MLP-DRIVE

The MLP-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), as a part of a complex multi-drive system
(Follower mode) or Follower mode with analog trim (Offset mode).

The MLP-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 MLP-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 MLP-Drive is unique among its competition because the MLP-Drive has
preprogramed software that integrates with your system with little effort from you. The
MLP-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 MLP-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 MLP-Drive's Monitor Parameters (MPs) allow you to monitor your
system's performance.

The MLP-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 MLP-Drive's advanced capabilities is the flexibility to
preset up to four setpoint entries.

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

1 - 3

EXAMPLES OF MLP-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 MLP-Drive compares the sensor shaft feedback to the scaled setpoint and
calculates any speed error. When the MLP-Drive finds speed error, the control
algorithm adjusts the drive output and reduces the error to zero.

Drive
Output

Contrex

89

7

CODE
SELECT

456

SET

POINT

23

1

TACH

.

0

–

ENTER

CLEAR

MLP-Drive

1 - 4

Motor

Sensor

Pump

Feedback Frequency

Figure 1-1 MLP-Drive Master Mode

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 MLP-Drive compares the setpoint ratio to the Follower sensor shaft
(feedback) and Lead sensor shaft to calculate any speed error. When the MLP-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

7

CODE
SELECT

4 5 6

SET
POINT

1

TACH

–

CLEAR

MLP-Drive

8 9

2 3

.

0

ENTER

Ingredient A

Final Product

Follower

Follower Motor

Lead Frequency

Drive
Output

Contrex

8 9

7

CODE
SELECT

4 5 6

SET
POINT

2 3

1

TACH

.

0

–

ENTER

CLEAR

MLP-Drive

Feedback Frequency

Sensor

Pump

Ingredient B

Figure 1-2 MLP-Drive Follower Mode

1 - 5

—NOTES—

1 - 6

Installation / Setup

Mounting
Wiring

Inputs
Outputs
Serial Communications

Calibration

Current Limit
Analog Input Calibration

2 - 1

,

,



Contrex

CUTOUT

(

3.65" .03"

6.00"

(

DOOR PANEL

Contrex

8 9

7

CODE

SELECT

4 5 6

SET

POINT

TACH

1

–

CLEAR

2 3

0

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 MLP–Drive Cutout Dimensions and Mounting Guide

MOUNTING

This section contains instructions for mounting the MLP–Drive in the door panel of a
NEMA Industrial Electrical enclosure. The MLP–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 MLP–Drive:

1) The NEMA Industrial Electrical Enclosure that will house the MLP–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 MLP–Drive and other equip­ment to provide for proper heat convection. Placing the MLP–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 MLP–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 MLP–Drive. Tighten the mounting screws until the MLP–Drive
is mounted securely in the NEMA Electrical Enclosure. Do not overtighten.

2 - 3

*

Use 115 VAC with MLP-Drive model # 3200-1938

Use 230 VAC with MLP-Drive model # 3200-1939

L1

*

Neut or L2

GND/PE

RS485 Serial

Communications

LEAD_FQ

FDBK_FQ

COM

RUN

JOG

R–STOP

F–STOP

COM

MST/FOL

SETPT

SCRL_UP

SCRL_DWN

COM

V_DO

DIG_OUT1

DIG_OUT2

COM

ANAL_IN

COM

J1

J4

J3

T / R +

T / R –

COM_AUX

RS485

COMM

I/O

PWR

L1

NEUT

GND

PE

AC

POWER

MOTOR

ARM

A1 +

A2 -

FREQ

INPUTS

DIGITAL

INPUTS

J5

DIGITAL

OUTPUTS

5V_DI

COM

Run

Jog

R-Stop

F-Stop

Lead

Frequency

Sensor

Feedback

Frequency

Sensor

+5VDC External

DC Power

Supply

+5V COM

+5V

SIG

COM

+5V

SIG

COM

50V

MAX

+V

COM

R1

R2

External

DC Power

Supply

TD/RD+

TD/RD–

COM

DC PM

Motor

123

1

2

3

4

5

1

2

Fuses

1A + FLA

250V

12345678910111213141516171819

ANAL

IN

AUX
PWR

5V

COM_AUX

1

2

J2

Master/

Follower

Setpoint

Select

Scroll Up

Scroll Down

+

-

A1

A2

2 - 4

Figure 2-2 MLP–Drive General Wiring

WIRING

This section contains the power supply, input, and output wiring for the MLP-Drive.
Please read this section prior to wiring the MLP-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 (J3) physically separated from all other wiring on the
MLP-Drive. Failure to do so could result in additional electrical noise and cause
the MLP-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 MLP-Drive should only be installed by

a qualified electrician.

2 - 5

–NOTES—

2 - 6

INPUTS

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)

For isolated operations, the
Frequency Inputs (J5 pins 1, 2, 3),
the Digital Inputs (J5 pins 4-13 ), the
Digital Outputs (J5 pins 14-17) and
Analog Input (J5 pins 18,19) require
an external source of +5VDC power.

The National Electrical Code

The Canadian Electrical Code

(NEC,) Article 430 published by the

(CEC).

1

2

+5V

COM

+5VDC *
External
Power
Supply

CAUTION: The MLP-Drive is
shipped from the factory non­isolated with J1 and J4 jumpers.
You must remove the J1 and J4
jumpers before you connect the
External Power supply or you can
damage the equipment. The
external supply should be free of
ripple and noise to prevent
analog signal bounce. Do not
exceed +5VDC on the I/O Power
input.

Use the Auxiliary Power Output
(J1 pins 1, 2) to supply power to
non-isolated operations. The
MLP-Drive is shipped from the
factory with the wiring in the non­isolated operation.

NOTE: The MLP-Drive should be

wired in the isolated mode
when using the analog
input for precision appli­cations (setpoint or
frequency replacement).

References: Appendix A

,

MLP–Drive Specifications.

J4

* Do not connect the External Power Supply
Common to Earth Ground.

Figure 2-3 I/O Power / Isolated

1

2

J1

1

2

J4

+5V

COM_AUX

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

2 - 7

AC Power (J3 pins 3, 4, 5)

The MLP–Drive model #3200-1938
operates on 115 VAC + 15%, 0.1
Amp., 50/60 Hz. The MLP–Drive
model #3200-1939 operates on 230
VAC + 15%, 0.1 Amp., 50/60 Hz.

* Fuse L1 for 115VAC applica­tions. Fuse L1 and L2 for
230VAC applications. Use
15 Amp 250V normal blow
fuses.

L1

Neutral or L2

GND/PE

*

*

Figure 2-5 Input Power

3

4

5

J3

Lead Frequency (J5 pins 1, 3)

The Lead Frequency is a pulse train
input that the MLP–Drive uses to
determine the speed of the lead
motor. For signal level specifications,
refer to

MLP–Drive Specifications.

2 - 8

References: Appendix A

,

1

3

J5

Signal

Common

Figure 2-6 Lead Frequency

Feedback Frequency

(J5 pins 2, 3)

The Feedback Frequency is a pulse
train input that the MLP–Drive uses to
determine the speed of the follower
motor. For signal level specifications
refer to

MLP–Drive Specifications

References: Appendix A

.

,

DANGER

If the Feedback Frequency is lost,
the MLP-Drive will command a 100% Speed Out
and the motor will run at 100% capacity.
This can cause severe injury, death or
equipment damage.

2

3

J5

Signal

Common

Figure 2-7 Feedback Frequency

Run (J5 pins 4, 8)

When the Run input (J5 pin 4) is
momentarily shorted to common, the
MLP–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 MLP–Drive will not
enter “Run”.

RUN

4

8

J5

Figure 2-8 Run

2 - 9

Jog (J5 pins 5, 8)

Jog is a maintained input. When Jog
is closed, the MLP–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

5

8

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 MLP–Drive
will not enter Jog.

R–Stop (J5 pins 6, 8)

R–Stop is a momentary input. When
it is opened, the MLP–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.

J5

Figure 2-9 Jog

6

8

R-STOP

J5

2 - 10

Figure 2-10 R–Stop

F-Stop (J5 pins 7, 8)

F-Stop is a momentary input. When
it is open, the MLP–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

7

8

J5

Figure 2-11 F–Stop

Master / Follower

(J5 pins 9, 13)

This input determines the MLP–
Drive's mode of operation and
resulting scaling formula that the
control algorithm uses. The MLP–
Drive is in Master mode when the
circuit is open, and Follower or Offset
mode if the circuit is shorted to the
common.

9

13

J5

MASTER

FOLLOWER

Figure 2-12 Master / Follower

2 - 11

Setpoint Select (J5 pins 10, 13)

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

10

13

J5

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

Scroll Up (J5 pins 11, 13)

The Scroll Up input increments the
active setpoint. The active setpoint
will be incremented whether or not it
is being currently displayed. There
are two methods to increment the
active setpoint using the Scroll Up
input. Each closure of the input
increments the active setpoint one
engineering unit. Also, if the Scroll Up
input is maintained closed, the active
setpoint will be incremented one
engineering unit every half second.

Scroll Down or Open/Closed
Loop (J5 pins 12, 13)

11

13

SCROLL UP

J5

Figure 2-14 Scroll Up

12

The function of this input is
determined by CP-60. If CP-60 is set
to "1", this input functions as the

13

J5

SCROLL DOWN

Scroll Down input. If CP-60 is set to
"2", this input functions as the Open/
Closed Loop input.

Figure 2-15 Scroll Down

The Scroll Down input decrements the active setpoint. The active setpoint will be
decremented whether or not it is being currently displayed. There are two methods to
decrement the active setpoint using the Scroll Down input. Each closure of the input
decrements the active setpoint one engineering unit. Also, If the Scroll Down input is
maintained closed, the active setpoint will be decremented one engineering unit every
half second.

The Open/Closed Loop input determines the basic manner in which the control
algorithm operates. In the Closed Loop position (J5 pin 12 open), the control algorithm
adjusts the drive output to reduce the error to zero (setpoint minus feedback). In the
Open Loop position (J5 pin 12 shorted to pin 13), the drive output is adjusted in
response to the setpoint changes only and feedback and error are ignored.

2 - 13

Analog Input (J5 pins 18, 19)

The Analog Input can be used for
frequency or setpoint replacement in
the Master and Follower modes of
operation, or the offset input in the
Offset mode of operation. Refer to
CP-84 for discussion on the
functional allocation of the analog
input.

18

19

J5

Signal

Common

Figure 2-16 Analog Input

2 - 14

OUTPUTS

Drive Output
(J3 pins 1, 2)

Connect the Drive Output
(J3 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 2-17 Drive Output

A1

A2

Digital Output 1 (J5 pin 15, 17)

The Digital Output 1 can be programmed to activate as a function of various alarm
conditions or as a function of the drive enable logic. Refer to CP-10 for function
allocation of Digital Output 1.

1

2

J3

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

Appendix A

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

-

MLP–Drive Specifications

. Use an external DC power supply to

References:

2 - 15

Digital Output 2 (J5 pin 16,17)

The Digital Output 2 can be programmed to activate as a function of various alarm
conditions or as a function of the drive enable logic. Refer to CP-11 for functional
allocation of Digital Output 2.

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

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

+V_DO

DIG_OUT1

DIG_OUT2

Common

14

15

16

17

J5

R1

R2

+

EXTERNAL
DC
POWER
SUPPLY

(50V Max)

–

Figure 2-18 Digital Output 1 and Digital Output 2

Auxiliary DC Power (J1 pin 1, 2)

The 5 volt output (J1 pin 1) is a DC regulated output that can be used to power
encoders or other auxiliary equipment that is used in conjunction with the MLP–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 - 16

Exceeding the maximum
current output
can damage the MLP–Drive.

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 MLP–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 MLP–Drive. See
information on using Serial Communications. The MLP-Drive is designed to use with
an isolated RS232 to RS485 converter.

Figure 2-19 illustrates a multidrop installation of the Serial Communications link and
Figure 2-20 illustrates the Serial Communications connections.

The National Electrical Code

The Canadian Electrical Code

Operations: Serial Communications,

(NEC,) Article 430 published by the

(CEC).

for

Contrex

8 9

7

CODE
SELECT

4 5 6

SET
POINT

2 3

1

TACH

.

0

–

ENTER

CLEAR

Isolated

RS232 to RS485

Converter

Contrex

8 9

7

CODE

SELECT

4 5 6

SET
POINT

2 3

1

TACH

.

0

–

ENTER

CLEAR

Figure 2-19 MLP–Drive Multidrop Installation

Contrex

7

CODE

SELECT

4 5 6

SET

POINT

1

TACH

–

CLEAR

Contrex

8 9

2 3

0

ENTER

Contrex

8 9

7

CODE

SELECT

4 5 6

SET

POINT

2 3

1

TACH

.

0

–

ENTER

CLEAR

Contrex

.

8 9

7

CODE
SELECT

4 5 6

SET
POINT

2 3

1

TACH

.

0

–

ENTER

CLEAR

8 9

7

CODE
SELECT

4 5 6

SET
POINT

2 3

1

TACH

.

0

–

ENTER

CLEAR

2 - 17

Isolated

RS232 to RS485

Converter

TXD/ TXD/
COM RXD RXD
— +

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.

J2

1

2

3

J2

2

1

2

3

1

MLP–Drive #1

T/R+
T/R–
COM

MLP–Drive #2

T/R+
T/R–
COM

2 - 18

Figure 2-20 MLP–Drive Serial Communications Connections

CALIBRATION

Calibration sets the MLP-Drive's current limit. Calibration also zero and spans the
analog input. The MLP–Drive must be properly installed prior to calibration. Refer to

Installation/Setup; Mounting

Hazardous voltages.
Can cause severe

injury, death or
damage
to the equipment.

, and

Installation/Setup; Wiring

DANGER

.

Make adjustments with caution.

2 - 19

CURRENT LIMIT

The MLP-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 MLP-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 MLP-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 MLP-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 MLP-Drive's Peak Current Limit (CP-81) can be set in the 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 “61” (Direct Enable)
Press “Enter”
Enter “1”
Press “Enter”

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.

2 - 20

Use Limit Status (MP-83) to display the present status of the current limit:

Press “Code Select”
Enter “83” (Limit Status)
Press “Enter”
The present status of the current limit is displayed

2 - 21

ANALOG INPUT CALIBRATION

The analog input is factory calibrated for zero and span levels at 0 - 10 VDC. If it is
necessary to field calibrate the analog input, follow these procedures.

Zero Adjust

1) Enter CP-85 (Analog Input Zero) by entering the following on the keypad:
Press "Code Select"

Enter "85" (Analog Input Zero)
Press "Enter"

2) Place zero volts (short) on the analog input (J5 pins 18, 19).

3) Press the "." (decimal point) key. The display should now read between 0.0

and 1.0. This step zero adjusts the analog input.

Span Adjust

1) Enter CP-86 (Analog Input Span) by entering the following on the keypad:

2 - 22

Press "Code Select"
Enter "86" (Analog Input Span)
Press "Enter"

2) Place 10.0 VDC on the analog input (J5 pins 18, 19).

3) Press the "." (decimal point) key. The display should now display a value from

90.0 to 100.0 for a 10 VDC input. This step span adjusts the analog input.

Operation

Keypad Operation
Keypad Lockout
Control Parameters (CP)

Direct Mode
Master Mode
Follower Mode
Offset Mode
Inverse Master Mode
Inverse Follower Mode
Acceleration/Deceleration
Tuning
Alarms
Limits
Jog

Logic Control

Logic Inputs
Logic Outputs

Monitor Parameters (MP)

Input Monitoring
Output Monitoring
Performance Monitoring
Status Monitoring

Serial Communications

Using Serial Communications
Communications Software Design

3 - 1

3 - 2

KEYPAD OPERATION

The front panel of the MLP–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 the above the keys. Figure 3-1 displays the location of the keys and LED display on
the keypad. Table 3-1 demonstrates basic keypad entry.

The keypad functions as follows:

Code Select Key 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.

3 - 3

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 MLP–Drive Front Panel

KEYPAD LOCKOUT

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

Code

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).

CP-79, Setpoint Lockout Mask, determines which setpoints are disabled when the
keypad is locked out. If CP-79 is set to "0", then none of the setpoints (CP-01 through
CP-04) are disabled. If CP-79 is set to "1", then all four of the setpoints are disabled. If
CP-79 is set to "2", then CP-02 and CP-04 are disabled while CP-01 and CP-03 remain
enabled.

Locked

Unlocked

3 - 5

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
Clear/7 procedure. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

section.

Troubleshooting: Troubleshooting

, for instructions on the

Record your numeric Keypad Lockout password here:

3 - 6

CONTROL PARAMETERS

Parameters are divided into two classifications; Control Parameters (CP) and Monitor
Parameters (MP). The numbered code that represents the Parameter is the Parameter
Code. The operational data is the Parameter's value.

Control Parameter 05 = 50 (default)

Parameters =

Monitor Parameter 40 = 200

(arbitrary)

Parameter Code Parameter Value

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

Operation: Monitor Parameters

The MLP–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 MLP–Drive for your specific needs
(e.g., maximum RPMs, setpoints, acceleration/deceleration ramp rates) by entering a
parameter value.

The MLP–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
and calibrate your MLP–Drive, determine which of the modes of operation your MLP–
Drive is set up for. The mode of operation that you use is determined by your systems
operational requirements.

.

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

3 - 7

Direct Mode

In the Direct mode of operation, the drive output from the MLP–Drive to the motor drive
can be set directly. Direct mode is an open-loop mode of operation. Scaling,
Acceleration/Deceleration, and closed loop compensation (PID) software are not
involved in the Direct mode. The Direct mode is used in conjunction with the Run and
Stop controls.

The Direct Setpoint (CP-06) is entered as a percentage of the MLP–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.

Table 3-2 Default Direct Mode Control Parameters

CP Parameter Name Parameter Value

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

3 - 8

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.

Master Mode

The Master, or stand-alone mode of operation, is a single motor operation. In this
simple mode of operation, the entire process is controlled by a single motor and one
MLP–Drive.

The MLP–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 MLP–Drive can determine how to operate at
those setpoints, you must enter Scaling Control Parameters into the MLP–Drive.
Scaling is a convenient method for translating the relationship of the motor RPMs into
Master Engineering Units. The Scaling Control Parameters give the MLP–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. Information on setpoint entry follows
Table 3-5.

3 - 9

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 J5 pins 10, 13), determines which of the two setpoints is active.

3 - 10

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.

3 - 11

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
MLP–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 15.0
CP-01 Master Setpoint 1 10.0
CP-02 Master Setpoint 2 5.0

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

Control Parameters, Acceleration/Deceleration.

3 - 12

Operation:

Master Mode - Analog Feedback

The MLP-Drive can be scaled for Engineering Unit setpoint entry and Tach display
operation using the analog input for the feedback signal. The following Control
Parameters give the MLP-Drive the necessary information for analog feedback
operation in Master mode.

Analog Input Allocation (CP-84)

Setting CP-84, Analog Input Allocation, to a value of "2" allocates the
analog input to be used as the feedback source.

Master Engineering Units (CP-20)

The actual value of the Master Engineering Units if the system were to
operate with an analog feedback level of 10.0 volts. This is the maxi­mum calibrated analog input level (refer to Installation/Setup: Calibra­tion, Analog Input Calibration).

Note: The analog input does not need to operate to 10.0 volts full scale to be

used for analog feedback.

Table 3-8 Default Scaling Control Parameters

CP Parameter Name Parameter Value

CP-84 Analog Input Allocation 0
CP-20 Master Engineering Units 2000

3 - 13

Table 3-9 Entering Master Scaling Analog Feedback Parameters

CP Parameter Name Parameter Value

CP-84 Analog Input Allocation

Enter a value of "2" to allocate the
analog input as the feedback source.

CP-20 Master Engineering Units

Enter the Master Engineering Unit
value for an analog feedback level of

10.0 volts.

Note: The Max RPM Feedback (CP-34) and PPR Feedback (CP-31) control

parameters, used for scaling Master mode with frequency feedback, are
ignored when using analog feedback scaling.

3 - 14

Master Mode Analog Feedback Example

The following example demonstrates Master mode scaling using analog feedback:

A pump delivers 20.0 gallons per minute when the pump motor rotates at 1800
RPM. A tachometer connected to the pump motor produces a 10.0 volt signal
when the motor rotates at 1800 RPM. Master Setpoint 1 will be setup for an
operation of 12.0 gallons per minute. Master Setpoint 2 will be setup for an
operation of 17.5 gallons per minute.

Table 3-10 shows the scaling Control Parameter that would be entered for the above
system operation.

Table 3-10 Master Mode Feedback Allocation Example

CP Parameter Name Value Remarks

CP-84 Analog Input

Allocation

CP-20 Master Engineering

Units

CP-01 Master Setpoint 1
CP-02 Master Setpoint 2

2

20.0

12.0

17.5

Allocates The analog input as the
feedback source.

This is the Engineering Unit value
that would be present if the analog
input were at 10.0 volts.

The desired Master Setpoint 1.
The desired Master Setpoint 2.

3 - 15

Master Mode - Analog Setpoint

The MLP-Drive can be scaled for Engineering Unit setpoint entry and Tach display
operation using the analog input for the setpoint. The following Control Parameters give
the MLP-Drive the necessary information for analog setpoint operation in Master mode.

Analog Input Allocation(CP-84)

Setting CP-84, Analog Input Allocation, to a value of "4" or "5" allocates
the analog input to be used as Master Setpoint 1 or Master Setpoint 2,
respectively.

Master Engineering Units (CP-20)

The actual value of the Master Engineering Units if the system were to
operate with an analog setpoint level of 10.0 volts. This is the maximum
calibrated analog input level (refer to Installation/Setup: Calibration,
Analog Input Calibration).

Note: The analog input does not need to operate to 10.0 volts full scale to be
used for setpoint replacement.

Max RPM Feedback (CP-34)

This is the maximum RPM of the feedback sensor shaft during system
operation.

PPR Feedback (CP-31)

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

CP Parameter Name Parameter Value

CP-84 Analog Input Allocation 0
CP-20 Master Engineering Units 0
CP-34 Max RPM Feedback 2000
CP-31 PPR Feedback 60

3 - 16

Table 3-11 Default Scaling Control Parameters

Table 3-12 Entering Master Scaling Analog Setpoint Parameters

CP Parameter Name Parameter Value

CP-84 Analog Input Allocation

CP-20 Master Engineering Units

CP-34 Max RPM Feedback

CP-31 PPR Feedback

Setting CP-84 to a value of "4" or "5"
allocates the analog input to be used
as Master Setpoint 1 or Master
Setpoint 2, respectively.

Enter the Master Engineering Unit
value for an analog setpoint level of

10.0 volts and feedback RPM of CP-34.
Enter the maximum operating RPMs

measured at the feedback sensor shaft.
Enter the resolution of the feedback

sensor.

3 - 17

Master Mode Analog Setpoint Example

The following example demonstrates Master mode scaling using analog setpoint:

A pump delivers 20.0 gallons per minute when the pump motor rotates
at 1800 RPM. The pump motor is equipped with a 60 tooth ring kit
feedback sensor. The pump will run at 20.0 gallons per minute with an
analog input of 10 volts.

Table 3-13 Master Mode Setpoint Allocation Example

CP Parameter Name Value Remarks

CP-84 Analog Input

Allocation

CP-20 Master Engineering

Units

CP-34 Max RPM Feedback

CP-31 PPR Feedback

4

20.0

1800

60

Allocates the analog input as
Master Setpoint 1.

This is the Engineering Unit value
that would be present if the analog
input were at 10.0 volts.

The maximum operating RPM of
the feedback shaft.

Feedback sensor resolution.

3 - 18

Follower Mode

The Follower mode of operation is the most frequently used mode of operation. It is a
multi-motor operation in which the entire process can be controlled by any number of
motors and MLP–Drives.

The MLP–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 MLP–Drive can determine how to operate at these setpoints, you must enter
Scaling Control Parameters into the MLP–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 MLP–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.

3 - 19

The factory default Control Parameters for Scaling are found on Table 3-14. To modify
these default parameters, refer to Table 3-15. If you are uncertain how to enter a
Control Parameter, review the

Table 3-14 Default Follower Scaling Control Parameters

Operations: Keypad

section.

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 3-15 Entering Follower Scaling Control Parameters

3 - 20

CP Parameter Name Parameter Value

CP-33 Max RPM Lead

Enter the maximum operating RPM of
the Lead motor, measured at the Lead

CP-34 Max RPM Feedback

sensor shaft (pulses per revolution).
Enter the maximum desired RPM of the

Follower motor, measured at the
Follower feedback sensor shaft.

CP-33 PPR Lead

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

CP-31 PPR Feedback

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

CP-21 Follower Engineering Units

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

With your scaling established, you can enter values for Follower Setpoints 1 and 2
(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 J6 pins 10, 13) determines which of the two
setpoints is active . The factory preset, default Follower Setpoints 1 and 2 (CP-03 and
CP-04) are set at “0”. To modify these default parameters, refer to Table 3-16.

Table 3-16 Entering Follower Setpoint Control Parameters

CP Parameter Name Parameter Value

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.

3 - 21

Follower Mode Examples A and B

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

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

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

Table 3-17 shows the Control Parameters that would be entered in the MLP–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 - 22

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

=

___

=3

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 - do not confuse this with the
full capacity gal/min that the Follower is capable of pumping.

Divided by

5 gal/min The Lead Engineering Units that the Lead is operating at - do

not confuse this with the full capacity that the Lead is capable
of operating at.

Equals

3.00 Follower Setpoint 1 (CP-03) value.

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

___

=3

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 - do not confuse this with the
full capacity gal/min that the Follower is capable of pumping.

Divided by

operating at - do not confuse this with the full capacity that the
Lead is capable of pumping.

Equals

___

= 4.50

3 - 23

Table 3-17 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 MLP–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.

3 - 24

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

a typical Follower mode of operation that uses a setpoint based on a percentage
setpoint:

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

Table 3-18 shows the Control Parameters that would be entered in the MLP–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 - 25

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 - do not confuse this
with the full capacity that the Follower is capable of pumping.

Divided by

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

that the Lead is operating at - do not confuse this with the full
capacity that the Lead is capable of operating at.

Multiplied by 100 (%) Equals

50 Follower Setpoint 1 (CP-03) value.

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

Setpoint 2 =

3 - 26

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 - do not confuse this
with the full capacity that the Follower is capable of pumping.

Divided by

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

that the Lead is operating at - do not confuse this with the full
capacity that the Lead is capable of operating at.

Multiplied by 100(%) Equals

70 Follower Setpoint 2 (CP-04) value.

Table 3-18 Follower Mode Control Parameters Example 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. 50.0

CP-03 Follower Setpoint 1 50.0

CP-04 Follower Setpoint 2 70.0

The MLP–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.

3 - 27

Follower Mode - Analog Lead

The MLP-Drive can be scaled for Engineering Unit setpoint entry and Tach display
operation using the analog input for the lead signal. The following Control Parameters
give the MLP-Drive the necessary information for analog lead operation in Follower
mode.

Analog Input Allocation(CP-84)

Setting CP-84, Analog Input Allocation, to a value of "1" allocates the
analog input to be used as the lead source.

Follower Engineering Units (CP-21)

The actual value of the Follower Engineering Units if the system were to
operate with an analog lead level of 10.0 volts and a feedback of Max
RPM Feedback (CP-34). This is the maximum calibrated analog input
level (refer to Installation/Setup: Calibration, Analog Input Calibration).

Note: The analog input does not need to operate to 10.0 volts full scale to be

used for analog lead.

Max RPM Feedback (CP-34)

This is the maximum RPM of the feedback sensor shaft during system
operation.

PPR Feedback (CP-31)

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

CP Parameter Name Parameter Value

CP-84 Analog Input Allocation 0
CP-21 Follower Engineering Units 1.000
CP-34 Max RPM Feedback 2000
CP-31 PPR Feedback 60

3 - 28

Table 3-19 Default Scaling Control Parameters

Table 3-20 Entering Follower Scaling Analog Lead Parameters

CP Parameter Name Parameter Value

CP-84 Analog Input Allocation

Setting CP-84 to a value of "1"
allocates the analog input to be used
as the lead signal.

CP-21 Follower Engineering Units

Enter the Follower Engineering Unit
value for an analog lead level of

10.0 volts and feedback of Max RPM
Feedback (CP-34). This is typically a
value of 1.000.

CP-34 Max RPM Feedback

Enter the maximum operating RPMs
measured at the feedback sensor shaft.

CP-31 PPR Feedback

Enter the resolution of the follower
feedback sensor.

Note: The Max RPM Lead (CP-33) and PPR Lead (CP-30) control parameters, used

for scaling Follower mode with a frequency lead, are ignored when using
analog lead scaling.

3 - 29

Follower Mode Analog Lead Example

The following example demonstrates Follower mode scaling using analog lead:

A pump delivers 20.0 gallons per minute of ingredient A when the pump
motor rotates at 1800 RPM. A second pump delivers 40.0 gallons per
minute of ingredient B when the pump motor rotates at 1800 RPM. A
potentiometer connected to the analog input of the MLP-Drive produces
a 10.0 volt signal when the pump A (lead) motor rotates at 1800 RPM.
The following motor B has an encoder feedback of 30 PPR. The Fol­lower setpoint is to reflect the flow ratio in gallons/minute of ingredient B
to ingredient A.

Table 3-21 Follower Mode Lead Allocation Example

CP Parameter Name Value Remarks

CP-84 Analog Input

Allocation

CP-21 Follower

Engineering Units

CP-34 Max RPM Feedback

CP-31 PPR Feedback

1

2.000

1800

30

Allocates The analog input as the
lead source.

This is the Engineering Unit value
that would be present if the analog
input were at 10.0 volts and the
feedback at Max RPM Feedback.

40.0 gal/min (ingredient B) = 2.000

20.0 gal/min (ingredient A)
The maximum operating RPM of

the feedback shaft.
The resolution of the feedback

sensor.

3 - 30

Follower Mode - Analog Feedback

The MLP-Drive can be scaled for Engineering Unit setpoint entry and Tach display
operation using the analog input for the feedback signal. The following Control
Parameters give the MLP-Drive the necessary information for analog feedback
operation in the Follower mode.

Analog Input Allocation (CP-84)

Setting CP-84, Analog Input Allocation, to a value of "2" allocates the
analog input to be used as the feedback source.

Follower Engineering Units (CP-21)

The actual value of the Follower Engineering Units if the system were to
operate with an analog feedback level of 10.0 volts and a lead of Max
RPM Lead (CP-33). This is the maximum calibrated analog input level
(refer to Installation/Setup: Calibration, Analog Input Calibration).

Note: The analog input does not need to operate to 10.0 volts full scale to be
used for analog feedback.

Max RPM Lead (CP-33)

This is the maximum RPM of the lead sensor shaft during system
operation.

PPR Lead (CP-30)

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

Table 3-22 Default Scaling Control Parameters

CP Parameter Name Parameter Value

CP-84 Analog Input Allocation 0
CP-21 Follower Engineering Units 1.000
CP-33 Max RPM Lead 2000
CP-30 PPR Lead 60

3 - 31

Table 3-23 Entering Follower Scaling Analog Feedback Parameters

CP Parameter Name Parameter Value

CP-84 Analog Input Allocation

Setting CP-84 to a value of "2"
allocates the analog input to be used
as the feedback signal.

CP-21 Follower Engineering Units

Enter the Follower Engineering Unit
value for an analog feedback level of

10.0 volts and lead of Max RPM Lead
(CP-33).

CP-33 Max RPM Lead

Enter the maximum operating RPMs
measured at the lead sensor shaft.

CP-30 PPR Lead

Enter the resolution of the lead
sensor.

Note: The Max RPM Feedback (CP-34) and PPR Feedback (CP-31) control param-

eters, used for scaling Follower mode with a frequency lead, are ignored when
using analog feedback scaling.

3 - 32

Follower Mode Analog Feedback Example

The following example demonstrates Follower mode scaling using analog feedback:

A pump delivers 20.0 gallons per minute of ingredient A when the pump
motor rotates at 1800 RPM. A second pump delivers 10.0 gallons per
minute of ingredient B when the pump motor rotates at 1800 RPM. A
tachometer connected to the analog input of the MLP-Drive produces a

10.0 volt signal when the pump B (follower) motor rotates at 1800 RPM.
The lead motor A has an encoder feedback of 1000 PPR. The Follower
setpoint is to reflect the flow ratio in gallons/minute of ingredient B to
ingredient A.

Table 3-24 Follower Mode Feedback Allocation Example

CP Parameter Name Value Remarks

CP-84 Analog Input

Allocation

CP-21 Follower

Engineering Units

CP-33 Max RPM Lead

CP-30 PPR Lead

2

0.500

1800

1000

Allocates the analog input as the
feedback source.

This is the Engineering Unit value
that is present if the analog input
were at 10.0 volts and the lead at
Max RPM Lead.

10.0 gal/min (ingredient B) = 0.500

20.0 gal/min (ingredient A)
The maximum operating RPM of

the lead shaft.
The resolution of the lead

sensor.

3 - 33

Follower Mode - Analog Setpoint

The MLP-Drive can be scaled for Engineering Unit setpoint entry and Tach display
operation using the analog input for the setpoint. The following Control Parameters give
the MLP-Drive the necessary information for analog setpoint operation in the Follower
mode.

Analog Input Allocation (CP-84)

Setting CP-84, Analog Input Allocation, to a value of "6" or "7" allocates
the analog input to be used as Follower Setpoint 1 (CP-03) or Follower
Setpoint 2 (CP-04), respectively.

Follower Engineering Units (CP-21)

The actual value of the Follower Engineeing Units if the system were to
operate with an analog setpoint level of 10.0 volts when the lead and
feedback are at their maximum operating RPMs. This is the maximum
calibrated analog input level (refer to Installation/Setup: Calibration,
Analog Input Calibration).

Note: The analog input does not need to operate to 10.0 volts full scale to be
used for the setpoint replacement.

Max RPM Feedback (CP-34)

This is the maximum RPM of the feedback sensor shaft during system
operation.

PPR Feedback (CP-31)

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

Max RPM Lead (CP-33)

This is the maximum RPM of the lead sensor shaft during system
operation.

PPR Lead (CP-30)

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

3 - 34

Table 3-25 Default Scaling Control Parameters

CP Parameter Name Parameter Value

CP-84 Analog Input Allocation 0
CP-21 Follower Engineering Units 1.000
CP-34 Max RPM Feedback 2000
CP-31 PPR Feedback 60
CP-33 Max RPM Lead 2000
CP-30 PPR Lead 60

3 - 35

Table 3-26 Entering Follower Scaling Analog Setpoint Parameters

CP Parameter Name Parameter Value

CP-84 Analog Input Allocation

CP-21 Follower Engineering Units

CP-34 Max RPM Feedback

CP-31 PPR Feedback

CP-33 Max RPM Lead

CP-30 PPR Lead

Setting CP-84 to a value of "6" or "7"
allocates the analog input to be used
as the Follower Setpoint 1 or Follower
Setpoint 2, respectively.

Enter the Follower Engineering Unit
value for an analog setpoint level of

10.0 volts with a lead of Max RPM
Lead (CP-33) and feedback of Max
RPM Feedback (CP-34).

Enter the maximum operating RPMs
measured at the feedback sensor shaft.

Enter the resolution of the feedback
sensor.

Enter the maximum operating RPMs
measured at the lead sensor shaft.

Enter the resolution of the lead
sensor.

3 - 36

Follower Mode Analog Setpoint Example

The following example demonstrates Follower mode scaling using analog setpoint:

A pump delivers 20.0 gallons per minute of ingredient A when the pump
motor rotates at 1750 RPM. A second pump delivers 60.0 gallons per
minute of ingredient B when the pump motor rotates at 1750 RPM. A
potentiometer connected to the analog input of the MLP-Drive produces
a 10.0 volt signal when the pump B and pump A motors rotate at 1750
RPM. The lead motor A has an encoder feedback of 1000 PPR. The
feedback motor is equipped with a 60 tooth ring kit sensor. The
Follower Setpoint 1 is to reflect the flow ratio in gallons/minute of
ingredient B to ingredient A.

Table 3-27 Follower Mode Setpoint Allocation

CP Parameter Name Value Remarks

CP-84 Analog Input

Allocation

CP-21 Follower

Engineering Units

CP-34 Max RPM Feedback

CP-31 PPR Feedback

CP-33 Max RPM Lead

CP-30 PPR Lead

6

3.000

1750

60

1750

1000

Allocates the analog input as the
Follower Setpoint 1.

This is the Engineering Unit value
that is present if the analog input
were at 10.0 volts and the lead and
feedback at max RPM.

60.0 gal/min (ingredient B) = 3.000

20.0 gal/min (ingredient A)
The maximum operating RPM of

the feedback shaft.
The resolution of the feedback

sensor.
The maximum operating RPM of

the lead shaft.
The resolution of the lead

sensor.

3 - 37

Offset Mode

Offset mode is a variation of Follower mode. In Offset mode, an additional quantity
(offset term) is added to or subtracted from the standard calculated follower scaled
reference. The quantity of the offset term is determined by the analog input level and
three additional scaling parameters; offset null, offset authority and offset polarity.

A common use for Offset mode is dancer pot control on a web follower operation. In this
application, the dancer pot is brought into the analog input of the MLP-Drive to provide
an offset to the web follower operation.

The following Control Parameters give the MLP-Drive the necessary information for
Offset mode:

Analog Input Allocation (CP-84)

Setting CP-84, Analog Input Allocation, to a value of "3" establishes the
Offset mode of operation.

Follower Engineering Units (CP-21)

The actual value of the Follower Engineering Units when the lead and
feedback are operating at their maximum speeds; i.e. Max RPM Lead
(CP-33) and Max RPM Feedback (CP-34). This entry is typically the
ratio of the maximum feedback RPM to the maximum lead RPM.

Max RPM Feedback (CP-34)

This is the maximum RPM of the feedback sensor shaft during system
operation.

PPR Feedback (CP-31)

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

Max RPM Lead (CP-33)

This is the maximum RPM of the lead sensor shaft during system
operation.

PPR Lead (CP-30)

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

Offset Null (CP-75)

Offset Null is used to determine the analog input level where the offset
term is zero (has no influence).

3 - 38

Offset Authority (CP-76)

Offset Authority determines the quantity of the offset term (amount of
influence) for a given analog input level.

Offset Polarity (CP-77)

Offset Polarity determines if the offset term is added or subtracted from
the follower scaled reference. If CP-77 is set to 1 (additive), analog
input voltages greater than CP-75 (Offset Null) will cause an increase in
follower speed. Analog input voltages less than Offset Null will cause a
reduction in follower speed.

If CP-77 is set to 2 (subtractive), analog input voltages greater than
Offset Null will cause a decrease in follower speed. Input voltages less
than Offset Null will cause an increase in speed.

Table 3-28 Default Scaling Control Parameters

CP Parameter Name Parameter Value

CP-84 Analog Input Allocation 0
CP-21 Follower Engineering Units 1.000
CP-34 Max RPM Feedback 2000
CP-31 PPR Feedback 60
CP-33 Max RPM Lead 2000
CP-30 PPR Lead 60
CP-75 Offset Null 000.0
CP-76 Offset Authority 100.0
CP-77 Offset Polarity 1

3 - 39

Table-29 Entering Offset Scaling Analog Setpoint Parameters

CP Parameter Name Parameter Value

CP-84 Analog Input Allocation

CP-21 Follower Engineering Units

CP-34 Max RPM Feedback

CP-31 PPR Feedback

CP-33 Max RPM Lead

CP-30 PPR Lead

CP-75 Offset Null

Setting CP-84 to a value of "3"allocates
the analog input to be used an offset.

The desired Follower Engineering Units
when the lead and feedback are
operating at their maximum speeds; i.e.
Max RPM Lead (CP-33) and Max RPM
Feedback (CP-34).

Enter the maximum operating RPMs
measured at the feedback sensor shaft.

Enter the resolution of the feedback
sensor.

Enter the maximum operating RPMs
measured at the lead sensor shaft.

Enter the resolution of the lead
sensor.

Enter the analog level, as a percent of
the full scale analog level, where no
offset is desired. This value can be
found in CP-88 (A/D Input Adjusted)
with the dancer pot placed in the zero
(neutral) position.

3 - 40

CP-76 Offset Authority

CP-77 Offset Polarity

Enter into CP-76 the percent of full
scale feedback that is desired when
the analog input is at full range.

Enter "1" if the offset is to be added to
and "2" if it is to be subtracted from the
scaled reference.

Offset Mode Analog Setpoint Example

The following example demonstrates Offset mode scaling using analog setpoint:

The lead nip motor on a web has a maximum operating speed of 1800
RPM and is equipped with a 60 tooth ring kit sensor. The follower motor
on the same web matches the line web speed when it is rotating at
1800 RPM. It also is equipped with a 60 tooth ring kit sensor. The
following setpoint is entered as the ratio of the follower web speed to
lead web speed. A dancer pot is placed on a web take-up between the
lead and follower nip rolls. When the potentiometer is in its desired
neutral position, the analog voltage level is 6.0 volts or 60.0% of the

10.0 volt analog full scale. Web operation is optimized by subtracting

15.0% of full scale feedback from the scaled reference when the analog
input is at full scale (10.0 volts).

3 - 41

Table 3-30 Offset Mode Example

CP Parameter Name Value Remarks

CP-84 Analog Input

Allocation

CP-21 Follower

Engineering Units

CP-34 Max RPM Feedback

CP-31 PPR Feedback

CP-33 Max RPM Lead

CP-30 PPR Lead

CP-75 Offset Null
CP-76 Offset Authority

CP-77 Offset Polarity

3

1.000

1800

60

1800

60

60.0

15.0

2

Allocates The analog input as the
Offset input.

This is the Engineering Unit value
that is present if the lead and
feedback at max RPM.

The maximum operating RPM of
the feedback shaft.

The resolution of the feedback
sensor.

The maximum operating RPM of
the lead shaft.

The resolution of the lead
sensor.

The neutral dancer pot position.
The authority of the dancer offset

term.
The offset is subtracted from the

scaled reference.

3 - 42

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 MLP–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 3-31. To modify these default parameters, refer to
Table 3-32.

Table 3-31 Default Inverse Master Control Parameters

CP Parameter Name Parameter Value

CP-62 Inverse Scaling 1 (Standard Scaling)

CP-20 Master E.U. 2000

Table 3-32 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 Master Engineering Units value
if the system were to operate at the
maximum RPMs entered in (CP-34).

3 - 43

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 3-33 shows the scaling Control Parameters that would be entered in the
MLP–Drive for this example.

Table 3-33 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.
Acceleration/Deceleration is discussed in

Deceleration

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

3 - 44

.

Operation: Control Parameters, Acceleration/

Inverse Follower Mode

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

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

The MLP–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 3-34. To modify these default parameters,
refer to Table 3-35.

Table 3-34 Default Inverse Follower Control Parameters

CP Parameter Name Parameter Value

CP-62 Inverse Scaling 1 (Standard Scaling)

CP-21 Follower E.U. 1.000

Table 3-35 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 Engineering Units if the system
were to operate at the Max RPM Lead
(CP-33) and the Max RPM Feedback
(CP-34).

3 - 45

Inverse Follower Mode Example

The Inverse Follower Mode Example demonstrates how the scaling and setpoint

Control Parameters are entered for a typical Inverse Follower mode of operation:

In a wire machine twisiting application, the Follower twists the wire as the Lead
pulls the wire. When the Follower is at the maximum revolutions per minute of
1800 RPM and the Lead is at the maximum revolutions per minute of 2000
RPM, then the twist length (lay) is at 2.0 inches. The Follower motor uses a
1200 PPR encoder and the Lead motor shaft is equipped with a 60 tooth ring
kit. Follower Setpoint 1 is setup for the twist lay of 2.0 inches. Follower
Setpoint 2 is setup for a twist lay of 5.0 inches.

Table 3-36 shows the scaling Control Parameters that would be entered in the
MLP–Drive for this example.

Table 3-36 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. Acceleration/Deceleration is discussed in the following section.

3 - 46

Acceleration/Deceleration

Acceleration/Deceleration (CP-16 and CP-17) control the rate of speed change in
response to setpoint changes. These parameters apply to both the Master and
Follower modes of operation.

The MLP–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 3-37. To modify these default parameters, refer to
Table 3-38.

Table 3-37 Default Master or Follower Acceleration/Deceleration Control

Parameters

CP Parameter Name Parameter Value

CP-16 Acceleration Time 5.0

CP-17 Deceleration Time 5.0

Table 3-38 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 - 47

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 MLP-Drive in the Master mode of
operation, using the default PID parameters and a setpoint value of 1000 RPM. When
the MLP-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, reduce the Gain (CP-65) until the system
becomes unstable, then increase slightly until the system stabilizes. In systems that
require greater accuracy, it may be necessary to adjust the Integral (CP-66) to reduce
any remaining speed error. In systems with low inertia, the speed error will be reduced
more quickly if you enter low values in CP-66. An entry that is too low, however, can
create instability or overshoot the setpoint before reaching the correct value. Generally,
use larger entries for CP-66 on systems with a large inertia. Sometimes performance
can be improved in systems with a large inertia by lowering the Derivative (CP-67). If
stability cannot be obtained with the above tuning procedure, reduce the Trim Authority
(CP-69) and repeat the tuning procedure.

The MLP–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
3-39. To modify these default parameters, refer to Table 3-40.

Table 3-39 Default Master or Follower Tuning Control Parameters

CP Parameter Name Parameter Value

CP-65 Gain (Proportional) 9000

CP-66 Integral 2000

CP-67 Derivative 9000

CP-69 Trim Authority 100

3 - 48

Table 3-40 Entering Master / Follower Tuning Control Parameters

CP Parameter Name Parameter Value

CP-65 Gain (Proportional)

CP-66 Integral

CP-67 Derivative

CP-69 Trim Authority

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.

Trim Authority determines how much
influence the PID term has on the control
output. If stability cannot be obtained
through the standard tuning procedure,
reduce CP-69 until stable tuning is
achieved. Setting CP-69 to zero will make
the MLP-Drive operate in open loop
(feedforward only).

3 - 49

Zero Error Loop

The MLP-Drive has the ability to eliminate any long term speed error in the follower
mode. This is equivalent to maintaining a follower position relative to the lead. This is
accomplished by keeping track of all the scaled lead and follower sensor pulses, and
then adjusting the setpoint to the speed control loop to eliminate any error.

The following control parameters are used by the MLP-Drive for zero error control:
Lag Pulse Limit (CP-18)

The Lag Pulse Limit sets a maximum pulse error for the lagging (fol­lower is behind in position) feedback pulses that are maintained in the
zero error loop. It may not always be desirable to recover all of the
position error lag.

Lead Pulse Limit (CP-19)

The Lead Pulse Limit sets a maximum pulse error for the leading
(follower is ahead in position) feedback pulses that are maintained in
the zero error loop. It may not always be desirable to recover all of the
position error lead.

Recovery Multiplier (CP-29)

The Recovery Multiplier determines the rate at which the pulse error
(position) is reduced to zero. This parameter multipied by the pulse
error count is the amount by which the speed setpoint is adjusted every
100 milliseconds.

3 - 50

Table 3-41 Default Zero Error Loop Control Parameters

CP Parameter Name Parameter Value

CP-18 Lag Pulse Limit 0

CP-19 Lead Pulse Limit 0

CP-29 Recovery Multiplier 0

Table 3-42 Entering Zero Error Loop Control Parameters

CP Parameter Name Parameter Value

CP-18 Lag Pulse Limit

Enter the desired lag (behind in
position) pulse limit.

CP-19 Lead Pulse Limit

Enter the desired lead (ahead in
position) pulse limit.

CP-29 Recovery Multiplier

Enter the desired position recovery
rate.

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

3 - 51

Alarms

The Control Parameters for Alarms are identical for both the Master and the Follower
modes of operations. By entering values in the Control Parameters for the Alarms
(CP-12, CP-13, CP-14, CP-15), you can establish circumstances under which the
MLP–Drive will alert you to potential operating problems. The Alarm 1 Format (CP-10)
and Alarm 2 Format (CP-11) can be set to activate at any combination of low speed,
high speed, ramped error or scaled error conditions. Alarm 1 Format is used to control
Dig_Out1 (J5 pins 15, 17). Alarm 2 Format is used to control Dig_Out2 (J5 pins 16, 17).
The alarm outputs can be wired to activate a warning light, a warning sound, or to shut
down the system under specified conditions.

The MLP–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 3-43. To modify these
default parameters, refer to Table 3-44.

Table 3-43 Default Alarms Control Parameters

CP Parameter Name Parameter Value

3 - 52

CP-10 Alarm 1 Format 15

CP-11 Alarm 2 Format 15

CP-12 Low Alarm 0

CP-13 High Alarm 2000

CP-14 Ramped Error Alarm 2000

CP-15 Scaled Error Alarm 2000

Table 3-44 Entering Alarms Control Parameters

CP Parameter Name Parameter Value

CP-10 Alarm 1 Format

CP-11 Alarm 2 Format

CP-12 Low Alarm

CP-13 High Alarm

CP-14 Ramped Error Alarm

CP-15 Scaled Error Alarm

Alarm 1 Format (CP-10) determines which
alarm conditions will activate the Dig_Out1
output, using the values that are entered in
Low Alarm (CP-12), High Alarm (CP-13),
Ramped Error Alarm (CP-14) and Scaled
Error Alarm (CP-15). Refer to Appendix C.

Alarm 2 Format (CP-11) determines which
alarm conditions will activate the Dig_Out2
output, using the values that are entered in
Low Alarm (CP-12), High Alarm (CP-13),
Ramped Error Alarm (CP-14) and Scaled
Error Alarm (CP-15). Refer to Appendix C.

Enter the RPMs at or below which you want
the alarm 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.

3 - 53

Limits

The MLP-Drive has the ablity to limit both the minimum and maximum operating speed
when in the Run state.

The following control parameters are used by the MLP-Drive for limit control:
Minimum Limit (CP-08)

This parameter sets the minimum level of operation in the Run state. It
is possible to enter a setpoint below this limit, however, the control will
always attempt to maintain a speed at or above this RPM level.

Maximum Limit (CP-09)

This parameter sets the maximum level of operation in the Run state. It
is possible to enter a setpoint above this limit, however, the control will
always attempt to maintain a speed at or below this RPM level.

Table 3-45 Default Limit Control Parameters

CP Parameter Name Parameter Value

CP-08 Minimum Limit 0

3 - 54

CP-09 Maximum Limit 2000

Table 3-46 Entering Limit Control Parameters

CP Parameter Name Parameter Value

CP-08 Minimum Limit
CP-09 Maximum Limit

Enter the desired minimum operating RPM.
Enter the desired maximum operating RPM.

Jog

Jog increases the RPMs at the acceleration rate that you specified in Acceleration Time
(CP-16) until the Jog Setpoint (CP-05) is 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 3-47. To modify this default parameter,
refer to Table 3-48.

Table 3-47 Default Jog Control Parameters

CP Parameter Name Parameter Value

CP-05 Jog Setpoint 50

Table 3-48 Entering Jog Control Parameters

CP Parameter Name Parameter Value

CP-05 Jog Setpoint

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

For information on the Jog Logic Input, refer to

Logic Control: Logic Inputs, Jog

.

3 - 55

—NOTES—

3 - 56

LOGIC CONTROL

This section addresses the four digital inputs and two digital outputs that control the
MLP–Drive's and connected drive's operating state.

The four digital inputs are F–Stop, R–Stop, Run and Jog. When the MLP–Drive is
powered up, it defaults to R–Stop. If either Run or Jog have been hardwired, the
MLP–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 motor drive is activated by the Drive Enable logic control. The sections that follow
demonstrate how to use the digital inputs and outputs.

Caution

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

3 - 57

Logic Inputs

F–Stop has priority over the other operating states. F–Stop brings the MLP–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

7

8

J5

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

6

R-STOP

3 - 58

F-STOP

Open Momentarily

J5

7

8

F-STOP

COMMON

Run has the third highest operating priority. Run ramps to the scaled setpoint speed,
using the Acceleration Time (CP-16). Run can be activated when the MLP–Drive is in
R–Stop or F–Stop, however Run cannot be activated when the MLP–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

4

5

6

7

8

J5

RUN

JOG

R-STOP

F-STOP

COMMON

3 - 59

Jog has the least operating priority. Jog ramps to the Jog Setpoint (CP-05), using the

Acceleration Time (CP-16). When Jog is terminated, the MLP–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

4

5

6

7

8

J5

RUN

JOG

R-STOP

F-STOP

COMMON

3 - 60

Logic Outputs

Drive Enable activates based on the Ramped Reference (MP-46) and the feedback.
The Ramped Reference (MP-46) is the calculated setpoint that is output from the
Acceleration/Deceleration routine.

Dig_Out1 or Dig_Out2 can be used as the Drive Enable output depending on the
setting of CP-10 and CP-11, respectively.

Drive Enable Logic (CP-74) determines which conditions of the Ramped Reference
(MP-46) and feedback will control the Drive Enable output. The factory defaults for
Drive Enable Logic (CP-74) are found in Table 3-49. To modify these default
parameter, refer to Table 3-50. If you are uncertain how to enter a Control Parameters,
review the

CP Parameter Name Parameter Value

CP-10 Alarm 1 Format 15

Operations: Keypad

Table 3-49 Default Drive Enable Logic Control Parameter

section.

CP-11 Alarm 2 Format 15

CP-74 Drive Enable Logic 0

3 - 61

Table 3-50 Entering Drive Enable Logic Control Parameter

CP Parameter Name Parameter Value

CP-10 Alarm 1 Format

CP-11 Alarm 2 Format

CP-74 Drive Enable Logic

Enter "16" to allocate Dig_Out1 as the drive
enable output.

Enter "16" to allocate Dig_Out2 as the drive
enable output.

Enter "0" in CP-74 to deactivate the drive
enable output (output high) when the Ramped
Reference is zero, and activate the drive
enable output (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.

3 - 62