CONTREX MLP-Trim User Manual

MLP–T rim

User Manual

0001-0129 Revision B

T echnical Assistance

If you have comments or questions concerning the operation of the MLP–Trim, please call us. A member of our Technical Support Staff will be happy to assist you. Ask for Technical Support: (763) 424-7800 or 1-800-342-4411

Contrex

8900 Zachary Lane North

Maple Grove, Minnesota 55369

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

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

Introducing the MLP–Trim ............................................................................. 1-3

Examples of MLP–Trim 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

Motor Drive Set Up............................................................................. 2-20

MLP–Trim Calibration ........................................................................ 2-21

Analog Input Calibration..................................................................... 2-23

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

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–Trim 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–Trim Fax Cover Sheet..................................................... F-1

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

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

Warranty ..............................................................Warranty-1

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

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

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

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

List of Illustrations

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

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

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

Figure 2-2 MLP–Trim 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 or 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 Speed Command Out ............................................................. 2-15

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

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

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

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

Figure 3-2 MLP–Trim 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–Trim 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 Start/Stop for Non-Regen with Armature Contactor .............. G-4

Figure G-5 Two Channel Start/Stop - Lead/Follower Logic ..................... G-5

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–Trim Response ................................ 3-80

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

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

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

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

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

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

–NOTES–

Introduction

Introducing the MLP–Trim Examples of MLP–Trim Applications

1 - 1

1 - 2

INTRODUCING THE MLP–TRIM

The MLP–Trim is a highly accurate, digital, motor controller. 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–Trim 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–Trim adds accurate digital control to virtually any AC, DC, Servo, Flux Vector or Clutch drives. The MLP–Trim 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–Trim is unique among its competition because the MLP–Trim has preprogramed software that integrates with your system with little effort from you. The MLP–Trim 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–Trim'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–Trim's Monitor Parameters (MPs) allow you to monitor your system's performance.

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

Integrating the MLP–Trim's applied intelligence with your system puts precise speeds and perfect synchronization at your fingertips, quickly, easily and cost effectively.

1 - 3

EXAMPLES OF MLP–TRIM

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–Trim compares the sensor shaft feedback to the scaled setpoint and calculates any speed error. When the MLP–Trim finds speed error, the control algorithm adjusts the Speed Command Out to the motor drive and reduces the error to zero.

Speed Command Out

ontrex

Motor Drive MLP–Trim

Contrex

CODE

SELECT

POINT

TACH

SET

456

–

ENTER

CLEAR

1 - 4

Motor

Sensor

Pump

Feedback Frequency

Figure 1-1 MLP–Trim 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–Trim compares the setpoint ratio to the Follower sensor shaft feedback and Lead sensor shaft feedback to calculate any speed error. When the MLP–Trim finds speed error, the control algorithm adjusts the Speed Command Out to the motor drive and reduces the error to zero.

Lead

Speed

Lead Motor

Command Out

ontrex

Motor Drive MLP–Trim

Sensor

Pump

Contrex

8 9

CODE SELECT

4 5 6

SET POINT

2 3

TACH

–

ENTER

CLEAR

Feedback Frequency

Ingredient A

Final Product

Follower

Follower Motor

Lead Frequency

Contrex

8 9

CODE SELECT

4 5 6

SET POINT

2 3

TACH

–

ENTER

CLEAR

ontrex

Speed Command Out

Motor Drive MLP–Trim

Feedback Frequency

Sensor

Pump

Ingredient B

Figure 1-2 MLP–Trim Follower Mode

1 - 5

—NOTES—

1 - 6

Installation / Setup

Mounting Wiring

Inputs Outputs Serial Communications

Calibration

Motor Drive Setup MLP–Trim Calibration Analog Input Calibration

2 - 1

Contrex



CUTOUT

(

3.65" .03"

6.00"

(

DOOR PANEL

Contrex

8 9

CODE

SELECT

4 5 6

SET

POINT

TACH

–

CLEAR

2 3

ENTER

)

3.60"

CUTOUT

(

3.65" .03"

3.60"

4.00"

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

4.00"

2 - 2

Figure 2-1 MLP–Trim Cutout Dimensions and Mounting Guide

MOUNTING

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

1) The NEMA Industrial Electrical Enclosure that will house the MLP–Trim 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–Trim and other equipment to provide for proper heat convection. Placing the MLP–Trim too close to adjacent equipment could cause the interior ambient temperature to exceed 55 degrees C. Spacing requirements depend on air flow and enclosure construction.

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–Trim 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–Trim. Tighten the mounting screws until the MLP–Trim is mounted securely in the NEMA Electrical Enclosure. Do not overtighten.

2 - 3

Use 115 VAC with MLP-Trim model # 3200-1936

Use 230 VAC with MLP-Trim model # 3200-1937

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

T / R +

T / R –

COM_AUX

RS485

COMM

I/O

PWR

NEUT

GND

POWER

SPD CMD

DRV_SIG

DRV_COM

FREQ

INPUTS

DIGITAL

INPUTS

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

COM

External

DC Power

Supply

TD/RD+

TD/RD–

COM

Motor Drive

SIG

COM

123

Fuses

250V

12345678910111213141516171819

ANAL

AUX PWR

COM_AUX

Master/

Follower

Setpoint

Select

Scroll Up

Scroll Down

2 - 4

Figure 2-2 MLP–Trim General Wiring

WIRING

This section contains the input, output and serial communications wiring information for the MLP–Trim. Please read this section prior to wiring the MLP–Trim to ensure that you make the appropriate wiring decisions.

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.

Use a minimum wire gauge of 18 AWG. Use shielded cable to minimize equipment malfunctions from electrical noise. Keep the AC power wiring (J4) physically separated from all other wiring on the

MLP–Trim. Failure to do so could result in additional electrical noise and cause the MLP–Trim 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 relay, 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 the best results, use resistance (r) values of 50 ohms and capacitance (c) values of 0.1 microfarads.

The National Electrical Code

The Canadian Electrical Code

(NEC,) Article 430 published by the

(CEC).

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

DANGER

Hazardous voltages. Can cause severe injury, death or damage to the equipment. The MLP–Trim 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 (J5 pins 1, 2)

For isolated operations, the Frequency Inputs (J6 pins 1, 2, 3), the Digital Inputs (J6 pins 4-13 ), the Digital Outputs (J6 pins 14-17) and Analog Input (J6 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).

+5V

COM

+5VDC External Power Supply

CAUTION: The MLP-Trim is shipped from the factory nonisolated with J1 and J5 jumpers. You must remove the J1 and J5 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-Trim is shipped from the factory with the wiring in the nonisolated operation.

NOTE: The MLP-Trim should be

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

References: Appendix A

MLP–Trim Specifications.

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

Figure 2-3 I/O Power / Isolated

+5V

COM_AUX

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

2 - 7

AC Power (J4 pins 1, 2, 3)

The MLP–Trim model #3200-1936 operates on 115 VAC + 15%, 0.1 Amp., 50/60 Hz. The MLP–Trim model #3200-1937 operates on 230 VAC + 15%, 0.1 Amp., 50/60 Hz.

* Fuse L1 for 115VAC applications. Fuse L1 and L2 for 230VAC applications. Use 1 Amp 250V normal blow fuses.

Neutral or L2

GND/PE

Figure 2-5 Input Power

Lead Frequency (J6 pins 1, 3)

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

MLP–Trim Specifications.

2 - 8

References: Appendix A

Signal

Common

Figure 2-6 Lead Frequency

Feedback Frequency

(J6 pins 2, 3)

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

MLP–Trim Specifications

References: Appendix A

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

Figure 2-7 Feedback Frequency

DANGER

Signal

Common

Run (J6 pins 4, 8)

When the Run input (J6 pin 4) is momentarily shorted to common, the MLP–Trim 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–Trim will not enter “Run”.

RUN

Figure 2-8 Run

2 - 9

Jog (J6 pins 5, 8)

Jog is a maintained input. When Jog is closed, the MLP–Trim sends a Speed Command Out signal to the drive at the selected jog speed. As a maintained input, Jog is only active when the operator device is closed.

JOG

NOTE: Close the R–Stop and

F–Stop inputs and open the Run input, prior to entering Jog. If you are only using one of the Stop inputs, wire short the other Stop input to common or the MLP–Trim will not enter Jog.

R–Stop (J6 pins 6, 8)

R–Stop is a momentary input. When it is opened, the MLP–Trim ramps to a zero Speed Command Out at the specified deceleration rate. As a momentary input, R–Stop is internally latched and does not need to be maintained by an operator device.

Figure 2-9 Jog

R-STOP

2 - 10

Figure 2-10 R–Stop

F-Stop (J6 pins 7, 8)

F-Stop is a momentary input. When it is open, the MLP–Trim stops immediately (zero RPM) and ignores the specified deceleration rate. As a momentary input, F-Stop is internally latched and does not need to be maintained by an operator device.

F-STOP

Figure 2-11 F–Stop

Master / Follower

(J6 pins 9, 13)

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

MASTER

FOLLOWER

Figure 2-12 Master / Follower

2 - 11

Setpoint Select (J6 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

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 (J6 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 (J6 pins 12, 13)

SCROLL UP

Figure 2-14 Scroll Up

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

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 (J6 pin 12 open), the control algorithm adjusts the speed command output to reduce the error to zero (setpoint minus feedback). In the Open Loop position (J6 pin 12 shorted to pin 13), the speed command output is adjusted in response to the setpoint changes only, and feedback and error are ignored.

2 - 13

Analog Input (J6 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.

Signal

Common

Figure 2-16 Analog Input

2 - 14

OUTPUTS

Speed Command Out (J3 pins 1, 2)

Speed Command Out is an isolated analog output signal that is sent to the motor drive to control the speed of the motor. Wire the Speed

SIGNAL INPUT

DRIVE COMMON

Speed Command Out

Isolated Common

Command Out into the speed signal input of the drive. If the motor drive has a potentiometer speed control, remove the potentiometer connections and wire the Speed Command Output to the

MOTOR DRIVE

Do not connect the Drive Isolated Common to other

logic commons

potentiometer wiper input. The MLP–Trim's isolated common should

Figure 2-17 Speed Command Out

always be connected to the drive common.

Digital Output 1 (J6 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 functional allocation of Digital Output 1.

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

Appendix A

MLP–Trim Specifications

. Use an external DC power supply to power the relays. Free-wheeling diodes are incorporated internally in the MLP– Trim and do not need to be added externally.

References:

2 - 15

Digital Output 2 (J6 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–Trim and do not need to be added externally.

+V_DO

DIG_OUT1

DIG_OUT2

Common

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–Trim. 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–Trim.

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–Trim 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–Trim. See information on using Serial Communications. The MLP-Trim 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

CODE

SELECT

4 5 6

SET

POINT

2 3

TACH

–

ENTER

CLEAR

Isolated

RS232 to RS485

Converter

Contrex

8 9

CODE SELECT

4 5 6

SET

POINT

2 3

TACH

–

ENTER

CLEAR

Figure 2-19 MLP–Trim Multidrop Installation

Contrex

CODE

SELECT

SET

POINT

TACH

4 5 6

–

CLEAR

Contrex

8 9

2 3

ENTER

Contrex

8 9

CODE

SELECT

4 5 6

SET

POINT

2 3

TACH

–

ENTER

CLEAR

Contrex

8 9

CODE SELECT

4 5 6

SET POINT

2 3

TACH

–

ENTER

CLEAR

8 9

CODE SELECT

4 5 6

SET POINT

2 3

TACH

–

ENTER

CLEAR

2 - 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.

MLP–Trim #1

T/R+ T/R– COM

MLP–Trim #2

T/R+ T/R– COM

2 - 18

Figure 2-20 MLP–Trim Serial Communications Connections

CALIBRATION

Calibration matches the Speed Command analog output of the MLP–Trim with the analog input of the motor drive. Calibration is accomplished in two steps. The first step is to set up the motor drive. The second step is to calibrate the MLP–Trim to the motor drive so that the speed is adjusted to the maximum operating speed. Calibration also zero and spans the analog input. The MLP–Trim must be properly installed prior to calibration. Refer to

Installation/Setup; Mounting

DANGER

Hazardous voltages.

, and

Installation/Setup; Wiring

Can cause severe injury, death or damage to the equipment.

Make adjustments with caution.

2 - 19

MOTOR DRIVE SET UP

1) Put the MLP–Trim in “R–Stop” by opening the R–Stop input (J6 pins 6, 8). Refer to

2) Set the drive's acceleration and deceleration potentiometers to their fastest rates (minimum ramp time). The goal is to make the drive as responsive as possible, which allows the MLP–Trim to control the speed changes.

3) If the drive has a maximum speed (span) potentiometer, set it to the highest setting at which the motor drive is capable of running. The maximum speed at which you want the system to operate will be controlled by the MLP–Trim.

4) If the drive has a zero speed potentiometer, adjust it to eliminate any motor creep.

5) If the drive has an IR compensation potentiometer, set it at minimum.

Installation/Setup: Wiring, Inputs, R–Stop

2 - 20

6) Each motor drive has settings that are unique to its particular model. Adjust any remaining drive settings according to the manufacturer's recommendations.

MLP–TRIM CALIBRATION

1) Make sure that the MLP–Trim is still in “R–Stop”. If the MLP–Trim is not in “R-Stop”, then put it in “R–Stop” by opening the R–Stop logic input (J6 pins 6, 8). Refer to

2) Enter the resolution (PPRs) of the feedback sensor in the PPR Feedback Control Parameter (CP-31) by entering the following on the keypad:

Press “Code Select” Enter “31” (PPR Feedback) Press “Enter” Enter the Pulses Per Revolution (PPR) of the feedback sensor Press “Enter”

The Tach for the Direct mode is now scaled.

3) Set the MLP–Trim's maximum speed potentiometer (located on the rear) as far counter clockwise as it will turn. This is the minimum speed setting.

4) Enable the MLP–Trim's Direct mode by entering the following on the keypad:

Press “Code Select” Enter “61” (Direct Enable) Press “Enter” Enter “1” Press “Enter”

Installation/Setup: Wiring, Inputs, R–Stop

5) Put the MLP–Trim into “Run” by deactivating (shorting) the R–Stop input (J6 pins 6, 8) and the F–Stop input (J6 pins 7, 8) and then activating (shorting) the Run input (J6 pins 4, 8). Although the motor is now in “Run”, it will have zero speed until you adjust the Direct Setpoint (in the next step).

6) Gradually set the MLP–Trim's Direct Setpoint to 90% by entering the following on the keypad:

Press “Code Select” Enter “6” (Direct Setpoint) Press “Enter” Enter “10” Press “Enter” Enter “20” Press “Enter”

2 - 21

Continue to gradually increase these increments by ten until you reach “90”. Since there are no acceleration/deceleration ramps in Direct mode, a sudden increase to “90” could cause damage in some systems.

7) Turn the MLP–Trim's maximum speed potentiometer clockwise until the drive motor's RPMs are at the maximum operating speed at which you want the system to operate. The maximum operating speed is the same speed that you will enter in Max RPM Feedback (CP-34) to scale for the Master mode of operation (Refer to

Operation: Control Parameters. Master Mode

Check the speed (RPMs) by pressing the “Tach” key. If the lowest setting on the MLP–Trim's maximum speed potentiometer still exceeds the maximum speed at which you want the system to operate, then adjust the maximum speed (span) potentiometer on the motor drive until the desired speed is reached.

8) Put the Direct Setpoint back to 0% by entering the following on the keypad:

Press “Code Select” Enter “6” (Direct Setpoint) Press “Enter” Enter “0” Press “Enter”

9) Disable the MLP–Trim's Direct mode by entering the following on the keypad:

2 - 22

Press “Code Select” Enter “61” (Direct Enable) Press “Enter” Enter “0” Press “Enter”

10) Put the MLP–Trim in “R–Stop” by opening the R–Stop input (J6 pins 6, 8).

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" Press "Enter"

2) Place zero volts (short) on the analog input (J6 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:

Press "Code Select" Enter "86" Press "Enter"

2) Place 10.0 VDC on the analog input (J6 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.

2 - 23

–NOTES—

2 - 24

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

The MLP–Trim 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–Trim, determine which of the modes of operation your MLP– Trim 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 Speed Command output from the MLP–Trim that is connected 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.

Caution: To avoid damage to your system, the MLP–Trim must be calibrated and the

motor drive set up before you enter the Direct Control Parameters. Refer to

Installation/Setup: Calibration

The Direct Setpoint (CP-06) is entered as a percentage of the MLP–Trim's calibrated full scale Speed Command 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

3 - 8

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

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 Speed Command 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–Trim.

Caution: To avoid damage to your system, the MLP–Trim must be calibrated and the

motor drive set up before you enter the Master Control Parameters. Refer to

Installation/Setup: Calibration

The MLP–Trim 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–Trim can determine how to operate at those setpoints, you must enter Scaling Control Parameters into the MLP–Trim. Scaling is a convenient method for translating the relationship of the motor RPMs into Master Engineering Units. The Scaling Control Parameters give the MLP–Trim 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. This number is identical to the maximum operating speed that you set in step 7 of the calibration procedure.

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 J6 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–Trim 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-Trim 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-Trim 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

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-Trim 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-Trim 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. This number should be the same as the maximum operating speed set during step 7 of the calibration procedure.

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

20.0

1800

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–Trims.

The MLP–Trim 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–Trim can determine how to operate at these setpoints, you must enter Scaling Control Parameters into the MLP–Trim. 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–Trim 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. This number is identical to the maximum operating speed that you set in step 7 of the calibration procedure.

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–Trim 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

___

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:

___

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–Trim 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–Trim 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–Trim 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-Trim 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-Trim 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. This number should be the same as the maximum operating speed set during step 7 of the calibration procedure.

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-Trim 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

2.000

1800

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

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-Trim 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

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

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. This number should be the same as the maximum operating speed set during step 7 of the calibration procedure.

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-Trim 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

3.000

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-Trim to provide an offset to the web follower operation.

The following Control Parameters give the MLP-Trim 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. This number should be the same as the maximum operating speed set during step 7 of the calibration procedure.

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 the follower speed. Analog input voltages less than Offset Null will cause a decrease in follower speed.

If CP-77 is set to 2 (subtractive), analog input voltages greater than CP75 (Offset Null) will cause an decrease in the follower speed. Analog input voltages less than Offset Null will cause a increase in follower 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

1.000

1800

60.0

15.0

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–Trim 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–Trim 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–Trim 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–Trim 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–Trim 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.

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–Trim 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.

3 - 48

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

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-Trim operate in open loop (feedforward only).

3 - 49

Zero Error Loop

The MLP-Trim 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-Trim 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–Trim 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 (J6 pins 15, 17). Alarm 2 Format is used to control Dig_Out2 (J6 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–Trim 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-Trim 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-Trim 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–Trim's and connected drive's operating state.

The four digital inputs are F–Stop, R–Stop, Run and Jog. When the MLP–Trim is powered up, it defaults to R–Stop. If either Run or Jog have been hardwired, the MLP–Trim 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–Trim's

Speed Command output to an immediate Zero. To activate F–Stop:

• Open the F–Stop Input. (F–Stop is latched and does not need to be maintained to remain active.)

F-STOP

Open Momentarily

F-STOP

COMMON

R–Stop has the second highest operating priority. R–Stop decelerates the Speed Command 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

3 - 58

F-STOP

Open Momentarily

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–Trim is in R–Stop or F–Stop, however Run cannot be activated when the MLP–Trim is in Jog.

To activate Run:

• Short the F–Stop and R–Stop inputs to common.

• Open the Jog input.

• Short the Run input to common. (Run is latched and does not need to be

maintained to remain active.)

RUN

JOG

R-STOP

F-STOP

Close Momentarily

RUN

JOG

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–Trim brings the Speed Command output to an immediate Zero. Unlike the other inputs, Jog is not latched and must be sustained to remain active.

To activate Jog:

• Short the F–Stop and R–Stop inputs to common.

• Open the Run input.

• Short the Jog input to common. (Jog must be sustained to remain active).

RUN

JOG

R-STOP

F-STOP

Maintain Closed

RUN

JOG

R-STOP

F-STOP

COMMON

3 - 60

CONTREX MLP-Trim User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Introduction

INTRODUCING THE MLP–TRIM

Installation / Setup

MOUNTING

WIRING

INPUTS

OUTPUTS

SERIAL COMMUNICATIONS

CALIBRATION

MOTOR DRIVE SET UP

MLP–TRIM CALIBRATION

ANALOG INPUT CALIBRATION

Operation

KEYPAD OPERATION

KEYPAD LOCKOUT

CONTROL PARAMETERS

Direct Mode

Master Mode

Follower Mode

Offset Mode

Inverse Master Mode

Inverse Follower Mode

Acceleration/Deceleration

Tuning

Alarms

Limits

LOGIC CONTROL

Logic Inputs