CONTREX M-Traverse User Manual

M–T raverse

User Manual

0001-0122 Revision F

Technical Assistance

If you have comments or questions concerning the operation of the M–Traverse, a member of our Technical Support Staff will be happy to assist you. Ask for Technical Support: (763) 424-7800 or (800) 342-4411

Contrex

8900 Zachary Lane North

Maple Grove, Minnesota 55369

DANGER

Improper installation or improper operation of this motion control unit can cause severe injury, death or damage your system.

Integrate this motion control unit into your system with caution.

Comply with the National Electrical Code and all applicable local and national codes.

Table of Contents

Introduction 1-1

Introducing the M–Traverse........................................................................... 1-3

Examples of M–Traverse Applications .......................................................... 1-4

Installation / Setup 2-1

Configuration.................................................................................................. 2-3

Mounting ........................................................................................................ 2-7

Wiring ............................................................................................................. 2-9

Inputs.................................................................................................. 2-10

Outputs............................................................................................... 2-19

Serial Communications ...................................................................... 2-24

Calibration.................................................................................................... 2-27

Motor Drive Set Up............................................................................. 2-29

Encoder Polarity Check ..................................................................... 2-29

M–Traverse Calibration...................................................................... 2-30

Operation3-1

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

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

Follower Mode...................................................................................... 3-8

Direct Mode........................................................................................ 3-29

Jog...................................................................................................... 3-30

Tuning ................................................................................................. 3-32

Output Control.................................................................................... 3-34

M–Traverse Operation................................................................................. 3-43

Follower Mode.................................................................................... 3-44

Home Set ........................................................................................... 3-45

Home Seek......................................................................................... 3-45

Home Return...................................................................................... 3-50

Direct Mode........................................................................................ 3-51

Jog...................................................................................................... 3-52

Monitor Variables ......................................................................................... 3-53

Input Monitoring ................................................................................. 3-54

Output Monitoring............................................................................... 3-56

Performance Monitoring..................................................................... 3-58

Status Monitoring ............................................................................... 3-60

Serial Communications................................................................................ 3-63

Using Serial Communications............................................................ 3-64

Communications Software Design..................................................... 3-66

Troubleshooting 4-1

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

Troubleshooting ........................................................................................... 4-13

EPROM Chip Replacement ......................................................................... 4-19

References 5-1

Glossary......................................................................................................... 5-3

Appendix A: M–Traverse Specifications ..................................................... 5-11

Appendix B: Formulas ................................................................................ 5-13

Appendix C: Parameter Summary - Numeric Quick Reference ................. 5-14

Appendix D: Control Parameter Reference................................................ 5-36

Appendix E: Monitor Variable Reference.................................................... 5-38

Appendix F: Fax Cover Sheet .................................................................... 5-39

Appendix G: Wiring Diagram Examples ..................................................... 5-40

Appendix H: Revision Log .......................................................................... 5-44

Service policy............................................................................................... 5-45

Warranty....................................................................................................... 5-46

Index ............................................................................................................ 5-47

List of Illustrations

Figure 1-1 M–Traverse Level Wind Application ........................................ 1-4

Figure 1-2 M–Traverse Web Scanning Application.................................... 1-5

Figure 2-1 Rear View of M–Traverse ........................................................ 2-3

Figure 2-2 Power Board / Isolator Jumper ................................................ 2-4

Figure 2-3 Power Board / SW1 Switch ...................................................... 2-5

Figure 2-4 M–Traverse Mounting and Cutout Dimensions ....................... 2-6

Figure 2-5 M–Traverse General Wiring Schematic ................................... 2-8

Figure 2-6 Input Power............................................................................. 2-10

Figure 2-7 Lead frequency ...................................................................... 2-10

Figure 2-8 Feedback frequency .............................................................. 2-11

Figure 2-9 Home Sync ............................................................................. 2-11

Figure 2-10 Setpoint Select A .................................................................... 2-12

Figure 2-11 Setpoint Select B .................................................................... 2-12

Figure 2-12 Home Set ................................................................................ 2-13

Figure 2-13 Home Seek ............................................................................. 2-13

Figure 2-14 Home Return........................................................................... 2-14

Figure 2-15 Batch Reset ............................................................................ 2-14

Figure 2-16 Run ......................................................................................... 2-15

Figure 2-17 Wait......................................................................................... 2-15

Figure 2-18 F-Stop ..................................................................................... 2-16

Figure 2-19 Keypad Lockout ..................................................................... 2-16

Figure 2-20 Forward Limit .......................................................................... 2-17

Figure 2-21 Reverse Limit ......................................................................... 2-17

Figure 2-22 Jog Forward/Reverse ............................................................. 2-18

Figure 2-23 Jog ......................................................................................... 2-18

Figure 2-24 Speed Command Out ............................................................2-19

Figure 2-25 Discrete Outputs ..................................................................... 2-23

Figure 2-26 M-Traverse Multidrop Installation .......................................... 2-24

Figure 2-27 M-Traverse Serial Communications Connections .................. 2-25

Figure 2-28 Location of M-Traverse Scale and Zero Pot........................... 2-28

Figure 3-1 M–Traverse Front Panel .......................................................... 3-5

Figure 3-2 M–Traverse Internal Structure ............................................... 3-58

Figure 4-1 Motor Does Not Stop Flowchart ............................................ 4-14

iii

Figure 4-2 Motor Does Not Run Flowchart ............................................. 4-15

Figure 4-3 Motor Runs at Wrong Speed Flowchart ................................ 4-16

Figure 4-4 Motor Runs Unstable Flowchart ............................................ 4-17

Figure 4-5 EPROM Location ................................................................... 4-18

Figure G-1 M–Traverse Wiring Connections without Relays .................. 5-40

Figure G-2 Relay Run/Stop Wiring Connections .................................... 5-41

Figure G-3 Run/Stop for Regen with Armature Contactor ...................... 5-42

Figure G-4 Run/Stop for Non-Regen with Armature Contactor .............. 5-43

List of Tables

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

Table 3-2 Default Control Mode Control Parameters .............................. 3-9

Table 3-3 Entering Control Mode Control Parameters ............................ 3-9

Table 3-4 Default Follower Scaling Control Parameters ....................... 3-11

Table 3-5 Entering Follower Scaling Control Parameters ..................... 3-12

Table 3-6 Default Setpoint Control Parameters ..................................... 3-13

Table 3-7 Entering Setpoint Control Parameters ................................... 3-14

Table 3-8 Default Traverse Length Control Parameters ........................ 3-15

Table 3-9 Entering Traverse Length Control Parameters ...................... 3-15

Table 3-10 Default Accel/Decel Length Control Parameters ................... 3-17

Table 3-11 Entering Accel/Decel Length Control Parameters ................. 3-17

Table 3-12 Default Dwell Control Parameters ......................................... 3-18

Table 3-13 Entering Dwell Control Parameters ...................................... 3-18

Table 3-14 Default Control Parameters for Changes .............................. 3-23

Table 3-15 Entering Control Parameters for Changes ............................ 3-23

Table 3-16 Default Resume Enable Control Parameter .......................... 3-25

Table 3-17 Entering Resume Enable Control Parameter ........................ 3-25

Table 3-18 Default Polarity Control Parameters ...................................... 3-27

Table 3-19 Entering Polarity Control Parameters .................................... 3-27

Table 3-20 Default Direct Mode Control Parameters ............................... 3-28

Table 3-21 Entering Polarity Control Parameters ................................... 3-28

Table 3-22 Default Direct Mode Control Parameters ............................... 3-29

Table 3-23 Entering Direct Mode Control Parameters ............................. 3-29

Table 3-24 Default Jog Control Parameters ............................................ 3-30

Table 3-25 Entering Jog Control Parameters .......................................... 3-30

Table 3-26 Default Tuning Control Parameters ....................................... 3-32

Table 3-27 Entering Tuning Control Parameters ..................................... 3-33

Table 3-28 Default Batch Control Parameters .........................................3-35

Table 3-29 Entering Batch Control Parameters ....................................... 3-35

Table 3-30 Default Alarm Control Parameter ........................................... 3-36

Table 3-31 Entering Alarm Control Parameter ......................................... 3-36

Table 3-32 Default At-Home Control Parameter ...................................... 3-37

Table 3-33 Entering At-Home Control Parameter .................................... 3-37

Table 3-34 Default Control Parameters for Output A ............................... 3-39

Table 3-35 Entering Control Parameters for Output A ............................. 3-39

Table 3-36 Default Control Parameters for Output B ............................... 3-41

Table 3-37 Entering Control Parameters for Output B ............................ 3-41

Table 3-38 Parameter Send - Host Transmission..................................... 3-67

Table 3-39 Parameter Send - M–Traverse Response ............................. 3-69

Table 3-40 Control Command Send - Host Transmission ....................... 3-71

Table 3-41 Control Command Send - M–Traverse Response ................. 3-73

Table 3-42 Data Inquiry - Host Transmission ........................................... 3-75

Table 3-43 Data Inquiry - M–Traverse Response .................................... 3-77

Table 3-44 ASCII to Binary ...................................................................... 3-79

Table 3-45 Binary Monitor Parameters .................................................... 3-80

Introduction

Introducing the M–Traverse Examples of M–Traverse Applications

1-1

1-2

INTRODUCING THE M–TRAVERSE

The M–Traverse is a highly accurate, digital, position controller. The M–Traverse's technically advanced, internally embedded, control software is specifically designed for the precise control of reciprocating lead/follower motion applications. These applications are characterized by symmetric forward and reverse follower profiles. The M–Traverse is often used for level winding, web scanning and fabric lapping, however it can be used in any operation that requires symmetrical follower profiling against a lead.

The M-Traverse allows you to enter information that is unique to your system's operation through user friendly Control Parameters. The M–Traverse uses this information to calculate and determine a variety of controls and functions and frees you from complex computations. When your system is engaged (Run), the traversing mechanism (Follower) accelerates from the “Home” position to the preset laypitch (Setpoint). Operating at the laypitch, the traverse mechanism can precisely align a product on a reel or web then decelerate the traversing mechanism to the end of the Traverse Length before beginning the end Dwell. At the “Dwell,” the M-Traverse assures that the product is properly aligned before returning in the opposite direction. The M–Traverse is remarkably precise - within one encoder line.

The M–Traverse accepts up to four preset pairs of “Setpoint” and “Traverse Length” parameters. These parameters can be engaged with a quick flip of a switch during a product change over. The M-Traverse features additional advanced control that includes; profile definition that uses engineering unit parameters, dynamic profile redefinition during a run, automatic profile generation, batch counting, unipolar/bipolar drive compatibility and dynamic system monitoring. There are seven discrete outputs for external control integration, which includes two user specified profile position outputs.

Although the M–Traverse has many advanced control capabilities, it is easy to use. The integrated keypad and display make access to the control and monitor parameters both direct and simple. A “Keypad Lockout” function allows you to restrict access to the control parameters after you have completed the setup process.

The M–Traverse features dedicated short-cut keys for quick access to the “Setpoint,” “Batch Count,” “Tach,” and “Status” parameters. In addition to the integrated user keypad and display, the M–Traverse has a RS-422 serial communications port through which you can gain computer access to all of the control and monitor parameters. Integrating the M–Traverse's applied intelligence with your system puts precise control and perfect synchronization at your fingertips, quickly, easily and cost effectively.

1-3

EXAMPLES OF M–TRAVERSE

APPLICATIONS

The Level Wind is one of the M–Traverse's principle applications. The Level Wind

application uses the Lay Adjusted option in the Follower mode of operation. In a Level Wind application, the M–Traverse locates the start or “Home” position and accelerates the traversing mechanism (Follower) to the preset laypitch (Setpoint). The traversing mechanism feeds a web product such as a wire, fiber optic cable or tape, onto the rotating reel (Lead) at this laypitch then decelerates the traversing mechanism to the end of the Traverse Length. At the “Dwell,” the M-Traverse assures that the web material is properly aligned on the reel before returning in the opposite direction. Figure 1-1 illustrates a typical Level Wind application.

HOME SYNC

FOLLOWER

DIRECTION

OF WIND

FEEDBACK FREQUENCY

LEAD

Cut

Position

Length

Batch

Status

Count

Alt

Enter

Clear

M-TRAVERSE

M–Traverse

CONTREX

LEAD FREQUENCY

1-4

Figure 1-1 M–Traverse Level Wind Application

Web Scanning is another common M–Traverse application. The Web Scanning

application frequently uses the Standard option in the Follower mode of operation, however, there are applications for which Web Scanning may use the Lay Adjusted option in the Follower mode of operation. The M–Traverse locates the start or “Home” position and accelerates the traversing mechanism (Follower) to the preset laypitch (Setpoint). The traversing mechanism applies a secondary product, such as glue or reinforcing fiber, onto the moving web. Then the M–Traverse decelerates the traversing mechanism to zero speed at the end of the “Traverse Length”. At the “Dwell” (which is usually set at zero) the traversing mechanism reverses its direction and returns with a symmetric reverse profile. Using zero or very low “Accel / Decel” and “Dwell” parameters creates a zigzag pattern. Figure 1-2 illustrates a typical Web Scanning application.

LEAD

HOME SYNC

FOLLOWER

LINE FLOW

FEEDBACK FREQUENCY

Cut

Position

Length Batch

Status

Count

Alt

Enter

Clear

M-TRAVERSE

M–Traverse

CONTREX

LEAD FREQUENCY

Figure 1-2 M–Traverse W eb Scanning Application

1-5

—NOTES—

1-6

Installation / Setup

Configuration Mounting Wiring

Inputs Outputs Serial Communications

Calibration

Motor Drive Setup M-Traverse Calibration

2 - 1

2 - 2

CONFIGURATION

This section will show you how to re-configure the M-Traverse for electrical compatibility. Complete these procedures prior to installation. These procedures do not require power to complete.

The two areas that are involved in re-configuring the M-Traverse are the Isolator Voltage jumper and the Power Voltage switch. Do not re-configure the M-Traverse's Frequency Input. Use the default Quadrature position.

To re-configure the Isolator Voltage jumper and the Power Voltage switch, remove the back plate, then carefully remove the Power Board. Figure 2-1 illustrates the location of the boards.

Power Board CPU Board

Figure 2-1 Rear View of M-Traverse

2 - 3

The Isolator Voltage jumper (J3) is located on the Power Board (see Figure 2-2). It configures the isolated analog output for either voltage that is ranged by an internal +15 volt reference or for voltage that is auto-ranged by the voltage level of the motor drive. The auto-range voltage position is the default configuration for the Isolator Voltage jumper.

NOTE: In most cases, the default configuration will be appropriate for your application

and it will not be necessary to re-configure.

If the motor drive does not have an external voltage reference, re-configure the Isolator Voltage by moving the jumper from the default auto-range voltage position (1) to the internal +15 volt reference position (2).

Internal Reference Position

115

2 1

Auto Range Position (default)

2 - 4

Figure 2-2 Power Board / Isolator Jumper

The Power Voltage switch (SW1) is located on the Power Board (see Figure 2-3). The default configuration for the Power Voltage switch is 115 VAC.

NOTE: In most cases, the default configuration will be appropriate for your application

and it will not be necessary to re-configure.

To re-configure for 230V, move the switch from the 115V position (left) to the 230V position (right).

115

115V (default)

115V

230V

Figure 2-3 Power Board / SW1 Switch

2 - 5

Set

Contrex

CUTOUT

(

7.25" .03"

CUTOUT

(

3.65" .03"

3.6"

7.2"

)

5.7"

(

DOOR PANEL

Contrex

7.5"

M-TRAVERSE

2 - 6

3.9"

Figure 2-4 M–Traverse Mounting and Cutout Dimensions

MOUNTING

This section contains instructions for mounting the M–Traverse in the door panel of a NEMA Industrial Electrical enclosure. The M–Traverse is packaged in a compact 1/2 DIN Vertical Instrument Enclosure that mounts easily in the door of your Industrial Electrical Enclosure.

To mount the M–Traverse:

1) The NEMA Industrial Electrical Enclosure that will house the M– Traverse must conform to the following environmental conditions:

Temperature: 0 - 55 degrees C

(Internal NEMA enclosure temperature)

Humidity: 0 - 90% RH non-condensing

2) The dimensions for the door panel cutout are 3.65"+ .03" X 7.25 +.03" (see figure 2-4). Allow two inches of clearance on all sides of the cutout for mounting clamp attachments, wire routing and heat convection.

3) Insert the M–Traverse through the door panel cutout until the gasket and bezel are flush with the door panel (see figure 2-4).

4) The mounting clamps can be inserted in the holes that are located either on the top and bottom or on the sides of the M–Traverse. Tighten the mounting screws until the M–Traverse is mounted securely in the NEMA Electrical Enclosure. Do not overtighten.

2 - 7

* Power for encoder and prox switches may be supplied by J3, pins 1 or 2.

Total +5 VDC current should not exceed 250 mA

Total +12 VDC current should not exceed 200 mA

+12 V OUT

50 MA MAX

TXD–+

RXD

–

COM

SIG

SIO

COM

DRIVE

ENABLE

BATCH

DONE

ALARM

PROFILE

DIRATHOME

OUTPUTAOUTPUT

+EXTDCSUPPLY–

RRR

SERIAL COMMUNICATIONS

RS 485

EDB

ACK

CHA

COM

CHB

SHIELD

CHA

COM

CHB

COM

HOME SYNC

STPT SEL A

(C)

COM

STPT SEL B

(C)

HOME SET

J3 (C)J4 COM

HOME

SEEK(C)

HOME

RETURN(C)

COM

BATCH

RESET(C)

RUN(C)

COM

WAIT (O)

F–STOP(O)

COM

KEYPAD

LOCKOUT(C)

FORWARD

LIMIT(C)

COM

REVERSE

LIMIT(C)

FWD(O)

JOG

REV(C)

COM

JOG(C)

SHIELD

+5 V OUT

500 MA MAX

+12 V OUT

150 MA MAX

INPUT VOLTAGE – 115/230 VAC

INPUT CURRENT – 0.25 AMP

INPUT FREQUENCY – 50/60 HZ

USE COPPER WIRE ONLY.

SELECT WIRE SIZE ACCORDING TO AMPACITY

FOR 60/75 C WIRE

TIGHTEN TERMINALS TO 5 IN/LB

120 V

123456789

1011121314151617181920

123

+ 12VDC AUX OUT

RRR

DRIVE

+ VDC

SIGNAL

ISO COMMON

DRIVE ENABLE

BATCH DONE

ALARM

PROFILE DIR

AT-HOME

OUTPUT A

OUTPUT B

EXT

SUPL

–

TXD +

TXD –

RXD +

RXD –

COMMON

RS422

SERIAL

COMM

CHASSIS GND

NEUTRAL / L2

POWER

50 V Max

123456789

101112131415161718

123456789

10111213141516

+ 5VDC AUX OUT

+12VDC AUX OUT

CHA

COM

CHB

SHLD

CHA

COM

CHB

LEAD *QUAD

ENCODER

FEEDBACK

QUAD

ENCODER

HOME

SYNC

SETPOINT

SELECT A

SETPOINT

SELECT B

HOME SET

HOME SEEK

HOME RETURN

BATCH RESET

RUN

WAIT

F–STOP

KEYPAD LOCKOUT

FORWARD LIMIT

REVERSE LIMIT

JOG FORWARD

/REVERSE

JOG

SHIELD

CHASSIS GND

NEUT/L2

2 - 8

Figure 2-5 M-Traverse General Wiring Schematic

WIRING

This section contains the input, output and serial communications wiring information for the M–Traverse. Please read this section prior to wiring the M–Traverse 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

and terminate the shields at the receiving end only. Keep the AC power wiring (J2) physically separated from all other wiring on

the M–Traverse. Failure to do so could result in additional electrical noise and cause the M–Traverse to malfunction.

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 M–Traverse should only be installed by a qualified electrician.

2 - 9

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.

Input Power (J2 pins 1, 2, 3)

The M–Traverse operates on either a 115 VAC or 230 VAC (-10% + 15%,

0.25 Amps., 50/60 Hz). Use the separate 3 pin connector (J2) for the power connection.

The National Electrical Code

The Canadian Electrical Code

(NEC,) Article 430 published by the

(CEC).

Chassis Gnd

Neutral / L2

Lead Frequency (J3 pins 3,4,5,6)

The Lead Frequency is a pulse train input that the M-Traverse uses to determine the Lead motor's speed and position. The Lead Frequency signal must be quadrature. For signal level specifications, refer to

References: Appendix A M–Traverse Specifications.

Figure 2-6 Input Power

CHA

COM

CHB

Shield

Lead Quad Encoder

2 - 10

Figure 2-7 Lead Frequency

Feedback Frequency (J3 pins 6,7,8,9)

The Feedback Frequency is a pulse train input that the M-Traverse uses to determine the Follower motor's speed and position. The Feedback Frequency signal must be quadrature. For signal level specifications, refer to

References: Appendix A, M–T raverse Specifications.

If the Feedback Frequency is lost, the M-Traverse will command a !00% Speed Out and the motor will run at 100% of the calibrated range. This can cause severe injury, death or it can damage your equipment.

Home Sync (J3 pins 6,11,12)

Figure 2-8 Feedback Frequency

WARNING

Shield CHA

COM

CHB

Feedback Quad Encoder

The Home Sync input identifies the location of “Home” for the Home Seek operation. This input is operated by either a proximity switch or an optical sensor switch (NPN output).

Shield

Common

Home Sync

Figure 2-9 Home Sync

2 - 11

Setpoint Select A

(J3 pins 13,14)

The Setpoint Select A and B inputs are used in conjunction with each other to select one of four M–Traverse setpoints and traverse lengths. The chart below displays these four setpoints.

Setpoint Select B

(J3 pins 14,15)

Setpoint Select A

Figure 2-10 Setpoint Select A

The Setpoint Select A and B inputs are used in conjunction with each other to select one of four M–Traverse setpoints and traverse lengths. The chart below displays these four setpoints.

Setpoint Select B

Open

Setpoint Select B

Closed

2 - 12

Figure 2-11 Setpoint Select B

Setpoint Select A

Open

Setpoint 1

Traverse Length 1

Setpoint 3

Traverse Length 3

Setpoint Select B

Setpoint Select A

Closed

Setpoint 2

Traverse Length 2

Setpoint 4

Traverse Length 4

Home Set (J3 pins 14,16)

Home Set is a momentary input that is edge triggered. When Home Set is closed, it sets the current position as the new “Home” position.

Home Set

Figure 2-12 Home Set

Home Seek (J4 pins 1,2)

Home Seek is a momentary input that is edge triggered. When Home Seek is closed, the Follower makes a sustained move at Jog speed, until it reaches the “Home” sensor. As a momentary input, Home Seek is internally latched and does not need to be maintained by an operator device.

Home Seek

Figure 2-13 Home Seek

2 - 13

Home Return (J4 pins 3,4)

Home Return is a momentary input that is edge triggered. When Home Return is closed, the follower returns to the established “Home” position. As a momentary input, Home Return is internally latched and does not need to be maintained by an operator device.

Home Return

Figure 2-14 Home Return

Batch Reset (J4 pins 4,5)

In a closed position, the Batch Reset input resets the batch count to zero.

2 - 14

Batch Reset

Figure 2-15 Batch Reset

Run (J4 pins 6,7)

When the Run input is momentarily closed, the M–Traverse enters Run. As a momentary input, Run is internally latched and does not need to be maintained by an operator device.

NOTE: Close the F–Stop input prior

to entering Run.

RUN

Figure 2-16 Run

Wait (J4 pins 7,8)

When the M–Traverse is in Run, it checks the Wait input before it proceeds with the next profile move in either the forward or reverse direction. If the Wait input is closed, it will pause at the end of the profile until the wait input opens.

Wait

Figure 2-17 Wait

2 - 15

F-Stop (J4 pins 9,10)

F-Stop is a momentary input. When it is opened, the Follower 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 2-18 F-Stop

Keypad Lockout (J4 pins 10,11)

When the Keypad Lockout is closed, it selectively disables the front keypad so that setpoint and other control parameters can not be changed. All of the monitoring functions remain enabled.

2 - 16

Keypad Lockout

Figure 2-19 Keypad Lockout

Forward Limit (J4 pins 12,13)

When Forward Limit is closed (edgetriggered), it prevents the follower from moving forward. When the M–Traverse detects a Forward Limit, it will go to F–Stop from Forward Jog, Home Seek or Run, if CP-37 is set to “1”. If CP-37 is set to “2”, then the M-Traverse will begin a reverse profile when it detects a Forward Limit. To deactivate Forward limit, use any reverse command (e.g., Reverse Jog).

Forward Limit

Figure 2-20 Forward Limit

Reverse Limit (J4 pins 13,14)

When Reverse Limit is closed (edgetriggered), it prevents the follower from moving in reverse. When the M–Traverse detects a Reverse Limit, it will go to F–Stop from either Run, Reverse Jog or Home Seek (any reverse move). To deactivate Reverse limit, use any forward command (e.g., Forward Jog).

Reverse Limit

Figure 2-21 Reverse Limit

2 - 17

Jog Forward/Reverse (J4 pins

15,16)

The Jog Forward/Reverse input controls the direction of the Speed Command Output while it is in Jog. Jog is in the forward direction when the input is open. Jog is in the reverse direction when the input is closed.

Jog (J4 pins 16, 17)

Jog Forward / Reverse

Figure 2-22 Jog Forward/Reverse

Jog is a maintained input. When the Jog input is closed, the M–Traverse 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.

NOTE: Close the F–Stop input and

open the Run input, prior to entering Jog.

2 - 18

Jog

Figure 2-23 Jog

OUTPUTS

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

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

Speed Command Out (J1 pins 8, 9,10,11)

The National Electrical Code

The Canadian Electrical Code

(NEC,) Article 430 published by the

(CEC).

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 Command Out (J1 pin 9) into the

± V (15V Max)

SIGNAL INPUT

DRIVE COMMON

Voltage Reference

Speed Command Out

Isolated Common

Shield

Speed Signal Input of the drive. If the motor drive has a potentiometer

MOTOR DRIVE

speed control, remove the potentiometer connections, then wire the Speed Command Output to the potentiometer wiper input and wire the Voltage Reference and Isolated

Figure 2-24 Speed Command Out

Common to the other two potentiometer input connections. The M–Traverse's isolated common should always be connected to the drive common.

Drive Enable (J1 pin 13)

The Drive Enable output is activated (driven low) when the M–Traverse is signaling a speed command to the motor drive. The Drive Enable output is driven high (relay deactivated) after Power Up and during F–Stop. Refer to Figure 2-25.

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

ences: Appendix A, M–Traverse Specifications

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

Refer-

2 - 19

Batch Done (J1 pin 14)

The Batch Done output is relay activated (driven low ) when the Batch count is completed. Refer to Figure 2-25.

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

ences: Appendix A

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

M–Traverse Specifications

. Use an external DC power

Refer-

Alarm (J1 pin 15)

The Alarm output is relay activated (driven low) if the system's speed is above the speed alarm setting that has been entered in the High Speed Alarm (CP-23) parameter. Refer to Figure 2-25.

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

ences: Appendix A

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

M–Traverse Specifications

. Use an external DC power

Refer-

Profile Direction (J1 pin 16)

The Profile Direction output indicates the commanded direction of the profile. This output is relay deactivated (driven high) when the profile is commanded to move forward. This output is relay activated (driven low) when the profile is commanded to move in reverse. Refer to Figure 2-25.

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

ences: Appendix A, M–Traverse Specifications

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

2 - 20

. Use an external DC power

Refer-

At-Home (J1 pin 17)

In order for this output to function, “Home” must have already been determined (using Home Set or Home Seek). Once ”Home” has been determined, this output is relay activated (driven low) when the traverse Follower Position is within the At-Home Band specified in CP-30. Refer to Figure 2-25.

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

ences: Appendix A

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

M–Traverse Specifications

. Use an external DC power

Refer-

Output A (J1 pin 18)

Output A can be set to activate at different segments of the forward and reverse profiles. The parameter values set in CP-90, CP-91 and CP-92 determine the profile segment and direction of activation, as well as the polarity (high or low). Refer to Figure 2-25.

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

ences: Appendix A

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

M–Traverse Specifications

. Use an external DC power

Refer-

Output B (J1 pin 19)

Output B can be set to activate at different segments of the forward and reverse profiles. The parameter values set in CP-93, CP-94 and CP-95 determine the profile segment and direction of activation, as well as the polarity (high or low). Refer to Figure 2-25.

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

ences: Appendix A, M–Traverse Specifications

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

. Use an external DC power

Refer-

2 - 21

Auxiliary DC Power (J3 pins 1, 2)

The 5 volt output (J3 pin 1) is a DC regulated output that can be used to power encoders or other auxiliary equipment that is used in conjunction with the M–Traverse. The 12 volt output (J3 pin 2) is a DC regulated output that can be used to power the proximity sensors or other auxiliary equipment that is used in conjunction with the M– Traverse. Refer to Figure 2-25.

WARNING

Do not exceed the maximum current output of 250 mA for +5 VDC and 200 mA for +12 VDC.

2 - 22

Exceeding the maximum current output can damage the M–Traverse.

Diode Protect

EXTERNAL DC POWER SUPPLY

(50V Max)

–

Drive Enable

Batch Done

Alarm

Profile Dir

At-Home

Output A

Output B

Common

Figure 2-25 Discrete Outputs

2 - 23

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 M–Traverse complies with EIA Standard RS–422 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 M–Traverse. See information on using Serial Communications.

Figures 2-26 and 2-27 illustrate a multidrop installation of the Serial Communications link and Serial Communications connections.

The National Electrical Code

The Canadian Electrical Code

Operations: Serial Communications

(NEC,) Article 430 published by the

(CEC).

for

2 - 24

M-TRAVERSE

RS-232 to RS-422

Converter

M-TRAVERSE

Figure 2-26 M-Traverse Multidrop Installation

M-TRAVERSE

RS232 to RS422

Converter

RXD TXD COM + — + —

M-Traverse #1

SHIELD

COMMON

- RXD + RXD

- TXD + TXD

1. Terminate 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 RS–422, for more information.

Figure 2-27 M–Traverse Serial Communications Connections

M-Traverse #2

SHIELD COMMON

- RXD + RXD

- TXD

+ TXD

2 - 25

2 - 26

CALIBRATION

Calibration matches the analog output of the M–Traverse 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 M–Traverse to the motor drive so that the speed is adjusted to the maximum operating speed. The M–Traverse must be properly installed prior to calibration. Refer to

Installation/Setup; Wiring

DANGER

Hazardous voltages. Can cause severe

injury, death or damage to the equipment.

Installation/Setup; Mounting

and

Make adjustments with caution.

2 - 27

Turn the screws fully clockwise for the maximum setting.

Turn the screws fully counterclockwise for the minimum setting.

Zero Pot

Scale Pot

R1 R2

2 - 28

Power Board

Figure 2-28 Location of M–Traverse Scale and Zero Pot

MOTOR DRIVE SET UP

1) Put the M–Traverse in “F–Stop” by opening the F–Stop input (J4 pins 9 and 10). 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 M–Traverse to control the speed changes.

3) If the drive has a Zero Speed Potentiometer, adjust it to eliminate any motor creep. If the drive does not have a zero speed pot, then adjust the zero speed pot on the M–Traverse to eliminate any motor creep. Figure 2-28 shows the location of the M–Traverse zero speed pot.

4) If the drive has an IR Compensation Potentiometer, set it at minimum.

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

Installation/Setup: Wiring, F–Stop.

ENCODER POLARITY CHECK

1) Observe MV-41 while you rotate the lead encoder in the direction that is “forward” during normal operation. Switch the lead encoder lines on J3 pins 3 and 5 if MV-41 is negative.

2) Observe MV-42 while you rotate the Follower encoder in the direction that is “forward” during normal operation. Switch the follower encoder lines on J3 pins 7 and 9 if MV-42 is negative.

2 - 29

M–TRAVERSE CALIBRATION

1) Make sure that the M–Traverse is still in “F–Stop”. If it is not, put the M–Traverse in “F–Stop” by opening the F–Stop Logic input (J4 pins 9 and 10). Refer to

2) Enter the resolution (PPRs) of the feedback sensor in the PPR Follower (CP-18) parameter by entering the following on the keypad:

Press “Code Select” Enter “18” Press “Enter” Enter the Pulses Per Revolution (PPR) of the feedback sensor Press “Enter”

The Tach is now scaled for feedback RPMs.

3) If the M–Traverse is using the drive voltage for reference (J1 pin 8), then set the drive's max speed potentiometer to its minimum setting. If the M–Traverse is using its internal voltage for reference (no connection to J1 pin 8) then set the drive's max speed potentiometer to its maximum setting and set the M–Traverse's scale pot to its minimum setting (fully counterclockwise). Figure 2-28 shows the location of the M–Traverse scale pot.

Installation/Setup: Wiring, F–Stop

2 - 30

4) The M-Traverse is defaulted for use with bi-directional drives that use bipolar (positive and negative) voltage commands to indicate the direction. If you are using a single quadrant (direction) drive, then change CP-29 to unipolar operation, as follows:

Press “Code Select” Enter “29” Press “Enter” Enter “1” Press “Enter”

5) Enable the M–Traverse's direct control mode by entering the following on the keypad:

Press “Code Select” Enter “14” Press “Enter” Enter “2” Press “Enter”

6) Put the M–Traverse into RUN by shorting the F–STOP input (J4 pins 9 and 10) and the RUN input (J4 pins 6 and 7). Although the motor is now in RUN, it will have zero speed until you adjust the Direct Analog Command (CP-62).

7) Gradually set the M–Traverse's Direct Analog Command to 90% (3686) by entering the following on the keypad:

Press “Setpoint” Enter “400” Press “Enter” Enter “800” Press “Enter”

Continue to gradually increase these increments by 400 until you reach “3686”. Since there are no acceleration/deceleration ramps in Direct mode, a sudden increase to “3686” could cause damage in some systems. If the Follower is not moving in a forward direction, then rewire the drive/motor leads for forward operation.

Note: A value of –3686 will change the direction of the motor.

8) Turn either the motor drive's max speed or the M–Traverse's scale potentiometer clockwise until the drive motor's RPMs are at the maximum operating speed at which you want the system to operate. Check the speed (RPMs) by pressing the Tach” key. “Tach” should display the RPM speed that you enter in CP-19.

9) Put the Direct Analog Command back to 0% by entering the following on the keypad:

Press “Setpoint” Enter “0” Press “Enter”

10) Disable the M–Traverse's direct mode by entering the following on the keypad:

Press “Code Select” Enter “14” Press “Enter” Enter “1” Press “Enter”

11) Put the M–Traverse in “F–Stop” by opening the F–Stop input (J4 pins 9 and 10). Refer to

Installation/Setup: Wiring, F–Stop

2 - 31

—NOTES—

2 - 32

Operation

Keypad Operation Control Parameters (CP)

Follower Mode Direct Mode Jog Tuning Output Control

M-Traverse Operation

Follower Mode Home Set Home Seek Home Return Direct Mode Jog

Monitor Variables (MV)

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 M–Traverse is an easy to use keypad that gives you direct access to the Parameters (Control Parameters and Monitor Variables) 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 and Clear. It also has numeric keys and four dedicated keys: Setpoint, Tach, Status and Batch Count. The LED display is the above the keys. Refer to figure 3-1 for 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 Use the “Code Select” key prior to entering a Parameter Code

for either a Control Parameter (CP) or Monitor Variable (MV).

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

Control Parameter (CP) or a Monitor Variable (MV) or to enter a value for a Control Parameter. Use the “Clear” key to delete your entry. Use the “Enter” key after each entry, to enter it in the M-Traverse.

—/Alt Use the “—/Alt” key to enter a negative value. In MVs 43, 44,

80, 81 and 84, the “—/Alt” key toggles between four lower and four higher digits because some numbers exceed the six digit display panel limit.

. Use the decimal key for values with a decimal point.

Clear The “Clear” key will delete the entry, if you have not used the

“Enter” key.

Tach The “Tach” key is a dedicated or shortcut key. You can access

the tach Parameters directly, rather than manually entering the Parameter Code (MV-40).

Setpoint The “Setpoint” Key is a dedicated or shortcut key. You can

directly access the active setpoint in the Follower mode (either CP-01, CP-03, CP-05 or CP-07) or the active setpoint in the Direct mode (CP-62).

3 - 3

Batch Count Key The “Batch Count” Key is a dedicated or shortcut key. You can

directly access the Batch Count parameter (MV-89).

Status Key The “Status” Key is a dedicated or shortcut key. You can

directly access the Alarm Status parameter (MV-51).

Lower LED Display The two-digit Parameter Code is displayed on the Lower LED

Display.

Upper LED Display The Parameter Code's value is displayed on the Upper LED

display. This value can be up to six digits.

Discrete LED Display There are five discrete LED display lights. When a specific

light is “on”, it indicates the following condition:

Run..................The M-Traverse is in Follower mode and is executing

a profile.

Wait .................The Wait input (J4 pin 8 ) is active.

Drive Enable....The Drive Enable output (J1 pin 13) is active.

At-Home ..........The Follower position is within the At-Home band of

the Home position.

Alarm ............... There is an active alarm condition.

To Enter a Parameter Code:

To Enter a Parameter Value:

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

To Use the Tach Key:

To Use the Status Key:

To Use the Setpoint Key:

To Use the Batch Count Key:

3 - 4

Table 3-1 Basic Keypad Entry

Press “Code Select”. Enter a Parameter Code (For a Control Parameter or Monitor Variable). Press “Enter” (within 15 seconds). The Parameter Code and its current value are displayed on the LED displays.

Follow the steps to enter a Parameter Code. Enter a new value (Use the numeric keys) . Press “Enter” (within 15 seconds).

Press “Tach”. The scaled Tach - Velocity is displayed (MV -40).

Press “Status”. The code for the alarm status is displayed (MV-51).

Press “Setpoint”. The value of the active setpoint is displayed, in engineering units. (CP-01, CP-03, CP-05, CP-07 or CP-62).

Press “Batch Count” . The number of complete batch counts is displayed (MV-89).

Upper LED Display

Setpoint Key

Set

Point

ONTREX

Parameter Value

(up to 6 digits)

Tach Key

Tach

Batch Count Key

Numeric Keys

—/Alt Key

Clear Key

Discrete LED Indicator Display

Batch

Count

Alt

Clear

Run

Wait Drive Enbl At-Home

Alarm

Status

Enter

Code

Select

Status Key

Decimal Key

Enter Key

Lower LED Display

Parameter Code

(2 digits)

Figure 3-1 The M–Traverse Front Panel

Code Select Key

3 - 5

3 - 6

CONTROL PARAMETERS

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

Control Parameter 14 = 1

Parameters =

Monitor Variable 40 = 200

Parameter Code Parameter Value

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

Operation: Monitor Parameters.

The M–Traverse 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 M–Traverse for your specific needs (e.g., maximum RPM, setpoints, acceleration/deceleration ramp rates) by entering a parameter value. Control Parameters can be "locked out" so that they become inaccessible from the Keypad. For details, refer to

References: Appendix C, CP-79.

The M–Traverse is designed to execute either the Direct mode of operation or the Follower mode of operation. The values that you enter in the relevant Control Parameters determine which of the modes of operation your M–Traverse is set up for. The mode of operation that you use is determined by your systems operational requirements.

The following sections demonstrate how to enter Control Parameters for the Direct mode or the Follower mode of operation. In addition, Control Parameters for Jog, Tuning and Output Control are addressed.

3 - 7

FOLLOWER MODE

The M-Traverse is a multi-motor operation that is specifically designed for the precise control of reciprocating lead/follower motion control applications. Its primary mode of operation is the Follower mode. This section discusses the set up procedures for the Follower mode of operation. Refer to

Applications Operation

Caution: To avoid damage to your system, the M-Traverse must be calibrated and the

In order to set up the M-Traverse for the Follower mode of operation, Control Parameters must be entered for the following procedures:

for an example of the Follower Mode. Refer to

for instructions on the operation of the Follower mode.

motor drive set up before you enter the Follower mode. Refer to

Setup: Calibration

Introduction: Examples of M-Traverse

Operation: M–Traverse

Installation/

Control Mode Parameter Follower Scaling Parameters Preset Parameters Follower Profile Parameters Other Follower Parameters

3 - 8

Control Mode Parameter

The Control Mode (CP-14) parameter allows you to choose between either the Standard (1) or Lay Adjusted (3) option in the Follower mode of operation. Both options will operate your system. The calculation of the Follower profile length is the only difference between the Standard and the Lay Adjusted option. In the lay adjusted option, one lay pitch is subtracted from the profile length to adjust for the initial lay on the reel.

NOTE: You can also use Control Mode (CP-14) to choose the Direct mode of opera-

tion, which is used for calibration and trouble shooting. Refer to

Direct Mode

The factory default for the Control Mode Control Parameter is found in Table 3-2. To modify the default parameter refer to Table 3-3. If you are uncertain how to enter a Control Parameter, review the

for information on the Direct mode.

Operations: Keypad

Table 3-2 Default Control Mode Control Parameter

section.

CP Parameter Name Parameter Value

CP-14 Control Mode 1 (Follower /Standard)

Operation:

Table 3-3 Entering Control Mode Control Parameters

CP Parameter Name Parameter Value

CP-14 Control Mode Enter “1” to enable the Follower Mode / Standard

Enter “3” to enable the Follower Mode / Lay Adjusted

3 - 9

Follower Scaling Parameters

The M-Traverse allows you to use Engineering Units (e.g., feet, inches) to control and monitor your system. Follower Scaling is a convenient method for converting encoder lines to Engineering Units. Scaling Control Parameters give the M-Traverse the following information:

Engineering Units (CP-15)

In a level wind application, CP-15 is your Engineering Unit (E.U.) measurement of a laypitch. In a web scanning application, CP-15 is your E.U. measurement for a traverse length. If your application uses the M-Traverse's setpoint flexibility to change over the operation, and you have more than one measurement, then pick one arbitrarily. However, be sure to reference that same measurement consistently throughout the scaling set up. In setting up the scaling, you are simply allowing the M-Traverse to establish a conversion of encoder lines to the E.U. that you prefer to use. Place the decimal in the location of your desired resolution (to the tens, hundreds or thousands place). All of the other Control Parameters or Monitor Parameters that display in E.U.s will automatically display the correct decimal position.

Lead PPR Reel (CP-16)

In a level wind application, CP-16 is the number of Lead encoder lines that the Lead Frequency input registers as a result of one revolution of the reel. In a web scanning application, CP-16 is the number of Lead encoder lines that the Lead Frequency input registers when the Follower travels one traverse length. When you calculate this variable, be sure to consider all gear reductions, belt reductions and other types of reducers. Use the following procedure to check CP-16:

• Place the M-Traverse in F-Stop.

• Activate the Home Set input (clears the Lead position to zero).

• Place the M-Traverse in F-Stop.

• Display MV-43 (Lead Position).

• Move the Lead either one revolution of the reel (level wind) or one traverse length (web scan).

• MV-43 should have the same value as CP-16.

Follower Lines per Engineering Units (CP-17)

In a level wind application, CP-17 is the number of Follower encoder lines that the Feedback Frequency input registers as a result of the Follower laypitch that was entered in CP-15. In a web scanning application,

3 - 10

CP-17 is the number of Follower encoder lines that the Feedback Frequency input registers when the Follower travels one traverse length. When you calculate this variable, be sure to consider all gear reductions, belt reductions and other types of reducers. Use the following procedure to check or find CP-17 :

• Place the M-Traverse in F-Stop.

• Activate the Home Set input (clears the Follower position to zero).

• Place the M-Traverse in F-Stop.

• Display MV-44 (Follower Position).

• Jog the Follower either one laypitch (CP-15) for level wind or one traverse length( CP-15) for web scan.

• MV-44 should have the same value as CP-17.

PPR Follower (CP-18)

The PPR Follower (CP-18) parameter is the number of pulses per revolution of the feedback encoder (encoder resolution in lines).

Maximum RPM Follower (CP-19)

The Maximum RPM Follower (CP-19) parameter is the RPM of the feedback encoder shaft when the Follower is operating at maximum speed. Although this entry does not need to be exact, highly inaccurate entries will make it difficult to tune the M-Traverse for precision Follower profiling. When you calculate this variable, be sure to consider all gear reductions, belt reductions and other types of reducers.

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

Operations: Keypad

section.

Table 3-4 Default Follower Scaling Control Parameters

CP Parameter Name Parameter Value

CP-15 Engineering Units 0.000 CP-16 Lead PPR Reel 1000 CP-17 Follower Lines/E.U. 1000 CP-18 PPR Follower (Feedback) 60 CP-19 Max RPM Follower 2000

3 - 11

Table 3-5 Entering Follower Scaling Control Parameters

CP Parameter Name Parameter Value

CP-15 Engineering Units In a level wind application, enter your E.U.

measurement of one laypitch. In a web scanning operation, enter your E.U. measurement for one traverse length.

CP-16 Lead PPR Reel In a level wind application, enter the number of Lead

encoder lines that the Lead Frequency input registers as a result of one revolution of the reel. In a web scanning application, enter the number of Lead encoder lines that the Lead Frequency input registers as a result of one traverse length. Include calculations for all gear reductions, belt reductions and other types of reducers.

CP-17 Follower Lines/E.U. In a level wind application, enter the number of Follower

encoder lines that the Feedback Frequency input registers as a result of one Follower laypitch (reference CP-15). In a web scanning application, enter the number of Follower encoder lines that the Feedback Frequency input registers when the Follower travels one traverse length. Include calculations for all gear reductions, belt reductions and other types of reducers.

CP-18 PPR Follower (fdbk) Enter the number of pulses per revolution of the

feedback encoder (encoder resolution in lines).

CP-19 Max RPM Follower Enter the RPM of the feedback encoder shaft when the

Follower is operating at maximum speed. Include calculations for all gear reductions, belt reductions and other types of reducers.

3 - 12

Preset Parameters

Setpoints (CP-01, CP-03, CP-05, CP-07)

The Setpoint parameters are set up as pairs in conjunction with the Traverse Length parameters. There are four pairs of Setpoint and Traverse Length parameters. The Setpoint value is entered in Engineering Units (E.U.s) and automatically displays the decimal position that was entered in the Engineering Units (CP-15). The Setpoint parameter determines how far the Follower travels based on the Lead. The Follower travels the setpoint distance while the Lead travels the distance entered into CP-17. In the level wind application, the Setpoint parameters are the laypitch (center-to-center distance between windings on the reel). In the web scanning application, the Setpoint parameters are the traverse length. These preset parameters can be switch selected (via the Setpoint Select switches) which gives the operator the option of changing over the product up to four times.

The factory defaults for the Default Setpoint Control Parameters are found in Table 3-6. To modify the default parameters refer to Table 3-7. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

section.

Table 3-6 Default Setpoint Control Parameters

CP Parameter Name Parameter Value

CP-01 Setpoint 1 0.000 CP-03 Setpoint 2 0.000 CP-05 Setpoint 3 0.000 CP-07 Setpoint 4 0.000

3 - 13

Table 3-7 Entering Setpoint Control Parameters

CP Parameter Name Parameter Value

CP-01 Setpoint 1 In a level wind application, enter your E.U.

measurement of one laypitch. In a web scanning operation enter your E.U. measurement for one traverse length.

CP-03 Setpoint 2 In a level wind application, enter your E.U.

measurement of one laypitch. In a web scanning operation enter your E.U. measurement for one traverse length.

CP-05 Setpoint 3 In a level wind application, enter your E.U.

measurement of one laypitch. In a web scanning operation enter your E.U. measurement for one traverse length.

CP-07 Setpoint 4 In a level wind application, enter your E.U.

measurement of one laypitch. In a web scanning operation enter your E.U. measurement for one traverse length.

Traverse Length (CP-02, CP-04, CP-06, CP-08)

The Traverse Length parameters are set up as pairs in conjunction with the Setpoint parameters. There are four pairs of Setpoint and Traverse Length parameters. The Traverse Length value is entered in Engineering Units (E.U.s) and the decimal position that was entered in the Engineering Units (CP-15) parameter is automatically displayed. The traverse length is the distance that the Follower mechanism will travel. In level wind applications, the traverse length is generally the length of the reel. In web scanning applications, the traverse length is generally the width of the web. The traverse length measurement, corresponds to the setpoint measurement. For example, in a level wind application, you may have a reel that measures one foot, that is wrapped with two inch hose. You would enter "2" (inches) in Setpoint 1 (CP-01) and "12" (inches) in Traverse Length 1 (CP-02).

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

3 - 14

Operations: Keypad

section.

Table 3-8 Default Traverse Length Control Parameters

CP Parameter Name Parameter Value

CP-02 Traverse Length 1 0.000 CP-04 Traverse Length 2 0.000 CP-06 Traverse Length 3 0.000 CP-08 Traverse Length 4 0.000

Table 3-9 Entering Traverse length Control Parameters

CP Parameter Name Parameter Value

CP-02 Traverse Length 1 In a level wind application, enter your reel length in

E.U.s (reference Setpoint 1). In a web scanning operation, enter the width of your web, in E.U.s (reference Setpoint 1).

CP-04 Traverse Length 2 In a level wind application, enter your reel length in

E.U.s (reference Setpoint 2). In a web scanning operation, enter the width of your web, in E.U.s (reference Setpoint 2).

CP-06 Traverse Length 3 In a level wind application, enter your reel length in

E.U.s (reference Setpoint 3). In a web scanning operation, enter the width of your web, in E.U.s (reference Setpoint 3).

CP-08 Traverse Length 4 In a level wind application, enter your reel length in

E.U.s (reference Setpoint 4). In a web scanning operation, enter the width of your web, in E.U.s (reference Setpoint 4).

3 - 15

The following chart demonstrates how Setpoint and Traverse Length pairs are selected by the various positions of the Setpoint Select A and Setpoint Select B discrete inputs.

Setpoint Select B

Open

Setpoint Select B

Closed

(Closed = shorted to common)

Setpoint Select A

Open

Setpoint 1(CP-01) Traverse Length 1(CP-02)

Setpoint 3 (CP-05) Traverse Length 3 (CP-06)

Setpoint Select A

Closed

Setpoint 2 (CP-03) Traverse Length 2 (CP-04)

Setpoint 4 (CP-07) Traverse Length 4 (CP-08)

3 - 16

Follower Profile Parameters

In addition to being part of a setpoint pair, the traverse length acts in conjunction with the Accel/Decel Length (CP-09) parameter and the Dwell (CP-10) parameter to define the Follower Profile. The Follower Profile creates a smooth transition to dwell before reversing directions. This takes place at the reel's end in level wind applications or at the edge of the web in web scanning applications.

Accel/Decel Length (CP-09)

The Accel/Decel Length (CP-09) parameter allows the Follower mechanism to ramp to either the constant pitch plateau or end dwell, either gradually or rapidly. This parameter is the number of encoder lines for the desired Accel/Decel Length. The lower the number, the more rapidly the Follower mechanism ramps to the constant pitch plateau or end dwell. The higher the number, the more gradually the Follower mechanism ramps to the control pitch plateau or end dwell. As a guideline, keep in mind that you do not want the accel/decel rate to exceed the load that the motor drive or mechanics can accommodate. The Accel/Decel Length parameter does not need to be an exact number, the system will perform adequately with a close estimate.

The factory default for the Accel/Decel Length Control Parameter is found in Table 3-10. To modify the default parameter refer to Table 3-11. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

section.

Table 3-10 Default Accel/Decel Length Control Parameter

CP Parameter Name Parameter Value

CP-09 Accel/Decel Length 0

Table 3-11 Entering Accel/Decel Length Control Parameter

CP Parameter Name Parameter Value

CP-09 Accel/Decel Length Enter the number of encoder lines for the desired

Accel/Decel Length.

3 - 17

Dwell (CP-10)

The Dwell (CP-10) parameter allows the Follower mechanism to pause at the end of the Follower profile before ramping back in the opposite direction. In level wind applications, this parameter is a portion of the encoder lines in one rotation of the reel (Lead). In web scanning applications, this parameter is a portion of the encoder lines in one traverse length. The Dwell parameter does not need to be an exact number, the system will perform adequately with a close estimate .

The factory default for the Dwell Control Parameter is found in Table 3-12. To modify the default parameter refer to Table 3-13. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

section.

Table 3-12 Default Dwell Control Parameter

CP Parameter Name Parameter Value

CP-10 Dwell 0

3 - 18

Table 3-13 Entering Dwell Control Parameter

CP Parameter Name Parameter Value

CP-10 Dwell In a level wind applications, enter a portion of the

encoder lines in one rotation of the reel In a web scanning applications, enter a portion of the encoder lines in one traverse length.

Other Follower Parameters

The orientation (edge or center) of “Home,” changes in the “Home” position and changes made on the fly, are determined by the following parameters:

Edge/Center Based Profile (CP-24)

The traverse length is measured from “Home”. The Edge/Center Based Profile (CP-24) parameter allows you to set “Home” relative to either the edge or the center of your reel or web. The Follower mechanism moves a traverse length from that position and then returns.

To set “Home” as an edge based profile, enter “1” in CP-24. All traverse length changes occur from the edge, in the forward direction and the “Home” position does not change. The diagram below illustrates this profile. Traverse length changes can be made on the fly and the timing on these changes is a crucial factor. For the timing on edge based traverse length changes, refer to the Change Activation (CP-25) parameter.

Edge Based

“Home”

12" Traverse Length 10" Traverse Length

5" Traverse Length

To set “Home” as a center based profile, enter “2” in CP-24. All traverse length changes occur from the center and the “Home” position changes to compensate for traverse length changes. The diagram below illustrates this profile. Traverse length changes will occur automatically when the Follower mechanism is in the center of the web.

Center Based

“Home”

12" Traverse Length 10" Traverse Length

5" Traverse Length

3 - 19

Change Activation (CP-25)

The Change Activation (CP-25) parameter works in conjunction with the Edge/Center Based Profile (CP-24) parameter. When CP-24 is set to “1” (edge based), then CP-25 determines when changes will occur. If CP-24 is set to “2” (center based), then CP-25 has no effect.

Change Activation (CP-25) can be set to “1”, “2” or “3”. Settings “2” and “3” have a number of variables:

If CP-25 is set to “1” then all of the changes will occur when the Follower is at “Home”.

If CP-25 is set to “2” and either the Accel/Decel Length or Dwell parameters are changed, the changes will only occur at “Home”.

If CP-25 is set to “2” and the setpoint speed is changed (either faster or slower), the change will occur immediately, but only if the change occurs within the new constant pitch plateau of the profile. Otherwise setpoint speed changes occur at “Home”.

If CP-25 is set to “2” and the traverse length is changed, the change will occur immediately, but only if the longer change occurs within the old constant pitch plateau and a shorter change occurs within the new constant pitch plateau of the profile, and either change is in a forward direction. Otherwise traverse length changes occur at “Home”.

3 - 20

If CP-25 is set to “2” and both the traverse length and the setpoint speed are changed, then use the switches to make the changes and stay within the profile parameters listed above for setpoint speed and traverse length changes. When any of the changes are not within the specified plateaus of the profile, then the changes will occur when the Follower mechanism reaches “Home”. Refer to the diagrams below.

Setpoint Changes

Traverse Length

Changes

Faster

accel/decel

Shorter

Slower

accel/decel

New

Plateau

New

Plateau

Dwell

accel/decel

New

Plateau

New

Plateau

Longer

Dwell

accel/decel

If CP-25 is set to “3”, the change will occur at the next forward or reverse dwell position. However, if there is no dwell position, a setpoint change will occur at the start of the reverse plateau in the forward direction or at the start of the forward plateau in the reverse direction. If the setpoint is changed to a slower speed, this change will cause a spike, which will momentarily cause an abrupt jolt to the Follower mechanism. Therefore, for a smooth operation, it is best to specify a Dwell (CP-10) parameter.

At-Home Band (CP-30)

The At-Home Band (CP-30) parameter allows for a certain amount of “range” in the Home position, measured in encoder lines. Although the Home Set and Home Seek inputs place home exactly at “0”, the AtHome Band parameter allows home to be located in a band that is measured in negative and positive encoder lines on each side of the "0" mark. Enter the desired number of encoder lines in CP-30.

NOTE: The Follower mechanism must be positioned within the AtHome Band before “Run” is entered. The Follower position must also be within the At-Home band to activate the At-Home LED indicator (front panel) and the At-Home discrete output.

The factory defaults for the Edge/Center Based Profile, Home Offset, Change Activation and At-Home Band Control Parameters are found in Table 3-14. To modify the default parameters refer to Table 3-15. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

section.

3 - 21

Home Offset (CP-31)

Sensor

LINE FLOW

FOLLOWER

LEAD

Home

Center Based

Home Offset

(CP-31)

The Home Offset parameter allows you to offset the “Home” position and relocate it somewhere other than the sensor.

If CP-24 is set at “1” (edge based), measure the distance from the sensor to the desired position of “Home”. Enter that E.U. amount in CP-31.

LEAD

Sensor

Home

FOLLOWER

DIRECTION

OF WIND

Edge Based Home Offset

(CP-31)

If CP-24 is set at “2” (center based), measure the distance from the sensor to the center. Enter that E.U. amount in CP-31. The M-Traverse will make a transparent, internal calculation and position “Home” at a distance that is CP-31 minus 1/2 of the traverse length. The position of “Home” will change to correspond with any changes in the traverse length.

3 - 22

NOTE: Since the “Home” position calculations are dependent on the

Traverse Length (CP-02, CP-04, CP-06, CP-08) parameter and the Engineering Units (CP-15) parameter, those values must have already been entered prior to entering a value in CP-31. To enter these parameters, refer to the

Operations: Control Parameters

section.

Table 3-14 Default Control Parameters for Changes

CP Parameter Name Parameter Value

CP-24 Edge/Center Based 1 CP-25 Change Activation 1 CP-30 At-Home Band 4 CP-31 Home Offset 0

Table 3-15 Entering Control Parameters for Changes

CP Parameter Name Parameter Value

CP-24 Edge/Center Based Enter “1” for an edge based profile.

Enter “2” for a center based profile.

CP-25 Change Activation When CP-24 is set to “1” (edge based), then:

Enter “1” to activate changes when the Follower is in the “Home position. Enter “2” to activate changes immediately. Enter “3” to activate changes when the Follower is in the end dwell position.

CP-30 At-Home Band Enter the number of encoder lines that you want to

allow on either side of the “0” Home Set position.

CP-31 Home Offset If CP-24 is set at “1” (edge based), enter the distance

from the sensor to the desired position of “Home”. If CP-24 is set at “2” (center based), enter the distance from the sensor to the center of the web.

3 - 23

The Resume Enable parameter allows you to specify the conditions under which you resume operation.

Resume Enable (CP-32)

If you interrupt the operation (F-Stop), the Resume Enable (CP-32) parameter allows you to keep track of error in both the Follower and Lead positions. It also allows you to freeze the Lead position and keep track of error in the Follower position. The M-Traverse will adjust for the error when you resume operation.

Resume is disabled by entering "1" in CP-32. To keep track of error in both the Follower and Lead positions enter "2" in CP-32. To freeze the Lead position and keep track of error in the Follower position, enter “3” in CP-32.

Both the Follower and the Lead information is saved at power-down. If there has been no change in the mechanical position at power-down, then the profile can be resumed at power-up.

If the mechanical position has changed and you resume operation, the Follower could make an abrupt shift to resolve the position error. This can severely injure you or damage the equipment. The specific consequences of this abrupt shift can vary, depending on your use of the equipment and your system's design. Install safety equipment that is appropriate for your application.

The factory default for the Resume Enable Control Parameter is found in Table 3-16. To modify the default parameter refer to Table 3-17. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

section.

DANGER

When you resume operation the Follower could make an abrupt shift.

This can cause severe injury or damage equipment.

Install safety equipment that is appropriate for your application.

3 - 24

Table 3-16 Default Resume Enable Control Parameter

CP Parameter Name Parameter Value

CP-32 Resume Enable 1

Table 3-17 Entering Resume Enable Control Parameters

CP Parameter Name Parameter Value

CP-32 Resume Enable Enter "1" disable resume.

Enter "2" to enable (Lead & Follower position tracking) Enter "3" to enable (Follower position tracking)

3 - 25

The polarity type and direction are determined by the following Control Parameters: Home Sync Polarity (CP-35)

The Home Sync Polarity (CP-35) parameter allows you to choose between rising edge polarity (positive going signal) or falling edge polarity (negative going signal) during "Home Seek". This feature is extremely useful when you use reflective or transmissive optical sensors for the Home sensor. Enter "1" in CP-35 for a rising edge, or "2" for a falling edge. Refer to the diagram below.

Rising Edge

+ Vdc

0 Vdc

Forward/Reverse Limit Polarity (CP-36)

The Forward/Reverse Polarity Limit (CP-36) parameter allows you to choose between rising edge polarity (positive going signal) or falling edge polarity (negative going signal) so that the Follower mechanism will not travel beyond the traverse length limit. This feature is extremely useful when you use reflective or transmissive optical sensors for the Home sensor. Enter "1" in CP-35 for a rising edge, or "2" for a falling edge.

The factory default for the Polarity Control Parameters are found in Table 3-18. To modify the default parameters refer to Table 3-19. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

Falling Edge

section.

+ Vdc

0 Vdc

3 - 26

Table 3-18 Default Polarity Control Parameters

CP Parameter Name Parameter Value

CP-35 Home Sync Polarity 1

CP-36 Fwd/Rev Limit Polarity 2

Table 3-19 Entering Polarity Control Parameters

CP Parameter Name Parameter Value

CP-35 Home Sync Polarity Enter “1” for Rising Edge

Enter “2” for Falling Edge

CP-36 Fwd/Rev Limit Polarity Enter “1” for Rising Edge

Enter “2” for Falling Edge

3 - 27

How the Forward Limit functions is determined by the following Control Parameter: Forward Limit Format (CP-37)

Use the Forward Limit Format (CP-37) parameter to determine how the Forward Limit will function during “Run”. If you set CP-37 to "1", then the M–Traverse will engage “F-Stop” when the Forward Limit is encountered during “Run”. However, if you want the M–Traverse to terminate the Constant Pitch Plateau, decelerate to zero speed, process the Forward End Dwell and then begin the reverse profile back to “Home” when the Forward Limit is encountered, then set CP-37 to "2".

Table 3-20 Default Polarity Control Parameters

CP Parameter Name Parameter Value

CP-37 Forward Limit Format 1

3 - 28

Table 3-21 Entering Polarity Control Parameters

CP Parameter Name Parameter Value

CP-37 Foward Limit Format Enter “1” to engage ”F-Stop”.

Enter “2” to terminate the Constant Pitch Plateau, decelerate to zero, process the dwell and begin the reverse profile.

DIRECT MODE

The Direct mode is used to calibrate and troubleshoot the M-Traverse. In the Direct mode of operation, you can set the level of the Speed Command Out directly from the M-Traverse to the motor drive. The Direct mode is an open-loop mode of operation. Therefore, Scaling, Accel/Decel, and closed loop compensation (PI) algorithms are bypassed in the Direct mode. The Direct mode is used in conjunction with the Run and the Stop controls.

Caution: To avoid damage to your system, the M-Traverse must be calibrated and the

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

Setup: Calibration.

The Direct Analog Command (CP-62) parameter uses the full 12 bit resolution of the analog Speed Command Output.

A value of 4095 is a 100% forward output command. A value of 2048 is a 50% forward output command. 0 is a zero output command.

A negative value indicates a reverse output command (e.g., - 4095 is a 100% reverse command).

To enable the Direct mode, enter "2" the Control Mode (CP-14) parameter.

The factory default Direct Mode Control Parameters are found in Table 3-20. To modify the default parameters, refer to Table 3-21. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

section.

Installation/

Table 3-22 Default Direct Mode Control Parameters

CP Parameter Name Parameter Value

CP-62 Direct Analog Command 0

CP-14 Control Mode 1

Table 3-23 Entering Direct Mode Control Parameters

CP Parameter Name Parameter Value

CP-62 Direct Analog Cmd Enter the DAC bits of the calitrated full scale

Speed Command Out at which you want your system to operate.

CP-14 Control Mode Enter “2” to enable the Direct Mode (disables

both Follower Mode options).

3 - 29

JOG

When you activate Jog, the RPM increase at the acceleration rate that you specified in the Accel/Decel (CP-60) parameter until the Jog Setpoint (CP-61) is achieved. Jog can only be entered from F-Stop and when Jog is terminated, the Follower mechanism returns to F-Stop. Jog is used when you need brief bursts of speed to align the Follower mechanism.

The factory default Jog Control Parameters are found in Table 3-22. To modify these default parameters, refer to Table 3-23. If you are uncertain how to enter a Control Parameter, review the

CP Parameter Name Parameter Value

CP-61 Jog Setpoint 50 CP-60 Accel/Decel 5.0

Operations: Keypad

Table 3-24 Default Jog Control Parameters

section.

Table 3-25 Entering Jog Control Parameters

CP Parameter Name Parameter Value

CP-61 Jog Setpoint Enter the RPM at which you want your system to

operate when it is in Jog.

CP-60 Accel/Decel Enter the number of seconds in which you want your

system to accelerate from zero RPM to the Jog Setpoint speed.

3 - 30

—NOTES—

3 - 31

TUNING

If your system is unstable, or the position error is unacceptable, tuning may stabilize your system or reduce the position error differences between the setpoint and feedback. You can achieve a stable system using conservative values in the Tuning Control parameters, however the position error may be unacceptable. On the other hand, aggressive values in the Tuning Control parameters may cause the system to become unstable. The goal is to reduce the position error to the level that you want, yet maintain the system's stability.

To achieve an acceptable level of position error, increase the Gain (CP-65) parameter until the system becomes unstable then reduce the CP-65 incrementally until the system stabilizes. In systems that require greater accuracy, it may be necessary to adjust the Integral (CP-66) parameter to reduce any remaining position error. In systems with low inertia, the position error will be reduced more quickly if you enter higher values in CP-66. An entry that is too high, however, can create instability or overshoot the setpoint before reaching the correct value. Generally, use lower entries for CP-66 on systems with a large inertia.

The M-Traverse comes factory pre-loaded with a complete set of default Tuning parameters. These default settings are suitable for most applications.

The factory defaults for the Follower Tuning Control Parameters are found in Table 3-

24. To modify the default parameters refer to Table 3-25. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

section.

3 - 32

Table 3-26 Default Tuning Control Parameters

CP Parameter Name Parameter Value

CP-65 Gain 3000 CP-66 Integral 1

Table 3-27 Entering Tuning Control Parameters

CP Parameter Name Parameter Value

CP-65 Gain With Integral (CP-66) set to “0” , increase the Gain

parameter value until the system becomes unstable, then decrease it slightly until the system stabilizes. Larger values will increase Gain. To verify the stability of the speed changes, you can access Tach through either the Tach key or the Tach (MV-40) parameter.

CP-66 Integral While switching between the high and low setpoints,

increase the Integral's default value of “1” until the position 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 Tach (MV-40) parameter.

3 - 33

OUTPUT CONTROL

Output Control is influenced by the Batch Control Parameters, the Alarm Output, the At-Home output and Outputs A and B. These parameters and outputs are discussed as follows:

The Batch Control Parameters allow you to make a specific amount of product and then automatically stop when that amount is reached.

Batch Format (CP-26)

Use the Batch Format (CP-26) parameter to indicate which type of count that you want the Batch Counter to do. You can count either Follower traverses or Lead reel revolutions. Enter “1” in CP-26 to count the Follower traverses. Enter “2” in CP-26 to count Lead revolutions.

Batch Limit (CP-27)

The Batch Counter is an up-counter that is cleared to zero by the Batch Reset input. Use the Batch Done Output to shut off the system when the Batch Count has been reached. You can count either the number of Follower traverses or the number of Lead reel revolutions. If you count Follower traverses, each direction counts as one traverse. If you count Lead revolutions, each wrap of the reel (or layer), is one lead revolution. Enter the total number that you want counted in Batch Limit (CP-

27).

Batch PreAct Distance (CP-28)

The Batch PreAct Distance (CP-28) parameter is used only if the Batch Format (CP-26) has been set to number “1” (Follower traverses). CP28 allows you to set a specific distance at which to activate the Batch Done. This can be at the end dwell or any distance from dwell, up to the Accel/Decel Length at the opposite end from dwell. If you enter a number that would go beyond the Accel/Decel Length, the M-Traverse will automatically default to the Accel/Decel Length. For example, your reel is 10 inches long, with an Accel /Decel Length of 1 inch on each end, and the laypitch profile is 8 inches. CP-28 will default at 9 inches for any amount above 9 inches that you enter in CP-28, because the opposite Accel /Decel is 9 inches from the dwell. See the diagram below for a profile representation of this example:

3 - 34

Laypitch

Accel/Decel

1" 8" 1"

Accel/Decel

Dwell

The factory defaults for the Batch Control Parameters are found in Table 3-26. To modify the default parameters refer to Table 3-27. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

section.

Table 3-28 Default Batch Control Parameters

CP Parameter Name Parameter Value

CP-26 Batch Format 1 CP-27 Batch Limit 0 CP-28 Batch PreAct Distance 999999

Table 3-29 Entering Batch Control Parameters

CP Parameter Name Parameter Value

CP-26 Batch Format Enter “1” in CP-26 for Follower traverses.

Enter “2” in CP-26 for Lead reel revolutions.

CP-27 Batch Limit Enter the total number of Follower traverses or Lead

reel revolutions that you want counted.

CP-28 Batch PreAct Dist Enter a specific preact distance at which to activate the

Batch Done (only if CP-26 is set at “1”).

3 - 35

The Alarm Output allows you to set a high speed RPM indication.

High Speed Alarm (CP-23)

Use the High Speed Alarm (CP-23) parameter to determine the RPM level that will activate the High Speed Alarm Output. When the Follower's motor RPM are at or above the value in CP-23, the High Speed Alarm Output will activate.

The factory default for the Default Alarm Control Parameter is found in Table 3-28. To modify the default parameter refer to Table 3-29. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

section.

Table 3-30 Default Alarm Control Parameter

CP Parameter Name Parameter Value

CP-23 High Speed Alarm 2000

Table 3-31 Entering Alarm Control Parameter

CP Parameter Name Parameter Value

CP-23 High Speed Alarm Enter the RPM limit that will activate the High Speed

Alarm Output.

3 - 36

The At-Home Output activates in response to the At-Home Band parameter.

At-Home Band (CP-30)

When the Follower is within the At-Home Band, the At-Home Output will be activated. The At-Home Band (CP-30) parameter allows for a certain amount of “range” in the Home position, measured in encoder lines. Although the Home Set input places home exactly at “0”, the AtHome Band (CP-30) allows home to be located in a band that is measured in negative and positive encoder lines on each side of the "0" mark. The desired number of encoder lines is entered in CP-30.

NOTE: The Follower must be within the At-Home Band before “Run” is entered. The Follower position must also be within the At-Home band to activate the front panel At-Home LED indicator and the At-Home discrete output.

The factory default for the At-Home Band Control Parameter is found in Table 3-30. To modify the default parameter refer to Table 3-31. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

section.

Table 3-32 Default At-Home Band Control Parameter

CP Parameter Name Parameter Value

CP-30 At-Home Band 4

Table 3-33 Entering At-Home Band Control Parameter

CP Parameter Name Parameter Value

CP-30 At-Home Band Enter the number of encoder lines that you want to allow

on either side of the “0” Home Set position.

3 - 37

Output A activates peripheral equipment in response to the Output A parameters. This

peripheral equipment can be set up to add material (e.g., adhesive or paint) during specific segments of the Follower profile.

Output A Segment (CP-90)

Use the Output A Segment (CP-90) parameter to determine what segment of the Follower profile will activate Output A.

Enter “1” in CP-90 to activate Output A during the constant pitch plateau segment of the Follower profile. Enter “2” in CP-90 to activate Output A during the constant pitch and Accel/Decel segments of the Follower profile. Enter “3” in CP-90 to activate Output A during the dwell segment of the Follower profile.

The diagram below illustrates the segments of the Follower profile :

Follower Profile

Accel/Decel

Constant

Pitch

Plateau

Accel/Decel

Dwell

Output A Direction (CP-91)

Use the Output A Direction (CP-91) parameter to specify the direction in which Output A will operate.

Enter “1” in CP-91 to activate Output A during the forward direction. Enter “2” in CP-91 to activate Output A during the reverse direction. Enter “3” in CP-91 to activate Output A during the forward and reverse directions.

Output A Polarity (CP-92)

Use the Output A Polarity (CP-92) parameter to specify the voltage polarity at which Output A will operate.

Enter “0” in CP-92 to activate Output A as Active Low Voltage Level. Enter “1” in CP-92 to activate Output A as Active High Voltage Level.

3 - 38

The factory defaults for the Output A Control Parameters are found in Table 3-32. To modify the default parameters refer to Table 3-33. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

section.

Table 3-34 Default Control Parameters for Output A

CP Parameter Name Parameter Value

CP-90 Output A Segment 1 CP-91 Output A Direction 0 CP-92 Output A Polarity 0

Table 3-35 Entering Output A Control Parameters

CP Parameter Name Parameter Value

CP-90 Output A Segment Enter “1” to activate Output A during the constant pitch

plateau segment of the Follower profile. Enter “2” to activate Output A during the constant pitch plateau and Accel/Decel segment of the Follower profile. Enter “3” to activate Output A during the Dwell segment of the Follower profile.

CP-91 Output A Direction Enter “1” to activate Output A during the forward

direction. Enter “2” to activate Output A during the reverse direction. Enter “3” to activate Output A during the forward and reverse directions.

CP-92 Output A Polarity Enter “0” to activate Output A as Active Low Voltage

Level. Enter “1” to activate Output A as Active High Voltage Level.

3 - 39

Output B activates peripheral equipment in response to the Output B parameters. This

peripheral equipment can be set up to add material (e.g., adhesive or paint) during specific segments of the Follower profile.

Output B Segment (CP-93)

Use the Output B Segment (CP-93) parameter to determine what segment of the Follower profile will activate Output B.

Enter “1” in CP-93 to activate Output B during the constant pitch plateau segment of the Follower profile. Enter “2” in CP-93 to activate Output B during the constant pitch plateau and Accel/Decel segments of the Follower profile. Enter “3” in CP-93 to activate Output B during the dwell segment of the Follower profile.

The diagram below illustrates the segments of the Follower profile :

Follower Profile

Accel/Decel

Constant

Pitch

Plateau

Accel/Decel

Dwell

Output B Direction (CP-94)

Use the Output B Direction (CP-94) parameter to specify the direction in which Output B will operate.

Enter “1” in CP-94 to activate Output B during the forward direction. Enter “2” in CP-94 to activate Output B during the reverse direction. Enter “3” in CP-94 to activate Output B during the forward and reverse directions.

Output B Polarity (CP-95)

Use the Output B Polarity (CP-95) parameter to specify the voltage polarity at which Output B will operate.

Enter “0” in CP-95 to activate Output B as Active Low Voltage Level. Enter “1” in CP-95 to activate Output B as Active High Voltage Level.

3 - 40

1 2

The factory defaults for the Output B Control Parameters are found in Table 3-34. To modify the default parameters refer to Table 3-35. If you are uncertain how to enter a Control Parameter, review the

Operations: Keypad

section.

Table 3-36 Default Control Parameters for Output B

CP Parameter Name Parameter Value

CP-93 Output B Segment 1 CP-94 Output B Direction 0 CP-95 Output B Polarity 0

Table 3-37 Entering Output B Control Parameters

CP Parameter Name Parameter Value

CP-93 Output B Segment Enter “1” to activate Output B during the constant pitch

plateau segment of the Follower profile. Enter “2” to activate Output B during the constant pitch plateau and Accel/Decel segment of the Follower profile. Enter “3” to activate Output B during the Dwell segment of the Follower profile.

CP-94 Output B Direction Enter “1” to activate Output B during the forward

direction. Enter “2” to activate Output B during the reverse direction. Enter “3” to activate Output B during the forward and reverse directions.

CP-95 Output B Polarity Enter “0” to activate Output B as Active Low Voltage

Level. Enter “1” to activate Output B as Active High Voltage Level.

3 - 41

—NOTES—

3 - 42

M–TRAVERSE OPERATION

The M–Traverse Operation section addresses the six modes that control the M–Traverse's operation. This section explains the function of each of these modes and how to use the modes for your specific system application. Diagrams are included to illustrate the profile sequences.

The six modes are:

Follower Mode (Standard or Lay Adjusted) Home Set Home Seek Home Return Direct Mode Jog

3 - 43

FOLLOWER MODE (WEB SCANNING OR LEVEL WIND)

The M–Traverse is specifically designed for the precise control of reciprocating lead/ follower motion control applications. Its primary mode of operation is the Follower mode. The Run input (J4, pins 6,7) activates the Follower mode when the following conditions have already been established:

• The Control Mode (CP-14) is set to the Follower mode: “1” for Standard. “3” for Lay Adjusted.

• The M–Traverse is either in F-Stop or a position hold state.

• The Follower mechanism is within the At-Home Band (CP-30).

• MV-58 displays “0”, indicating that there is a valid Follower profile.

When the Follower mode has been activated, the Follower mechanism will begin to move from “Home” in a forward direction (toward the Forward Limit). As the Follower mechanism travels along the Traverse Length (CP-02, CP-04, CP-06, or CP-08), it accelerates for the specified Accel/Decel Length (CP-09) then travels the constant pitch plateau at the Process Ratio (MV-86). At the end of the constant pitch plateau, the Follower mechanism decelerates the specified Accel/Decel Length (CP-09) to Dwell (CP-10). The Follower mechanism remains at zero speed for the specified Dwell then repeats the same profile in reverse. If the Wait input (J4, pins 7, 8) is shorted to common (low) the Follower mechanism will pause at the closest end of the profile until the Wait input is open (high). The Drive Enable discrete output is active during the Follower mode.

Caution: To avoid damage to your system, the M–Traverse must be calibrated and the

motor drive set up before you enter the Follower mode. Refer to

Setup: Calibration.

The following diagram illustrates the Follower profile:

Follower/Lead

3 - 44

Process

Ratio

(MV-86)

Ratio

Accel/

Length

(CP-09)

Home

Sync

Sensor

Decel

Forward

Traverse Length

Constant Pitch

Plateau

Accel/

Decel

(CP-09)

Dwell

(CP-10)

Accel/

Decel

(CP-09)

Reverse

Traverse Length

Constant Pitch

Plateau

Installation/

Dwell

Accel/

(CP-10)

Decel

Length

(CP-09)

HOME SET

Home Set is one of two ways in which you can establish “Home” (Home Seek is the other way). When the Home Set input is closed, it sets the current position of the Follower mechanism as “Home”. Home Set will establish “Home” at any arbitrary position that you choose. You can use the Jog input to position the Follower mechanism or you can position it manually.

Home Set enables the Drive Enable logic output, which allows the Follower mechanism to hold its position at “Home” despite any outside force (such as gravity). The Home Set is a momentary input that is edge triggered and is activated through the Home Set input (J3, pin 14,16).

NOTE: “Home” must be established before the Follower mode can be used. “Home”

is identified by a Follower position of zero. In the Follower mode, “Home” is the position from which the profile traverses in the Forward direction.

HOME SEEK

Home Seek also establishes “Home”. Home Seek finds and sets “Home” by locating the Home Sync Sensor. When the Home Seek input is closed, the Follower mechanism makes a profiled move at jog speed, until it aligns with the Home Sync sensor, which then becomes “Home”.

Home Seek enables the Drive Enable logic output, which allows the Follower mechanism to hold its position at “Home” despite any outside force (such as gravity). Home Seek is a momentary input that is edge triggered and is activated through the Home Seek input (J4, pin 1, 2). Home Seek is internally latched and does not need to be maintained by an operator device.

NOTE: “Home” must be established before the Follower mode can be used. “Home”

is identified by a Follower position of zero. In the Follower mode, “Home” is the position from which the profile traverses in the Forward direction.

Home Seek will always begin to move the Follower mechanism in the reverse direction (towards the reverse limit). When Home Seek locates the Home Sync sensor, it ramps down at the Accel/Decel rate (CP-60) to zero. This causes the Follower mechanism to overshoot the Home Sync sensor and the M–Traverse compensates with a triangulated forward Accel/Decel move that aligns the Follower mechanism with the Home Sync sensor. There are a variety of profile possibilities, since Home Seek can find home from any position on the traverse length. The following examples will illustrate four possible Home Seek profiles.

3 - 45

Example of an Edge Based Profile with no Home Offset.

Home Seek moves the Follower mechanism in the reverse direction (toward the reverse limit). When Home Seek locates the Home Sync sensor, it ramps down at the Accel/Decel (CP-60) rate to zero. This causes the Follower mechanism to overshoot the Home Sync sensor and the M–Traverse compensates with a forward, triangulated Accel/Decel move that aligns the Follower mechanism with the Home Sync sensor. This profile is used in both web scan and level wind applications.

Reverse

Limit

(CP-60)

Accel/Decel

Home Sync Sensor

Jog Speed

(CP-61)

Forward

Limit

Accel/Decel

(CP-60)

Start Here

3 - 46

Example of an Edge Based Profile with Home Offset.

Home Seek moves the Follower mechanism in the reverse direction, bypasses the Home Sync sensor, and establishes “Home” at the Home Offset position. The Home Offset position is measured in E.U.s and is the length away from the Home Sync sensor that has been specified in the Home Offset (CP-31) parameter. When Home Seek locates the Home Offset position, it ramps down at the Accel/Decel rate (CP-60) to zero. This causes the Follower mechanism to overshoot the Home Offset position. The M–Traverse compensates by continuing Home Seek in a forward, triangulated Accel/ Decel move that aligns the Follower mechanism with the Home Offset and establishes “Home” . This profile is commonly used for applications that can not establish “Home” at the Home Sync sensor because of interference (e.g., the physical edge of the reel or a bracket that is in the way). This profile is used in both web scan and level wind applications.

Reverse

Limit

(CP-60)

Accel/Decel

Home

Home Offset

(CP-31)

Sensor

Home

Sync

Jog Speed

(CP-61)

Forward

Limit

Accel/Decel

(CP-60)

Start Here

3 - 47

Example of a Center Based Profile with Home Offset.

Home Seek moves the Follower mechanism in the reverse direction, detects the Home Sync sensor, then ramps down at the Accel/Decel rate (CP-60) to zero. Then the M–Traverse makes a forward, triangulated move (in the forward direction) to the “Home” position. The M–Traverse uses Home Sync as the starting point and determines the “Home” position by subtracting is one-half of the Traverse Length from Home Offset (CP-31).

Jog Speed

(CP-61)

Reverse

Limit

(CP-60)

AccelDecel

Home

Sync

Sensor

Home Offset

(CP-31)

1/2Traverse

Length

Home

(Subtract one-half traverse length from CP-31)

Forward

Limit

Accel/Decel

(CP-60)

Start Here

3 - 48

Example of an Edge Based Profile with Reverse Rebound.

Home Seek moves the Follower mechanism in the reverse direction. Home Seek reaches the Reverse Limit without detecting the Home Sync sensor and immediately stops. Home Seek moves the Follower mechanism in the forward direction (toward the Forward Limit). When Home Seek locates the Home Sync sensor, it ramps down at the Accel/Decel rate (CP-60) to zero. This causes the Follower mechanism to overshoot the Home Sync sensor. The M–Traverse compensates by reactivating Home Seek in the reverse direction, then a forward, triangulated Accel/Decel move that aligns the Follower mechanism with the Home Sync senor. This profile is used in both web scan and level wind applications.

Note : If Home Seek does not detect the Home Sync sensor by the time it reaches

the Forward Limit, the M–Traverse automatically shuts the system off (F-Stop).

Reverse

Limit

(CP-60)

Accel/Decel

Jog Speed

(CP-61)

accel/decel

(CP-60)

Forward

Limit

Accel/Decel

(CP-60)

Start Here

Home

Sync

Sensor

3 - 49

HOME RETURN

If “Home” has been established through either Home Set or Home Seek, then Home Return can return the Follower mechanism to “Home”. When the Home Return input is closed, the Follower mechanism makes a profiled move at jog speed until it aligns with “Home”.

The Follower mechanism will move toward “Home”, in either the reverse or forward direction, depending on which direction is closer to “Home”. When the Follower mechanism travels in the reverse direction to locate “Home”, it ramps down at the Accel/Decel rate (CP-60) to zero. This causes the Follower mechanism to overshoot the Home Sync sensor by a distance that is equal to the At-Home Band (CP-30). The M–Traverse compensates with a forward, triangulated Accel/Decel move that aligns the Follower mechanism with “Home”.

Reverse

Limit

At-Home

Band

(CP-30)

Accel/Decel

(CP-60)

Jog Speed

(CP-61)

Accel/Decel

(CP-60)

Forward

Limit

Start Here

Home

Sync

Sensor

When the Follower mechanism travels in the forward direction to locate “Home”, it decelerates directly down to the “Home” position from a predetermined position that ramps the Follower directly to the “Home” position.

Reverse

Limit

(CP-60)

Accel/Decel

Start Here

Jog Speed

(CP-61)

Home

Sync

Sensor

Accel/Decel

(CP-60)

Forward

Limit

Home Return enables the Drive Enable logic output, which allows the Follower mechanism to hold its position at “Home” despite any outside force (such as gravity). The Home Return is a momentary input that is edge triggered and is activated through the Home Return input (J4, pin 3, 4). Home Seek is internally latched and does not need to be maintained by an operator device.

3 - 50

DIRECT MODE

The Direct mode is used to calibrate and troubleshoot the M–Traverse. In the Direct mode of operation, you can set the Speed Command Out from the M–Traverse that is connected to the motor drive, directly. The Direct mode is an open-loop mode of operation. Therefore, Scaling, Acceleration/Deceleration, and closed loop compensation (PI) software are not involved in the Direct mode.

The Direct mode is used in conjunction with the Run and F-Stop controls. The Run input (J4, pins 6,7) activates the Direct mode when the Control Mode (CP-14) parameter has been set to “2” (enable Direct mode). When the Direct mode has been activated, the analog output level goes immediately to the DAC bits specified in the Direct Analog Command (CP-62). The Direct Analog Command (CP-62) parameter uses the full 12 bit resolution of the analog Speed Command Output. A positive value indicates a forward direction and a negative value indicates a reverse direction. The FStop input will move the Speed Command Out to zero immediately.

The Drive Enable logic output is active during Run and deactivated during F-Stop. The Forward and Reverse Limits are also active. If the Follower mechanism encounters a Forward or Reverse Limit, it will immediately stop (F-Stop) and go to zero speed with no deceleration. The Follower mechanism can be moved away from either limit by any control mode that move the Follower mechanism in the opposite direction from the limit. All of the setpoint, Run and F-Stop changes will occur without the Accel/ Decel ramps.

Caution: To avoid damage to your system, the M–Traverse must be calibrated and the

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

Installation/

Setup: Calibration.

3 - 51

JOG

Jog is used in conjunction with Home Set to move the Follower mechanism to “Home”. Jog can also be used when you need brief bursts of speed to align the Follower mechanism. When you activate Jog, the RPMs increase at the acceleration rate that you specified in Acceleration/Deceleration (CP-60) until the Jog Setpoint (CP-61) is achieved. When Jog is terminated, the RPMs return to zero immediately, with no deceleration. The Jog direction is determined by the Jog Forward/Reverse Input (J4, pins 15,16), which controls the direction of the Speed Command Output. The Drive Enable logic output is active during the Jog mode.

Jog (J4, pins 16,17) is a maintained input. When the Jog input is closed, the M– Traverse 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.

3 - 52

MONITOR VARIABLES

Control Parameter 14 = 1

Parameters =

Monitor Variable 40 = 200

Parameter Code Parameter Value

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

Operation: Control Parameters.

The M–Traverse has a number of Monitor Variables (MVs) that monitor the performance of the M–Traverse and your system, help you troubleshoot for problems, and confirm the wiring and tuning. MVs can be accessed at any time during the M–Traverse's operation, including during Run, Jog, and F–Stop.

Note: Monitor Variables are status indicators only - you can not directly affect an MV. There are four categories of Monitor Variables:

Input Monitoring Output Monitoring Performance Monitoring Status Monitoring

In the sections that follow, the Monitor Variables are listed according to these categories.

3 - 53

CONTREX M-Traverse User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

INTRODUCING THE M–TRAVERSE

Installation / Setup

CONFIGURATION

MOUNTING

WIRING

INPUTS

OUTPUTS

SERIAL COMMUNICATIONS

CALIBRATION

MOTOR DRIVE SET UP

ENCODER POLARITY CHECK

M–TRAVERSE CALIBRATION

Operation

KEYPAD OPERATION

CONTROL PARAMETERS

FOLLOWER MODE

DIRECT MODE

TUNING

OUTPUT CONTROL

M–TRAVERSE OPERATION

FOLLOWER MODE (WEB SCANNING OR LEVEL WIND)

HOME SET

HOME SEEK

HOME RETURN

DIRECT MODE

MONITOR VARIABLES